Safety Instructions for YKS Wellhead Plunger Pumps
Most YKS products are used in high‑pressure liquid environments. Therefore, personnel operating these products must receive rigorous training to ensure safe, proficient and correct operation. Meanwhile, proper use and timely maintenance are also critical.
WARNING
Improper operation, lateral loads, inadequate maintenance, disassembly under pressurized conditions and other factors may cause personal injury or even fatalities.
The following guidelines help users safely operate YKS products. They serve only as general reminders and shall not replace users' existing safety regulations and codes of conduct.
High‑Temperature Zones: When YKS wellhead plunger pumps operate normally, the temperature of process fluid can reach up to 100°C. To prevent scald injuries, suppliers are obligated to provide sufficient and prominent warning signs and install adequate protection around the pump fluid end and discharge manifold.600 Triplex Plunger Pump
YKS wellhead plunger pumps operate under extremely high pressure with fast‑moving external components. During pump operation, customers are responsible for posting sufficient and prominent warning signs and implementing adequate protective measures. Unauthorized personnel are prohibited from approaching the working area while the pump is running.
A Staff Code of Conduct
A‑1 Personnel operating the pump must wear hard hats, safety goggles and durable safety footwear. Hammering any component may generate flying debris or metal shavings.
A‑2 If hammering is required, only strike YKS‑specialized striking wrenches - never the pump body directly. Use only soft‑headed hammers for hammering. Repeated hammering may induce internal defects in components.
A‑3 Never strike valve retainer nuts or any other pump components when the pump is under pressure.
A‑4 Do not lift components weighing over 40 pounds during pump maintenance; lifting equipment must be used for such components. For parts weighing 40 pounds or less, maintain proper leg posture and never lift with a bent back.
A‑5 Use suitable tools when maintaining the pump. Special tools supplied with new pumps shall be kept with the pump for routine maintenance. Only professionally trained and experienced staff shall use these tools properly and proficiently for daily maintenance. Pumps contain internal and external moving parts. All irrelevant personnel must stay clear of the pump area during operation. Only professionally trained staff are allowed in the pump area, especially during operation or maintenance.
B On‑Site Requirements
B‑1 Each pump shall be clearly marked with its maximum rated working pressure. This rating must never be exceeded, otherwise severe personal injury or death may occur.
B‑2 Each pump shall be clearly marked with its maximum rated power. This rating must never be exceeded, otherwise mechanical damage leading to personal injury or death may result.
B‑3 When connecting discharge manifolds, clean and apply appropriate light‑grade oil to connectors before joining each manifold section. Inspect and replace any pipe fittings with worn, damaged or missing seals during connection.
B‑4 When connecting suction manifolds, clean and apply appropriate light‑grade oil to connectors before installing steel‑reinforced hoses. Prior to pump startup, inspect and replace any pipe fittings with worn, damaged or missing seals. Leaking connections may cause pump cavitation, leading to pump failure and potentially severe personal injury or death in extreme cases.
B‑5 Any fluid end subjected to pressure exceeding its rated value shall be returned to YKS for disassembly, inspection and recertification.
B‑6 Welding, brazing or heating of any components is prohibited by YKS. Use bolted or clamped connections when attaching additional accessories. Consult YKS for further inquiries.
B‑7 When using booster centrifugal pumps connected to YKS wellhead plunger pumps, the maximum rated flow shall be limited to the lower value between the centrifugal pump's rated flow and the plunger pump's rated flow.
B‑8 Conduct a comprehensive visual inspection of the power end and fluid end before each pump use. Repair, replace or replenish all leaking seals, damaged bolts, leaking hoses and improper connections prior to pump startup.
B‑9 For pumps connected to permanent manifolds, frame bending and structural deformation must be taken into account. Never install suction or discharge manifolds in blind areas. Inspect all manifold components (including valves) for erosion, corrosion and abrasion every 90 days; replace defective parts immediately upon detection.
