fd 1600 mud pump parts factory

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

MANUFACTURING PLANT PRESERVATION PRIOR TO PAINTDrain all water and clean out liner wash tank. Remove drain plug in bottom of liner washpump and drain water then reinstall plug. Remove discharge flange from liner wash pumpand pour one (1) pint of inhibiting oil-based concentrate (Cortec VpCI 329 Vapor CorrosionInhibiting 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 inspectioncovers. 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-basedconcentrate (Cortec VpCI 329 Vapor Corrosion Inhibiting oil-based concentrate orequivalent). Rotate pump turn and re-spray. Pour quantity of inhibiting oil-basedconcentrate specified in the table below into power end sump.Mud Pump Models

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

Replace all guards and seals as necessary using specified gasket material and sealingcompounds.Remove fluid end valve covers, seals, valves springs and seats and treat internal cavitiesof fluid ends, discharge manifold, discharge strainer block and suction manifold with rustpreventative (CRC SP400 or equivalent). Coat threads with anti-seize (KOPR KOTE10002 or equivalent) and coat bottom side of valve cover with rust preventative. Reinstallseals and fluid end valves covers hand tight. Customer liners, pistons, piston rods, valves,seats, springs and liner retention parts are not used for plant testing. These expendablesare checked for preservation when packed and then shipped with the loose parts.

MANUFACTURING PLANT PRESERVATION AFTER PAINTRemove breather and pack with loose parts for later shipment with pump. Seal breatherhole with a greased solid plug. Affix a warning label near the breather opening (see Exhibit1).Spray all external unpainted machined parts of pump with rust preventative (CRC SP400 orequivalent).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 andstyle. 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 pressuregauges 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 withrust preventative (CRC SP400 or equivalent). All parts will be wrapped or boxed to preventdamage.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 loosepart container. In cases where the equipment will be boxed at an offsite export packer, asufficient number of warning labels will be supplied with the shipment.

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

PRESERVATION PROCEDURE WHEN STORAGE EXCEEDS SIX (6) MONTHS OFINITIAL PRESERVATION.Note: It is recommended that inspections be carried out on six (6) month cycles whenpumps 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 internalcorrosion. 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 STORAGEAny pump that has been in storage will need a thorough inspection prior to start-up toinsure it has not been damaged in any way and that all parts are properly in place. Failureto 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 inhibitingadditive. The Cortec brand products used for preservation are compatible with alllubricating 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 andthoroughly clean and inspect all of the parts and finished surfaces. Check all of thebearings to make certain they are clean and in good condition. Fill the power end withclean EP oil of the proper viscosity to the proper level. Make sure oil is poured into the oildistribution trough and is worked into all of the bearings. Replace all covers and installbreather.To service the Fluid End after storage and prior to start-up, remove covers and thoroughlyclean and inspect inside of the fluid end cylinders. Properly install valves, pistons, linersand all other fluid end parts. Carefully tighten all bolts, nuts, studs and workingconnections to specified torque requirements.

Pre-Start Up Requirements.....................................................................................1. Power End..................................................................................................2. Main Electric Drive Motors3. 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 Strainer12. Mud Pump Drive Assembly.a. Belt Drive Unitsb. Chain Drive Units.

INITIAL STARTUP PROCEDURESGENERAL: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.

Reservoir Capacity: 100 US Gallons (379 Liters)Note: The rust preventative on the internal surfaces of the pump is oil-soluble and iscompatible with the lubricants recommended above. It is not necessary to flush and drainunless 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 extensionrods.

Check to assure that all liners, valves, and pistons are installed properly in accordance withthe installation instructions.Ensure that the liner end covers are installed on the rear end of the liners.Ensure that the baffle discs are installed on the end of the crosshead extension rods.Clean grease and paint from the exposed parts of the extension rods, checking for burrs.Coat rods with a light oil.

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

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 byinspecting the sight glass. Add or release air pressure through the Shraeder valve to keep thediaphragm 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 securelytied 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 themanufacturing site; therefore, the following recommendations for the commissioning test are madefor the purpose of checking the overall unitization functions, including instrumentation, and toassure 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, volumetricdisplacement 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-CommissioningRequirements in Part I.Check the discharge mudline to assure that all necessary valves are open. Ensure that the mud tanksare 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 thethrottle 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 andcontinue operating the mud pump while making the following inspections to assure that all systemsare 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 thepressure rating for the liner size being used.Refer to the nameplates on each side of the pump or the pump datasheet to obtain theoperating 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 wastest 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 inthe discharge line.NOTE: There can be short intervals of shut-down time to fix leaks, make adjustments, etc., withouthaving to restart the test program.1. LOWER PRESSURE TEST DURATION: TWO (2) HOURS:TIMESTARTSTOP0-500 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 theeight hour test program. The following checks should be made and recorded each two hours ofoperation.START

INSTALLATION OF NEW PUMPYour National Oilwell Varco pump has been completely assembled and test operated underpressure before being shipped to the field. Unless otherwise instructed, the lubrication isdrained 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 beperformed or checked.In order to prevent personal injury during the performance of any maintenance orinspection 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 PUMPThe skids under the National Oilwell Varco pumps are suitable for most any type ofinstallation. It should be noted, however, that the box type construction of the power framehas high resistance to bending but relatively less resistance against twist. Therefore, thesupport under the pump must be level and adequate to support the weight and operatingforces exerted by the pump.

