mud pump handbook pdf for sale

13 Special Tools List For HHF-1300 / 1600 Mud Pump, delivered together with the pump...5214 Spare Parts Lift For HHF1300 / 1600 Mud Pump, delivered together with the pump.. 5315 Recommended spare parts . 55

HHF-1300/1600 Mud Pumps are horizontal, triplex single acting reciprocating pumps. It feedshigh-pressure circulated drilling fluid to bottom hole, which flushes the bore-hole bottom andcrushes rocks; furthermore, cools and lubricates drill- bits and carries the cuttings (rock chips) tothe surface.The Pump mainly consists of two components, power and fluid ends. The power end includes theassemblies of frame, pinion shaftcrankshaftcrossheads etc.

assemblies of hydraulic cylindervalves, cylinder liner, piston, suction and discharge manifolds andso on. It is designed and manufactured that all parts and components of the pump conform with therequirements specified by the Specification for Drilling and Well Servicing Equipment (API Spec7K). All easily worn parts at the fluid end such as cylinder liner, piston and valve assemblies etc areuniversal and interchangeable and could be replaced with the same type parts and components inconformity to the above-said API Specification. To avoid air hammer and reduce outlet pressurefluctuationa suction stabilizer and discharge pulsation dampener were respectively installed at thesuction pipes and one side of pump outlet. At the other side of pump outlet, a reset safety valve isinstalled to guarantee that the pump pressure would not excess the rated working pressure. Eachmud pump is equipped with a charging pump to ensure good suction performances for the pumpwhile operating at high strokes.A combination of splash and forced lubrication systems has been used to lubricate all gears,bearings and crossheads in the power end. The cylinder liners and pistons in the fluid end will belubricated, cleaned and cooled by water supplied from a spray pump.For conveniences of daily maintenance, a set of special removers/tools will be delivered togetherwith the pump.Except for differences in the gears and bearings at the power end of the pumps., Frame, fluid endand so on for pump HHF1300 are the same as pump HHF1600. For convenience of usersunderstanding and use, the two pumps are introduced simultaneously in the following texts.

2.2 Performance parametersThe performance parameters for pump HHF1300/1600 are shown in the following table II:Table II Performance parameters for pump HHF1300/1600Diameter of cylinder liner and rated pressureStrokenumbers

The mud pump HHF-1300/1600, manufactured by our company, has been completely assembledand test-operated under full load and then discharged all lube oils from power end before beingdelivered to our customers. The pump must be checked and operated according to the followingmethods and measures before being put into formal services. In order to prevent personal injuryduring the performance of any checking and maintenance processes, it must be shut down and notoperating, all safety and protection facilities installed on the prime mover and drive device shouldbe put in safe positions.

The skid under the HHF-1300/1600 pumps is fit for all types of installations, but it is worth to bementioned that although the frame with box structure at the power end has high resistances tobending, but relatively lower resistances against twist; therefore, the supports under the frame mustbe level and with enough strength to bear the pumps dead load and dynamic forces exerted uponduring operation.3.2

In land installation, it is suggested that a mat base with, at least eight pieces of 31276mm305mmboards be placed under the pump skids along the entire length the positions as shownin the Figure 2. The board under the pump skids must, at least, be 12305mmwider than thewidth of the pump skid runner. More solid foundations are required in case of the installation beinglocated in wet or marshy land.

3.3 Permanent installationsWhile the pump being permanently installed on the structural base or concrete slab on a barge ordrilling platform and the pump skid being fixed by bolts, it is essential that the skid be properlyshimmed to prevent the power frame from possible distortion or twists. The pump skid must besolidly sat down on all shims when all bolts are tightened.In case of barge installation, the pump skid is usually bolted to T-beam, the positions for installingshims are shown in the Figure 2 and 3. Properly shimming should be noted to avoid possible twistor distortion. All shims must exceed the full width of the skid beam flanges and have a minimumlength of 12 (305mm).When integral installations for power unit or electric motor and pump skids are required thepump must be fixed on the skids of the T beam, with retention blocks rather than bolts in thisway the pump could be a bit floating so as to reduce greatly the possible deformation of thepump frame caused by the deformation of barge deck or platform.

Whether to use V- belt or multi-strand chain or universal shaft for the drive between power sourceand the pump, it must be very careful during the whole installation to ensure the longest service lifeand minimize the shut- downs caused by failures from the drive.Upon installation of drive sheave or sprocket, make sure all rust preventatives or greases in the huband on the shaft are removedBurs and rough spots on the keyskeyways and shaft must beremoved so that all keys fit properly in the keyways on the shaft and drive elements. The shaft ofthe pinion gear should be coated with light lube oil or anti-seize oil, and then fit the hub of sheaveor sprocket, tighten all bolts according to the following requirements:Tightening bolts with wrench or wrench with extension pipe may lead to exceeding torque,therefore, it is imperative to adhere to the torque value given in the following table to tighten allbolts, otherwise, it may damage the hub and the sheave by the exceeding tightening force, which isagain multiplied by the wedging action of the tapered surface. In addition, all bolts of hub must betightened alternately and gradually.

3.4.1.1 Checking sheave groove statusBefore installation, check that the sheave grooved are not worn out and getting rounded, otherwise,the V-belt will be damaged quickly. The groove sidewall must be level and straight and there are nodusts, rusts.3.4.1.2 Checking sheave alignmentHaving installed all sheaves and tightened them to working status check their alignment. If thedistances from one side of the two sheaves to the centerline of sheave groove are equal, check thealignment with two tightened strings (for fishing or better for piano) along one side of the twosheaves; one is put above the sheave center and another below the center, and then move one oftwo sheaves until the strings have touched 4 points of the sheave rim; in this way determining thetwo centerlines of the drive sheaves are parallel and their side face be vertical with their axle line.3.4.1.3 adjustment of V-belt pretension forceTo adjust the belt tension, change/increase the central distance between two sheaves until no sag tobe found on the tightening belt side, and the slack side is also tightened but has a bit of sags. Andthen increase a certain of central distance again, for example, if the center distance is 100(2540mm), 1/2 (13mm) is to be increased after completion of adjustment of the central distance;again if the center distance is 150 (3810mm), 3/4 (19mm) is to be increased.Note: Dont obtain belt tension by lifting the pump or by lowing the pump below ground level toallow the belt to be tensioned by pumps weight.3.4.2 Chain drive3.4.2.1 InstallationInstallation and maintenances correctly are important means to extend the service life of chaindrive and chains and sprockets themselves. Many factors such as the width of chain, center distance,speed and load etc. are to be considered when determining the allowable alignment tolerance ofsprockets; since there is no perfect operating method to be applied, therefore, what we can do isto make the chain alignment as exactly as possible. As mentioned above in 3.4.1.2, a more precisealignment can be made with two stretching steel wires (better for piano) along one side of the bothsprockets; one is put above the centerline and another below the centerline, and then move one oftwo sprockets until the strings have touched 4 points of the sprocket rim; in this way, to determine

the two centerlines of sprockets are parallel and their end face be vertical with their axle line.3.4.2.2 Lubrication of chain driveThe lubrication system used for all chain drive in HHF series pumps is an independent one, whichhas its own lube oil pump, reservoir and drive. Filling the lube oil into the chain case must be up tothe indicated height. The lube oil to be used are as follows:Ambient temperature above 32 F 0C

