7. FD-1600 Triplex Mud Pump User Manual

http://slidepdf.com/reader/full/7-fd-1600-triplex-mud-pump-user-manual 1/386
Document Number: D2G1008930-FDD-001
a l
REVISION HISTORY
01 8/11/2014 For Information T. Schutt J. Olson B. Schumer
Rev Date (dd/mm/yyyy) Reason for Issue Prepared Checked Approved
CHANGE DESCRIPTION
www.nov.com
Revision:
Page:
1 2 Installation, Operation & Maintenance
1 2.1 Procedures
1 3.2 System / Process Diagrams Section Not Applicable
1 3.3 Electrical / Instrument Section Not Applicable
1 3.4 Performance Data
1 4 Vendor Documentation
Revision:
Page:
www.nov.com
Revision:
Page:
1 2.1 Procedures
www.nov.com
REFERENCE REFERENCE DESCRIPTION
Triplex Mud Pump
This document contains proprietary and confidential information which belongs to National-Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively 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 design or distribution of this information to others is not permitted without the 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 which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV.
National Oilwell Varco
National Oilwell Varco
11000 Corporate Centre Drive Suite 200 Houston, Texas 77041 U.S.A.
Phone: +1-281-854-0400 Fax: +1-281-854-0607
REMARKS
Pre-Shipment And Storage Preservation For New-Build NOV Triplex Mud Pumps
8/16/2019 7. FD-1600 Triplex Mud Pump User Manual
www.nov.com
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION
02 Added NOV Standard Front Cover & Updated Page Formats
www.nov.com
3 MANUFACTURING PLANT PRESERVATION AFTER PAINT ........................................ 5
4 STORAGE AT MANUFACTURING PLANT OR FINAL DESTINATION .......................... 6
5 STORAGE PREPARATIONS FOR MAIN DRIVE MOTORS. ........................................... 6
6 PRESERVATION PROCEDURE WHEN STORAGE EXCEEDS SIX (6) MONTHS OF INITIAL PRESERVATION. .......................................................................................................... 6
7 START-UP AFTER STORAGE ........................................................................................ 7
8 CONTACT DETAILS FOR NOTED CORROSION PREVENTATIVE MATERIALS ......... 7
9 EXHIBIT 1 ......................................................................................................................... 8
10 EXHIBIT 2 ......................................................................................................................... 9
www.nov.com
1 SCOPE
This specification covers the preservation and storage procedure for shipment of new-build
NOV Triplex Mud Pumps shipped from the manufacturing plant.
This specification is intended to provide preservation of new-build NOV Triplex Mud Pumps for six (6) months from the shipment of the mud pump from the manufacturing facility. If a pump is to be stored for a period of time exceeding six (6) months, additional precautions should be taken as outlined in this specification.
National Oilwell Varco recommends that all pumps are inspected for any signs of corrosion and for proper preservation at a minimum every three (3) months for pumps stored outside and every six (6) months for pumps stored indoors.
Sub-tier: National Oilwell PS-3081
2 MANUFACTURING PLANT PRESERVATION PRIOR TO PAINT
Drain all water and clean out liner wash tank. Remove drain plug in bottom of liner wash pump and drain water then reinstall plug. Remove discharge flange from liner wash pump and pour one (1) pint of inhibiting oil-based concentrate (Cortec VpCI 329 Vapor Corrosion Inhibiting oil-based concentrate or equivalent) into liner wash pump. Rotate two (2 revolutions by hand to distribute the product. Re-install discharge flange.
Drain all oil from pump power end sump and remove crosshead covers and inspection covers. Clean out oil sump as per National Oilwell PS-3081 (Mud Pump Cleanliness) Spray all internal machined parts of power end and crosshead area with inhibiting oil-based concentrate (Cortec VpCI 329 Vapor Corrosion Inhibiting oil-based concentrate o equivalent). Rotate pump ½ turn and re-spray. Pour quantity of inhibiting oil-based concentrate specified in the table below into power end sump.
Mud Pump Models 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 Gallons7P, 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).
www.nov.com
Replace all guards and seals as necessary using specified gasket material and sealing compounds.
Remove fluid end valve covers, seals, valves springs and seats and treat internal cavities
of fluid ends, discharge manifold, discharge strainer block and suction manifold with rus preventative (CRC SP400 or equivalent). Coat threads with anti-seize (KOPR KOTE 10002 or equivalent) and coat bottom side of valve cover with rust preventative. Reinsta seals 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 expendables are checked for preservation when packed and then shipped with the loose parts.
3 MANUFACTURING PLANT PRESERVATION AFTER PAINT
Remove breather and pack with loose parts for later shipment with pump. Seal breathe hole with a greased solid plug. Affix a warning label near the breather opening (see Exhib 1).
Spray all external unpainted machined parts of pump with rust preventative (CRC SP400 o equivalent).
Cover large diameter pipe and other openings with hardboard and protective plastic wrap Liner bushing openings shall also be covered and sealed.
Seal all other pipe work (air, water, and electrical) with plastic caps of the correct size and
style. Electrical J-boxes are to be encased in protective plastic wrap. Place two (2) one pound bags of desiccant inside each J-box before sealing with tape. Wrap pressure gauges with bubble paper and plastic.
Tape or band down loose hinged guards and inspection covers.
Spray all machined unpainted loose parts and expendables to be shipped with pump with rust preventative (CRC SP400 or equivalent). All parts will be wrapped or boxed to preven 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.
www.nov.com
7 START-UP AFTER STORAGE
Any pump that has been in storage will need a thorough inspection prior to start-up to insure it has not been damaged in any way and that all parts are properly in place. Failure
to observe the following points can result in serious damage. Before servicing the pump the power end sump and chain drives housings will need to be drained of any inhibiting additive. The Cortec brand products used for preservation are compatible with a lubricating oils and need not be totally removed when putting equipment into service.
To service the Power End after storage and prior to start-up, remove all covers and thoroughly clean and inspect all of the parts and finished surfaces. Check all of the bearings to make certain they are clean and in good condition. Fill the power end with clean EP oil of the proper viscosity to the proper level. Make sure oil is poured into the o distribution trough and is worked into all of the bearings. Replace all covers and insta breather.
To service the Fluid End after storage and prior to start-up, remove covers and thoroughly clean and inspect inside of the fluid end cylinders. Properly install valves, pistons, liners and all other fluid end parts. Carefully tighten all bolts, nuts, studs and working connections to specified torque requirements.
