mud pump handbook pdf supplier

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.},

TABLE OF CONTENTS12-P-160 TRIPLEX MUD PUMP WITH FORGED CRANKSHAFTPAGE 1 2 3 4 5 6 7 8 9 10 11 DRAWING NO. PL 1292900-001 PL 1292901 PL 1292119 PL 1292902 PL 1292903 PL 1292120 PL 1292290 PL 1292225 PL 1292369 PL 1292125 PL 1292004 REV. A B DRAWING DESCRIPTION 12-P-160 TRIPLEX MUD PUMP COMPLETE POWER END COMPLETE PINION SHAFT SUB-ASSEMBLY FORGED CRANKSHAFT AND GEAR ASSEMBLY FORGED CRANKSHAFT AND GEAR SUB-ASSY. LINER SPRAY SYSTEM LINER FLUSHING SYSTEM STRAINER CROSS ASSEMBLY SUCTION STABILIZER HOIST COMPLETE OUTLINE DRAWING

Technical Specification Pre-Shipment And Storage PS-4030 02 Preservation For New-Build NOV Triplex Mud Pumps

Product Information Bulletin Triplex Mud Pumps Power 01-05-01-MP 06 End Lubrication Oil Additive and wear-in Period

RIG/PLANT REFERENCE REFERENCE DESCRIPTION Triplex Mud PumpADDITIONAL CODE SDRL CODE TOTAL PGS This document contains proprietary and confidential information National Oilwell Varco which belongs to National-Oilwell Varco, L.P., its affiliates orREMARKS subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. 11000 Corporate Centre Drive Reproduction, in whole or in part, or use of this design or Suite 200MAIN TAG NUMBER DISCIPLINE distribution of this information to others is not permitted without the Houston, Texas 77041 express written consent of NOV. This document is to be returned to NOV upon request and in any event upon completion of the use for U.S.A.CLIENT PO NUMBER which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. Phone: +1-281-854-0400 National Oilwell Varco Fax: +1-281-854-0607CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

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.

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 turn and re-spray. Pour quantity of inhibiting oil-based concentrate specified in the table below into power end sump.

Mud Pump Models Quantity of Inhibitor 14P, FC 2200 5 Gallons 12P, 10P, HD or A1700/1400PT, FB/FC/FD 1600, FB 1300 3 Gallons 9P, 8P, B or A850-1100PT, F/FD 1000, F 800 2 Gallons 7P, A600PT, FD 500 1 Gallon

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).

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 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.

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.

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.

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.

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

DOCUMENT TITLE: Commissioning Procedure, FB/FD-1600 Triplex Mud Pump DOCUMENT OR DRAWING NO. PAGE 2 of ENGINEERING EDN-1688 12SUBJECT COMMISSIONING PROCEDURE, FB/FD-1600 APPROVED REVISED DATE REV.

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

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

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

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

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.).

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

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.

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

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. DOCUMENT OR DRAWING NO. PAGE 6 of ENGINEERING EDN-1688 12SUBJECT COMMISSIONING PROCEDURE, FB/FD-1600 APPROVED REVISED DATE REV.

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

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.

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:

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

Pump A/C motor operating properly. Valves open for the proper volume of drilling fluid. Gauges/controls functioning properly.

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. DOCUMENT OR DRAWING NO. PAGE 8 of ENGINEERING EDN-1688 12SUBJECT COMMISSIONING PROCEDURE, FB/FD-1600 APPROVED REVISED DATE REV.

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

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.

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

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.

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

TRIPLEX MUD PUMP GDH 02PREPARED BY DATE CHECKED BY DATE

Triplex Mud Pump For Models: FD-500, FD-800, FD-1000 & FD-1600

RIG/PLANT REFERENCE REFERENCE DESCRIPTION Triplex Mud PumpADDITIONAL CODE SDRL CODE TOTAL PGS This document contains proprietary and confidential information National Oilwell VarcoREMARKS which belongs to National Oilwell Varco; it is loaned for limited 1530 W Sam Houston Pkwy. N purposes only and remains the property of National Oilwell Varco. Reproduction, in whole or in part; or use of this design or Houston, TX 77043MAIN TAG NUMBER DISCIPLINE distribution of this information to others is not permitted without the Phone 713-935-8000 express written consent of National Oilwell Varco. This document is Fax 713-935-8382 to be returned to National Oilwell Varco upon request and in anyCLIENT PO NUMBER event upon completion of the use for which it was loaned. National Oilwell VarcoCLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

