NB/SH/T 0846-2010 Anti-wear hydraulic oil high-pressure plunger pump test method

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Card type: Test method

1. Method number / full name / English name / replacement relationship

• Standard number: NB/SH/T 0846—2010
• Chinese name: Anti-wear hydraulic oil high-pressure plunger pump test method
• English name: Test method for evaluating performance of hydraulic oil in high pressure piston type pump
• Replacement relationship: not provided in the available source (the foreword does not give replacement standard information)
• Publication/implementation: published on 2011-01-09, implemented on 2011-05-01; issued by the National Energy Administration
• Drafting unit: PetroChina Dalian Lubricant Research and Development Center
• Main drafters: Liang Dejun, Chen Guohua
• Formulation reference: formulated with reference to the test conditions and procedures of the American Denison P46 high-pressure plunger pump
• Nature of appendices: Appendix A, Appendix B, Appendix C, and Appendix D are all informative appendices

2. Scope of application and non-applicability

• 1.1 This standard specifies a test method for evaluating anti-wear hydraulic oils using a high-pressure plunger pump bench.
• 1.2 This standard uses the International System of Units [SI] units.
• 1.3 The application of this standard may involve certain hazardous materials, operations, and equipment, but it does not address all safety issues related to them. Users are responsible for establishing appropriate safety and protection measures before using this standard, and for determining the applicability of relevant regulatory restrictions.
• Non-applicable scope: not provided in the available source.

3. Method principle

• Chapter 4 Method summary: under the conditions of a pump speed of 2400 r/min ±100 r/min and a pump outlet pressure of 34.47 MPa ±0.69 MPa, circulate 300 L test oil through the plunger pump bench for 100 h. The test temperature is 71 ℃ ±5 ℃ for the first 60 h and 99 ℃ ±5 ℃ for the latter 40 h. The degree of wear of pump parts and the conditions of copper transfer and oxidative corrosion are used as test results to evaluate the performance of anti-wear hydraulic oils.
• Chapter 5 Significance and use: mainly used to determine the anti-wear performance in high-pressure plunger pumps, as well as the anti-oxidation and anti-corrosion performance of steel-copper friction pair components. Excessive wear may cause failure of industrial hydraulic systems or mobile hydraulic devices.

4. Reagents and materials (purity / preparation)

• 7.1 Solvent naphtha: meets the requirements for No. 2 solvent naphtha in GB 1922, or an equivalent product. (The source writes “CB 1922”; requires confirmation against the source standard (source-text extraction); should be GB 1922)
• 7.2 Petroleum ether: 60 ℃～90 ℃.
• 7.3 Industrial enclosed gear oil: L-CKD 20 gear oil, meeting the requirements of the GB/T 5903 standard. (The source extraction starts with LFCKD20 followed by garbled characters; requires confirmation against the source standard (source-text extraction))
• 7.4 Calibration oil: Shell Turbo T46, product number 65603.
• Warning: the use of the materials used should comply with safety regulations.
• Test oil: 10.1 Prepare about 600 L of test oil; 10.2 the test oil should be able to represent the properties of the oil sample under test, and the portion extracted from it each time for testing should also be able to represent the test oil.

5. Instruments and equipment

• 6.1 The basic system includes equipment (see Figure A.1 in Appendix A):
  • 6.1.1 Denison One set of high-pressure plunger pump test bench. Denison P46 High-pressure plunger pump product number: P46 F-02D-103-1101 5D; P48/-05D-###-1N03-1D00. (The numbering part source-text extraction is doubtful; requires confirmation against the source standard (source-text extraction))
  • 6.1.2 Main motor start and stop system.
  • 6.1.3 Test pump speed measurement system.
  • 6.1.4 Test pump pressure measurement and control system.
  • 6.1.5 Temperature measurement and control system for each point of the oil tank.
  • 6.1.6 External flow measurement and control system.
  • 6.1.7 External filtration system.
  • 6.1.8 Automatic gearbox cooling control system.
• 6.2 Auxiliary equipment and instruments:
  • 6.2.1 Low-speed motor start and stop system.
  • 6.2.2 Cooling water system.
  • 6.2.3 Compressed air system.
  • 6.2.4 Oil cleanliness tester.
  • 6.2.5 Calipers: specifications are respectively 0 mm～125 mm, 0 mm～50 mm, with an accuracy of 0.001 mm. (The source source-text extraction writes “0 725mp-50mm”; requires confirmation against the source standard (source-text extraction))
  • 6.2.6 Balance: range 0 g～200 g, readability 0.001 g; range 0 kg～5 kg, readability 0.001 g. (The extracted term preceding 0.001g is garbled; requires confirmation against the source standard (source-text extraction))
  • 6.2.7 Tools: box-end wrenches, open-end wrenches, torque wrenches, etc.

