mud pump handbook pdf quotation

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 dampener into place, tighten the 1-1/4”*nut (6) to 750 ft.lbs*. torque. To insure uniform make-up, tighten nuts in a criss-cross order. Precharge dampener before starting up pump. Precharge pressure should not be more than 2/3 of the pump discharge pressure, or a maximum of 650 PSI. (46 kg/cm²) CAUTION: USE ONLY COMPRESSED NITROGEN OR AIR. DO NOT CHARGE WITH OXYGEN. * 1-1/4” = 32mm 750 ft. lbs. = 104 meter kgs 9

LUBRICATION Proper lubrication of the moving parts in any piece of machinery is the most important single factor affecting its ultimate life. To obtain maximum trouble-free service life from the power end of the National Oilwell Varco pump, it is necessary to perform routine maintenance care and inspections to insure the proper amount of CLEAN lubricant is being provided.

The FD-Series pumps utilize the controlled flow oil bath splash and pressure system to lubricate the entire power end. The type of pressure system provided in each individual pump will govern the minimum SPM at which the pump can be operated, i.e. pumps which have pressure lubrication only to the main and pinion bearings, have a minimum rated speed of 40 SPM. Pumps in which pressure lubrication is provided to the main, pinion, and crosshead bearings and crosshead compartments may be operated at a minimum speed of 25 SPM, provided there is a minimum of 5 PSI oil pressure. (352 grams/cm²) 9.1

Minimum Operating Speeds The minimum speed for all pumps is 40 SPM. CAUTION: The pressure lubricating system can be provided with an externally mounted oil pump driven through V-belts or electric AC motor; or an internally mounted oil pump driven from the main gear. When an internally mounted oil pump is used, the direction of rotation of the pinion shaft must be as shown in Fig. 11.

Controlled Flow Splash System The controlled flow splash lubrication system is the same for all FD-Series pumps, regardless of the type of oil pump drive provided for the pressure system. In the controlled flow splash system, the main gear picks oil up from the reservoir, and when the teeth mesh with the pinion, the oil is displaced into various troughs and compartments in the frame. With reference to Figure 13, the oil thrown into trough (7) is directed through the oil tube (8) to the two pinion bearings. Oil passage from the top of the crosshead guide compartment to the crosshead bearing is shown in Figure 12. Oil accumulates in the compartment over the crossheads. The oil runs through the nipple (6) into the crosshead retainer to the oil passages (5) and on to the crosshead pin bearing. As noted, the duplicate set of passageways (5) in the crosshead pin permits the crosshead pins to be rotated without having to give attention to hole alignment. This permits the installation of crosshead pins from either direction.

Total Pressure lubrication System The total pressure lubrication system, incorporating the internally mounted oil pump for the FD-series pumps, is shown in Figure 13.

In this system, filtered oil is supplied to the pump through the suction filter (1) and is discharged from the pump into the manifold block (2). Oil is distributed from the manifold block to the pinion shaft bearing oil line (3) and spray nozzle (3A); and to the main bearing oil line (4) and the crosshead compartment manifold block (4A) located above the crosshead compartment. The crosshead compartment manifold block (4A) distributes oil to the crosshead, crosshead bearings, and extension rods. Pumps which do not have the crosshead compartment manifold block (4A) do not have the total pressure lubrication system, and therefore have a minimum rated speed of 40 SPM.

A pressure gauge (5) is mounted on the back wall of the frame to show oil pressure being maintained in the manifold block. The oil pressure will, of course, vary with the speed of the main pump, however if a sudden pressure drop or increase occurs, refer to the section on maintenance of lubrication system for possible cause. A pressure relief valve (6) is mounted to the manifold block to keep excess pressure form damaging oil pump and drive. The relief valve is preset at 40 PSI and must not be tampered with. NOTE: If specified, the oil pump for the pressure lubrication system can be independently powered by an electric motor or some other type of prime mover. When the independently driven oil pump is used, some type of alarm device or power interlock must be installed to assure the oil pump is operating when the main pump is put into service. When installing the internally mounted oil pump (9, Fig. 13), position pump so that the back face of the drive gear is flush and parallel with the edge of the main gear, and gear teeth have*.010-.015 backlash. Remove inspection plate on power end cover for access to the internally mounted oil pump and filter screen. (* .25 - .38mm)