If Ambient temperature below 0F-18C, Please consult a reputable lube oil dealer forrecommendations. As for those approved lube-oil specifications and their supplements, referencesmight be made to the reports/bulletins usually used on lube oil, which are written and published byoil-manufacturer. If there is any discrepancy between manual and the reports/bulletins, thesuggestion from the reports/bulletins shall be prevailed.Owing to the chain lube system being an independent system, the maintenance must be carried outbased on equipments special requirements, which include:n Daily checking oil leveln Daily checking oil statusn Daily checking oil pressure (515psi 0.0350.103MPan Supplying some oils to chainn Checking nozzles working status on the spray tuben Checking the working conditions of the oil pumps drive (V-belts, or chain)Note:a. There is a pressure relief adjusting screw on the rear of the pump housing to adjust the oilpressure.b. When oil pressure is too high or too low, which indicate that the suction and discharge filterscreens need cleaning.

The design of pump suction system has been considered to install the system independently. Toobtain a satisfied suction performance, the HHF series pumps must have positive head (pressure);

the optimum pressure for suction manifold is 2030psi 0.140.21Mpa. Under this pressure,the pump could have the maximum volumetric efficiency and the longest service life forconsumable parts. This pressure can be obtained by 56 charging pump with a 40 hp, 1150-rpmelectric motor. A special kind of device is necessary to keep the charging pump and the triplexpump automatically and synchronously turned on and off. For drilling rigs driven by DC motor,usually a signal sending out from DC control panel actuates the electromagnetic starter; at this time,the air line of drilling pump clutch can provide a group of contactors when clutch is engaged,through which supply power to the electromagnetic starter.The suction pipeline should be arranged with a by pass for the charging pump, to facilitate thedrilling pumps continuous operation when the charging pump is in maintenance or failure. Whenthe drilling pump is operated without charging pump, usually replace a softer suction valve springto improve suction performances.Suction stabilizer is a very efficient supplementary device, which can fully charge the fluid intocylinder liner and greatly eliminate the fluid fluctuations in suction pipes resulting in a smootherflow in the discharge line.Note: Dont connect the discharge pipe of the safety valve to the suction pipeline, since when thesafety valve opens it causes a sudden rise to the system internal pressure; if the pressure is higherthan the rated pressure of the system, it will damage the manifold, suction stabilizer and centrifugalpump etc.

5 Preparation of power endBefore being shipped to the users, the HHF series pump manufactured by our company has beencompletely assembled and test operated. All lube oils have been drained. Before operating thepump, the following operations and checks must be carried out.5.1 Power end lubricationBefore filling lubricant, open inspection window on cover and check power end oil reservoir forpossible accumulation of condensation, and drain and flush the inner chamber by removing thepipe plugs on each side of the pump (see item 2, Fig.7). Fill in the proper brand and quantity oflubrication oil in the power end according to the requirements specified on the designation plate of

pump frame.Recheck oil level after pump has operated for a period of 15 minutes. Shut pump down for about 5minutes until oil stabilized, check oil level gauge (see item 1, Figure 7). It is usually necessary for afew more gallons (10 liters) of oil to be added due to a certain amount being retained in thecrosshead and frame cavities.5.2 Installation and inspection of Crosshead Extension Rods and Diaphragm Stuffing BoxSeals for HHF-1300/1600 PumpAs shown in Figure 4, remove the diaphragm stuffing box and splash- guard (1) and rotatepump so that crosshead is at the front of the stroke, check bolt-tightening status. If the cleanlinessof front part of crosshead and its extension rod and bolt- tightening are not up to the requirements,remove the extension rod and thoroughly clean the crosshead front and the end face of theextension rod; and then insert alignment boss on crosshead extension rod outer circle into thecrosshead bore and install the bolts (2) to the torque: 350370 ft.lbs, (475500N.M), finally lockit with steel wire.

6 Spray pump assemblyThe spray pump assembly consists of spray pump, water tank and spray pipe with nozzles etc. Thefunction of spray pump is to supply water in the form of spray to the cylinder liner and piston toflush, lubricate and cool them to extend the service life of the cylinder liner and piston.

The spray pump is a centrifugal pump, which is electric motor driven and uses water as cooling andlubrication fluid. Attention must be paid to assure the cooling fluid is supplied to the cylinder linerand piston, otherwise immediate damage of piston rubber parts and cylinder liner will occur.The HHF series mud-pumps manufactured by our company use a stationary spray pipe, as shown inFigure 5, which consists of a fixture (1), connecting pipe (2) and spray nozzle pipe (3). It sprays thecooling fluid to inner holes of cylinder liner and piston. The spray nozzle pipe should be checkedoften as the pump works. Through adjustment of water supply to the manifold, to assure enoughcooling fluid to be sprayed directly to piston.

Figure 5Cooling fluid will be transfused by pump (item3, Figure 7), and sucked from water tank (item 5,Fig.7), to the manifold located in the left (right) wall plate of the frame. By regulating the ballvalve (item 4, Fig.7), the pump will supply water to the inside of the cylinder liner withoutsplashing back on the crosshead extension rod. Water should not splash on the extension rodotherwise some of water will spray into the power end contaminating the lube oil.The cooling fluid is returned from frame drainage hole to water tanks setting chamber, and as thefluid flows through the filter screen, the solids settle as shown in Fig. 6.

7 Assembly of fluid end partsThe cross-section of the fluid end is shown in Figure 8, clean and install all parts of the fluid endmust follow the methods as follows.Note: The parts in the fluid end are designed for metal to metal installations to reduce wearcaused by high-pressure fluid which is used in modern high-pressure-pump operations. Based onthis consideration, in order to ensure a reliable sealing between parts in the fluid end, it is requiredto clean all parts thoroughly and have no burs, scores or rusty spots etc7.1 Valves and seatsRemove all three valves pot cover (18), three cylinder heads (16) and plugs (15), andthoroughly clean all machined surfaces in the fluid end with a good cleaning solvent.Make sure all valve seat bores are very clean and dry (free of dirt, grease, anti-rust additivesetc.), and remove all burs and nicks with a fine emery cloth. Clean and dry thoroughly the valveseats and install suction and discharge valve seats into the valve cavity bores and then install thevalve body; knock the upper part of the guidepost with a copper hammer to drive the valve seats inplace, finally install valve springs and other parts.7.2 Cylinder linerInsert liner- seal- rings (1) into the counter-bore of the cylinder. Install the wear plate (2) in placewith stud bolt, and then install liner flange (3), be sure that the liner lock starting point is at the 5oclock position; and coat the inner bore of nut with Locktite gelatin 277, and finally tighten the nutto torque 470510ft.lbs640690N.m.Note: the purpose of putting the thread start point at the position of 5 oclock is to keep the linerlock threads from being damaged. Insert liner seal rings (1) into the counter-bore of the wear plate(2). Coat inner surface of cylinder liner lock (4) with grease and then put the two-half liner-latchingring on the liner and hold them with the O-ring. Lift the cylinder liner and coat cylinder liner lockthreads with grease and put the lead thread start point at the position equivalent to 7 O clock andpush while turning the liner into the liner flange (3). Tighten the liner lock (4) and press the linerend face into position and knock the liner lock tightly with a hammer.