PREFACE.................................................................................................................................... 31 INSTALLATION OF NEW PUMP ................................................................................... 112 SETTING THE PUMP ..................................................................................................... 11 2.1 Land Installations.................................................................................................. 113 SUCTION SYSTEM REQUIREMENTS........................................................................... 16 3.1 Caution ................................................................................................................. 164 PREPARATION OF POWER END ................................................................................. 17 4.1 Power End Lubrication.......................................................................................... 17 4.2 Installation of Crosshead Extension Rods and Diaphragm Stuffing Box Seals..... 185 PISTON AND LINER COOLING SYSTEM ..................................................................... 19 5.1 Stationary spray (View A, Fig. 6) .......................................................................... 20 5.2 Moving Nozzle ...................................................................................................... 206 ASSEMBLY OF FLUID END PARTS ............................................................................. 23 6.1 Valves and Seats.................................................................................................. 237 FD-500, FD-800 & FD-1000............................................................................................ 24 7.1 Liners.................................................................................................................... 25 7.2 Piston Rod ............................................................................................................ 25 7.3 Piston Rod Clamps ............................................................................................... 25 7.4 Liner Cage and Lower Valve Guide ...................................................................... 26 7.5 Cylinder head ....................................................................................................... 26 7.6 Discharge Valve Pot Covers ................................................................................. 268 FD-1600 .......................................................................................................................... 27 8.1 Liner...................................................................................................................... 28 8.2 Piston Rod ............................................................................................................ 28 8.3 Piston Rod Clamps ............................................................................................... 29 8.4 Lower Valve Guide and Cylinder Head................................................................. 29 8.5 Discharge Valve Pot Covers ................................................................................. 29 8.6 Discharge Manifold all models .............................................................................. 30

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.

2 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.

2.1 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.

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.

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.

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.

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 (13mm) for each 100 (2540 mm) center distance. Example: On 150 (3810 mm) center, move pump an additional (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.

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:

- Daily check of oil level. - Daily check on condition of oil. - Frequent check on oil pressure. (5-15 psi) (.352 - 1.06 kg/cm) - 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/cm) 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.

3.1 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.

4 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:

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.

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.

With reference to Fig. 7, maintain electric motor (1) and centrifugal pump (2) according to manufacturers specifications. Rotation of the pump should be clockwise when viewed from the impeller end.

7.4 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 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.

7.5 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.

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.

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.

8.7 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 ), (356mm OD x 343mm I.D. x 6.35mm Dia.)

8.8 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).

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.

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/cm)

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/cm)

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.

9.2 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.

9.3 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.

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.

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.

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.

- Clogged suction screen - Low oil level - Slipping V-belt drive - Broken or loose connections - Damaged or worn oil pump - Defective Relief Valve

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.

11.2 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.

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.

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.

11.5 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)

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.

11.7 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:

* 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.

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.

12 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. 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.

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.

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.

RIG/PLANT REFERENCE REFERENCE DESCRIPTION Triplex Mud PumpADDITIONAL CODE SDRL CODE TOTAL PGS This document contains proprietary and confidential information which is the National Oilwell Varco, L.P.REMARKS property of National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively 1530 W Sam Houston Pkwy. N referred to hereinafter as NOV). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this Houston, TX 77043MAIN TAG NUMBER DISCIPLINE design or distribution of this information to others is not permitted without the written consent of NOV. This document is to be returned to NOV upon request or Phone 713-935-8000 upon completion of the use for which it was loaned. This document and the Fax 713-935-8382 information contained and represented herein is the copyrighted property of NOV.CLIENT PO NUMBER

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)

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!

3. The through capacity of the valve, when fully opened, must be sufficient to relieve the full capacity of the pump without excessive overpressure.

1.3 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.

SUGGESTED SET PRESSURES FOR PUMP RELIEF VALVESPump Type Operating Pump PressureDouble 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%

Product Information Bulletin No. 01-05-01-MP TRIPLEX MUD PUMPS Date: July 12, 2013 Rev. 06

Objective: Recommended power end lube oil additive to reduce corrective pitting found on mud pump gears. Provide wear-in period information.