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

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

2.1.1 Permanent InstallationsOn 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 toprevent possibility of twisting or distorting the power frame. The pump skids must sit solidon all shim points with bolts loose.On barge installations, the pumpskids are generally bolted down toT-beams running parallel and in linewith the pump skids. Install shims atpoints shown in Figs. 2 and 4 andobserve caution of proper shimmingto prevent twist or distortion.The shims on all installations shouldextend the full width of the skidbeam flanges and have a minimumlength of 12 (305mm).On installations where the power unit or electric motor is mounted integrally with the pumpskids, the preferred installation would be to set the pump package on the T-beam skids andprovide retention blocks rather than bolts to hold it in place. This will allow the pump tofloat and minimize the transfer of barge deck or platform distortion into the frame.2.1.2 Installation of the DriveThe drive between the mud pumps and the power source, whether V-belts or multi-widthchains, should be installed with the greatest care to assure maximum operating life withminimum of unexpected or undesirable shutdowns due to drive failures.When installing the drive sheave or sprocket, make sure all grease or rust preventative isremoved from the shaft and the bore of the drive. Remove all burrs or rough spots from theshaft, key, and keyway. Fit key to the keyways in both the shaft and drive and install keyinto shaft keyway.Coat pinion shaft with a light coating of anti-seize compound or light oil and install the drivesheave 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 beeneliminated 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 ANDALLOWING BELTS TO TIGHTEN UNDER WEIGHT OF PUMP AS END ISBEING LOWERED TO THE GROUND.2.1.2.2 Chain Drivesa.InstallationProper installation and maintenance of the sprocket and chain drives are essential ifgood service life is to be obtained. Since many factors, such as chain width, centerdistances, speeds, and loads must be considered when determining the allowabletolerance for sprocket alignment, no good rule of thumb can be applied. The chainalignment must simply be held as nearly perfect as possible. A more precisealignment can be made by stretching two steel wires (piano wire) along one face ofthe two sprockets, one above and one below the centerline, and moving one of thesprockets until the wires touch at four points. This will determine that the centerlinesof the drives are parallel and the faces of the sprockets are square.b.

Drive chain lubricationThe pump drive chain lubrication system on the majority of National Oilwell Varcopumps is an independent system having its own oil pump, reservoir, and drive. Fillchain case to the indicated level with a non-detergent oil as follows:Ambient temperature above 32F (0C) SAE-30Ambient temperature below 32F (0C) SAE-20For temperatures below 0F, consult a reputable lubrication dealer forrecommendations.REFER TO GENERAL LUBRICATION BULLETIN for approved lubricants andadditional specifications. If any discrepancy exists between the recommendations inthis manual and the General Lubrication Bullletin, those in the Lubrication Bulletinwill take precedence.Since this is an independent system, it will require the same maintenance or serviceattention 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/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 screwon the rear of the pump housing. Pressure drops may also indicatesuction and discharge filter screens need cleaning.3

SUCTION SYSTEM REQUIREMENTSIndividual installation conditions will dictate the design of the suction system. The suctionof 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 maximumvolumetric efficiency and expendable parts life. This head pressure is best supplied by a 5x 6 centrifugal pump with 40 h.p. 1150 rpm electric motor. This type of drive requires adevice to automatically start and stop the centrifugal pump motor simultaneously with thetriplex pump. On DC electric powered rigs a signal can usually be supplied from the DCcontrol panel to energize a magnetic starter when the mud pump clutch air line will providea 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 ofdrive 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 islow viscosity and suction line must be short, straight and of at least the same diameter assuction manifold inlet.The suction lines should be piped with valve arrangements so the charging pump can beby-passed so operation can be continued in event of charging pump failure or formaintenance. Operation without a charging pump can be improved by replacing thesuction valve springs with a weaker spring.Suction desurgers are a very effective aid for complete filling of the liners and dampeningpulsations in the suction line which results in a smoother flow in the discharge line. If yourpump is equipped with a suction desurger it must be pre-charged with compressed airbefore operations are begun. See suction desurger manual for charging instructions.

CautionDo not pipe the return line from the shear relief valve back into the suction system as arelief valve operation will cause a sudden pressure rise in the system vastly greater thanthe system pressure ratings, resulting in damage to manifold, suction desurger andcentrifugal pump.