8 CONTACT DETAILS FOR NOTED CORROSION PREVENTATIVE MATERIALS
Product Name Company Contact Number Cortec VpCI 329 Gulf Corrosion Control (713)681-7500
CRC Industries Inc. SP400 Fastenal (713)983-7715
KOPR-KOTE Drago Supply Co. (800)553-2363
www.nov.com
PUMP INTO SERVICE
NOV PN xxxxxxx
www.nov.com
MONTH DAY YEAR
MANUAL
EDN-1688 1 of 12
SUBJECT COMMISSIONING PROCEDURE, FB/FD-1600
B. Schumer 12 Apr 2012 Bryce Brock 13 Apr 2012
SELLER INFORMATION
ADDRESS: 11000 Corporate Centre Drive Houston, TX 77041
TELEPHONE: (281) 854-0400
TELEFAX: (281) 854-0505
DOCUMENT NUMBER: EDN-1688
EDN-1688 2 of 12
COMMISSIONING INDEX
4. Instrumentation........................................................................................... 4 5. Liner Wash System..................................................................................... 4
11. Discharge Strainer………………………………………………………… 5
12. Mud Pump Drive Assembly………………………………………………. 5 a. Belt Drive Units…………………………………………………… 5
b. Chain Drive Units…………………………………………………. 5
Part II. Commissioning Procedures
1. Pre-Commission Checks………………………………………………….. 6
3. Inspections/Check-Offs during Test Program…………………………….. 9
EDN-1688 3 of 12
INITIAL STARTUP PROCEDURES
GENERAL:
The initial startup procedures are written to assist the operator in preparing the pump packages for normal
operation. The startup procedures are separated into two categories: Part I: Pre-Commissioning, and Par
II: Commissioning Procedures. It is suggested that a copy of these pages be made for each pump to be used as a check-off sheet.
PART I. PRE-COMMISSIONING PROCEDURES:
1. Power End of Pump:
a. Drain and flush any moisture or contamination that has accumulated in the power end reservoir. Fill to the “FULL” mark on the dipstick with the recommended oil.
Ambient Temperature: 0°F to 85°F (-18°C to 33°C) = AGMA No. 4 EP
30°F to 155°F (-1°C to 68°C) = AGMA No. 6 EP
Reservoir Capacity: 100 US Gallons (379 Liters)
Note: The rust preventative on the internal surfaces of the pump is oil-soluble and is
compatible with the lubricants recommended above. It is not necessary to flush and drain unless the preservative has become contaminated (water, sand etc.).
b. Oil Filters:
Assure that the oil filters in the power end reservoir and external oil pump system are clean.
2. Main Electric Drive Motors:
Megger test the motors. Check each motor separately for the correct rotation. Reconnect if necessary.
Megger test the blower motors. Check blower motors for correct rotation and quantity of air flow.
EDN-1688 5 of 12
9. Pressure Gauge:
Check to assure that the gauge is installed and there is no shut-off valve between it and the
discharge system.
10. Reset Relief Valve:
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.
11. Discharge Housing with Strainer:
Remove the strainer screen from the housing and assure that it is clean and free from obstructions.
Check the stud nuts for proper make-up torque.
12. Mud Pump Drive Assembly:
Belt Drive Units:
Check the belt guards to ensure that belts will not drag on the guard.
Check the belt tension as instructed in the maintenance section of the operations manual. Check the alignment of the drive motors.
Chain Drive Units:
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.
EDN-1688 6 of 12
PART II. COMMISSIONING PROCEDURES:
GENERAL:
The power end and the fluid end have gone through rigorous tests prior to being shipped from the
manufacturing site; therefore, the following recommendations for the commissioning test are made for the purpose of checking the overall unitization functions, including instrumentation, and to
assure that there are no problems which may have occurred during transportation and storage.
Operation of the pump in parallel to check the SCR-Motor assignments and controls, volumetric displacement and mudline systems are at the option of the purchaser.
A. PRE-COMMISSIONING CHECKS:
Prior to starting the unitized pump package, review the previously outlined Pre-Commissioning
Requirements in Part I.
Check the discharge mudline to assure that all necessary valves are open. Ensure that the mud tank
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:
Check oil pressure: Max. = 60 PSI (4.14 bar) cold oil.
Min. = 5 PSI (0.344 bar) at any speed.
Normal = 7-40 PSI (0.483-2.76 bar)
2) Liner Wash System:
Adjust the regulator valve for proper volume of cooling fluid. 10 US Gallons (38 Liter per minute per liner.
Check the coolant temperature. 150°F (66°C) maximum.
3) Check for oil leaks around the power end covers and seals.
4) Check for interference or dragging in the belt/chain drive assemblies.
EDN-1688 7 of 12
5) Visually inspect the mud pump drive assembly for any unusual conditions, i.e. loose bolts,
vibration, noise, etc.
Pump A/C motor operating properly.
Valves open for the proper volume of drilling fluid. Gauges/controls functioning properly.
7) Check the relief valve:
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.
EDN-1688 8 of 12
B. COMMISSIONING OPERATIONAL TEST:
DURATION: EIGHT (8) HOURS TOTAL RUNNING TIME.
The following are basic guidelines for conducting of an eight (8) hour operational test. The pump was test run under pressure in the manufacturing plant but with different motors and drives.
The discharge pressure can be regulated by temporarily installing an adjustable choke at some point in
the discharge line.
NOTE: There can be short intervals of shut-down time to fix leaks, make adjustments, etc., without having to restart the test program.
1. LOWER PRESSURE TEST – DURATION: TWO (2) HOURS: TIME
START STOP
1000 PSI (68.9 bar)………………………..40 min. @ 60 SPM _______ _______
2. MEDIUM/HIGH PRESSURE TEST – DURATION: SIX (6) HOURS:
1500 PSI (103.4 bar)………………………60 min. @ 80 SPM _______ _______
2000 PSI (138 bar)………………………...60 min. @ 100 SPM _______ _______
2500 PSI (172.4 bar)………………………60 min. @ 100 SPM _______ _______
RATED LINER PRESSURE*…………...180 min. @ 100 SPM _______ _______ * Not to exceed pressure rating of fluid end.
EDN-1688 9 of 12
C. INSPECTIONS/CHECK-OFFS DURING TEST PROGRAM:
The overall performance of the unitized pump package should be continuously monitored during the
eight hour test program. The following checks should be made and recorded each two hours of
operation.
1. POWER END LUBRICATION:
COOLING AIR TEMP………… ______ _____ _____ _____ _____
EDN-1688 10 o
TRIPLEX MUD PUMP
START 2 HR 4 HR 6 HR 8 HR
4. MAIN DRIVE MOTOR NO. 2:
COOLING AIR TEMP………… ______ _____ _____ _____ _____
EDN-1688 11 o
TRIPLEX MUD PUMP
START 2 HR 4 HR 6 HR 8 HR
7. OVERALL VISUAL EXAMINATION (Yes/No):
OIL LEAKS………….………… ______ _____ _____ _____ _____
GUARDS DRAGGING..……… ______ _____ _____ _____ _____
LOOSE BOLTS……..…………. ______ _____ _____ _____ _____
EDN-1688 12 o
TRIPLEX MUD PUMP
COMMISSIONING ACCEPTANCE:
Date Complete: ________________________________
REMARKS
CLIENT PO NUMBER
CLIENT DOCUMENT NUMBER
Client Document Number
REFERENCE REFERENCE DESCRIPTION
Triplex Mud Pump
This document contains proprietary and confidential information which belongs to National Oilwell Varco; it is loaned for limited purposes only and remains the property of National Oilwell Varco. Reproduction, in whole or in part; or use of this design or distribution of this information to others is not permitted without the express written consent of National Oilwell Varco. This document is to be returned to National Oilwell Varco upon request and in any event upon completion of the use for which it was loaned.