6. Recommended operating conditions

• The test operating conditions are shown in Table 1 and Table 2 (the original tables source-text extraction are severely incomplete; the following is the identifiable content, and the rest requires confirmation against the source standard (source-text extraction)).

Table 1 Break-in conditions (the original is incomplete; requires confirmation against the source standard (source-text extraction))

Table 2 Test conditions (the original is incomplete; requires confirmation against the source standard (source-text extraction))

• 12.3.1 According to test procedure 1, run for 60 h.
• 12.3.2 According to test procedure 2, run for 40 h.
• 12.3.3 The test conditions are shown in Table 2.
• 12.3.4 Test records.

7. Sampling and sample preparation

• 12.1.4 Collect oil sample: the sampling conditions and method shall be carried out in accordance with GB/T 17489.
• 12.1.5 The solid particle contamination level of the test oil shall be tested in accordance with GB/T 14039.
• 12.1.5.1 Before the formal test, the solid particle contamination level of the test oil shall at least reach the 18/16/13 specified in GB/T 14039, and the calculation of the number of particles should satisfy GB/T 18854.
• 12.1.5.2 The test oil may also be filtered and cleaned with a filter before being loaded into the system, and it must be ensured that it is not contaminated by residual test oil from the previous test.
• 12.1.5.3 If the solid particle contamination level of the test oil does not meet the requirements, repeat the 12.1.2 step until the required solid particle contamination level standard is reached.
• 12.6.1 The method of collecting the oil sample is the same as 12.1.4.
• 12.6.2 The test of the solid particle contamination level of the test oil is the same as 12.1.5.
• 12.6.3 Observe and record the condition of the test oil, paying attention to any abnormal appearance and odor.
• 12.6.4 Open the shut-off valve of the oil tank and the drain valve of the oil circulation system, and drain all the test oil. Note: If necessary, a sample after the test may be collected (the source text source-text extraction is incomplete, requires confirmation against the source standard (source-text extraction)).