PREPARATION OF POWER ENDYour National Oilwell Varco pump has been completely assembled and test operatedbefore being shipped to the field. Unless otherwise instructed, the lubrication is drainedfrom the power end, and the expendables are removed from the fluid end for storageprotection. Before operating the pump, the following must be performed or checked:

Power End LubricationBefore installing lubricant, open inspection door in cover and check oil reservoir forpossible accumulation of condensation, etc., and drain and flush by removing the pipeplugs on each side of the pump.Add the proper type and quantity of lubrication in the power end. Refer to the LubricationSection 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 downand 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 acertain amount being retained in the crosshead area and frame cavities.

With reference to Figure 5, remove the diaphragm stuffing box and plate (1) and rotatepump so that crosshead is at the front of the stroke. Thoroughly clean the front of thecrosshead and the face of the crosshead extension rod. Insert alignment boss oncrosshead extension rod into the crosshead bore and tighten the retainer bolts (2) to thefollowing torque. Safety wire bolt heads.FD-50050-60 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)

Clean bore and face of diaphragm stuffing box plate. Clean OD and flange ofdiaphragm stuffing box. Coat OD of diaphragm stuffing box with light oil and install Oring seal (4). Insert diaphragm stuffing box in plate bore and tighten capscrews to thefollowing torque: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 VarcoFD-Series Pumps -- the stationary spray type and a moving nozzle type. Ref. Fig. 6. Themanifold (1) for supplying cooling fluid to the piston and liner assemblies is identical on bothsystems. Cooling fluid from either a remote source such as a water line, or from a pumpand reservoir system unitized on the pump skids (Ref. Fig. 7) must be piped into themanifold at the connection located in the pump frame under the crosshead extension rodsection.CAUTION:

With reference to Fig. 7, maintain electric motor (1) and centrifugal pump (2) accordingto manufacturers specifications. Rotation of the pump should be clockwise whenviewed from the impeller end.Adjust regulating valve (3) to apply as much water as possible to the liners withoutsplashing 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 onthe crosshead extension rods, some of the water may work back into the power end tocontaminate the lubrication oil.

Piston RodClean piston and piston rod, making sure they are free of nicks and burrs. Install O ringseal (20) in groove in piston head. Slide piston head on rod while observing that O ringdoes not fall out of groove. Tighten piston rod nut (21) to 1200-1600 ft. lbs. (166-121m/kgs.).Coat liner I.D. and piston O.D. with grease. Check ends of piston rod and extension rod tobe sure they are clean and free of burrs. Insert piston rod through liner holding piston rodcentered at the rear of the liner. Drive the piston into the liner with a driving tool or a pieceof hardwood and sledge hammer. Use caution as the piston rod approaches the crossheadextension rod that the dowel on the end of the piston rod is not damaged. The piston rodmust be supported and the dowel guided into the pilot bore.

Piston Rod ClampsThe piston rod clamps are machined as one piece and then cut in half. The two pieces arestenciled with matching numbers on each half and have a chain link connecting themtogether. The two pieces with the same matching numbers should always be kept togetheras a set. Install the clamp around the rod end flanges with the water connection holes attop dead center. Tighten cap screws to the following torque values.FD-500-368 ft. lbs.

Liner Cage and Lower Valve GuideInstall 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 turnedcrosswise to the pump. Press down on the guide, compressing the valve spring (7) untilthe guide can be rotated turn and seat into place underneath the cage. Insert the lowervalve guide locking clip (9) through the pad eyes on the lower valve guide and rotate clip tothe right to lock the valve guide tight against the OD of the liner cage. It may sometimes benecessary to put more or less bend in the center of the clip to make it retain the guidetightly while the clip handle snaps into position on the right hand side.

Cylinder headInsert the outer seal (5) in the fluid end bore against the liner cage. Slide the cylinder headplug (10) into fluid end. Apply a liberal coat of grease to both mating thread surfaces of thecylinder head (2). Screw cylinder head in and tighten with wrench furnished with pump andsledge 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 9BA cross section through the fluid end is shown in fig. 9B. With reference to fig. 9Bthoroughly 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 seatingto alleviate friction wear from breathing action encountered in modern highpressure pump operation. For this reason it is essential that all parts be cleanand free of rust, nicks and burrs before being assembled.

LinerInstall wear plate seal (1) in counterbore of fluid end. Slide wear plate (2) over studs until itseats against fluid end. Slide liner thread ring (3) over studs with the starting thread at the5 oclock position and tighten nuts to 470-510 ft. lbs. (65-70 m/kgs.) torque.Note: Placing the starting thread at 5 oclock position makes engaging the liner lockthreads much easier.Place liner seal (4) in counterbore of wear plate. Apply thin coat of grease to ID of linerlock (5) and slide over rear of liner (6). Install two-piece liner lock ring (7) in liner grooveand O ring to hold them in position.Slide liner handling tool over liner up against liner lock ring and tighten set screw to secureit in place. Hoist liner assembly into position with jib hoist.Note: FD pumps are factory equipped with jib booms and liner handling tools. If olderpumps are converted to FD fluid ends a jib boom should be added to the pumpframe 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 oclock position and insert the liner into the liner thread ring (3) screw liner lockin until liner seats in position . Tighten with sledge hammer on hammer lugs.