A typical layout for the pinion shaft driven oil pump is shown in Fig. 14. The oil pump (1) is piped into the oil system through the suction and pressure connections on the bottom inside wall of the power frame. Ref. Item 10, Fig. 13. The V-belt drive (2) is adjusted by moving pump up or down on the mounting bracket. Adjust the V-belt drive (2) to a point where the two halves of the belt can almost be “pinched” together between the thumb and fingers at the center of the drive. Overtightening can cause premature failure of the pump. When link type belting is used, caution should be exercised in predetermining belt elongation. Link type belting in A, B and C widths will elongate approximately 1” per foot (25mm per 305mm). When installing a drive, subtract 1” per foot from actual required length (132” required - install 121”) and stretch to fit. (Subtract 25mm/305mm) To prevent possible injury, always install guard (3, Fig. 14) over V-belts before putting pump into service. 10

MAINTENANCE OF THE LUBRICATION SYSTEM Adequate lubrication of the moving parts is, as stated, the most important single factor affecting the ultimate service life of the pump. CARE AND MAINTENANCE of the system is the sole responsibility of the operator or crew to which it has been assigned, and the extent to which this is applied will determine the amount of trouble-free service life that will be obtained. The lubricant recommendations shown below, on the name plate on the side of the pump, or in the General Lubrication Bulletin included with this manual, are the result of extensive field tests. Substitutions should be made only in extreme emergencies. 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 Bulletin, those in the Lubrication Bulletin will take precedence. Lubrication Specifications: Use extreme pressure, non-corrosive, anti-foaming gear lubricant as follows: Temperatures +30°F to 155°F (-1°C to 68°C) AGMA No. 6 EP Temperatures 0°F to 85°F (-18°C to 33°C) AGMA No. 4 EP (Consult lubrication manual) Oil reservoir capacity: FD-500 FD-1000

ONCE EACH TOUR, check and maintain oil level at the FULL mark on the bayonet gauge. PUMP MUST BE SHUT DOWN and allowed to stand idle for approximately five minutes to allow oil level to equalize. ONCE EACH SIX MONTHS, or more often if oil becomes contaminated with abrasive particles or corrosive compounds, drain and flush the oil reservoir and refill with new lubricant. Oil drains are located on either side of the pump frame. During the flushing procedure, thoroughly clean the oil troughs and the compartment in top of the crosshead guide. Also clean or replace the filter element in the air breather cap and clean suction screen. Remove covers from settling chamber and purge out contaminants before adding new oil. Routine inspection on condition of oil should be made as condensation of moisture in the air, intrusion of mud, water or dirt, can necessitate a more frequent oil change. A settling chamber is located in the forward area of the power end floor. Contamination in the oil splashed into this area is allowed to settle out and should be drained out of the pump through the clean out covers located on the frame wall underneath the crosshead inspection doors. Once each month, remove clean out covers on both sides of pump to drain contaminated oil from settling chamber. Approximately 15-gallons of oil will be lost; replenish the main reservoir to compensate for the amount drained out. Once each week, remove one of the lower ½” capscrews that secure the clean out cover to the frame to drain off water condensate. ONCE EACH TOUR, check oil level in main reservoir. Maintain at full mark on dipstick to the manifold block. If loss of pressure occurs, check for: - Clogged suction screen - Low oil level - Slipping V-belt drive - Broken or loose connections - Damaged or worn oil pump - Defective Relief Valve For an abnormal increase in oil pressure, check for: - Plugged oil lines - Contamination causing oil to be viscous - Relief valve inoperative - Defective gauge - Other conditions www.nov.com