8. Analysis procedure

• 8 Test bench maintenance:
  • 8.2 Pump shaft, shaft seal, pressure sensor, and all control switches, to ensure their normal and reliable operation. They should be replaced every ten tests (if the previous test had large mass loss, vibration, cavitation, or visible damage). (The source text source-text extraction is incomplete, requires confirmation against the source standard (source-text extraction))
  • 8.3 Inspect the pump cover and pump body; if obvious damage is found, replace them promptly.
  • 8.4 Inspect the inner surface of the pump body and the oil seal of the shaft seal to avoid shaft seal leakage.
  • 8.5 Periodically inspect the threads of the four bolt holes on the pump cover. Apply anti-rust oil to the threads to prevent corrosion. To better secure the test pump, if the threads of the pump body and pump cover bolts are damaged, they must be replaced promptly.
  • 8.6 Periodically inspect the bolt holes at the pump inlet and outlet; apply anti-rust oil to the threads to prevent corrosion. To better secure the inlet and outlet lines, if the threads of the pump body and inlet/outlet bolts are damaged, they must be replaced promptly.
  • 8.7 The pressure control valve needs to be periodically disassembled, cleaned, and inspected.
• 9 Calibration of the test bench:
  • 9.1.1 There are many factors affecting high-pressure pump bench tests. To make the test accurate, perform a calibration test every two years; calibration tests should also be performed after a new test bench is installed and after major overhaul of the test bench. Note: If no sample testing has been performed during the two-year period, a calibration test should be performed before the next sample testing.
  • 9.2.1 The calibration report format is the same as the test report format; see Appendix B.
  • 9.3.1 Use Shell Turbo T46 as the calibration oil.
  • 9.4.1 Compare the surface wear condition of the test pieces after the test, as well as copper transfer and oxidative corrosion, with the results of the previous calibration oil test. If the comparison result is equivalent to the previous calibration oil test result, the bench calibration is qualified.
  • 9.4.2 Compare the surface wear condition of the test pieces after the test, as well as copper transfer and oxidative corrosion, with the previous calibration oil result. If the comparison result is better or worse than the previous calibration oil test result, the bench calibration is unqualified.
• 11 Test preparation:
  • 11.1 System flushing: 11.1.1 To prevent cross-contamination of the test oil, the entire system should be flushed before the test.
  • 11.1.2 Flushing procedure:
    • 11.1.2.1 Drain all old oil from the system.
    • 11.1.2.2 Install the prepared flushing pump on the bench according to the test specification and connect the oil lines.
    • 11.1.2.3 Close all drain valves on the bench.
    • 11.1.2.4 Fill the pump with test oil from the oil filler port and remove air from the pump.
    • 11.1.2.5 Open the pump inlet shut-off valve on the oil tank.
    • 11.1.2.6 Connect the compressed air hose to the air inlet of the pneumatic oil pump (adjust the compressed air pressure to 0.2 MPa～0.5 MPa).
    • 11.1.2.7 Open the compressed air valve; the pneumatic oil pump starts working and fills the oil tank with test oil.
    • 11.1.2.8 When the oil level rises to the middle of the scale on the oil tank level gauge window, stop the pneumatic oil pump.
    • 11.1.2.9 Check the main heat exchanger ball valve and the rotary switch on the instrument operation panel; the position should be in the “plunger pump” mode.
    • 11.1.2.10 Check the gear oil level in the gearbox; if it is below the lowest mark on the dipstick, add gear oil up to the standard mark on the dipstick.
    • 11.1.2.11 Open the internal leakage oil outlet valve switch of the plunger pump.
    • 11.1.2.12 Fully open the pressure regulating valve so that no pressure is generated when flushing begins.
    • 11.1.2.13 Open the gas distribution valve.
    • 11.1.2.14 Start the cooling water system.
    • 11.1.2.15 Press the “start” button of the low-speed motor; the high-pressure plunger pump starts running.
    • 11.1.2.16 Under the conditions of motor speed 500 r/min ±50 r/min and outlet pressure 3.5 MPa ±0.2 MPa, run the system for at least 1 h.
    • 11.1.2.17 not provided in the available source (source-text extraction is incomplete, requires confirmation against the source standard (source-text extraction))
    • 11.1.2.18 After flushing is completed, reduce the pressure to 1.5 MPa ±0.1 MPa and stop the machine.
    • 11.1.2.19 If, according to the opinion of the test manager, the bench needs additional flushing, repeat 11.1.2.15～11.1.2.17. If the system is still contaminated, after replacing the flushing oil, repeat 11.1.2.15～11.1.2.17.
    • 11.1.2.20 Drain all test oil from the system.
    • 11.1.2.21 Remove the flushing pump.
    • 11.1.2.22 Remove all filters from the system.
    • 11.1.2.23 Install new filters. (The source text is numbered 11.1.2.22 Install new filters, requires confirmation against the source standard (source-text extraction))
  • 11.2 Preparation of the test pump:
    • 11.2.1 Prepare one set of Denison P46 test pump cartridge.
    • 11.2.2 Inspect all component parts of the pump cartridge for machining or material defects. For each test, use a new set of plunger slippers, a new valve plate, a new lining plate, and a new sliding plate.
    • 11.2.3 Clean all parts of the plunger pump with solvent naphtha and petroleum ether.