Piston RodClean piston (9) and piston rod (8), making sure they are free of nicks and burrs. Install Oring seal (10) in groove in piston head. Slide piston head on rod while observing that Oring does not fall out of groove. Tighten piston rod nut (11) to 1200-1600 ft. lbs. (166-121m/kgs.).Coat liner I.D. and piston O.D. with grease. Check ends of piston rod and extension rod tobe sure they are clean and free of burrs. Insert piston rod into liner through cylinder headopening holding piston rod centered at the rear of the liner. Drive the piston into the linerwith a driving tool or a piece of hardwood and sledge hammer. Use caution as the pistonrod approaches the crosshead extension rod that the dowel on the end of the piston rod isnot damaged. The piston rod must be supported and the dowel guided into the pilot bore.

Piston Rod ClampsThe piston rod clamps are machined as one piece and then sawed in half. The two piecesare stenciled with matching numbers on each half. The two pieces with the same matchingnumbers should always be kept together as a set. Install the clamp around the rod endflanges with the water connection holes at top dead center. Tighten cap screws to thefollowing torque values:FD-1600

Discharge Manifold all modelsA 5-1500*RTJ flange connection is provided on the discharge manifold. REMOVE flangeand protect gasket area before welding (customers option) to the discharge piping.(*127mm)Tighten discharge flange connection bolts to *1200-1600 ft. lbs. torque. To insure uniformmake-up of the ring joint connection, tighten flange bolt nuts in a crisscross order. (*166121 meter kgs.)If a blind flange is installed on the opposite end of the discharge manifold, check flangebolts and tighten to same specification as noted above.

Suction FlangeThe suction flange has a 12 (305mm) standard pipe thread connection and is custommade to match the companion flange on the pump suction manifold. The flange connectionis sealed off by an O-ring seal (14 OD x 13-1/2 ID x ), (356mm OD x 343mm I.D. x6.35mm 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 ManifoldFig. 10 is not the standarddischarge arrangement on themodel FD-1600 pump, which usesthe strainer cross configuration.An accessory manifold, Fig.10, isavailable for installation on thedischarge manifold opposite thedischarge end. The manifold willaccommodate a dischargepulsation dampener (1) andprovides two 3-6000 PSI*sideoutlet connections for such items asa pressure gauge (2) and a shearrelief valve (3).When manifold is used, install andmaintain as follows:

The flange on the accessory manifold is a 5-1500 *RTJ. Thoroughly clean ring jointgroove, install ring (4) and tighten the flange bolts (5) to 1200 ft. lbs. torque. To assureuniform 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 ofprotecting the pump from excessively high pressure overloads.The relief valve must be installed so that it will be directly exposed to the mud. DO NOTPUT ANY TYPE OF SHUT OFF VALVE between the relief valve and the manifold. Pipethe discharge side of the relief valve directly into the mud pit with as few turns in the line aspossible. IT IS NOT RECOMMENDED for the discharge side of the valve to be piped intothe suction line of the pump.* 5 -

3 - 6000 PSI = two 76.2mm - 422 kg/cmThe relief valve setting should be just above the maximum pressure rating of the particularliner size being used. CHANGE SETTINGS with each liner size change. DO NOT USEALLEN WRENCHES, WELDING RODS, or material other than that called for by themanufacturer 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 ringgasket. Before installing dampener, thoroughly clean ring groove and ring, and after settingdampener into place, tighten the 1-1/4*nut (6) to 750 ft.lbs*. torque. To insure uniformmake-up, tighten nuts in a criss-cross order.Precharge dampener before starting up pump. Precharge pressure should not be morethan 2/3 of the pump discharge pressure, or a maximum of 650 PSI. (46 kg/cm)CAUTION: USE ONLY COMPRESSED NITROGEN OR AIR. DO NOT CHARGE WITHOXYGEN.* 1-1/4 = 32mm750 ft. lbs. = 104 meter kgs9

LUBRICATIONProper lubrication of the moving parts in any piece of machinery is the most importantsingle factor affecting its ultimate life. To obtain maximum trouble-free service life from thepower end of the National Oilwell Varco pump, it is necessary to perform routinemaintenance care and inspections to insure the proper amount of CLEAN lubricant is beingprovided.

The FD-Series pumps utilize the controlled flow oil bath splash and pressure system tolubricate the entire power end. The type of pressure system provided in each individualpump will govern the minimum SPM at which the pump can be operated, i.e. pumps whichhave pressure lubrication only to the main and pinion bearings, have a minimum ratedspeed of 40 SPM. Pumps in which pressure lubrication is provided to the main, pinion, andcrosshead bearings and crosshead compartments may be operated at a minimum speed of25 SPM, provided there is a minimum of 5 PSI oil pressure. (352 grams/cm)9.1

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

Controlled Flow Splash SystemThe 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 controlledflow splash system, the main gear picks oil up from the reservoir, and when the teeth meshwith 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 isshown in Figure 12. Oil accumulates in the compartment over the crossheads. The oilruns through the nipple (6) into the crosshead retainer to the oil passages (5) and on to thecrosshead pin bearing. As noted, the duplicate set of passageways (5) in the crossheadpin permits the crosshead pins to be rotated without having to give attention to holealignment. This permits the installation of crosshead pins from either direction.