2. Safety wires Check safety wires on all bolts including the main bearing hold-down bolts, eccentric bearing retainer bolts, and gear retainer bolts. Replace any broken wires after retightening the bolts. Refer to crankshaft assembly section for bolt torque requirements. 3. Oil lines Check all oil lines to insure they are intact and free of obstructions. Check oil pump suction hose for damage or flat areas. 4. Suction filter Check condition of suction filter. Clean and replace as required. 5. Main bearing cover Remove the main bearing cover and check tightness of main bearing retainer bolts, condition of the bearing rollers, etc. Clean and remove any sludge or foreign substance that might have accumulated at the bottom of the bearing area. 6. Main gear and pinion teeth Inspect the condition of the main gear teeth and pinion gear teeth for any indications of abnormal wear. During the initial break-in period there will be some pitting on the face of the gear teeth. This is referred to as “initial pitting” and is not harmful to the life of the gear. However, if routine inspection indicates the degree of pitting continues to increase, immediately contact the local representative of the pump manufacturer for a more thorough inspection of the gear. www.nov.com

Roller Bearings Although the basic construction of the various sizes of National Oilwell Varco pumps varies somewhat, they all have one very important detail in common -- roller bearings. A roller bearing is a precisely built machine within itself; therefore, careful handling is required in order to obtain the long service life and high load carrying characteristics associated with anti-friction bearings. The main bearings are self-aligning spherical roller bearings. The pinion shaft is mounted on straight roller bearings. The eccentric bearings are straight roller with thrust plates on each side to keep the eccentric straps in line, and the crosshead pin bearings are straight needle roller bearings. None of the bearings require special adjustments. All inner and outer races are assembled by means of very accurate fits. This accuracy is necessary; therefore, if the bearings are to be used again, the inner and outer races and the roller assemblies of each bearing must be kept together, and reinstalled exactly as they came off.

The running clearances of the bearings are predetermined by their precision fit to the shaft and the bearing carrier. When performing maintenance or overhaul, make sure the fits shown in Chart I are obtained. When installing the pinion shaft assembly in the pump, observe the following precautions: a. Insure pinion bearing carrier gasket (1) and oil seal carrier gasket (2) are in place and in good condition. b. The pinion bearing carrier (3) and the oil seal carrier (4) have the word “TOP” cast in the face of the flange. MAKE SURE THE CARRIERS ARE INSTALLED WITH THIS MARK AT THE TOP to correctly position oil troughs and align drain holes. c. Remove burrs, dents or gouges from the OD of the oil seal spacer (5) before sliding oil seal carrier (4) into place. Exercise care when sliding lip of seal over end of shaft to prevent it from being damaged by the sharp edge of the keyway. Also pay particular attention to insure oil seal lip IS NOT TURNED UNDER by edge of spacer when sliding seal onto the spacer. d. Tighten pinion bearing carrier bolts (6) to the approximate torque shown below: FD-500 100-125 ft. lbs. (14-17 m/kgs.) FD-1000 80-160 ft. lbs. (11-22 m/kgs.)

Set crankshaft on a set of rollers (at main bearing position) and check runout on face of gear with a dial indicator. If total indicator runout exceeds .006”, remove gear and determine cause of misalignment. (.15mm) NOTE: If runout on face of gear is checked while crankshaft is mounted in the pump frame, the running clearance in main bearings will require that a simultaneous set of dial indicator readings be taken at the end of the shaft and the face of the gear; the actual face runout at any point being the difference between these readings. b. Install the outer races of the eccentric bearings (13) and the outer race retainer ring (3) in the three eccentric straps. Outer race retainer ring must be positioned so that oil scoop is at the bottom when pump is at mid-stroke. Tighten retainer bolts (4) to the following torque; safety wire heads. FD-500 FD-1000

NOTE: Even though the main bearing carriers (10 RH and 11 LH) have different configurations on the OD, they are interchangeable and will fit into the pump frame on either side. The purpose of the shoulders on the OD of one of the carriers is to locate and retain the crankshaft in its respective position in the frame. www.nov.com