© National Oilwell Varco
National Oilwell Varco 1530 W Sam Houston Pkwy. N Houston, TX 77043 Phone 713-935-8000 Fax 713-935-8382
DOCUMENT NUMBER
www.nov.com
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION
www.nov.com
PREFACE
This manual is provided for guidance of those who wish to install, repair, maintain, or adjust the National Oilwell Varco equipment covered herein. This information has been prepared with a basic viewpoint to give accurate and concise data needed to perform minor adjustments as well as major overhauls.
This information is not elementary, as it is intended for operators and servicemen who are familiar with drilling equipment in general. It is not intended, nor would it be possible in such limited space, to cover every possible condition which may be encountered. Always use good, sound mechanical practices and safety precautions.
All specifications are in accordance with Engineering designs and should be adhered to in all
repairs. Operation and maintenance information on equipment other than National Oilwell Varco’sis taken in part from the various manufacturers’ manuals. If the equipment manufacturers issue later instructions, or in the event of conflict, the manufacturer’s information will take precedence over that shown in this manual, unless specifically stated otherwise.
Refer to the General Lubrication Bulletin for approved lubricants. If any discrepancy exists between the recommendations in this manual and the General Lubrication Bulletin, those in the Lubrication Bulletin will take precedence.
The manual sections follow logical divisions in major components, and cover all standard production unless otherwise specified. Specifications and components covered are for standard
equipment current at the time this manual was approved for printing.
National Oilwell Varco reserves the right to discontinue models at any time, or change specifications or design of any model without notice and without incurring any obligation.
www.nov.com

IN ORDER TO PREVENT PERSONAL INJURY during performance of any maintenance or inspection procedures, this equipment must be shut down and not operating. Each motor and generator is equipped with a motor cutout switch. This switch should be IN, and the safety bar in place, when any maintenance or inspection procedures are performed. Employ good mechanical practices when making maintenance repairs, adjustments, inspections, etc.
When operating all mechanical and electrical equipment, all safety devices must be engaged, properly adjusted, and in good operating condition, including overtravel devices for traveling blocks, warning or shutdown devices for engines, etc.
www.nov.com
2 SETTING THE PUMP..................................................................................................... 11
4.1 Power End Lubrication.......................................................................................... 17
Installation of Crosshead Extension Rods and Diaphragm Stuffing Box Seals..... 18
5 PISTON AND LINER COOLING SYSTEM..................................................................... 19
5.1 Stationary spray (View A, Fig. 6) .......................................................................... 20
5.2 Moving Nozzle ...................................................................................................... 20
6.1 Valves and Seats.................................................................................................. 23
7 FD-500, FD-800 & FD-1000............................................................................................ 24
7.5 Cylinder head ....................................................................................................... 26
8.5 Discharge Valve Pot Covers................................................................................. 29
8.6 Discharge Manifold all models.............................................................................. 30
www.nov.com
11 MAINTENANCE.............................................................................................................. 38
11.6 Installation of Crosshead Guides.......................................................................... 48
11.8 Checking crosshead alignment............................................................................. 51
12 FLUID END MAINTENANCE.......................................................................................... 51
12.2
12.5 Welding and Repairs ............................................................................................ 54
12.6 Welding Procedures ............................................................................................ 58
www.nov.com
www.nov.com
www.nov.com
FD-500 (mm) FD-800 ( mm ) FD-1000 ( mm ) FD-1600 ( mm
A 3’-11-3/8” (1203) 4’-8-7/8” (1445) 4’-10-5/8” (1489) 5’-0-5/8” (1540
B --- --- --- -- ---- -- 5’-7-13/16” (1722
C 3’-2-15/16” (989) 3’-4-1/2” (1029) 3’-8-3/8” (1127) 4’-0-1/8” (1222
D 3’-11-3/16” (1198) --- -- ---- -- 4’-8-1/16” (1424
E 12-1/16” (305) 12-7/16” ( 316 ) 13-3/4” ( 349 ) 13-3/16” ( 335
F 3’-1” (939) --- -- ---- -- 4’-3-3/4” (1315
G 3’-8-1/2” (1197) 3’-11-1/8” (1197) 4’-5-1/2” (1359) 4’-11-3/4” (1518
H 4’-9” (1448) 5’-1-3/4” (1568) 8’-0” 92438) 7’-10” (2388
J 6’-9-7/8” (2079) 7’-11-3/8” (2423) 8’-4-1/4” (2546) 8’-11-7/8” (2740
** K --- --- 4’-6-1/4” (1378) 4’-6-7/8” (1394) 4’-10-1/4” (1480
L (Dia.) 5.5” (139) 7.00” (177.8) 7.750” (196.85) 8.500” (215.90
(Keyway) 1-1/4” x 5/8” (31.7 x 15.8) 1-3/4 x 7/8” (44.45 x 22.225) 2” x 1” (50.8 x 25.4) 2” x 1” (50.8 x 2
M 3’-11” (1193) 4’-3-3/8” (1305) 4’-9-3/8” (1457) 5’-5-3/4” (1670
N 5’-0-3/4” (1543) 5’-5-1/4” (1657) 5’-11-1/8” (1807) 6’-10” (2083
P 4’-3-3/8” (1305) 4’-6” (1372) 5’-1” (1549) 6’-1-3/8” (1864
Q 12’-0” (3658) 13’-0” (3962) 13’-6” (4115) 16’ (4877
R 1’-3-5/16” (389) 1’-3-5/8” ( 397 ) 1’-6-7/8” ( 479 ) 1’-9-3/4” ( 553 S 10” (254) 10” ( 254 ) 12” ( 305 ) 12-1/4” ( 311
T --- --- 1’-1” ( 330 ) 1’-1” ( 330 ) 1’-4-1/2” ( 419
U --- --- 2’-0-1/2” ( 622 ) 1’-2-3/8” ( 365 ) 1’-1-3/4” ( 349
V 3’-0-3/4” (933) 3’-1-1/2” ( 953 ) 2’-2-3/8” ( 670 ) 2’-6-1/4” ( 768
W 9-3/4” (250) 10-3/4” ( 273 ) 10-3/4” ( 273 ) 12-9/16” ( 319
X 1’-4-7/8” (422) --- -- ---- -- 1’-7-1/4” ( 489
**Required to remove Suction Desurger.
www.nov.com
Specifications
6-3/4” (171.45 mm) 7-1/2” (191 mm)
6-3/4” (171.45 mm) 9” (228.6 mm)
6-3/4” (171.45 mm) 10” (254 mm)
7-1/2” (190.5 mm) 12” (304.8 mm)
Nominal HP Rating
Lubrication Pressure and Splash to all Moving Parts
Valve Pots API No. 6 API No. 6 API No. 6 API No. 7
Approx. Wt. (Lbs.)