7.5 Lower valve rod guide and cylinder headInstall the lower valve rod guide (12) and slip it on valve body, through flashboard (13) press downthe valve rod guide and press the valve spring simultaneously. Install the locating disk (11) into thecylinder bore; install cylinder head O-ring (14) on the cylinder head plug (15). Coat the O-ring andouter circle of the cylinder head plug with lightweight oil. And push the cylinder head plug andknock the end lightly into the cylinder front-end inner bore. Coat the threads of the cylinder headwith grease; rotate the cylinder head (16) in against and on the plug (15), and then tighten thecylinder head with a force-multiplier tool and hammer provided together with the pump.If the fluid is leaking through the bleeder holes it indicates that the O-rings are damaged or thecylinder head is loose. Never block the bleeder. Once the O-ring fails it will cause the head threadsand other parts be washed out and damaged.

The reset relief valve (3) is installed on the accessory manifold for the purpose of protecting thepump from pressure exceeded the rated value and discharge all the fluids to guarantee safety of themud pump. The reset relief valve must be installed to be able to contact directly to the mud tanks;and no valves may be installed between the relief valve and the discharge line. Pipe the outlet of therelief valve directly to the mud tank by seamless steel pipe and with as few turns in this line aspossible. If a turn is necessary, the elbow bend should be > 120. It is not allowed to pipe theoutlet of the relief valve to the suction pipes of the pump.The flange on the bottom of the KB-75 pulsation dampener (1) is supplied together with R39 ringgasket(6); before installation of pulsation dampener , clean the ring gasket and groove thoroughlyand after installation, tighten the nuts (7) to the torque: 750850ft.lbs10201150N.m. Toensure balanced forces to be exerted, all nuts should be tightened alternately cross ways.Before starting the pump, pre-charge the pulsation dampener to not be more than 2/3 of the pumpdischarge pressure. Maximum pressure is not to exceed 650 psi (4.5 Mpa). The pulsation dampenerwill be charged with nitrogen only.Do not charge with air, oxygen, hydrogen or other easily-burnt and explosion gases.The charging will be conducted with a set of charging equipment (pulsation dampener charginghoses assembly) provided together with the pump, as shown in Figure 10 and the operationsequences are as follows:

To achieve the best results, the dampener pre-charging pressure must not be more than2/3 of the pump discharge pressure, and the maximum charging pressure is 650 psi (4.5Mpa).

For maintenance of the dampener, the pressure in the dampener must be zero and thepump pressure also is zero. Be careful that dont fully rely on the pressure gaugereadings. The vent valve cap must be open to release pressure, the remaining pressuremay be low and the pressure gauge may not read correctly. This low pressure may stillcause an accident.

systems is adopted for HHF series pumps. When a gear oil pump is driven mechanically (exceptdriven by a electric motor), the types of pressure system adopted, in fact, govern the minimumSPM, at which the pump being operated. As for the pressure lubrication systems adopted for HHFseries pumps, they could operate at a minimum 25 SPM; at this time, the lowest oil pressure is 5 psi(0.035 Mpa).Big gear rim

Figure 11Note: The pressure lube oil pump could be installed outside of mud- pump and driven by v-belt orinstalled inside of mud- pump and driven by big gear rim. When the later installation is used, therotating direction of the pinion gear should be as shown in figure 11.

8.2 Flow- controlled splash lubrication systemThe flow- controlled splash lubrication systems are the same for all HHF series pumps, regardlessof the types of oil pump provided for the lubrication system. In the flow-controlled splash system,the big gear rim brings up the oil from the sump; and when its teeth mesh with the pinion, the oil issqueezed out and splashed to various oil troughs and oil cavities in the frame. With reference tofigure 13, the oils are thrown into the trough (7) and flow through pipe (8), to the bearings on thetwo sides of the pinion shaft.The passage that oil flow from the top of the crosshead guide into the crosshead bearings is shownin figure 12. The oils accumulated in oil chamber above the crossheads flow through oil nozzle (1),into the crosshead pin baffle, and then to oil passages (5) to lubricate crosshead bearing. There are- 24 -

8.3 Pressure lubrication systemThe pressure lubrication systems used for HHF series mud- pumps have installed a lube oil pump,as shown in Figure 13; in this system, the filtered oil is sucked in, through the suction filter (1), bythe pump, and then through the block II (2), distributed to the pinion shaft nozzle (3A), mainbearing oil-pipe (4) and the block I (4A) in crosshead chamber again through the block I (4A),distribute oil to the crosshead, its bearing and extension rod.

Figure 13A pressure gauge (5) is mounted on the back base plate of the frame to show oil pressure inthe block oil-distributor, which is obviously changing with the speed of the pump. However, if asudden pressure drop or increase occurs, the reasons caused must be found according to the sectionon Maintenance of lubrication system.A pressure relief valve (6) is mounted on the block II (2) to prevent the pump and its drivefrom possible damage caused by excessive pressure. The relief valve is preset to 80 psi (0.55 Mpa)and then locked down to avoid the preset pressure changing.

Upon built-in installation of the lube oil pump, as shown item 9 in Figure 13, the pump must bewell positioned according to the requirements as shown in the Figure. The side face of the oil pumpgear must be flush and parallel with the side edge of the mud pump main gear rim, and the gearteeth have 0.024-0.0355 (0.60-0.90 mm) backlash.A typical layout for oil pump driven by pinion shaft is shown in Figure 14. The oil pump (1) ispipe-connected to the lube oil pipes system through the suction and discharge adapters mounted onthe bottom inside walls of the power end. Dont over-tighten the V-belt (2) to prevent the pumpfrom premature damage. To avoid possible injury, the V-belt guard, as shown item 3 in Figure 14,must be installed before the pump being operated.

8.4 Maintenance of lubrication systemSufficient lubrication of all moving parts is the most important factor to extend the service life ofthe pump; being meticulous in maintenance of the lube oil system is a duty for all operators. In fact,a good or poor maintenance of the lube oil system determines a long or short trouble-free servicelife of the pump.The recommended lubrication oil is as follows; and also shown on nameplate fixed on the pumpside. All data recommended are the results of long-period tests in the oil field; therefore, anysubstitution of oil recommended could only be used for emergency conditions.