Installing Crankshaft Assembly in Frame In order to obtain a more precise fit between the main bearing housing and the frame bore on F-Series pumps, the installation procedures outlined below are to be followed: (Refer to Fig. 17) 1. Place piece of wood between eye of eccentric strap and crosshead guide (as shown in Fig. 18) to protect guide from scoring or gouging as the straps are sliding into position. 2. Rotate the main bearing carrier so that the two flat spots (180° apart) are parallel with the main bearing bolt holes, and slowly lower the crankshaft into position. (The flat spot provides clearance for the main bearing bolts.) 3. After placing crankshaft in the frame, and before installing the main bearing caps, check the rollers in the main bearings to assure that each row of rollers in each bearing is equally loaded. Equal loading is obtained by positioning the floating bearing carrier so that the same number of inner and outer rollers supporting the weight of the crankshaft in each bearing are tight. Because of tolerances, etc., the total number of tight rollers could vary slightly between individual bearings. 4. Install and shim main bearing caps to obtain .003” (.076 mm) clamp or preload on the main bearing carrier. This preload is obtained by placing the correct amount of shims under the main bearing cap. The required amount of shims is determined as follows:

Installation of Crosshead Guides When installing crosshead guides observe the following procedures and precautions: 1. Thoroughly clean all dirt or contamination and remove all burrs or rough edges from both sides of the guides and the frame bore where the guides fit. 2. If old guides are to be reused, inspect the wearing surfaces for wear and scoring streaks. Pumps with serial numbers below those shown have identical upper and lower crosshead guides which may be reversed to provide a smooth surface for the lower guide. Worn guides may be used at the top as forces on the crosshead are always downward.

Installation of Crossheads The crossheads in the pumps can be installed through the front (fluid end) or back end of the crosshead guide. Reference Fig. 19. When installing crossheads, observe the following precautions:

3. Install the left hand crosshead first. Rotate eccentric assembly to move “eye” into center crosshead and right hand eccentric strap “eye” back, affording clearance to install center pin through right hand crosshead inspection door. Remove diaphragm stuffing box plate (1, Fig. 19) and install right hand crosshead through this bore. Slide into place and install crosshead pin. * NOTE: If old crossheads are to be reused, inspect the sliding surfaces for wear or scoring. If necessary, the crossheads may be switched to opposite sides of the pump and rotated 180° to provide a smooth surface for the bottom of the crosshead. The center crosshead can be rotated 180° and the crosshead pin installed from the opposite side of pump. Slide crosshead pin into bore but do not seat on taper until the crosshead pin retainer (2) has been installed. 4. Install crosshead pin retainer (2) and retainer bolts (3) and rotate pin until the four crosshead retainer to crosshead bolt holes (4) are in alignment. Install the crosshead retainer to crosshead bolts (4) and make up hand tight. Referring back to fig.12, page B-2, crosshead pin (4) can be installed without regard to oil holes (5). Two holes are provided so the pin can be rotated 180° in relation to pin to retainer plate screws (3). Seat crosshead pin in tapered bore by bumping large end with a light blow. Tighten retainer bolts (3 and 4, Fig. 19) to the following torque and safety wire: FD-500 FD-1000

Checking crosshead alignment To obtain optimum service life from the pistons and liners, the horizontal centerline of the crosshead extension rod must be positioned as near as possible to the center of the liner. To check and adjust the crosshead alignment, proceed as follows; 1. Remove diaphragm stuffing box from the diaphragm plate, (fig. 19). Do not remove the plate. 2. Position crosshead at mid point of stroke. With inside calipers or telescoping gauges and a micrometer, accurately measure the distance from the diaphragm plate bore to the crosshead extension rod at the top and bottom. Compare the two measurements to determine the position of the rod relative to the centerline of the bore. 3. If the top reading is more than .030” (.76mm) greater than the bottom measurement, shims should be inserted under the lower crosshead guide to bring the extension rod back to center, provided there is ample clearance between the top of crosshead and upper guide. Cut shims from steel shim stock long enough to reach completely across the guides. Cut tabs on the sides to bend down over frame supports to hold shims in place. Refer to items 3 and 4 under Installation of Crosshead guides. 4. Some older pumps were manufactured with large crosshead clearance which will cause a loud knocking noise under poor suction conditions. Specifications have been revised to .020” - .030” (.51 - .76 mm) clearance. After proper alignment has been obtained, the top guide should be shimmed down to provide the specified clearance.

FLUID END MAINTENANCE For many years, the fluid end of a pump was considered a non-wearing part which did not cause any concern other than possible infrequent repairs or replacements resulting from fluid cuts or washouts. However, the higher pressures of the present-day drilling requirements have resulted in higher stresses being imposed on the fluid end which , when combined with the corrosive characteristics of the drilling fluid, have resulted in the demand that more and better maintenance be given to the fluid end parts and pieces if a reasonable operating life is to be obtained.