18,657 (8,463 kg) 26,603 (12,067 kg) 33,770 (15,318 kg) 46,820 (21,238 kg)
*FD Max. liner size 7” (177.8 mm)
www.nov.com
1 INSTALLATION OF NEW PUMP
Your National Oilwell Varco pump has been completely assembled and test operated unde
pressure before being shipped to the field. Unless otherwise instructed, the lubrication is drained from the power end and the expendable parts are removed from the fluid end. Before putting the pump into service, the following precautions and operations must be performed or checked.
In order to prevent personal injury during the performance of any maintenance or
inspection procedures, this equipment MUST BE SHUT DOWN AND NOT OPERATING,
and all safety devices on prime movers, drives, etc., MUST BE IN THE SAFE POSITION.
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.
www.nov.com
Fig. 2
Suitable means, such as National Oilwell Varco pump spacers as shown in Fig. 3, should be used to keep the pump anchored and the drive in alignment. National Oilwell Varco mud pump spacers provide 8-1/2” (215.9mm) adjustment. Any desired length may be obtained by lengthening the standard pipe spacer, which is made of 3” (76.20mm) extra strong pipe.
Three types of attaching heads are available with this spacer:
1. The chain type to fit pipe.
2. The hinged flange type for attachment to flat surfaces.
3. Any combination of the two.
www.nov.com
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 a points shown in Figs. 2 and 4 and observe caution of proper shimming to prevent twist or distortion.
The shims on all installations should extend the full width of the skid beam flanges and have a minimum length of 12” (305mm).
On installations where the power unit or electric motor is mounted integrally with the pump skids, the preferred installation would be to set the pump package on the T-beam skids and provide retention blocks rather than bolts to hold it in place. This will allow the pump to “float” and minimize the transfer of barge deck or platform distortion into the frame.
2.1.2 Installation of the Drive
The drive between the mud pumps and the power source, whether V-belts or multi-width chains, should be installed with the greatest care to assure maximum operating life with minimum of unexpected or undesirable shutdowns due to drive failures.
When installing the drive sheave or sprocket, make sure all grease or rust preventative is removed from the shaft and the bore of the drive. Remove all burrs or rough spots from the shaft, key, and keyway. Fit key to the keyways in both the shaft and drive and install key into shaft keyway.
Coat pinion shaft with a light coating of anti-seize compound or light oil and install the drive sheave or sprocket hub. Tighten hub bolts as indicated below:
www.nov.com
When a wrench or length of pipe is used to increase leverage in tightening draw-up bolts, it is imperative to adhere to the wrench torque values given in the chart below. This adherence is important, because in mounting the hub, the tightening force on the bolts is multiplied many times by the wedging action of the tapered surface. This action
compresses the hub for a snug fit on the shaft. If the bolt tightening forces are extreme, bursting pressure is created in the hub of the mounted pulley; this pressure may cause the pulley to crack. The hub bolts should always be tightened alternately and progressively.
QD
Hub
Lbs.
FD-500 P 540 (62 meter kg) 30 (.76 meters) 180 (82 kg)
FD-800 W 600 (83 meter kg) 36 (.90 meters) 200 (92.2 kg)
FD-1000 W 600 (83 meter kg) 36 (.90 meters) 200 (92.2 kg) FD-1600 W 600 (83 meter kg) 36 (.90 meters) 200 (92.2 kg)
2.1.2.1 V-Belt Drives
a. Check sheave groove condition.
Before installing the V-belts, check sheave grooves for wear. Worn or rounded grooves will destroy V-belts rapidly. The side walls must be straight. Sheave grooves must be free of dirt, rust or other extrusions which could damage the V- belts.
b. Check sheave alignment.
The final alignment of the V-belt sheaves should be checked after the V-belts have been installed and adjusted to their operating tension. If the sides of the sheaves are of equal distance from the centerline of the groove, check alignment by stretching TWO strings (fish line or piano wire preferred) along one side of the two sheaves, one above and one below the centerline, and moving one of the sheaves until the strings touch four points on the side of the sheave rims. This will determine that the centerline of the drives are parallel and the faces of the sheaves are square
c. Adjust V-belts for proper tension.
Adjust the belt tension by moving the sheaves apart until all of the sag has just been eliminated from the tight side of the belt and some of the belts on the slack side. Then increase the centers approximately ½” (13mm) for each 100” (2540 mm) center distance. Example: On 150” (3810 mm) center, move pump an additional ¾ (19.5 mm).
www.nov.com
DO NOT OBTAIN BELT TENSION BY PICKING UP END OF PUMP AND
ALLOWING BELTS TO TIGHTEN UNDER WEIGHT OF PUMP AS END IS BEING LOWERED TO THE GROUND.
2.1.2.2 Chain Drives
a. Installation
Proper installation and maintenance of the sprocket and chain drives are essential if good service life is to be obtained. Since many factors, such as chain width, center distances, speeds, and loads must be considered when determining the allowable tolerance for sprocket alignment, no good “rule of thumb” can be applied. The chain alignment must simply be held as nearly perfect as possible. A more precise alignment can be made by stretching two steel wires (piano wire) along one face of the two sprockets, one above and one below the centerline, and moving one of the
sprockets until the wires touch at four points. This will determine that the centerlines of the drives are parallel and the faces of the sprockets are square.
b. Drive chain lubrication
The pump drive chain lubrication system on the majority of National Oilwell Varco pumps is an independent system having its own oil pump, reservoir, and drive. Fill chain case to the indicated level with a non-detergent oil as follows:
Ambient temperature above 32°F (0°C) SAE-30 Ambient temperature below 32°F (0°C) SAE-20
For temperatures below 0°F, consult a reputable lubrication dealer for recommendations.
REFER TO GENERAL LUBRICATION BULLETIN for approved lubricants and additional specifications. If any discrepancy exists between the recommendations in this manual and the General Lubrication Bullletin, those in the Lubrication Bulletin will take precedence.
Since this is an independent system, it will require the same maintenance or service attention employed on any other piece of machinery, including:
- Daily check of oil level. - Daily check on condition of oil. - Frequent check on oil pressure. (5-15 psi) (.352 - 1.06 kg/cm²) - Volume of oil being applied to chain. - Condition of nozzles in spray tube. - Condition of oil pump drive (V-belts or chain)
www.nov.com
NOTE: Oil pressure may be adjusted with the pressure relief adjusting screw
on the rear of the pump housing. Pressure drops may also indicate suction and discharge filter screens need cleaning.
3 SUCTION SYSTEM REQUIREMENTS
Individual installation conditions will dictate the design of the suction system. The suction of the FD-series pumps must have a positive head (pressure) for satisfactory performance. The optimum suction manifold pressure is 20-30 psi (1.75-2 kg/cm²) for maximum volumetric efficiency and expendable parts life. This head pressure is best supplied by a 5 x 6 centrifugal pump with 40 h.p. 1150 rpm electric motor. This type of drive requires a device to automatically start and stop the centrifugal pump motor simultaneously with the triplex pump. On DC electric powered rigs a signal can usually be supplied from the DC control panel to energize a magnetic starter when the mud pump clutch air line will provide
a set of contacts for energizing the magnetic starter when clutch is engaged.
