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Test of samples made of Oxafen OPM-94

ESP thrust bearing in abrasion wear conditions test:
Laboratory tests of friction couples were carried out on a machine which imitates the operation of an ESP stage thrust bearing in abrasion wear conditions (lithium grease + 5% quartz sand by mass). Washer material: a) PTK grade fabric-reinforced epoxy laminate; b) Oxafen OPM-94. Abrasive material properties: quartz sand (Mohs hardness ≈ 7). Mean size of abrasive material particles: 15 μm (dispersion: 2 to 100 μm) Abrasive lubricant feed: continuous feed, 0.20 mL/min. Axial loading of bearing washer: 6.4 kg. Washer rotation speed — 2900 RPM. Mean sliding velocity — 5.9 m/s. Test duration — 150 min. Results are listed in Table 1.

Table 1. Wear test results for bearing washers made of different materials
Axial and radial stage bearings of the ESP test:
Additionally tests of axial (bottom washer of runner — shoulder of distributor) and radial (shaft liner — hub of distributor) stage bearings of the ESP were performed on a testing rig imitating the operation of the pump in hydro-abrasive wear conditions (water + 2 g/L of quartz sand). The experimental pump consisted of four ESP 5-50 stages manufactured using a powder metallurgy process. Duration of testing was 1 hour. Results of experiments are listed in Table 2.

Table 2. Effect of runner bottom washer on wear of axial and radial friction bearings of ESP stages
Comparison with textolite test:
Test conditions:
Run-in for 10 minutes at 2000 RPM spindle speed and 10 kgf axial force acting on the friction couple.
Wear test was performed for 1.5 hours at 2000 RPM spindle speed and 10 kgf axial force acting on the friction couple.
Lubrication in the friction area: Litol 24 lithium grease with 5% by mass aluminum dioxide with particle size of 45 μm max and Mohs hardness ≈ 7. The results are presented on Graph 1 and Table 3.
Graph 1. Linear wear of Oxafen OPM-94 as compared with textolite
Table 3. Linear wear of Oxafen OPM-94 as compared with textolite
Wear resistance of runner washer made of Oxafen OPM-94
Comparative tests of submersible pump stage runner washer manufactured from a pilot plate of Oxafen OPM-94 were carried out at a friction laboratory. Abrasion wear resistance tests of washer material were carried out on a testing rig imitating the operation of a pump stage thrust bearing. The experiments used ~ 40 μm mean particle size quartz sand as the abrasive material. The abrasive material was fed in Litol-24 lithium grease. Litol contained 5% quartz sand by mass. Abrasive-laden grease was fed continuously at a rate of 5 cm³/h. Axial force acting on bearing washer (dout.= 44 mm, din = 35 mm) matched the maximum possible load in operation conditions, Nос = 6.40 kg (Pос = 1.58 kg/cm²). Washer rotation speed n = 2900 RPM. Mean sliding velocity v = 5.9 m/s.
Test duration: two washers for 360 minutes each, one washer for 29 hours. Material of busing imitating the distributor shoulder: U8 steel. Overall dimensions of bushing: dout.= 42 mm, din= 36 mm, h = 23 mm. Test results are listed in Tables 4, 5 and 6.
Note: mean wear rate was determined by dividing total wear of washer (400 μm) and bushing (170 μm) by total test duration (29 h).
Table 4. Abrasive wear rate and coefficient of friction of friction coupling during the first 6 hours of testing
Table 5. Effect of test duration on abrasive wear rate of tribocoupling
For comparison, Table 6 lists wear rate data for materials tested in the same conditions.


Table 6. Effect of material of runner thrust bearing washer on abrasive wear rate and coefficient of friction of tribocoupling
Conclusion
Mean wear rate of two outside plies of an Oxafen OPM-94 washer was determined. It was found to be substantially lower than the wear rate of prior tested materials.

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