Every shift should make their rounds to check the oil level and maintain the level at the FULLposition; in view of oil level compensation, it is allowed to drive the pump for 5 minutes at a slowspeed and make sure the oil level at the specified position.Check once every 6-month if the oil has any sand and corrosive compounds in it or not; it shouldbe drained. Drain all the oil and flush the oil reservoir before adding new oil. The oil drains arelocated on either side of the pump frame. During flushing, thoroughly clean the oil troughs and thechambers under the crosshead guides, and also clean or replace the filter element in the suction oilfilter, and clean the suction filter screens. Before filling new oil remove the drain cover from settingchamber and clean out contaminants.Regularly check the condition of the lube oil and replace if contaminated ;moisture in the air,ingress of water and mud, and dirt may enter and contaminate the oil.The settling chamber (deposit chamber) is located in the crosshead guide area of power end; thecontamination in the oil splashed into this area is allowed to settle and be drained out by removingthe drain cover that located on the two sides of the frame under crosshead inspection cover.Check once every month. Remove drain covers at pump two sides to drain out the contaminated oilfrom the settling chamber. This will lose about 15-gallons of oil and must be compensated byadding the same amount of oil to the main reservoir.Check once every week. Remove the 2 1/2 plugs below the frame and drain out the accumulated

water. Every shift makes their round of inspection of oil level once and keep the level to the fullposition.In case of oil pressure drop occurs; check the following items:--- Suction filter screen may be blocked--- Oil level may be too low--- V-belt slipped--- Connections or joints may be broken or loosen--- Oil pump may be worn or damaged--- Relief valve may be failedIn case of oil pressure increase occurs; check the following items:--- Oil pass-way may be blocked--- Contaminations may make the oil be viscous--- Relief valve may be inoperative--- Pressure gauge may be defective--- Other abnormal conditions

9.1 Power endRegular inspection of the power end is the most important way to conduct preventive maintenance;it could find various failures in time, small or big and enable the mud pump to be repairedaccording to plan or in the normal shutdown time.a.

Oil pipe-lineCheck all oil pipelines and make sure that they are complete and free of obstructions. Checkthe pump suction pipelines are free of damage.

Teeth of main and pinion gearCheck the condition of the main and pinion gear teeth for any abnormal wear. During therunning-in period there will be some pitting on the face of the gear teeth. This is referred to asinitial pitting and is not harmful to the life of the gears; however, during the regular check ifthe pitting is expanding, immediately contact the pump manufacturer to inspect the gearsthoroughly.

9.2 Roller bearingRoller bearings are used for all HHF series mud- pumps. As very precise mechanical parts, allroller bearings must be carefully maintained to ensure that higher load capacity and longer servicelife to be obtained.

9.6 Installation of crosshead guide9.6.1Clean thoroughly the surfaces of the guide and frame bore used for installation of the guideand remove all burs or rough edges.9.6.2If an old guide is to be reused, check the friction surface for wear and scoring etc. If it is notup to the requirements, replace it.Note: As for HHF 1300/1600-mud pumps, the upper and lower crosshead guides are notinterchangeable. The guides are differently machined so that the lower one places the crosshead on

9.7.1Thoroughly clean all dirt or contaminations and remove all burs or rough edges from OD,pinhole of the crosshead and guide inner bore etc. Wipe and dry crosshead pinhole so that theconnection with the pin taper bore is made up as metal to metal one. See following note.9.7.2 Position the small end of the link at the side hole of the crosshead guides. Support the linkwith a piece of wood so that the crosshead pin can pass through the bore of link small end whilesliding the crosshead into the pinhole at the aligned positions. See Figure 18.9.7.3 Install the left side crosshead first and then rotate the crankshaft assembly to make themiddle link hole into the middle crosshead; at this time the right link hole backs, remove thesplash guard disk (see item1, Figure 19); push the right crosshead to the middle extension rodchamber so that enough clearances are provided for installation of middle crosshead, and theninstall the right crosshead.Note: If an old guide is to be reused, check the wearing surface for wear and scoring etc. Thecrosshead might be installed to opposite side of the pump if necessary i.e. the left and rightcrosshead could be exchange- installed into the bores. However, dont install the pin into the taperhole until the crosshead pin baffle (2) is mounted.9.7.4 Install crosshead pin baffle (2) and bolts (3), (4); align the taper hole of crosshead with thelink small end hole, and push the pin by hand or knock the big end of the pin lightly by a hammerto install the pin into the taper bore. Put the adjusting shims between crosshead pins and baffle(note: as to a set of pin and its hole, the thickness of shims needed are determined and notexchangeable with other shims, otherwise, failures may occur); rotate crosshead pin until the 8bolt- holes on the pin baffle align with the holes below and install 6 bolts (4) and 2 bolts (3)separately and tighten them by hand (refer to Figure 19 and 19A). The oil catcher of crosshead pinbaffle should be upwards.

0.015 (0.381mm), shims should be inserted under the lower guide to make the extension rodmove just towards the aligned center. In the meantime, enough clearance between the upper andlower guides should be ensured; in general, the lower guide is loaded heavily and a bigger force isexerted at the back part since the angle of link, thus the lower guide is fast worn; therefore, it ispermissible to shim the guides a bit skewed to take up the wear..During shimming, the clearance between the upper guide and crosshead upper surface must not beless that 0.020 (0.5mm). Larger clearances are acceptable since the characteristics of triplexpump operation and the crosshead pressure is always exerted on the lower guide when clockwiserotating.Note: When the pump must be driven anti-clockwise the crosshead pressure is exerted on theupper guide, therefore, the guide clearance must be controlled between 0.010.0160.250.40mm.9.8.5 Cut shims being long enough to make them completely pass through the guide; and cut tabson the shim side and exceeding over the frame supports (refer to installation of crosshead guide,9.6.3 and 9.6.4).

manifold must be open. While the valve are closed, the pump starting will exert an impact stress tothe pump and may cause fatigue cracks; and finally the pump head would be damaged by fatiguefailure if the situation continued.9.9.2

Properly maintain the fluid ends for storage. When a pump will not be used for 10 days more, it issuggested to remove the pistons. piston rods, liner etc and flush thoroughly the fluid end withclean water and then wiping them clean after flushing; grease all parts removed and all machinedsurfaces. This will not only extend the life of the fluid end parts but also protects them in goodcondition to be installed when the pump will be operated again.The fluid end assembly for triplex pumps consists of 3 forged fluid cylinder blocks, liner, valvepot cover and cylinder head cover, suction and discharge manifold etc.a.