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

In this system, filtered oil is supplied to the pump through the suction filter (1) and isdischarged from the pump into the manifold block (2). Oil is distributed from the manifoldblock to the pinion shaft bearing oil line (3) and spray nozzle (3A); and to the main bearingoil line (4) and the crosshead compartment manifold block (4A) located above thecrosshead compartment. The crosshead compartment manifold block (4A) distributes oil tothe crosshead, crosshead bearings, and extension rods. Pumps which do not have thecrosshead compartment manifold block (4A) do not have the total pressure lubricationsystem, 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 beingmaintained in the manifold block. The oil pressure will, of course, vary with the speed ofthe main pump, however if a sudden pressure drop or increase occurs, refer to the sectionon maintenance of lubrication system for possible cause.A pressure relief valve (6) is mounted to the manifold block to keep excess pressure formdamaging oil pump and drive. The relief valve is preset at 40 PSI and must not betampered with.NOTE: If specified, the oil pump for the pressure lubrication system can be independentlypowered by an electric motor or some other type of prime mover. When theindependently driven oil pump is used, some type of alarm device or powerinterlock must be installed to assure the oil pump is operating when the main pumpis put into service.When installing the internally mounted oil pump (9, Fig. 13), position pump so that the backface of the drive gear is flush and parallel with the edge of the main gear, and gear teethhave*.010-.015 backlash. Remove inspection plate on power end cover for access to theinternally 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) ispiped into the oil system through the suction and pressure connections on the bottominside wall of the power frame. Ref. Item 10, Fig. 13. The V-belt drive (2) is adjusted bymoving 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 bepinched 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 beltelongation. 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 requiredlength (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 puttingpump into service.10

MAINTENANCE OF THE LUBRICATION SYSTEMAdequate lubrication of the moving parts is, as stated, the most important single factoraffecting the ultimate service life of the pump. CARE AND MAINTENANCE of the systemis the sole responsibility of the operator or crew to which it has been assigned, and theextent to which this is applied will determine the amount of trouble-free service life that willbe 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 extensivefield tests. Substitutions should be made only in extreme emergencies.REFER TO GENERAL LUBRICATION BULLETIN for approved lubricants and additionalspecifications. If any discrepancy exists between the recommendations in this manual andthe 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 +30F to 155F (-1C to 68C) AGMA No. 6 EPTemperatures0F to 85F (-18C to 33C) AGMA No. 4 EP(Consult lubrication manual)Oil reservoir capacity:FD-500FD-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 toallow oil level to equalize.ONCE EACH SIX MONTHS, or more often if oil becomes contaminated with abrasiveparticles or corrosive compounds, drain and flush the oil reservoir and refill with newlubricant. Oil drains are located on either side of the pump frame.During the flushing procedure, thoroughly clean the oil troughs and the compartment in topof the crosshead guide. Also clean or replace the filter element in the air breather cap andclean suction screen. Remove covers from settling chamber and purge out contaminantsbefore adding new oil.Routine inspection on condition of oil should be made as condensation of moisture in theair, 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 inthe oil splashed into this area is allowed to settle out and should be drained out of the pumpthrough the clean out covers located on the frame wall underneath the crossheadinspection doors.Once each month, remove clean out covers on both sides of pump to drain contaminatedoil from settling chamber. Approximately 15-gallons of oil will be lost; replenish the mainreservoir to compensate for the amount drained out.Once each week, remove one of the lower capscrews that secure the clean out cover tothe frame to drain off water condensate.ONCE EACH TOUR, check oil level in main reservoir. Maintain at full mark on dipstick tothe 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 ValveFor an abnormal increase in oil pressure, check for:- Plugged oil lines- Contamination causing oil to be viscous- Relief valve inoperative- Defective gauge- Other conditionswww.nov.com

Power EndRoutine inspection of the power end is the most important form of preventive maintenanceand will result in considerable savings by detecting any major trouble that might bedeveloping and allowing the necessary repairs to be made on a planned or normal rig-downtime.1. Check tightness of the main bearing bolts. Bolts must be tightened to the followingtorque:FD-500FD-1000

2. Safety wires Check safety wires on all bolts including the main bearing hold-down bolts, eccentricbearing retainer bolts, and gear retainer bolts. Replace any broken wires afterretightening the bolts. Refer to crankshaft assembly section for bolt torquerequirements.3. Oil lines Check all oil lines to insure they are intact and free of obstructions. Check oil pumpsuction 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 substancethat 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 ofabnormal wear. During the initial break-in period there will be some pitting on the faceof the gear teeth. This is referred to as initial pitting and is not harmful to the life of thegear. However, if routine inspection indicates the degree of pitting continues toincrease, immediately contact the local representative of the pump manufacturer for amore thorough inspection of the gear.www.nov.com

