Hydraulic Power Station

I. Overview

The hydraulic power station for YZF1C2-120/800 diesel engine can provide hydraulic power for

mechanized drilling tools in onshore and offshore oil mines. The power station is driven by a diesel

engine and has the characteristic of fast heat dissipation, enabling the hydraulic power station for

diesel engine to operate normally for a long time. It is suitable for working conditions such as

deserts, plateaus, and oceans.

The YZF1C2-120/800 hydraulic power station mainly provides power for drilling tools such as drill

pipe power tongs and casing power tongs.

The hydraulic power station has many characteristics, such as compact structure, easy installation,

strong applicability, and obvious heat dissipation effect.

II. Technical Parameters

1. Maximum operating pressure: 20Mpa

2. Maximum flowrate: 120L／min

3. Diesel model: WP4CD66E200 (Weichai 4)

4. Rated power of diesel engine: 60Kw

5. Diesel engine overload power: 66Kw

6. Rated speed of diesel engine: 1500r／min

7. Idle speed of diesel engine: 700～750r／min

8. Rated fuel consumption rate under operating conditions: 205g/kw.h

9. Startup method of diesel engine: DC24V electric start

10. Diesel engine speed regulation method: electronic speed regulation

11. Plunger pump model: QL100SCY14

12. Hydraulic oil tank volume: 800L

13. Diesel tank capacity: 120L

14. Overall dimensions (L x W x H)(mm): 2500×1600×1940

15. Weight: 3100kg

16. Pipeline joint specification:

a) High pressure port joint: Quick-change coupling NPT1”

b) Return port joint: Quick-change coupling NPT1¼”

c) Oil drainage port: Quick-change coupling NPT1/4”

Note:

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1. The specifications of pipeline joints can be processed specially according to needs

2. There are 3, 4, and 5 types of control according to user needs.

III. Main Structure

The YZF1C2-120/800 hydraulic power station is composed of a diesel engine, pumps, fuel tanks,

inlet and outlet ports, switching valves, pressure control components, pressure gauges, etc. The

overall layout of the power station is a side-mounted structure, allowing the pumps to fully absorb

oil. The pump unit is installed on the side of the oil tank, with fast heat dissipation. The diesel

engine is equipped with a diesel engine monitoring instrument, which is used to control the starting

of the diesel engine as well as detect water temperature, oil temperature, oil pressure, voltage, and

others. One side of the oil tank is a hydraulic control panel, which is equipped with oil suction filter,

oil return filter, level sensor, anti-seismic pressure gauge, overflow valve, etc. For the convenience

of lifting, four lifting lugs were welded on each of the four corners of the hydraulic power station.

The bottom of the oil tank is equipped with an oil drain valve, which is used to drain oil when

changing hydraulic oil.

The bottom of the hydraulic power station is an integral oil pool, which can be loosened and drained

through the oil drain plug .

Operating Instructions:

After connecting the high-pressure oil inlet and return ports of the drill pipe or casing power tong to

the hydraulic power station, when using the drill pipe or casing power tong, thehandleof the

switching valve (4WMM16G-L6X/F) on the valve plate must be pulled to the Neutral Status

position shown in the figure before starting the diesel engine.

Before starting the diesel engine, turn the idle/rated

button to the idle before starting. After

starting, run at the idle speed for 2~3 minutes, and then operate the key to the Rated position, wait

until the speed of the diesel engine reaches about 1500 rpm, then operate the handle of the switch

valve (4WMM16G-L6X/F) to push inward, and then use the drill pipe or casing power tong.

For the use of diesel engines, refer to the "Maintenance Manual and User Service Guide for

Diesel Engine ".

Note: [Check the diesel oil level and engine oil level before starting the diesel engine every time]

Adjust the system pressure by adjusting the overflow valve. The method of adjustment is to first

loosen the locking nuts of the overflow valve, then rotate the adjusting handwheel of the overflow

valve, observe the value on the shockproof pressure gauge. And when the value on the shockproof

pressure gauge meets the usage requirements, tighten the locking nuts to complete the setting.

Before the hydraulic power station is delivered from the factory, the pressure of the overflow valve

has been adjusted and generally does not need to be adjusted again.

IV. Use and Maintenance

(handle)

Middle position

Pressure gauge

(Engine oil)

Inspection

port

Shock-resistant pressure

gauge

High-pressure ball

valve

(Handle)

Overflow valve

I.Installation and Use

l.Carefully inspect the appearance of the hydraulic station for completeness and damage, tighten

external components and accessories to prevent loosening during loading, unloading, and

transportation.

2. Install a hydraulic station in a well ventilated area within 10 meters of the wellhead machinery.

3. It is recommended that YB-N32 and YB-N46 anti-wear hydraulic oil is used as the hydraulic

oil for the oil tank of hydraulic station; When the ambient temperature is below -25°C,

YC-N32 and YC-N46 low-freezing hydraulic oil can be used; equivalent transparent oil can be

used for temporary use.

4. Connect the pipelines (high-pressure pipe, return pipe, and oil drainage port) between the

hydraulic station and the control console or hydraulic tool.

5. After the oil pump works normally, check the pressure gauge reading to see if the hydraulic

station operates normally. Check for oil leakage at each interface of the hydraulic pipeline.

II.Maintenance

The hydraulic station provides hydraulic power for other hydraulic tools, and ensures the normal

use of hydraulic tools and the smooth operations. Regardless of the use and stoppage, it is required

to provide maintenance for the hydraulic station, so as to ensure the normal, safe, stable & reliable

operation.

For the maintenance of diesel engines, refer to the "Maintenance Manual and User Service

Guide for Diesel Engine ".

Maintenance during normal use:

1. Check the oil level in oil tank frequently to ensure that the liquid level is within the display

range of liquid level meter. Too much or less oil is bad for normal work of hydraulic station.

2. Check for oil leakage and others at the joints of each pipe in the hydraulic station. In case of

leakage, shut down for maintenance.

Note: Do not carry out repairs or other operations on hydraulic pipeline joints while working at

the hydraulic station.

3. Check if the pressure gauge displays normally; confirm the fluctuation of pressure and flow by

observing the reading of pressure gauge and stability of dial.

4. Check whether the fixed components of the hydraulic station are loose or not.

5. Check whether the plunger pump of the hydraulic station rotates abnormally and whether the

return pressure is too high. In case of any abnormality, stop the machine and replace the oil

suction filter element and oil return filter element in time.

6. The appearance of the power station shall be kept clean and efforts shall be made to prevent

the moisture and foreign matters from entering the oil tank of power station and polluting the

hydraulic oil.

7. Before replacing vulnerable parts or other components, shut down the machine to ensure

safety.

8. The hydraulic oil of the hydraulic station is generally replaced once a year or six months after

the hydraulic system works normally. At the same time, the oil tank and oil suction pipeline are

cleaned to prevent water and impurities from mixing into the oil or pipeline. If the power

station is not used for a long time, clear the oil stain and dust on the appearance, cover the

power station with a cover, and store it in a place that is not vulnerable to impact and strong

vibration.