10 Daily maintenances of PumpTo maintain the pump properly is a necessary measure to ensure the pump is working correctlyand extend its service life. Importance should be attached to this key task during operation.10.1 Daily maintenances10.1.1 Shut down the pump and check oil level at power end. Check once each day; if the pump isdriven by chain transmission the oil level in chain reservoir should also be checked. Duringoperation, the lube-oil pressure changes in the system shown on the oil pressure gauge should bechecked.10.1.2 Observe working status of the cylinder liner and piston; if a little bit mud-leakage is foundit is normal, but if mud leaked is excessive the piston needs to be replaced and the cylinder linerwear should also be carefully checked. If excessive wear is found replace the liner.10.1.3 Check the liner cavity of the frame and wash out the accumulated mud10.1.4 Check the cooling water quantity in the spray pump water tank. Replenish and replace thecontaminated cooling water if necessary

10.4 Maintenances every year10.4.1 Check the tightness of the crosshead guide and running clearance up to the requirements ornot, if not it could be adjusted by adding shims under the guide. If the crankshaft assembly isremoved for any reason it is recommended to rotate the crossheads 180for use again.10.4.2 It is recommended to inspect the pump fully every two or three years; check the wear anddamage status of the main bearings, eccentric bearings, crosshead and pinion bearings. Replacewith new if excessive wear on the old parts.10.4.3 Check all gears wear, if severely worn out in one face, the crankshaft and pinion shaft maybe turned to use the gears other unworn face.

10.5 Other points for attention in maintenance10.5.1 Wipe the 25taper face clean before installing the piston and extension rod clamps.10.5.2 While replacing the cylinder liner the liner seal rings must be replaced together.10.5.3 The pump was shut down or temporarily be shut down for more than 10 days.10.5.4 Close all inspection covers well to prevent the oil from being contaminated by sand or dirt.10.5.5 The pulsation dampener will be charged only with compressed nitrogen or other inert gases.- 50 -

12.1 If a mud-pump will not be used for a long period, it should be mothballed.12.2 Before mothballing, all fluids in the fluid end should be drained out, remove all dirt, washwith water and wipe clean. Coat all machined surfaces of all parts and components in the fluid endwith grease.12.3 Drain out all lube- oils in power end oil reservoir, crosshead guide at two sides, oil-settlingchamber and remove all accumulated dirt.12.4 Coat all machined surfaces on all bearings, crosshead, gears, piston rod, extension rod etcwith heavy oil.12.5 Block all suction and discharge flanges with blind plates.12.6 Seal all crosshead hole end cover, back cover, inspection-opening cover etc tightly.

abstractNote = {Based on extensive research, development, and field testing of mud pumps and accessory equipment, this book offers cost-saving methods in operation and maintenance of triplex and duplex pumps. It covers practical engineering concerns such as pressure losses from friction in the piping and inertia in the drilling mud; suction dampeners in pump operation; charging the suction pipe for greater efficiency and smoother operation; hydraulic and mechanical knocking; hydraulic pressure losses; discharge lines.},

SCOPE This specification covers the preservation and storage procedure for shipment of new-build NOV Triplex Mud Pumps shipped from the manufacturing plant. This specification is intended to provide preservation of new-build NOV Triplex Mud Pumps for six (6) months from the shipment of the mud pump from the manufacturing facility. If a pump is to be stored for a period of time exceeding six (6) months, additional precautions should be taken as outlined in this specification. National Oilwell Varco recommends that all pumps are inspected for any signs of corrosion and for proper preservation at a minimum every three (3) months for pumps stored outside and every six (6) months for pumps stored indoors. Sub-tier: National Oilwell PS-3081

MANUFACTURING PLANT PRESERVATION PRIOR TO PAINT Drain all water and clean out liner wash tank. Remove drain plug in bottom of liner wash pump and drain water then reinstall plug. Remove discharge flange from liner wash pump and pour one (1) pint of inhibiting oil-based concentrate (Cortec VpCI 329 Vapor Corrosion Inhibiting oil-based concentrate or equivalent) into liner wash pump. Rotate two (2) revolutions by hand to distribute the product. Re-install discharge flange. Drain all oil from pump power end sump and remove crosshead covers and inspection covers. Clean out oil sump as per National Oilwell PS-3081 (Mud Pump Cleanliness). Spray all internal machined parts of power end and crosshead area with inhibiting oil-based concentrate (Cortec VpCI 329 Vapor Corrosion Inhibiting oil-based concentrate or equivalent). Rotate pump ½ turn and re-spray. Pour quantity of inhibiting oil-based concentrate specified in the table below into power end sump. Mud Pump Models

For pumps equipped with chain drives, spray internal machined parts inside chain cases with inhibiting oil-based concentrate (Cortec VpCI 329 Vapor Corrosion Inhibiting oil based concentrate or equivalent).

MANUFACTURING PLANT PRESERVATION AFTER PAINT Remove breather and pack with loose parts for later shipment with pump. Seal breather hole with a greased solid plug. Affix a warning label near the breather opening (see Exhibit 1). Spray all external unpainted machined parts of pump with rust preventative (CRC SP400 or equivalent). Cover large diameter pipe and other openings with hardboard and protective plastic wrap. Liner bushing openings shall also be covered and sealed. Seal all other pipe work (air, water, and electrical) with plastic caps of the correct size and style. Electrical J-boxes are to be encased in protective plastic wrap. Place two (2) onepound bags of desiccant inside each J-box before sealing with tape. Wrap pressure gauges with bubble paper and plastic. Tape or band down loose hinged guards and inspection covers. Spray all machined unpainted loose parts and expendables to be shipped with pump with rust preventative (CRC SP400 or equivalent). All parts will be wrapped or boxed to prevent damage. Affix one (1) warning label (see Exhibit 2) to the power end pump cover and one (1) warning label on the fluid end assembly of the pump. Affix warning labels on each loose part container. In cases where the equipment will be boxed at an offsite export packer, a sufficient number of warning labels will be supplied with the shipment.

STORAGE AT MANUFACTURING PLANT OR FINAL DESTINATION Indoor storage is preferred whenever possible; but if outside storage is required, ensure pump is stored away from salt water spray, sand blast or other adverse conditions. It is highly recommended that ship loose parts be stored indoors to eliminate conditions that promote condensation and direct sources of moisture. It is also recommended to store pump on blocks and cover entire pump with plastic sheeting.

PRESERVATION PROCEDURE WHEN STORAGE EXCEEDS SIX (6) MONTHS OF INITIAL PRESERVATION. Note: It is recommended that inspections be carried out on six (6) month cycles when pumps are in indoors and three (3) month cycles when stored outside. Remove plastic sheeting. Remove side crosshead covers and top inspection covers and inspect for any internal corrosion. Correct any adverse conditions. Replenish rust inhibitor to quantities previously listed. Rotate pinion shaft five (5) revolutions using supplied tool. Inspect for condition of external protection (rust preventative and paint). adverse conditions.