7. Crosshead pin bolts and crosshead guides Remove cover and check condition of the crosshead pin bolts and safety wires. (Centercrosshead pin bolts can be reached by removing back cover and placing eccentric onouter top dead center.) Tighten crosshead bolts (Item 4, Fig.19) to the following torque:FD-500FD-800

FD-1000 165-175 ft. lbs. (23 - 24 meter kgs)FD-1600 165-175 ft. lbs. (23 - 24 meter kgs)DO NOT EXCEED THESE VALUES. USE TORQUE WRENCHIf the crosshead or guide shows abnormal wear or scoring, replace immediately as themetal particles can cause damage to the bearings, etc. Excess wear can also causerapid wear to the piston and liners.8. Oil and oil reservoir Check condition of the oil and cleanliness of the oil reservoir. Service oil system asdescribed in the Lubrication Section of this manual.11.2

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

It is always necessary to completely replace any roller bearing that fails, even though onlyone part of the bearing shows damage. Since the running clearances of these bearings areextremely small, excessive clearances, worn or grooved raceways, and any pitting orflaking of the parts is indicative of failure and the entire bearing should be changed as soonas possible.All roller bearings are assembled to their shafts by means of shrink fits. (Ref. bearing fitdata under each shaft assembly.) Damaged or worn bearings and raceways can beremoved by driving them off the shaft with a bar and hammer. They can be cut off the shaftwith a burning torch, but care must be taken not to burn into the shaft. Bearings shouldalways be heated in an oil bath, the temperature of which should not exceed 300F(149C). Be certain that both the oil and the container are very clean. If the oil container isin direct contact with the fire, place a rack into the container so that the bearings will notrest on the bottom. Do not leave the bearings in the oil bath longer than three minutes.Do not heat the bearings with a torch unless it is the only possible means available. Whenit is necessary to use a torch, it should be used only by an experienced welder ormechanic. Hold the torch at least 6 inches (150mm) away from the bearing and keep thetorch moving at all times. Heat the bearing only until it is hot to the touch. Use a Tempilstick. DO NOT OVERHEAT THE BEARING. Overheating draws the temper of the metaland makes the bearing soft.Once the heated bearing is in place on the shaft, hold it in place until it cools. NEVER USEWATER OR ANY OTHER LIQUID TO COOL A HOT BEARING. Rapid cooling will causethe surfaces of the races and rollers to check or crack and the bearing will failimmediately.Never strike a roller bearing with a steel hammer. If the bearing must be driven intoposition, use wood or a soft hammer and strike lightly.Always lubricate the shaft or housing before installing the bearing. Clean white lead, or ananti-seize compound, is the best lubricant for this purpose.Do not remove a new bearing from the box or wrapping until it is to be installed. Protect itfrom dirt and other foreign matter at all times. If a bearing must be cleaned, use cleankerosene or other solvent.

The running clearances of the bearings are predetermined by their precision fit to the shaftand the bearing carrier. When performing maintenance or overhaul, make sure the fitsshown 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 placeand in good condition.b. The pinion bearing carrier (3) and the oil seal carrier (4) have the word TOP cast inthe face of the flange. MAKE SURE THE CARRIERS ARE INSTALLED WITH THISMARK 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 slidingoil seal carrier (4) into place. Exercise care when sliding lip of seal over end of shaftto prevent it from being damaged by the sharp edge of the keyway. Also payparticular attention to insure oil seal lip IS NOT TURNED UNDER by edge of spacerwhen 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.)

a. Mount gear on flangeThoroughly clean mating faces of ring gear and flange and bolt flange into position.Tighten flange bolts (2) to the following torque:FD-500 160-240 ft. lbs. (22-33 meter kgs)FD-1000 800-1200 ft. lbs.

Set crankshaft on a set of rollers (at main bearing position) and check runout on face ofgear with a dial indicator. If total indicator runout exceeds .006, remove gear anddetermine cause of misalignment. (.15mm)NOTE: If runout on face of gear is checked while crankshaft is mounted in the pumpframe, the running clearance in main bearings will require that a simultaneous set of dialindicator readings be taken at the end of the shaft and the face of the gear; the actualface 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 oilscoop is at the bottom when pump is at mid-stroke. Tighten retainer bolts (4) to thefollowing torque; safety wire heads.FD-500FD-1000

c. Install the outer race of the crosshead bearings (19) in the three eccentric straps. It ispreferred that the outer race assembly be pressed into position or frozen in dry ice ora deep freeze until it can be inserted into the bore. Under emergency circumstances,the outer race assembly can be installed by using a large torch and heating the eye ofthe eccentric strap. DO NOT EXCEED 300F (149C) (USE Tempil-Stik) and DO NOTUSE WATER to cool the strap.NOTE: The inner and outer races of the crosshead bearings are matched and shouldnot be intermixed.d. Install the inner race of the crosshead bearing on the crosshead pin and mark accordingto their respective eccentric strap positions. Remove all nicks and burrs beforeshrinking race into place. Refer to bearing fit Position H, Chart II.e. Install inner race of the center eccentric bearing on the shaft. Slide center strap intoposition and install inner race clamp (5). Tighten socket head screws (8A) in clamp tothe following torque:FD-500FD-1000