The charging pump can also be belt driven from the triplex pinion shaft charging type of drive is not as efficient at slow speeds with viscous fluids.
Under some conditions the FD-Series pumps may be operated without a charging pump, provided the fluid level in mud pits is higher than the top of the liners, fluid being pumped is low viscosity and suction line must be short, straight and of at least the same diameter as suction manifold inlet.
The suction lines should be piped with valve arrangements so the charging pump can be
by-passed so operation can be continued in event of charging pump failure or for maintenance. Operation without a charging pump can be improved by replacing the suction valve springs with a weaker spring.
Suction desurgers are a very effective aid for complete filling of the liners and dampening pulsations in the suction line which results in a smoother flow in the discharge line. If your pump is equipped with a suction desurger it must be pre-charged with compressed air before operations are begun. See suction desurger manual for charging instructions.
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.
www.nov.com
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:
4.1 Power End Lubrication
Before installing lubricant, open inspection door in cover and check oil reservoir for possible accumulation of condensation, etc., and drain and flush by removing the pipe plugs on each side of the pump.
Add the proper type and quantity of lubrication in the power end. Refer to the Lubrication
Section of this manual, or lubrication plate on pump frame for type and quantity required.
Recheck oil level after pump has operated for a period of 15 minutes. Shut pump down and allow approximately five minutes for the oil level to equalize. Check at oil level gauge, Item 1, Fig. 1. It is usually necessary for a few more gallons of oil to be added due to a certain amount being retained in the crosshead area and frame cavities.
www.nov.com
4.2 Installation of Crosshead Extension Rods and Diaphragm Stuffing Box Seals.
With reference to Figure 5, remove the diaphragm stuffing box and plate (1) and rotate pump so that crosshead is at the front of the stroke. Thoroughly clean the front of the crosshead and the face of the crosshead extension rod. Insert alignment boss on crosshead extension rod into the crosshead bore and tighten the retainer bolts (2) to the following torque. Safety wire bolt heads.
FD-500 50-60 ft. lbs. (7-8 meter kgs) FD-800 80-100 ft. lbs. (11-14mkgs.) FD-1000 350-370 ft. lbs. (48-51 meter kgs) FD-1600 350-370 ft. lbs. (48-51mkgs.
Thoroughly clean face of power frame and diaphragm stuffing box plate at Position “A”. Install gasket (3) and capscrews (10). Tighten capscrews as follows:
FD-500 12-14 ft. lbs. FD-800 12-18 ft. lbs. FD-1600 90-120 ft. lbs. (1.7 - 1.9 meter kgs) (1.7 - 2.5 meter kgs) (12 - 17 meter kgs)
FD-1000 12-18 ft. lbs. (1.7 - 2.5 meter kgs)
www.nov.com
Clean bore and face of diaphragm stuffing box plate. Clean OD and flange of diaphragm stuffing box. Coat OD of diaphragm stuffing box with light oil and install O- ring seal (4). Insert diaphragm stuffing box in plate bore and tighten capscrews to the following torque:
FD-500 12-14 ft. lbs. FD-800 12-18 ft. lbs. FD-1600 90-120 ft. lbs. (1.7 - 1.9 meter kgs) (1.7 - 2.5 meter kgs) (12 - 17 meter kgs)
FD-1000 12-18 ft. lbs. (1.7 - 2.5 meter kgs).
The diaphragm stuffing box packing assembly consists of a single lip oil seal (6), a double lip wiper seal (11), a separator spring (7), an O-ring (8), and a lock spring (9). Install the assembly as follows:
a. Remove pressure spring (5) from single lip oil seal (6) and place seal in the inner
(power end) position on the crosshead extension rod, with lip toward power end. Replace the pressure spring in the seal lip and slide the seal into position in the stuffing box. SEE NOTE BELOW.
b. Insert the separator spring (7) over rod and slide it into stuffing box bore.
c. Install the O-ring (8) in groove in stuffing box bore.
d. Remove pressure spring (5) from double lip oil seal (11) and place seal in the outer position on the crosshead extension rod with main lip toward power end. Replace the pressure spring in the seal lip and slide the seal into position in the
stuffing box. SEE NOTE BELOW.
CAUTION: The double lip seal can be used in the inner, or power end, position to replace the single lip seal, but DO NOT use the single lip seal in the outer position.
e. Install the lock spring (9).
NOTE: CAUTION must be taken to assure the pressure spring (5) does not slip out of the groove in the oil seal lip, as severe scoring of the crosshead extension rod can occur. Coat extension rod with a light oil to facilitate
installation of the packing assembly.
5 PISTON AND LINER COOLING SYSTEM
Proper attention must be paid at all times to assure adequate cooling fluid is being applied to the piston and liner assembly. Stoppage of the cooling fluid will result in almost instant failure of the piston rubbers and possibly extensive damage to the liner bore.
www.nov.com
See sections 5.1 and 5.2 for call out numbers descriptions shown in figure 6.
www.nov.com
A typical rod cooling assembly consisting of fluid pump driven from pinion shaft and fluid reservoir mounted in the skids is shown in Figure 7.
With reference to Fig. 7, maintain electric motor (1) and centrifugal pump (2) according to manufacturer’s specifications. Rotation of the pump should be clockwise when viewed from the impeller end.
Adjust regulating valve (3) to apply as much water as possible to the liners without splashing back on the crosshead extension rods and diaphragm stuffing box plate. 10- gallons per minute per liner is the preferred flow rate. If water is allowed to splash on the crosshead extension rods, some of the water may work back into the power end to contaminate the lubrication oil.
www.nov.com

The cooling fluid is returned from the crosshead extension rod compartment to the settling chamber, and as the fluid overflows through the filter screen between the two sections of
the tank, the solids are allowed to settle out. The filter screen will catch much of the foreignmaterial floating in the fluid.
Check condition of the cooling fluid at frequent intervals and CLEAN and FLUSH reservoir as required. Contaminated fluid will cause premature liner and piston wear from abrasion or stoppage of the spray nozzle or spray tube.
6 ASSEMBLY OF FLUID END PARTS
6.1 Valves and Seats
Remove all three discharge valve pot covers (1), and three cylinder heads and plugs (2), and thoroughly clean all machined surfaces in the fluid end with a good cleaning solvent.
Make sure all valve seat bores are VERY CLEAN AND DRY (free of dirt, grease, anti-rust compound, etc.) and remove all burrs or nicks with a fine emery cloth, using circular motion around seat surfaces.
www.nov.com
7.1 Liners
Inspect liner bore again to make sure it is clean and free of foreign particles to assure meta to metal contact between the liner and fluid end. Foreign particles can cause the liner to
make up in a “cocked” position resulting in premature wear on liners and pistons.
7.2 Piston Rod
Clean piston and piston rod, making sure they are free of nicks and burrs. Install “O” ring seal (20) in groove in piston head. Slide piston head on rod while observing that “O” ring does not fall out of groove. Tighten piston rod nut (21) to 1200-1600 ft. lbs. (166-121 m/kgs.).