A few of the obvious points are as follows: a. Make sure all valves on the discharge side of pump are opened before pump is put into operation. Kicking pump in against a closed valve can often be the start of a fatigue crack. An open crack may not necessarily occur at the precise moment, however a small crack could occur and start the process of “corrosion fatigue failure”. b. Do not engage pump clutch when prime mover is running at a high rate of speed. To do so can cause undesirable shock loads against both power end and fluid end. c. Properly maintain pressure relief valve to assure it is set for the pressure rating on the liner size being used. d. Do not operate the pump for an extended period of time if a severe fluid knock is present. The additional stress cycle, although of a lesser magnitude than normal operating loads, must be added to the total number of cycles when considering the fatigue life of the equipment. e. Properly prepare fluid end for storage. When pump is to be shut down or not operated for a period of ten days or more, it is recommended that the fluid end parts such as liners, pistons, rods, etc., be removed from the pump and the fluid end flushed out completely with fresh water. After a thorough flushing, apply grease or a rust preventative to all of the machined surfaces such as valve pot cover threads, valve pot cover gasket surfaces, valve seats, liner bores, etc. The parts removed from the pump including liners, piston rods, etc., should of course be protected from the elements. This will not only extend the life of the fluid end through resistance to corrosion, but will also protect the usable life still left in the expendable parts and maintain them in good condition for installation in the pump at the next start-up period. Maintenance and repairs should be made on the fluid end assembly by observing the following precautions. Refer to Figure 20. The fluid end assembly for these triplex pumps consists of three forged cylinder blocks, complete with valve pot covers and cylinder heads, a suction manifold, and a discharge manifold. 12.1

PRESSURE RELIEF VALVES ! Notice ! Our Technical Publications relative to reciprocating pumps, state that pressure relief valves must be installed in the discharge systems from these units. This supplement is issued to emphasize the importance of relieving the discharge system of all pressure which exceeds the rated working pressure applied by the manufacturer to the specific pistons and liners ( or plungers and packing) in any particular unit.

For the protection of persons and properly the discharge system form each Reciprocating Pump must be equipped with a device which relives the system of all pressures which exceed the pressure rating applied by the manufacturer to each particular piston or plunger diameter. Allowances will be made for pressure surges which are inherent with the reciprocating action of piston and plunger pumps. The percentage of pressure allowance appears later in this publication and the “Standards of the Hydraulic Institute” (13th Edition) The relieving device must provide for instantaneous pressure relief, it may be a valve designed for automatic or manual resetting; however, if preferred, rupture discs or burst may be installed. Failure to comply with the procedures outlined in the Warning may result in damage to the pump and related equipment and more importantly may cause serious bodily injury or death! 1.1

Location of the Relief Valve 1. The relief valve must be placed in the discharge line as close as possible to the pump fluid end or it may be mounted on the pump discharge manifold. 2.

Note: Follow the foregoing instructions if rupture discs or burst discs are installed. SUGGESTED SET PRESSURES FOR PUMP RELIEF VALVES Pump Type Operating Pump Pressure Double Acting – Duplex Piston Pressure Rating – Plus 25% Double Acting – Triplex Piston Pressure Rating – Plus 10% Double Acting – Quintuplex Piston Pressure Rating – Plus 10% Single Acting – Triplex Piston Pressure Rating – Plus 10% Single Acting – Simplex Plunger Pressure Rating – Plus 25% Single Acting – Duplex Plunger Pressure Rating – Plus 10% Single Acting – Triplex Plunger Pressure Rating – Plus 10% Single Acting – Quintuplex Plunger Pressure Rating – Plus 10% Single Acting – Septuplex Plunger Pressure Rating – Plus 10% Note: The above set pressures are to be observed when installing rupture discs or burst discs. www.nov.com