f. Install snap ring (7) in the groove on RH eccentric and shrink inner race of eccentricbearing on shaft. After sliding the RH eccentric strap into position, install inner bearingretainer (14).Tighten inner race retainer bolts (8) to the following torque and safety wire:FD-500FD-1000

g. Install the LH eccentric bearing (other than for snap ring) and eccentric strap under thesame procedure outlined in step (f) above.h. Place main bearings (9) in the main bearing carriers (10 RH and 11 LH) and installouter race retainer (12) and retainer bolts (15). Tighten bolts to the following torque andsafety wire:FD-500FD-1000

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

i. After installing the two main bearing spacers (16), shrink main bearings (9) on each endof the shaft. Install inner race retainers (17) and retainer bolts (18). Tighten retainerbolts to the following torque and safety wire:FD-500FD-1000

Installing Crankshaft Assembly in FrameIn order to obtain a more precise fit between the main bearing housing and the frame boreon F-Series pumps, the installation procedures outlined below are to be followed: (Refer toFig. 17)1. Place piece of wood between eye of eccentric strap and crosshead guide (as shown inFig. 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 withthe main bearing bolt holes, and slowly lower the crankshaft into position. (The flat spotprovides clearance for the main bearing bolts.)3. After placing crankshaft in the frame, and before installing the main bearing caps, checkthe rollers in the main bearings to assure that each row of rollers in each bearing isequally loaded. Equal loading is obtained by positioning the floating bearing carrier sothat the same number of inner and outer rollers supporting the weight of the crankshaftin each bearing are tight. Because of tolerances, etc., the total number of tight rollerscould vary slightly between individual bearings.4. Install and shim main bearing caps to obtain .003 (.076 mm) clamp or preload on themain bearing carrier. This preload is obtained by placing the correct amount of shimsunder the main bearing cap. The required amount of shims is determined as follows:

Installation of Crosshead GuidesWhen installing crosshead guides observe the following procedures and precautions:1. Thoroughly clean all dirt or contamination and remove all burrs or rough edges fromboth 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 scoringstreaks. Pumps with serial numbers below those shown have identical upper and lowercrosshead guides which may be reversed to provide a smooth surface for the lowerguide. Worn guides may be used at the top as forces on the crosshead are alwaysdownward.

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

3. Install the left hand crosshead first. Rotate eccentric assembly to move eye intocenter crosshead and right hand eccentric strap eye back, affording clearance toinstall center pin through right hand crosshead inspection door. Remove diaphragmstuffing box plate (1, Fig. 19) and install right hand crosshead through this bore. Slideinto place and install crosshead pin.* NOTE: If old crossheads are to be reused, inspect the sliding surfaces for wear orscoring. If necessary, the crossheads may be switched to opposite sides of thepump and rotated 180 to provide a smooth surface for the bottom of thecrosshead. The center crosshead can be rotated 180 and the crosshead pininstalled 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 fourcrosshead retainer to crosshead bolt holes (4) are in alignment. Install the crossheadretainer 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 tooil holes (5). Two holes are provided so the pin can be rotated 180 in relation to pin toretainer plate screws (3).Seat crosshead pin in tapered bore by bumping large end with a light blow. Tightenretainer bolts (3 and 4, Fig. 19) to the following torque and safety wire:FD-500FD-1000

Checking crosshead alignmentTo obtain optimum service life from the pistons and liners, the horizontal centerline of thecrosshead 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 theplate.2. Position crosshead at mid point of stroke. With inside calipers or telescoping gaugesand a micrometer, accurately measure the distance from the diaphragm plate bore tothe crosshead extension rod at the top and bottom. Compare the two measurements todetermine 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 rodback to center, provided there is ample clearance between the top of crosshead andupper guide. Cut shims from steel shim stock long enough to reach completely acrossthe guides. Cut tabs on the sides to bend down over frame supports to hold shims inplace. Refer to items 3 and 4 under Installation of Crosshead guides.4. Some older pumps were manufactured with large crosshead clearance which will causea loud knocking noise under poor suction conditions. Specifications have been revisedto .020 - .030 (.51 - .76 mm) clearance. After proper alignment has been obtained, thetop guide should be shimmed down to provide the specified clearance.