B‑10 As specified in the pump maintenance manual, YKS pumps shall only be installed and operated in a horizontal position. Operation on highly inclined surfaces may cause equipment failure due to improper lubricant flow or valve sealing issues, resulting in personal injury.
B‑11 All personnel performing major repairs, overhauls or routine maintenance must be professionally trained certified technicians for high‑pressure reciprocating plunger pumps. All maintenance and overhauls shall be carried out under supervision of authorized managers or returned to YKS. Only genuine YKS replacement parts shall be used. Non‑genuine parts lack quality assurance and may cause personal injury or death. YKS operates a professional pump maintenance technician training school to certify staff qualifications.
B‑12 YKS wellhead service pumps must never handle gaseous media, explosive substances or unapproved corrosive fluids. Such media may cause equipment failure and casualties.
B‑13 Never place hands in the reciprocating area of crossheads or plungers. If work must be performed in this area, ensure the pump is disconnected from the input drive shaft prior to operation.
C Special Precautions
C‑1 Use of non‑YKS‑certified pump components or unauthorized component repairs may cause pump damage or failure, potentially resulting in severe personal injury or death.
C‑2 After pump operation, clean the fluid end and associated manifolds with fresh water. Thoroughly drain all liquid from cylinders and dry them with compressed air in anticipation of freezing weather (valve seats must be opened, drained and dried completely). Failure to clean with fresh water may lead to freezing of cylinders and valve seats. Undrained water in freezing conditions may crack pump components.
C‑3 Except for specially designed configurations, all threaded connections adopted by YKS are right‑hand threads; components can be disassembled by turning bolts counterclockwise. Regardless of thread type, proper torque specifications must be followed.
C‑4 All products shall undergo comprehensive inspection before use, and be cleaned, coated with grease and protective oil after use.
C‑5 Pressure‑seal threaded (tubing) connections are not recommended for manifolds operating above 10,000 PSI with pulsation, lateral loads or potential erosion. In such cases, non‑pressure‑seal threaded (pipe) connections or solid integral connections are preferred. Threads shall be tightened with power‑driven tools to achieve the recommended vibration‑free cold working pressure. Consult YKS for operating modes other than normal constant‑flow working pressure. Integral connections are preferred over threaded connections for pump applications.
C‑6 Each integral fitting is clearly marked with a pressure rating code (e.g., "1502" indicating 15,000 PSI). The marked pressure value must not be exceeded. Mating integral components shall carry the same pressure rating code; improper matching may cause equipment failure. The complete connection assembly, including dimensions, connection types and pressure ratings, shall be compatible with each other and the designated operating manifolds.
D Inspection & Testing
D‑1 Thoroughly inspect the drive system and hydraulic manifolds before each pump startup. Replace all worn, damaged or missing components immediately.
D‑2 Tighten all cylinder connection nuts sequentially with calibrated torque wrenches before pump startup. Failure to do so may separate the fluid end, potentially causing fatal injuries.
D‑3 Tighten all studs and bolts to specified torque values before pump startup. Loose connections between the fluid end and power end may cause fatigue failure of studs or bolts in either assembly. Consult YKS for detailed thread torque specifications.
D‑4 All cover plates shall be tightened to proper torque values; otherwise, cover plate fatigue failure may occur, leading to fluid end or other component malfunctions.
D‑5 Disassemble and inspect each fluid end individually before pump use. Fluid ends with reduced wall thickness caused by erosion or corrosion pits must be returned to YKS for maintenance and recertification.
D‑6 During routine pump maintenance, disassemble all fluid ends and inspect for cracks using ultraviolet lights or magnetic particle inspection equipment. Even minor cracks in any area during pump operation may cause severe casualties.
D‑7 All fluid ends shall undergo hydrostatic testing by authorized professional technicians at least twice a year. All air must be purged from the system prior to pressure testing; failure to do so may cause personal injury or death. The maximum test pressure shall not exceed the equipment's rated working pressure. After hydrostatic testing, inspect internal bores with ultraviolet lights or magnetic particle inspection equipment before reassembly for pressurized service.