START-UP AFTER STORAGE Any pump that has been in storage will need a thorough inspection prior to start-up to insure it has not been damaged in any way and that all parts are properly in place. Failure to observe the following points can result in serious damage. Before servicing the pump, the power end sump and chain drives housings will need to be drained of any inhibiting additive. The Cortec brand products used for preservation are compatible with all lubricating oils and need not be totally removed when putting equipment into service. To service the Power End after storage and prior to start-up, remove all covers and thoroughly clean and inspect all of the parts and finished surfaces. Check all of the bearings to make certain they are clean and in good condition. Fill the power end with clean EP oil of the proper viscosity to the proper level. Make sure oil is poured into the oil distribution trough and is worked into all of the bearings. Replace all covers and install breather. To service the Fluid End after storage and prior to start-up, remove covers and thoroughly clean and inspect inside of the fluid end cylinders. Properly install valves, pistons, liners and all other fluid end parts. Carefully tighten all bolts, nuts, studs and working connections to specified torque requirements.

Pre-Start Up Requirements..................................................................................... 1. Power End.................................................................................................. 2. Main Electric Drive Motors……………………………………………… 3. Auxiliary A/C Motors……………………………………………………. 4. Instrumentation........................................................................................... 5. Liner Wash System..................................................................................... 6. Fluid End.................................................................................................... 7. Suction Dampener/Desurger....................................................................... 8. Pulsation Dampener.................................................................................... 9. Pressure Gauge............................................................................................ 10. Reset Relief Valve....................................................................................... 11. Discharge Strainer………………………………………………………… 12. Mud Pump Drive Assembly………………………………………………. a. Belt Drive Units…………………………………………………… b. Chain Drive Units………………………………………………….

INITIAL STARTUP PROCEDURES GENERAL: The initial startup procedures are written to assist the operator in preparing the pump packages for normal operation. The startup procedures are separated into two categories: Part I: Pre-Commissioning, and Part II: Commissioning Procedures. It is suggested that a copy of these pages be made for each pump to be used as a check-off sheet.

Reservoir Capacity: 100 US Gallons (379 Liters) Note: The rust preventative on the internal surfaces of the pump is oil-soluble and is compatible with the lubricants recommended above. It is not necessary to flush and drain unless the preservative has become contaminated (water, sand etc.). b. Oil Filters: Assure that the oil filters in the power end reservoir and external oil pump system are clean. 2. Main Electric Drive Motors:     

Clean liner wash tank, if needed, and fill with fresh clean water. Ensure that supply hoses and spray nipples are installed correctly. Start pump and adjust regulating valve to maximum flow without splash onto the extension rods.

NOTE: When charging the bladder, make sure that the mud pump suction line valve has been closed and that all pressure has been bled off of the suction manifold surrounding the suction desurger  

If a dampener is used, charge dampener with a hand-operated air pump to 10 PSI (0.7 bar). Once pump operations have been started, check the operation of the suction dampener by inspecting the sight glass. Add or release air pressure through the Shraeder valve to keep the diaphragm between the midpoint and the bottom of the sight glass.

Check the installation and the setting. NO SHUT-OFF VALVE is to be between the pump discharge and the relief valve. Ensure that piping from the discharge port goes directly to the mud tank/pit and is securely tied down, with a minimum downward slope of 1/4” per foot. Ensure that piping has pressure rating equal to the relief valve highest setting.

Check the chain guards to ensure that the chains will not drag on the guard. Check the oil pump to ensure that the relief valve is installed on the suction side. Start the pump and ensure that the spray nozzles are spraying oil over the full width of the chain. Adjust the relief valve to 15-25 PSI output with the warm oil.

PART II. COMMISSIONING PROCEDURES: GENERAL: The power end and the fluid end have gone through rigorous tests prior to being shipped from the manufacturing site; therefore, the following recommendations for the commissioning test are made for the purpose of checking the overall unitization functions, including instrumentation, and to assure that there are no problems which may have occurred during transportation and storage. Operation of the pump in parallel to check the SCR-Motor assignments and controls, volumetric displacement and mudline systems are at the option of the purchaser. A. PRE-COMMISSIONING CHECKS: Prior to starting the unitized pump package, review the previously outlined Pre-Commissioning Requirements in Part I. Check the discharge mudline to assure that all necessary valves are open. Ensure that the mud tanks are full of test fluid (mud/water) prior to startup. Make the desired assignment of the SCR-Motor Control System to the pump motors, and open the throttle slightly. Check to ensure that charge pump and liner wash motors have started. If no immediate problems are encountered, slowly throttle the pump to approximately 60 SPM and continue operating the mud pump while making the following inspections to assure that all systems are working properly: 1) Power End Lubrication: Check oil pressure:

5) Visually inspect the mud pump drive assembly for any unusual conditions, i.e. loose bolts, vibration, noise, etc. 6) Check the performance of the supercharging system:   

Check the valve for proper relief setting. The valve should be set 10% above the pressure rating for the liner size being used. Refer to the nameplates on each side of the pump or the pump datasheet to obtain the operating pressure for that particular size liner.

B. COMMISSIONING OPERATIONAL TEST: DURATION: EIGHT (8) HOURS TOTAL RUNNING TIME. The following are basic guidelines for conducting of an eight (8) hour operational test. The pump was test run under pressure in the manufacturing plant but with different motors and drives. The discharge pressure can be regulated by temporarily installing an adjustable choke at some point in the discharge line. NOTE: There can be short intervals of shut-down time to fix leaks, make adjustments, etc., without having to restart the test program. 1. LOWER PRESSURE TEST – DURATION: TWO (2) HOURS: TIME START STOP 0-500 PSI (0.34-34.5 bar)…………………40 min. @ 40 SPM

C. INSPECTIONS/CHECK-OFFS DURING TEST PROGRAM: The overall performance of the unitized pump package should be continuously monitored during the eight hour test program. The following checks should be made and recorded each two hours of operation. START

INSTALLATION OF NEW PUMP Your National Oilwell Varco pump has been completely assembled and test operated under pressure before being shipped to the field. Unless otherwise instructed, the lubrication is drained from the power end and the expendable parts are removed from the fluid end. Before putting the pump into service, the following precautions and operations must be performed or checked. In order to prevent personal injury during the performance of any maintenance or inspection procedures, this equipment MUST BE SHUT DOWN AND NOT OPERATING, and all safety devices on prime movers, drives, etc., MUST BE IN THE SAFE POSITION.

SETTING THE PUMP The skids under the National Oilwell Varco pumps are suitable for most any type of installation. It should be noted, however, that the box type construction of the power frame has high resistance to bending but relatively less resistance against twist. Therefore, the support under the pump must be level and adequate to support the weight and operating forces exerted by the pump.

Land Installations In land installations, a mat of 3” X 12” (76.20 mm x 304.8 mm) boards laid side crosswise to the pump skids for the entire length, or at a minimum, at the points indicated in Fig. 2, is usually sufficient. The boards should be a few feet wider than the width of the pump skid runners. Wet or marshy locations may require a more stable foundation.