Coat liner I.D. and piston O.D. with grease. Check ends of piston rod and extension rod to be sure they are clean and free of burrs. Insert piston rod through liner holding piston rod
centered at the rear of the liner. Drive the piston into the liner with a driving tool or a piece of hardwood and sledge hammer. Use caution as the piston rod approaches the crosshead extension rod that the dowel on the end of the piston rod is not damaged. The piston rod must be supported and the dowel guided into the pilot bore.
7.3 Piston Rod Clamps
The piston rod clamps are machined as one piece and then cut in half. The two pieces are stenciled with matching numbers on each half and have a chain link connecting them together. The two pieces with the same matching numbers should always be kept together as a set. Install the clamp around the rod end flanges with the water connection holes at
top dead center. Tighten cap screws to the following torque values.
FD-500-368 ft. lbs. (51 Meter/kgs.)
FD- 800-100 ft. lbs. (14 Meter/kgs.)
FD-1000-160 ft. lbs. (22 Meter/kgs.)
When rods and rod clamps are new a gap in excess of ½” (13 MM) could be present between the two halves of the clamp. This is satisfactory provided the faces of the rods are seating metal to metal. As wear occurs, the halves will pull closer together. Clamping
action will be lost when a gap no longer exist. At this time clamps must be replaced.
www.nov.com
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 ¼ turn and seat into place underneath the cage. Insert the lower valve guide locking clip (9) through the pad eyes on the lower valve guide and rotate clip to the right to lock the valve guide tight against the OD of the liner cage. It may sometimes be necessary to put more or less bend in the center of the clip to make it retain the guide tightly while the clip handle snaps into position on the right hand side.
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.
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.
7.6 Discharge Valve Pot Covers
Install discharge valve pot gasket (3) into bore, and after liberal application of grease or too
joint compound to the gasket and thread area, tighten the discharge valve pot covers into place, using a sledge hammer and bar.
www.nov.com
Figure 9B
A cross section through the fluid end is shown in fig. 9B. With reference to fig. 9B thoroughly clean and assemble the fluid end parts in the following manner:
Note: All of the parts in this fluid end assembly are designed with metal to metal seating to alleviate friction wear from breathing action encountered in modern high pressure pump operation. For this reason it is essential that all parts be clean and free of rust, nicks and burrs before being assembled.
www.nov.com
8.1 Liner
Install wear plate seal (1) in counterbore of fluid end. Slide wear plate (2) over studs until it seats against fluid end. Slide liner thread ring (3) over studs with the starting thread at the 5 o’clock position and tighten nuts to 470-510 ft. lbs. (65-70 m/kgs.) torque.
Note: Placing the starting thread at 5 o’clock position makes engaging the liner lock threads much easier.
Place liner seal (4) in counterbore of wear plate. Apply thin coat of grease to ID of liner lock (5) and slide over rear of liner (6). Install two-piece liner lock ring (7) in liner groove and “O” ring to hold them in position.
Slide liner handling tool over liner up against liner lock ring and tighten set screw to secure it in place. Hoist liner assembly into position with jib hoist.
Note: FD pumps are factory equipped with jib booms and liner handling tools. If older pumps are converted to FD fluid ends a jib boom should be added to the pump frame as considerable weight is involved in handling the liner assembly.
Apply liberal coat of grease to liner lock threads. Align the starting thread of the liner lock (5) to the 7 o’clock position and insert the liner into the liner thread ring (3) screw liner lock in until liner seats in position . Tighten with sledge hammer on hammer lugs.
8.2 Piston Rod
Clean piston (9) and piston rod (8), making sure they are free of nicks and burrs. Install “O
ring seal (10) in groove in piston head. Slide piston head on rod while observing that “O” ring does not fall out of groove. Tighten piston rod nut (11) to 1200-1600 ft. lbs. (166-121 m/kgs.).
Coat liner I.D. and piston O.D. with grease. Check ends of piston rod and extension rod to be sure they are clean and free of burrs. Insert piston rod into liner through cylinder head opening holding piston rod centered at the rear of the liner. Drive the piston into the liner with a driving tool or a piece of hardwood and sledge hammer. Use caution as the piston rod approaches the crosshead extension rod that the dowel on the end of the piston rod is not damaged. The piston rod must be supported and the dowel guided into the pilot bore.
www.nov.com
8.3 Piston Rod Clamps
The piston rod clamps are machined as one piece and then sawed in half. The two pieces are stenciled with matching numbers on each half. The two pieces with the same matching
numbers should always be kept together as a set. Install the clamp around the rod end flanges with the water connection holes at top dead center. Tighten cap screws to the following torque values:
FD-1600 245 ft. lbs. (34 m/kgs.)
When rods and rod clamps are new a gap in excess of ½” (13 mm) could be present between the two halves of the clamp. This is satisfactory provided the faces of the rods are seating metal to metal. As wear occurs, the halves will pull closer together. Clamping action will be lost when a gap no longer exists. At this time clamps must be replaced. Install splash plate on rear of liner.
8.4 Lower Valve Guide and Cylinder Head
Slide the alignment ring (12) into the cylinder head opening engaging the alignment dowel at the 3 o’clock position. Do not drive on this piece as dowel or dowel hole will be damaged. It will slide easily into place when it is properly aligned.
Insert the lower valve guide (13) through the alignment ring and position the guide over the valve stem. Start the lock bolt (14) and draw it down, compressing the valve spring and seating the valve guide in the tapered slot. Tighten lock bolt to 300 to 340 ft. lbs. 41 to 47 m/kg².
Install head seal (15) on cylinder head plug (16). Coat seal and O.D. of plug with light oil. Screw a 3 ft. (1 M) length of pipe into the threaded opening on the plug. Using the pipe to balance the plug, slide it straight into the fluid end opening. Apply a liberal coat of grease to the cylinder head (17) with wrench provided and sledge hammer.
Fluid leakage through the weep hole will indicate a defective seal or loose cylinder head. DO NOT plug weep hole as this can result in severe damage to cylinder head threads, thread rings, etc., in event of a liner seal failure.
8.5 Discharge Valve Pot Covers Install discharge valve pot gasket (18) into bore, and after liberal application of grease or tool joint compound to the gasket and thread area, tighten the discharge valve pot covers (19) into place, using a sledge hammer and bar.
www.nov.com
8.6 Discharge Manifold all models
A 5”-1500*RTJ flange connection is provided on the discharge manifold. REMOVE flange and protect gasket area before welding (customer’s option) to the discharge piping. (*127mm)
Tighten discharge flange connection bolts to *1200-1600 ft. lbs. torque. To insure uniform make-up of the ring joint connection, tighten flange bolt nuts in a crisscross order. (*166- 121 meter kgs.)
If a blind flange is installed on the opposite end of the discharge manifold, check flange bolts and tighten to same specification as noted above.
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 ¼ “), (356mm OD x 343mm I.D. x 6.35mm Dia.)