    • 11.2.4 Measure and record the diameter dimension of each plunger.
    • 11.2.5 Measure and record the step thickness of the plunger slippers.
    • 11.2.6 Weigh and record each plunger-slipper assembly.
    • 11.2.7 Weigh and record the valve plate.
    • 11.2.8 Weigh and record the lining plate.
    • 11.2.9 Weigh and record the sliding plate.
  • 11.3 Assembly of the test pump:
    • 11.3.1 Dip the cleaned parts in a small amount of clean test oil and assemble them into a complete pump according to the test specification.
    • 11.3.2 During assembly, avoid parts striking and damaging each other, and the tightness should be appropriate so that they rotate flexibly.
    • 11.3.3 Tighten the pump cover screws according to the specified torque.
    • 11.3.4 Fill the pump with test oil from the oil filler port and remove air from the pump.
  • 11.4 Preparation of the test oil:
    • 11.4.1 Close all drain valves on the bench.
    • 11.4.2 Open the compressed air valve; the pneumatic oil pump starts working and fills the oil tank with test oil.
    • 11.4.3 When the oil level rises to the middle of the scale on the high-position oil tank level gauge window, stop the pneumatic oil pump.
• 12 Test procedure:
  • 12.1 Clean filtration of the test oil and system venting:
    • 12.1.1 Press the “start” button of the low-speed motor. The high-pressure plunger pump starts running.
    • 12.1.2 Under the conditions of motor speed 500 r/min ±50 r/min, no pressure applied at the pump outlet, and pump outlet temperature controlled within 60 ℃, run the system for at least 1 h.
    • 12.1.3 Confirm that there is no air in the system piping, then press the “stop” button of the low-speed motor.
    • 12.1.4 Collect an oil sample: The sampling conditions and method shall be carried out in accordance with GB/T 17489.
    • 12.1.5 The solid particle contamination level of the test oil shall be tested in accordance with GB/T 14039.
    • 12.1.6 Remove the V-belt of the low-speed motor and place it properly.
  • 12.2 Running-in stage:
    • 12.2.1 Press the “start” button of the main motor; the high-pressure plunger pump starts running.
    • 12.2.2 Increase the pump outlet pressure: jog the “pressure increase” button to slowly increase the pump outlet pressure. Warning: Whether increasing or decreasing pressure, it must not be too fast, otherwise accidents are likely to occur.
    • 12.2.3 Running-in procedure I, duration 15 min.
    • 12.2.4 Running-in procedure II, duration 35 min.
    • 12.2.5 Running-in operating conditions are shown in Table 1.
  • 12.3 Test run:
    • 12.3.1 According to test procedure 1, run 60 h.
    • 12.3.2 According to test procedure 2, run 40 h.
    • 12.3.3 Test conditions are shown in Table 2.
    • 12.3.4 Test records.
  • 12.4 Restarting the test:
    • 12.4.1 In case of a sudden fault:
      • 12.4.1.1 Press and hold the “pressure decrease” button and the main motor “stop” button simultaneously to stop the pump.
      • 12.4.1.2 Close the oil tank shut-off valve.
    • 12.4.2 If the test has been stopped for any reason, when the test parameters again meet the test conditions, the test may continue.
    • 12.4.2.1 According to running-in procedure I, run 15 min.
    • 12.4.2.2 According to running-in procedure II, run 25 min.
    • 12.4.3 Only after the test conditions have been re-established may the timer start timing, accumulating a run of 100 h.
  • 12.5 Test shutdown:
    • 12.5.1 Pressure reduction: After the test is completed, press the “pressure decrease” button to slowly reduce the pump outlet pressure to 1.5 MPa ±0.1 MPa.
    • 12.5.2 Temperature reduction: Adjust the temperature so that the outlet temperature drops below 60 ℃. (The source text source-text extraction says “reduce all 0° below”, requires confirmation against the source standard (source-text extraction))
    • 12.5.3 Shutdown: Press the “stop” button; the test pump stops running.
    • 12.5.4 Stop the water pump: Press the water pump “stop” button; the cooling water pump stops running.
    • 12.5.5 Close (the source text is incomplete, requires confirmation against the source standard (source-text extraction))
  • 12.6 Collect an oil sample:
    • 12.6.1 The method of collecting the oil sample is the same as 12.1.4.
    • 12.6.2 The test of the solid particle contamination level of the test oil is the same as 12.1.5.
    • 12.6.3 Observe and record the condition of the test oil, paying attention to any abnormal appearance and odor.
    • 12.6.4 Open the shut-off valve of the oil tank and the drain valve of the oil circulation system, and drain all the test oil.
• 13 Post-test inspection:
  • 13.1 Remove the pump cover and disassemble the Denison P46 plunger pump according to the test specification.
  • 13.2 Clean all pump components with solvent naphtha and petroleum ether and air dry.
  • 13.3 Measurement and inspection:
    • 13.3.1 Measure and record the diameter of each plunger.
    • 13.3.2 Measure and record the step thickness of the plunger slipper.
    • 13.3.3 Weigh and record each plunger slipper assembly.
    • 13.3.4 Weigh and record the valve plate.
    • 13.3.5 Weigh and record the lining plate.
    • 13.3.6 Weigh and record the sliding plate.
    • 13.3.7 Inspect the wear, copper transfer, and oxidative corrosion of each test component of the plunger pump.
    • 13.3.8 Photograph each test component of the test pump.
    • 13.3.9 For evaluation of test results, see Appendix D. (The source text source-text extraction writes "Appendix 1", requires confirmation against the source standard (source-text extraction))