FLUID END MAINTENANCEFor many years, the fluid end of a pump was considered a non-wearing part which did notcause any concern other than possible infrequent repairs or replacements resulting fromfluid cuts or washouts. However, the higher pressures of the present-day drillingrequirements have resulted in higher stresses being imposed on the fluid end which , whencombined with the corrosive characteristics of the drilling fluid, have resulted in the demandthat more and better maintenance be given to the fluid end parts and pieces if a reasonableoperating 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 putinto operation. Kicking pump in against a closed valve can often be the start of afatigue crack. An open crack may not necessarily occur at the precise moment,however a small crack could occur and start the process of corrosion fatiguefailure.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 onthe liner size being used.d. Do not operate the pump for an extended period of time if a severe fluid knock ispresent. The additional stress cycle, although of a lesser magnitude than normaloperating loads, must be added to the total number of cycles when considering thefatigue life of the equipment.e. Properly prepare fluid end for storage. When pump is to be shut down or notoperated for a period of ten days or more, it is recommended that the fluid end partssuch as liners, pistons, rods, etc., be removed from the pump and the fluid endflushed out completely with fresh water. After a thorough flushing, apply grease or arust 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 removedfrom the pump including liners, piston rods, etc., should of course be protected fromthe elements. This will not only extend the life of the fluid end through resistance tocorrosion, but will also protect the usable life still left in the expendable parts andmaintain them in good condition for installation in the pump at the next start-upperiod.Maintenance and repairs should be made on the fluid end assembly by observing thefollowing 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 dischargemanifold.12.1

PRESSURERELIEFVALVES! Notice !Our Technical Publications relative to reciprocating pumps, state that pressure relief valvesmust be installed in the discharge systems from these units. This supplement is issued toemphasize the importance of relieving the discharge system of all pressure which exceedsthe 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 ReciprocatingPump must be equipped with a device which relives the system of all pressures whichexceed the pressure rating applied by the manufacturer to each particular piston or plungerdiameter. Allowances will be made for pressure surges which are inherent with thereciprocating action of piston and plunger pumps. The percentage of pressure allowanceappears 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 valvedesigned for automatic or manual resetting; however, if preferred, rupture discs or burstmay be installed.Failure to comply with the procedures outlined in the Warning may result in damage to thepump and related equipment and more importantly may cause serious bodily injury ordeath!1.1

Location of the Relief Valve1.The relief valve must be placed in the discharge line as close as possible to thepump 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 VALVESPump TypeOperating Pump PressureDouble Acting DuplexPiston Pressure Rating Plus 25%Double Acting TriplexPiston Pressure Rating Plus 10%Double Acting QuintuplexPiston Pressure Rating Plus 10%Single Acting TriplexPiston Pressure Rating Plus 10%Single Acting SimplexPlunger Pressure Rating Plus 25%Single Acting DuplexPlunger Pressure Rating Plus 10%Single Acting TriplexPlunger Pressure Rating Plus 10%Single Acting QuintuplexPlunger Pressure Rating Plus 10%Single Acting SeptuplexPlunger Pressure Rating Plus 10%Note: The above set pressures are to be observed when installing rupture discs or burstdiscs.www.nov.com

It is National Oilwell Varcos recommendation to use a Molybdenum Disulfideoil additive with the Mud Pump Gear Oil during initial running and when signsof 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 ofinitial pitting common on Mud Pump gears.Moly oil additives such as Dow-Corning Molykote M Gear Guard (mixture5% by volume) or TS-90 Moly Gear Concentrate have been used in thisapplication with good results. The oil additive would need to be compatiblewith 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 Schaeffer209A Gear Lube, would assure the amount suspended in the oil is correctand it is thoroughly mixed. It is also extremely important to follow the NationalOilwell Varco gear oil recommendations as seen in Table 1. Therecommended gear oils have the film strength necessary to withstand the

Page 2 of 3impact loading encountered in oilfield drilling operations. The results of notusing the recommended gear oil may permit metal-to-metal contact of thegear teeth, which will be noticeable in the form of excessive pitting and wearon the load side of the gear teeth. Excessive pitting and wear can result in anincreased risk of mud pump damage. National Oilwell Varco recommendsthat an ISO viscosity grade 460 oil be used during the wear-in periodfor all P-Series Mud Pumps. The duration of the wear-in period isconsidered the first 2000 hours of use but can vary depending on usage.After the wear-in period has been accomplished, the lubricating oilshould be selected from the appropriate temperature range in Table 1below:PSERIESMUDPUMPSAGMAINDUSTRIALEPGEAROIL

Table 1. Mud Pump Lube OilsThe Mud Pump bull gears may develop corrective pitting during the earlystages of the product life. This corrective pitting process can be exaggeratedby operating a Mud Pump for extended periods at high load, especially if thelube oil temperature exceeds 140F (60C). As a result of the correctivepitting process, small metal particles will be present in the lubrication oil.These metal particles normally accumulate on the power end magnets, in thelube oil filter, in the settling chamber and in the main sump. National OilwellVarco recommends that the magnets, filter and sumps be checked regularlyand maintained/cleaned as needed.It is further recommended that all commissioning and endurance tests bedesigned such that the pump speed and discharge pressure is graduallyincreased from the lower speeds and pressures to the higher ones. This is toallow the gears to wear in gradually and reduce the occurrence of excessivegear pitting.

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

This procedure establishes the method for the selection and application of safety wire.Lock