NOTE: Thoroughly clean O-ring groove and face of flanges before making up connection. Flanges must make up metal to metal to insure proper seal. Tighten flange bolts to 360- 490 ft. lbs. (50-68 meter kgs.) torque.
CAUTION: If suction pipe is welded to suction flange, remove O-ring prior to welding.
8.8 Accessory Manifold
An accessory manifold, Fig.10, is available for installation on the discharge manifold opposite the discharge end. The manifold will accommodate a discharge pulsation dampener (1) and
provides two 3”-6000 PSI*side outlet connections for such items as a pressure gauge (2) and a shear relief valve (3).
When manifold is used, install and maintain as follows:
Fig. 10 is not the standard discharge arrangement on the model FD-1600 pump, which uses the strainer cross configuration.
www.nov.com
The flange on the accessory manifold is a 5”-1500 *RTJ. Thoroughly clean ring joint groove, install ring (4) and tighten the flange bolts (5) to 1200 ft. lbs. torque. To assure uniform make-up of the ring joint connection, tighten the nuts in a criss-cross order.
The shear relief valve (3) is installed on the discharge manifold for the purpose of protecting the pump from excessively high pressure overloads.
The relief valve must be installed so that it will be directly exposed to the mud. DO NOT PUT ANY TYPE OF SHUT OFF VALVE between the relief valve and the manifold. Pipe the discharge side of the relief valve directly into the mud pit with as few turns in the line as possible. IT IS NOT RECOMMENDED for the discharge side of the valve to be piped into the suction line of the pump.
* 5” - = 127mm
3” - 6000 PSI = two 76.2mm - 422 kg/cm²
The relief valve setting should be just above the maximum pressure rating of the particular liner size being used. CHANGE SETTINGS with each liner size change. DO NOT USE
ALLEN WRENCHES, WELDING RODS, or material other than that called for by the manufacturer of the relief valve, as this will affect the rating of the relief valve.
The mounting for the dischage pulsation dampener (1) is a RTJ flange with R-39 ring gasket. Before installing dampener, thoroughly clean ring groove and ring, and after setting dampener into place, tighten the 1-1/4”*nut (6) to 750 ft.lbs*. torque. To insure uniform
make-up, tighten nuts in a criss-cross order.
Precharge dampener before starting up pump. Precharge pressure should not be more than 2/3 of the pump discharge pressure, or a maximum of 650 PSI. (46 kg/cm²)
CAUTION: USE ONLY COMPRESSED NITROGEN OR AIR. DO NOT CHARGE WITH OXYGEN.
* 1-1/4” = 32mm
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.
www.nov.com
The FD-Series pumps utilize the controlled flow oil bath splash and pressure system to lubricate the entire power end. The type of pressure system provided in each individual pump will govern the minimum SPM at which the pump can be operated, i.e. pumps which
have pressure lubrication only to the main and pinion bearings, have a minimum rated speed of 40 SPM. Pumps in which pressure lubrication is provided to the main, pinion, and crosshead bearings and crosshead compartments may be operated at a minimum speed of 25 SPM, provided there is a minimum of 5 PSI oil pressure. (352 grams/cm²)
9.1 Minimum Operating Speeds
The minimum speed for all pumps is 40 SPM.
CAUTION: The pressure lubricating system can be provided with an externally mounted oi
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.
www.nov.com
9.2 Contro lled Flow Splash System
The controlled flow splash lubrication system is the same for all FD-Series pumps,
regardless of the type of oil pump drive provided for the pressure system. In the controlled flow splash system, the main gear picks oil up from the reservoir, and when the teeth mesh with the pinion, the oil is displaced into various troughs and compartments in the frame. With reference to Figure 13, the oil thrown into trough (7) is directed through the oil tube (8) to the two pinion bearings.
Oil passage from the top of the crosshead guide compartment to the crosshead bearing is shown in Figure 12. Oil accumulates in the compartment over the crossheads. The oil runs through the nipple (6) into the crosshead retainer to the oil passages (5) and on to the crosshead pin bearing. As noted, the duplicate set of passageways (5) in the crosshead pin permits the crosshead pins to be rotated without having to give attention to hole
alignment. This permits the installation of crosshead pins from either direction.
www.nov.com
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 thecrosshead 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.
www.nov.com
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)
www.nov.com
A typical layout for the pinion shaft driven oil pump is shown in Fig. 14. The oil pump (1) is piped into the oil system through the suction and pressure connections on the bottom inside wall of the power frame. Ref. Item 10, Fig. 13. The V-belt drive (2) is adjusted by moving pump up or down on the mounting bracket.
Adjust the V-belt drive (2) to a point where the two halves of the belt can almost be “pinched” together between the thumb and fingers at the center of the drive. Overtightening can cause premature failure of the pump.
When link type belting is used, caution should be exercised in predetermining belt elongation. Link type belting in A, B and C widths will elongate approximately 1” per foot (25mm per 305mm). When installing a drive, subtract 1” per foot from actual required length (132” required - install 121”) and stretch to fit. (Subtract 25mm/305mm)
To prevent possible injury, always install guard (3, Fig. 14) over V-belts before putting
pump into service.
10 MAINTENANCE OF THE LUBRICATION SYSTEM
Adequate lubrication of the moving parts is, as stated, the most important single factor affecting the ultimate service life of the pump. CARE AND MAINTENANCE of the system is the sole responsibility of the operator or crew to which it has been assigned, and the extent to which this is applied will determine the amount of trouble-free service life that will be obtained.
The lubricant recommendations shown below, on the name plate on the side of the pump, or in the General Lubrication Bulletin included with this manual, are the result of extensive
field tests. Substitutions should be made only in extreme emergencies.
REFER TO GENERAL LUBRICATION BULLETIN for approved lubricants and additional specifications. If any discrepancy exists between the recommendations in this manual and the General Lubrication Bulletin, those in the Lubrication Bulletin will take precedence.
Lubrication Specifications:
Use extreme pressure, non-corrosive, anti-foaming gear lubricant as follows:
Temperatures +30°F to 155°F (-1°C to 68°C) AGMA No. 6 EP
Temperatures 0°F to 85°F (-18°C to 33°C) AGMA No. 4 EP(Consult lubrication manual)
Oil reservoir capacity:
FD-500 65 U.S. Gal. (246 liters) FD-800 65 U.S. Gal. (246 liters) FD-1000 75 U.S. Gal. (284 liters) FD-1600 100 U.S. Gal. (379 liters)
www.nov.com
ONCE EACH TOUR, check and maintain oil level at the FULL mark on the bayonet gauge. PUMP MUST BE SHUT DOWN and allowed to stand idle for approximately five minutes to allow oil level to equalize.
ONCE EACH SIX MONTHS, or more often if oil becomes contaminated with abrasive particles or corrosive compounds, drain and flush the oil reservoir and refill with new lubricant. Oil drains are located on either side of the pump frame.
During the flushing procedure, thoroughly clean the oil troughs and the compartment in top of the crosshead guide. Also clean or replace the filter element in the air breather cap and clean suction screen. Remove covers from settling chamber and purge out contaminants before adding new oil.