It is National Oilwell Varco’s recommendation to use a Molybdenum Disulfide oil additive with the Mud Pump Gear Oil during initial running and when signs of corrective (also known as “initial”) pitting are observed on Mud Pump gears. The oil additive will help to polish the gear tooth surfaces and in some cases, if used in the initial Mud Pump “wear-in” period, can reduce the amount of initial pitting common on Mud Pump gears. Moly oil additives such as Dow-Corning “Molykote M Gear Guard” (mixture 5% by volume) or TS-90 Moly Gear Concentrate have been used in this application with good results. The oil additive would need to be compatible with the mud pump seals and not adversely affect the oil filtration system. Using gear oil with Moly already included in the gear oil, like the Schaeffer “209A Gear Lube”, would assure the amount suspended in the oil is correct and it is thoroughly mixed. It is also extremely important to follow the National Oilwell Varco gear oil recommendations as seen in Table 1. The recommended gear oils have the film strength necessary to withstand the

Page 2 of 3 impact loading encountered in oilfield drilling operations. The results of not using the recommended gear oil may permit metal-to-metal contact of the gear teeth, which will be noticeable in the form of excessive pitting and wear on the load side of the gear teeth. Excessive pitting and wear can result in an increased risk of mud pump damage. National Oilwell Varco recommends that an ISO viscosity grade 460 oil be used during the “wear-in” period for all P-Series Mud Pumps. The duration of the “wear-in” period is considered the first 2000 hours of use but can vary depending on usage. After the “wear-in” period has been accomplished, the lubricating oil should be selected from the appropriate temperature range in Table 1 below: P‐SERIES MUD PUMPS  AGMA INDUSTRIAL EP GEAR OIL

Table 1. Mud Pump Lube Oils The Mud Pump bull gears may develop corrective pitting during the early stages of the product life. This corrective pitting process can be exaggerated by operating a Mud Pump for extended periods at high load, especially if the lube oil temperature exceeds 140°F (60°C). As a result of the corrective pitting process, small metal particles will be present in the lubrication oil. These metal particles normally accumulate on the power end magnets, in the lube oil filter, in the settling chamber and in the main sump. National Oilwell Varco recommends that the magnets, filter and sumps be checked regularly and maintained/cleaned as needed. It is further recommended that all commissioning and “endurance” tests be designed such that the pump speed and discharge pressure is gradually increased from the lower speeds and pressures to the higher ones. This is to allow the gears to wear in gradually and reduce the occurrence of excessive gear pitting.

FAILURE TO FOLLOW THESE RECOMMENDATIONS COULD RESULT IN CATASTROPHIC FAILURE OF THE PUMP WHICH MAY RESULT IN DEATH, BODILY INJURY AND/OR PROPERTY DAMAGE.

GENERAL REQUIREMENTS 3.2.1 Safety wire shall be new upon each application. 3.2.2 Parts shall be lockwired in such a manner that the lockwire shall be put in tension when the part tends to loosen. 3.2.3 The lockwire should always be installed and twisted so that the loop around the head stays down and does not tend to come up over bolt head and leave a slack loop. 3.2.4 Care shall be exercised when installing lockwire to ensure that it is tight but not over stressed. 3.2.5 Properly twisted lockwire will have 7-12 twists per inch for .032 wire and 6-8 turns for .052 wire. More twists will over stress the wire and cause fatigue and breakage. 3.2.6 A pigtail should be ½” to 5/8” in length (4-8 twists) at the end of the wiring. This pigtail shall be bent back or under to prevent it from becoming a snag. 3.2.7 As per the Machinery’s Handbook 27th edition the following rules apply: a) No more than three (3) bolts may be tied together. b) Bolt heads may be tied as shown only when the female thread receiver is captive.(see figure 1) c) Lockwire must fill a minimum of 50% of the drilled hole provided for the use of lockwire. d) Diameter of lockwire is determined by the thread size of the fastener to be lockwired. 1) Thread sizes of 6 mm (0.25 inch) and smaller use 0.508mm (0.020 inch) wire. 2) Thread sizes of 6 mm (0.25 inch) to 12 mm (0.5 inch) use 0.8128 mm (0.032 inch) wire. 3) Thread sizes > 12 mm (0.5 inch) use 1.1938 mm (0.047 inch) OR 1.295mm (0.051) wire. The larger wire may be used in smaller bolts in cases of convenience, but smaller wire must not be used in larger fastener sizes.