Fig. 2 Suitable means, such as National Oilwell Varco pump spacers as shown in Fig. 3, should be used to keep the pump anchored and the drive in alignment. National Oilwell Varco mud pump spacers provide 8-1/2” (215.9mm) adjustment. Any desired length may be obtained by lengthening the standard pipe spacer, which is made of 3” (76.20mm) extra strong pipe. Three types of attaching heads are available with this spacer:

2.1.1 Permanent Installations On permanent installations such as barge, platform, structural base, or concrete slab, where pump skids are bolted down, it is essential that the skids be properly shimmed to prevent possibility of twisting or distorting the power frame. The pump skids must sit solid on all shim points with bolts loose. On barge installations, the pump skids are generally bolted down to T-beams running parallel and in line with the pump skids. Install shims at points shown in Figs. 2 and 4 and observe caution of proper shimming to prevent twist or distortion. The shims on all installations should extend the full width of the skid beam flanges and have a minimum length of 12” (305mm). On installations where the power unit or electric motor is mounted integrally with the pump skids, the preferred installation would be to set the pump package on the T-beam skids and provide retention blocks rather than bolts to hold it in place. This will allow the pump to “float” and minimize the transfer of barge deck or platform distortion into the frame. 2.1.2 Installation of the Drive The drive between the mud pumps and the power source, whether V-belts or multi-width chains, should be installed with the greatest care to assure maximum operating life with minimum of unexpected or undesirable shutdowns due to drive failures. When installing the drive sheave or sprocket, make sure all grease or rust preventative is removed from the shaft and the bore of the drive. Remove all burrs or rough spots from the shaft, key, and keyway. Fit key to the keyways in both the shaft and drive and install key into shaft keyway. Coat pinion shaft with a light coating of anti-seize compound or light oil and install the drive sheave or sprocket hub. Tighten hub bolts as indicated below:

Adjust V-belts for proper tension. Adjust the belt tension by moving the sheaves apart until all of the sag has just been eliminated from the tight side of the belt and some of the belts on the slack side. Then increase the centers approximately ½” (13mm) for each 100” (2540 mm) center distance. Example: On 150” (3810 mm) center, move pump an additional ¾” (19.5 mm).

DO NOT OBTAIN BELT TENSION BY PICKING UP END OF PUMP AND ALLOWING BELTS TO TIGHTEN UNDER WEIGHT OF PUMP AS END IS BEING LOWERED TO THE GROUND. 2.1.2.2 Chain Drives a. Installation Proper installation and maintenance of the sprocket and chain drives are essential if good service life is to be obtained. Since many factors, such as chain width, center distances, speeds, and loads must be considered when determining the allowable tolerance for sprocket alignment, no good “rule of thumb” can be applied. The chain alignment must simply be held as nearly perfect as possible. A more precise alignment can be made by stretching two steel wires (piano wire) along one face of the two sprockets, one above and one below the centerline, and moving one of the sprockets until the wires touch at four points. This will determine that the centerlines of the drives are parallel and the faces of the sprockets are square. b.

Drive chain lubrication The pump drive chain lubrication system on the majority of National Oilwell Varco pumps is an independent system having its own oil pump, reservoir, and drive. Fill chain case to the indicated level with a non-detergent oil as follows: Ambient temperature above 32°F (0°C) SAE-30 Ambient temperature below 32°F (0°C) SAE-20 For temperatures below 0°F, consult a reputable lubrication dealer for recommendations. REFER TO GENERAL LUBRICATION BULLETIN for approved lubricants and additional specifications. If any discrepancy exists between the recommendations in this manual and the General Lubrication Bullletin, those in the Lubrication Bulletin will take precedence. Since this is an independent system, it will require the same maintenance or service attention employed on any other piece of machinery, including: - Daily check of oil level. - Daily check on condition of oil. - Frequent check on oil pressure. (5-15 psi) (.352 - 1.06 kg/cm²) - Volume of oil being applied to chain. - Condition of nozzles in spray tube. - Condition of oil pump drive (V-belts or chain)

NOTE: Oil pressure may be adjusted with the pressure relief adjusting screw on the rear of the pump housing. Pressure drops may also indicate suction and discharge filter screens need cleaning. 3

SUCTION SYSTEM REQUIREMENTS Individual installation conditions will dictate the design of the suction system. The suction of the FD-series pumps must have a positive head (pressure) for satisfactory performance. The optimum suction manifold pressure is 20-30 psi (1.75-2 kg/cm²) for maximum volumetric efficiency and expendable parts life. This head pressure is best supplied by a 5 x 6 centrifugal pump with 40 h.p. 1150 rpm electric motor. This type of drive requires a device to automatically start and stop the centrifugal pump motor simultaneously with the triplex pump. On DC electric powered rigs a signal can usually be supplied from the DC control panel to energize a magnetic starter when the mud pump clutch air line will provide a set of contacts for energizing the magnetic starter when clutch is engaged. The charging pump can also be belt driven from the triplex pinion shaft charging type of drive is not as efficient at slow speeds with viscous fluids. Under some conditions the FD-Series pumps may be operated without a charging pump, provided the fluid level in mud pits is higher than the top of the liners, fluid being pumped is low viscosity and suction line must be short, straight and of at least the same diameter as suction manifold inlet. The suction lines should be piped with valve arrangements so the charging pump can be by-passed so operation can be continued in event of charging pump failure or for maintenance. Operation without a charging pump can be improved by replacing the suction valve springs with a weaker spring. Suction desurgers are a very effective aid for complete filling of the liners and dampening pulsations in the suction line which results in a smoother flow in the discharge line. If your pump is equipped with a suction desurger it must be pre-charged with compressed air before operations are begun. See suction desurger manual for charging instructions.

Caution Do not pipe the return line from the shear relief valve back into the suction system as a relief valve operation will cause a sudden pressure rise in the system vastly greater than the system pressure ratings, resulting in damage to manifold, suction desurger and centrifugal pump.

PREPARATION OF POWER END Your National Oilwell Varco pump has been completely assembled and test operated before being shipped to the field. Unless otherwise instructed, the lubrication is drained from the power end, and the expendables are removed from the fluid end for storage protection. Before operating the pump, the following must be performed or checked:

Power End Lubrication Before installing lubricant, open inspection door in cover and check oil reservoir for possible accumulation of condensation, etc., and drain and flush by removing the pipe plugs on each side of the pump. Add the proper type and quantity of lubrication in the power end. Refer to the Lubrication Section of this manual, or lubrication plate on pump frame for type and quantity required. Recheck oil level after pump has operated for a period of 15 minutes. Shut pump down and allow approximately five minutes for the oil level to equalize. Check at oil level gauge, Item 1, Fig. 1. It is usually necessary for a few more gallons of oil to be added due to a certain amount being retained in the crosshead area and frame cavities.