9. Qualitative and Quantitative and Calculation Formulas

• 14 Determination of test results:
  • 14.1 Compare the surface wear, copper transfer, and oxidative corrosion of the test pieces after the test with the previous calibration oil test results (see figure, the source text is incomplete, requires confirmation against the source standard (source-text extraction)).
  • 14.2 Description of test results:
    • 14.2.1 Valve plate: the entire plate is circularly polished, with circular slight scratches of about 30% area, smearing and coloring of about 30% area, and slight cavitation pits. (The source text source-text extraction is incomplete, requires confirmation against the source standard (source-text extraction))
    • 14.2.2 Lining plate: not provided in the available source (source-text extraction is incomplete, requires confirmation against the source standard (source-text extraction))
    • 14.2.3 Sliding plate: circularly polished, with circular copper transfer and coloring of about 30% area.
    • 14.2.4 Plunger: the plunger has slight scratches of area. (The source text source-text extraction is incomplete, requires confirmation against the source standard (source-text extraction))
    • 14.2.5 Slipper: the slipper has random circular smearing and scratches of about 50% area.
  • 14.3 Determine the test by comparison:
    • 14.3.1 If the comparison result is better than the calibration oil test result, it passes.
    • 14.3.2 If the comparison result is equivalent to the calibration oil test result, it is a borderline pass.
    • 14.3.3 If the comparison result is worse than the calibration oil test result, it fails.
    • 14.3.4 If the comparison result of any pump component after the test is worse than the calibration oil test result, it is considered a failure.
• Calculation formulas: not provided in the available source.

10. Precision

• Not provided in the available source.

11. Report

• 9.2.1 The calibration report format is the same as the test report format, see Appendix B.
• Appendix C (informative appendix) Anti-wear hydraulic oil high-pressure plunger pump test record: Table C.1 is the Denison P46 high-pressure plunger pump test record, and the recorded parameters include: test date, cumulative time, test pump speed/(r/min), test pump inlet pressure/MPa, test pump outlet pressure/MPa, test pump internal leakage pressure/MPa, test pump inlet oil temperature/℃, outlet temperature/℃, internal leakage temperature/℃, leakage temperature/℃, outlet water temperature/℃, heat exchanger outlet water temperature/℃, flow rate/(L/min), plunger pump internal leakage flow rate/(L/min), hydraulic motor internal leakage flow rate/(L/min), pressure regulating valve flow rate/(L/min), main motor current, gear oil pump motor current, etc., and there are signature columns for the tester and inspector. (The source table source-text extraction is severely incomplete, requires confirmation against the source standard (source-text extraction))
• Appendix D (informative appendix) Example of evaluation of anti-wear hydraulic oil high-pressure plunger pump test results: includes columns such as test date, test number, test results of the oil, comparison standard, evaluation, etc. (The source text source-text extraction is severely incomplete, requires confirmation against the source standard (source-text extraction))

12. Referenced Documents

• GB 1922 Solvent naphtha for paints and cleaning (the source text writes "CB 1922", requires confirmation against the source standard (source-text extraction))
• GB/T 5903 Industrial enclosed gear oil
• GB/T 14039 Hydraulic fluid power — Fluids — Method for coding the level of contamination by solid particles (GB/T 14039—2002 ISO 4406:1999, MOD)
• GB/T 17489 Hydraulic fluid power — Particulate contamination analysis — Extraction of fluid samples from lines of an operating system (GB/T 17489—1998 IDT ISO 4021:1992)
• GB/T 18854 Hydraulic fluid power — Calibration of automatic particle counters for liquids (GB/T 18854—2002 ISO 11171:1999, MOD)

13. Source and verification

This page is an AI translation of the available Chinese method card. Human verification is pending. It is not an official translation of the standard. Check the source standard and product certificate before use.

14. Quick Reference Q&A