Change Description Updated to electronic format from pdf to ms word in new template Updated Logo Spelling changed from Overrruning to Overruning. Spelling changed from Overrruning to Overrunning. Removed Recommended Lubrication Product Chart from the document.

Drawworks, Compound Transmissions, Unitized Rotary Transmissions, ECR Units & Pump Drives: ..................................................................................... 5

SUPPLEMENTARY INSTRUCTIONS FOR TRIPLEX MUD PUMP TRANSMISSION LUBE OIL ......................................................................................................................... 6

Drawworks, Compound Transmissions, Unitized Rotary Transmissions, ECR Units & Pump Drives: Grease lubricated bearings, drum brake centralized lubrication system, and all miscellaneous grease fittings – Use a multipurpose lithium base grease. Ambient temperatures

Duplex & Triplex MUD & Slurry Pumps: Use a extreme pressure, non-corrosive, anti-foaming gear lubricant. Ambient temperatures 0°F to 155°F (-18°C to 68°C) AGMA #6EP -20°F to 40°F (-29°C to 4°C) AGMA #4EP Note: See Section 2 for initial filling of triplex pumps.

SUPPLEMENTARY INSTRUCTIONS FOR TRIPLEX MUD PUMP TRANSMISSION LUBE OIL National Oilwell has recently made a change in the design and material of the gears used in our triplex mud pump line. The new gears will be made from a harder material which will ultimately provide better performance and longer life but they do require some special treatment during the break-in period. Effective immediately National Oilwell will begin using specially designed gear oil, for the test runs in our manufacturing facilities, which is highly saturated with liquid soluble molybdenum disulfide, and other extreme pressure and corrosion resistant additives. This oil will help to polish the gear tooth surfaces to prevent initial pitting which is common on mud pump gears. This is especially important on the new harder gears as they are more susceptible to cold welding and scoring during the break-in period. The product will also provide rust prevention during storage periods. It is strongly recommended that the End User also use this product for at least the initial filling of the pumps. At the first oil change it would be at the user’s discretion whether to continue its use or change to another AGMA EP gear oil that meets the general specifications. A manufacturer of the above product is made by:

C-1 Type II C-1 Type III C-2 Type II C-2 Type III C-3 Type I C-3 Type II C-3 Type III D-1 D-2 D-3 EH-II EH-III, IV & V Type AU= Catworks W/Right Angle Drive CT-5 CT-7 CT-9 D-221 W/Separate Lube System D-232 W/Separate Lube System F-350 F-500 F-650 F-750 F-800 F-1000 F, FA, FB & FC-1300 F, FA, FB & FC-1600 FC-2200 Unitized Pump Drive for Electric Motor, Per Guard F-350 F-500 F-650 F-800 F-1000 www.nov.com

Drawworks 105 U.S. Gal. 400 Liters 105 U.S. Gal. 400 Liters 110 U.S. Gal. 420 Liters 110 U.S. Gal. 420 Liters 60 U.S. Gal, 230 Liters 60 U.S. Gal. 230 Liters 60 U.S. Gal. 230 Liters 78 U.S. Gal. 296 Liters 115 U.S. Gal. 436 Liters 85 U.S. Gal. 332 Liters 41 U.S. Gal. 155 Liters See Operation & Maintenance Manual 45 U.S. Gal. 170 Liters 50 U.S. Gal. 190 Liters Compounds 130 U.S. Gal. 493 Liters 130 U.S. Gal. 493 Liters 148 U.S. Gal. 560 Liters 80 U.S. Gal. 303 Liters 80 U.S. Gal. 303 Liters F-Series Triplex Pump 40 U.S. Gal. 152 Liters 65 U.S. Gal. 246 Liters 55 U.S. Gal. 208 Liters 55 U.S. Gal. 208 Liters 65 U.S. Gal. 246 Liters 75 U.S. Gal. 284 Liters 100 U.S. Gal. 380 Liters 100 U.S. Gal. 380 Liters 120 U.S. Gal. 454 Liters