Issue: During the initial mud pump wear-in period, it is common to see initial pitting on the tooth faces of Triplex Mud Pump gears.

Solution: It is National Oilwell Varcos 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.

PSERIESMUDPUMPS TEMPERATURE AGMAINDUSTRIALEPGEAROIL AGMA#7EPorASTM/ISOVGGrade46050Fto155F(10Cto68C) Viscosity414506CST@100F(38C) AGMA#6EPorASTM/ISOVGGrade32020Fto100F(7Cto38C) Viscosity288352CST@100F(38C) AGMA#2EPorASTM/ISOVGGrade6820Fto60F(29Cto16C) Viscosity6175CST@100F(38C) FSERIESMUDPUMPS TEMPERATURE AGMAINDUSTRIALEPGEAROIL AGMA#6EPorASTM/ISOVGGrade32030Fto155F(1Cto68C) Viscosity288352CST@100F(38C) AGMA#4EPorASTM/ISOVGGrade1500Fto85F(18Cto33C) Viscosity135165CST@100F(38C) 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 140F (60C). 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. Page 3 of 3FAILURE TO FOLLOW THESE RECOMMENDATIONS COULD RESULT INCATASTROPHIC FAILURE OF THE PUMP WHICH MAY RESULT IN DEATH,BODILY INJURY AND/OR PROPERTY DAMAGE. PROCEDURE

Revision Change Description 02 Updated to electronic format from pdf to ms word in new template 03 Updated Logo 04 Spelling changed from Overrruning to Overruning. 05 Spelling changed from Overrruning to Overrunning. 06 Removed Recommended Lubrication Product Chart from the document.

1 GENERAL LUBRICATION INSTRUCTIONS FOR CONTINENTAL EMSCO PRODUCTS DRILLING EQUIPMENT .............................................................................. 4 1.1 Crown and Traveling Blocks: .................................................................................. 4 1.2 Swivels: .................................................................................................................. 4 1.3 Rotary Machines and Unitized Rotary Chain Coupling: .......................................... 4 1.4 GB & GBH CATHEADS: ......................................................................................... 5 1.5 Drawworks, Compound Transmissions, Unitized Rotary Transmissions, ECR Units & Pump Drives: ..................................................................................... 5 1.6 Electrohoist II Gear Box .......................................................................................... 5 1.7 Electrohoist II, IV & V Gear Box .............................................................................. 5 1.8 Airline Lubricators: .................................................................................................. 5 1.9 Duplex & Triplex MUD & Slurry Pumps: ................................................................. 5 1.10 Overrunning Clutch: ................................................................................................ 6 1.11 Caution: .................................................................................................................. 62 SUPPLEMENTARY INSTRUCTIONS FOR TRIPLEX MUD PUMP TRANSMISSION LUBE OIL ......................................................................................................................... 63 GENERAL LUBRICATION BULLETIN ............................................................................ 7

1.5 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.

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

2 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 users discretion whether to continue its use or change to another AGMA EP gear oil that meets the general specifications.

DrawworksC-1 Type II 105 U.S. Gal. 400 LitersC-1 Type III 105 U.S. Gal. 400 LitersC-2 Type II 110 U.S. Gal. 420 LitersC-2 Type III 110 U.S. Gal. 420 LitersC-3 Type I 60 U.S. Gal, 230 LitersC-3 Type II 60 U.S. Gal. 230 LitersC-3 Type III 60 U.S. Gal. 230 LitersD-1 78 U.S. Gal. 296 LitersD-2 115 U.S. Gal. 436 LitersD-3 85 U.S. Gal. 332 LitersEH-II 41 U.S. Gal. 155 LitersEH-III, IV & V See Operation & Maintenance ManualType AU= Catworks 45 U.S. Gal. 170 LitersW/Right Angle Drive 50 U.S. Gal. 190 Liters CompoundsCT-5 130 U.S. Gal. 493 LitersCT-7 130 U.S. Gal. 493 LitersCT-9 148 U.S. Gal. 560 LitersD-221 W/Separate Lube System 80 U.S. Gal. 303 LitersD-232 W/Separate Lube System 80 U.S. Gal. 303 Liters F-Series Triplex PumpF-350 40 U.S. Gal. 152 LitersF-500 65 U.S. Gal. 246 LitersF-650 55 U.S. Gal. 208 LitersF-750 55 U.S. Gal. 208 L