With reference to Figure 5, remove the diaphragm stuffing box and plate (1) and rotate pump so that crosshead is at the front of the stroke. Thoroughly clean the front of the crosshead and the face of the crosshead extension rod. Insert alignment boss on crosshead extension rod into the crosshead bore and tighten the retainer bolts (2) to the following torque. Safety wire bolt heads. FD-500 50-60 ft. lbs. (7-8 meter kgs) FD-800 80-100 ft. lbs. (11-14mkgs.) FD-1000 350-370 ft. lbs. (48-51 meter kgs) FD-1600 350-370 ft. lbs. (48-51mkgs.) Thoroughly clean face of power frame and diaphragm stuffing box plate at Position “A”. Install gasket (3) and capscrews (10). Tighten capscrews as follows: FD-500 12-14 ft. lbs. (1.7 - 1.9 meter kgs)

Two types of piston and liner cooling systems have been used on National Oilwell Varco FD-Series Pumps -- the stationary spray type and a moving nozzle type. Ref. Fig. 6. The manifold (1) for supplying cooling fluid to the piston and liner assemblies is identical on both systems. Cooling fluid from either a remote source such as a water line, or from a pump and reservoir system unitized on the pump skids (Ref. Fig. 7) must be piped into the manifold at the connection located in the pump frame under the crosshead extension rod section. CAUTION:

With reference to Fig. 7, maintain electric motor (1) and centrifugal pump (2) according to manufacturer’s specifications. Rotation of the pump should be clockwise when viewed from the impeller end. Adjust regulating valve (3) to apply as much water as possible to the liners without splashing back on the crosshead extension rods and diaphragm stuffing box plate. 10gallons per minute per liner is the preferred flow rate. If water is allowed to splash on the crosshead extension rods, some of the water may work back into the power end to contaminate the lubrication oil.

Liner Cage and Lower Valve Guide Install rear liner seal (5) and push into position against liner shoulder. Slide liner cage (6) into fluid end, align one hole in the cage with lower valve pot bore. Set lower valve guide (8) over valve stem through lower hole in cage with the wings on the guide turned crosswise to the pump. Press down on the guide, compressing the valve spring (7) until the guide can be rotated ¼ turn and seat into place underneath the cage. Insert the lower valve guide locking clip (9) through the pad eyes on the lower valve guide and rotate clip to the right to lock the valve guide tight against the OD of the liner cage. It may sometimes be necessary to put more or less bend in the center of the clip to make it retain the guide tightly while the clip handle snaps into position on the right hand side.

Cylinder head Insert the outer seal (5) in the fluid end bore against the liner cage. Slide the cylinder head plug (10) into fluid end. Apply a liberal coat of grease to both mating thread surfaces of the cylinder head (2). Screw cylinder head in and tighten with wrench furnished with pump and sledge hammer. Fluid leakage through the weep hole will indicate a defective seal or loose cylinder head. DO NOT plug weep holes as this can result in severe damage to cylinder head threads, thread rings, etc., in event of a liner seal failure.

Figure 9B A cross section through the fluid end is shown in fig. 9B. With reference to fig. 9B thoroughly clean and assemble the fluid end parts in the following manner: Note: All of the parts in this fluid end assembly are designed with metal to metal seating to alleviate friction wear from breathing action encountered in modern high pressure pump operation. For this reason it is essential that all parts be clean and free of rust, nicks and burrs before being assembled.

Liner Install wear plate seal (1) in counterbore of fluid end. Slide wear plate (2) over studs until it seats against fluid end. Slide liner thread ring (3) over studs with the starting thread at the 5 o’clock position and tighten nuts to 470-510 ft. lbs. (65-70 m/kgs.) torque. Note: Placing the starting thread at 5 o’clock position makes engaging the liner lock threads much easier. Place liner seal (4) in counterbore of wear plate. Apply thin coat of grease to ID of liner lock (5) and slide over rear of liner (6). Install two-piece liner lock ring (7) in liner groove and “O” ring to hold them in position. Slide liner handling tool over liner up against liner lock ring and tighten set screw to secure it in place. Hoist liner assembly into position with jib hoist. Note: FD pumps are factory equipped with jib booms and liner handling tools. If older pumps are converted to FD fluid ends a jib boom should be added to the pump frame as considerable weight is involved in handling the liner assembly. Apply liberal coat of grease to liner lock threads. Align the starting thread of the liner lock (5) to the 7 o’clock position and insert the liner into the liner thread ring (3) screw liner lock in until liner seats in position . Tighten with sledge hammer on hammer lugs.

Suction Flange The suction flange has a 12” (305mm) standard pipe thread connection and is custom made to match the companion flange on the pump suction manifold. The flange connection is sealed off by an O-ring seal (14” OD x 13-1/2” ID x ¼ “), (356mm OD x 343mm I.D. x 6.35mm Dia.) NOTE: Thoroughly clean O-ring groove and face of flanges before making up connection. Flanges must make up metal to metal to insure proper seal. Tighten flange bolts to 360490 ft. lbs. (50-68 meter kgs.) torque. CAUTION: If suction pipe is welded to suction flange, remove O-ring prior to welding.

Accessory Manifold Fig. 10 is not the standard discharge arrangement on the model FD-1600 pump, which uses the strainer cross configuration. An accessory manifold, Fig.10, is available for installation on the discharge manifold opposite the discharge end. The manifold will accommodate a discharge pulsation dampener (1) and provides two 3”-6000 PSI*side outlet connections for such items as a pressure gauge (2) and a shear relief valve (3). When manifold is used, install and maintain as follows:

The flange on the accessory manifold is a 5”-1500 *RTJ. Thoroughly clean ring joint groove, install ring (4) and tighten the flange bolts (5) to 1200 ft. lbs. torque. To assure uniform make-up of the ring joint connection, tighten the nuts in a criss-cross order. The shear relief valve (3) is installed on the discharge manifold for the purpose of protecting the pump from excessively high pressure overloads. The relief valve must be installed so that it will be directly exposed to the mud. DO NOT PUT ANY TYPE OF SHUT OFF VALVE between the relief valve and the manifold. Pipe the discharge side of the relief valve directly into the mud pit with as few turns in the line as possible. IT IS NOT RECOMMENDED for the discharge side of the valve to be piped into the suction line of the pump. * 5” -

3” - 6000 PSI = two 76.2mm - 422 kg/cm² The relief valve setting should be just above the maximum pressure rating of the particular liner size being used. CHANGE SETTINGS with each liner size change. DO NOT USE ALLEN WRENCHES, WELDING RODS, or material other than that called for by the manufacturer of the relief valve, as this will affect the rating of the relief valve. The mounting for the dischage pulsation dampener (1) is a RTJ flange with R-39 ring gasket. Before installing dampener, thoroughly clean ring groove and ring, and after setting damp