20 U.S. Gal 76 Liters Type “F” Unitized Pump Chain Drive 15 U.S. Gal. 57 Liters 30 U.S. Gal 15 Liters 30 U.S. Gal. 115 Liters 30 U.S. Gal. 115 Liters 30 U.S. Gal. 115 Liters

Duplex Pumps 25 U.S. Gal. 53 U.S. Gal. 58 U.S. Gal. 65 U.S. Gal. 100 U.S. Gal. 100 U.S. Gal. Rotaries 6 U.S. Gal. 12 U.S. Gal. 8 U.S. Gal. 10 U.S. Gal. 5 U.S. Gal. 6 U.S. Gal. 9 U.S. Gal. 13 U.S. Gal. 10 U.S. Gal. 15 U.S. Gal. 15 U.S. Gal. 25 U.S. Gal. Rotary Transmissions 21 U.S. Gal. 28 U.S. Gal. 1 U.S. Gal. Swivels 3-3/4 U.S. Gal. 4-3/4 U.S. Gal. 6-3/4 U.S. Gal 10 U.S. Gal 15 U.S. Gal 19-1/2 U.S. Gal

This document provides a list of recommended spare parts for the FD-1600 mud pump. The parts are grouped to the sub-assemblies in which they are used.

Fluid End Tools Chaser, 1-1/4”-8 Tap & Die Thread Chaser, 1-1/2”-8 Tap & Die Thread Tap, 1-1/4”-12-2B Special Taper Tap, 1-1/2”-12-2B Special Taper Puller, Hydraulic Seat w/ Puller Head to fit API #7 seats (Specify Manufacturer of Seats) Pump, Hand Air Gauge, Tire Pressure 5-50 PSI These items should be available for commissioning

Power End Tools Wrench, ¾” Square Drive Torque (600 ft.-lb. capacity) Machine, HY-25 SL 2-1/2” Square Drive Hydraulic Torque Pump, Air/Hydraulic 10,000 PSI Capacity Socket, 3-5/8” Impact w/ 2-1/2” Square Drive

DESCRIPTION TOOL LIST FOR F-1600 SERIES PUMPS (CONSISTS OF THE FOLLOWING) SNAP ON SOCKET (FOR MAIN BEARING HOUSING BOLTS) BAR, VALVE COVER SOCKET (FOR 1-1/2” HVY. HEX NUTS) (CYLINDER THRD. RING & BLOCK TO FRAME) SOCKET (FOR 1-1/4” HVY. HEX NUTS) (DISCHARGE MANIFOLD) BAR, SLIDING PLUG, SLIDING 8” EXTENSION WRENCH, CYLINDER HEAD ADAPTER SOCKET (FOR 1” STD. HEX NUT) (LINER THREAD RING) WRENCH, 12 POINT BOX (FOR VALVE GUIDE LOCK BOLT) EXTENSION, WRENCH (FOR PART NO. 7602-3010-65)

7’’ 6 ¾” (178) (171) 3423 3688 Max. Discharge Pressure, psi (240) (259) (kg/cm2) Pump Speed, Input HP, GPM** GPM** spm HP (kW) (LPM**) (LPM**) 1600* 719 669 120* (1193*) (2721) (2532) 1467 659 613 110 (1094) (2494) (2320) 1333 599 557 100 (994) (2267) (2108) 1200 539 502 90 (895) (2040) (1900) 1067 479 446 80 (796) (1813) (1688) 933 419 390 70 (696) (1586) (1476) 800 359 334 60 (597) (1359) (1264) 5.99 5.57 Volume/Stroke, gal. (Liters) (22.67) (21.08) *Rated maximum input horsepower and speed **Based on 90% Mechanical and 100% Volumetric Efficiency Liner size, inches (mm)

Figure 1: FD-1600 Triplex Pumps (7"" x 12"") Dimension, ft in (mm) A 6’ 10’’ (2,083) B 5’ 5 ¾’’ (1,670) C 6’ 1 ⅜’’ (1,864) D 7’ 4 ⅜’’ (2,245) E 2’ 6 ¼” (768) F 1’ 5 11⁄16‘’ (449) G 4’ 11 ¾’’ (1,518) H 1’ 9 ¾’’ (552) I 1’ 1 ¾’