Routine inspection on condition of oil should be made as condensation of moisture in the air, intrusion of mud, water or dirt, can necessitate a more frequent oil change.
A settling chamber is located in the forward area of the power end floor. Contamination in the oil splashed into this area is allowed to settle out and should be drained out of the pump through the clean out covers located on the frame wall underneath the crosshead inspection doors.
Once each month, remove clean out covers on both sides of pump to drain contaminated oil from settling chamber. Approximately 15-gallons of oil will be lost; replenish the main reservoir to compensate for the amount drained out.
Once each week, remove one of the lower ½” capscrews that secure the clean out cover to
the frame to drain off water condensate.
ONCE EACH TOUR, check oil level in main reservoir. Maintain at full mark on dipstick to the manifold block. If loss of pressure occurs, check for:
- Clogged suction screen - Low oil level - Slipping V-belt drive - Broken or loose connections - Damaged or worn oil pump - Defective Relief Valve
For an abnormal increase in oil pressure, check for:
- Plugged oil lines - Contamination causing oil to be viscous - Relief valve inoperative - Defective gauge - Other conditions
www.nov.com
11.1 Power End
Routine inspection of the power end is the most important form of preventive maintenance
and will result in considerable savings by detecting any major trouble that might be developing and allowing the necessary repairs to be made on a planned or normal rig-down time.
1. Check tightness of the main bearing bolts. Bolts must be tightened to the following torque:
FD-500 3000 ft. lbs. (415 meter kgs.) FD-800 6360 ft. lbs. (880mkg.) FD-1000 8800 ft. lbs. (1217 meter kgs.) FD-1600 9750 ft. lbs. (1349mkg.)
2. Safety wires -
Check safety wires on all bolts including the main bearing hold-down bolts, eccentric bearing retainer bolts, and gear retainer bolts. Replace any broken wires after retightening the bolts. Refer to crankshaft assembly section for bolt torque requirements.
3. Oil lines -
Check all oil lines to insure they are intact and free of obstructions. Check oil pump suction hose for damage or flat areas.
4. Suction filter -
Check condition of suction filter. Clean and replace as required.
5. Main bearing cover -
Remove the main bearing cover and check tightness of main bearing retainer bolts, condition of the bearing rollers, etc. Clean and remove any sludge or foreign substance that might have accumulated at the bottom of the bearing area.
6. Main gear and pinion teeth -
Inspect the condition of the main gear teeth and pinion gear teeth for any indications of abnormal wear. During the initial break-in period there will be some pitting on the face of the gear teeth. This is referred to as “initial pitting” and is not harmful to the life of the gear. However, if routine inspection indicates the degree of pitting continues to increase, immediately contact the local representative of the pump manufacturer for a more thorough inspection of the gear.
www.nov.com
7. Crosshead pin bolts and crosshead guides -
Remove cover and check condition of the crosshead pin bolts and safety wires. (Cente
crosshead pin bolts can be reached by removing back cover and placing eccentric on outer top dead center.) Tighten crosshead bolts (Item 4, Fig.19) to the following torque:
FD-500 90-100 ft. lbs. FD-800 140-150 ft. lbs. (11 - 12 meter kgs)
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 WRENCH
If the crosshead or guide shows abnormal wear or scoring, replace immediately as the metal particles can cause damage to the bearings, etc. Excess wear can also cause rapid 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 as described in the Lubrication Section of this manual.
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.
The main bearings are self-aligning spherical roller bearings. The pinion shaft is mounted on straight roller bearings. The eccentric bearings are straight roller with thrust plates on each side to keep the eccentric straps in line, and the crosshead pin bearings are straight needle roller bearings.
None of the bearings require special adjustments.
All inner and outer races are assembled by means of very accurate fits. This accuracy is necessary; therefore, if the bearings are to be used again, the inner and outer races and the roller assemblies of each bearing must be kept together, and reinstalled exactly as they came off.
www.nov.com
It is always necessary to completely replace any roller bearing that fails, even though only one part of the bearing shows damage. Since the running clearances of these bearings are extremely small, excessive clearances, worn or grooved raceways, and any pitting or flaking of the parts is indicative of failure and the entire bearing should be changed as soon
as possible.
All roller bearings are assembled to their shafts by means of shrink fits. (Ref. bearing fit data under each shaft assembly.) Damaged or worn bearings and raceways can be removed by driving them off the shaft with a bar and hammer. They can be cut off the shaf with a burning torch, but care must be taken not to burn into the shaft. Bearings should always be heated in an oil bath, the temperature of which should not exceed 300°F (149°C). Be certain that both the oil and the container are very clean. If the oil container is in direct contact with the fire, place a rack into the container so that the bearings will not rest 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. When it is necessary to use a torch, it should be used only by an experienced welder or mechanic. Hold the torch at least 6 inches (150mm) away from the bearing and keep the torch moving at all times. Heat the bearing only until it is hot to the touch. Use a Tempil stick. DO NOT OVERHEAT THE BEARING. Overheating draws the temper of the metal and makes the bearing soft.
Once the heated bearing is in place on the shaft, hold it in place until it cools. NEVER USE WATER OR ANY OTHER LIQUID TO COOL A HOT BEARING. Rapid cooling will cause the surfaces of the races and rollers to “check” or crack and the bearing will fail immediately.
Never strike a roller bearing with a steel hammer. If the bearing must be driven into position, use wood or a soft hammer and strike lightly.
Always lubricate the shaft or housing before installing the bearing. Clean white lead, or an anti-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 it from dirt and other foreign matter at all times. If a bearing must be cleaned, use clean kerosene or other solvent.
www.nov.com
Inner Race to Shaft A T.0012-T.0022 T.0014-T.0024 T.002 -T.0042 T.0016-T.0038
Outer Race to Bore B L.0015-T.0005 L.0004-L.0024 L.0042-L.0006 L.0004-L.0040
Carrier to Frame Bore C L.003 -L.008 L.003 -L.008 L.003 -L.008 L.003 -L.005
Millimeters
Inner Race to Shaft A T.03 -T.06 T.036 -T.061 T.051 -T.107 T.041 -T.097
Outer Race to Bore B L.04 -T.01 L.010 -L.061 L.107 -L.015 L.010 -L.102
Carrier to Frame Bore C L.08 -L.21 L.076 - L.203 L.076 - L.203 L.076 -L.127
The pinion is an integral part of the shaft, leaving only the installation of the bearings and o seal spacer to complete the assembly.
www.nov.com
The running clearances of the bearings are predetermined by their precision fit to the shaft and the bearing carrier. When performing maintenance or overhaul, make sure the fits shown in Chart I are obtained.
When installing the pinion shaft assembly in the pump, observe the following precautions:
a. Insure pinion bearing carrier gasket (1) and oil seal carrier gasket (2) are in place and in good condition.
b. The pinion bearing carrier (3) and the oil seal carrier (4) have the word “TOP” cast in the face of the flange. MAKE SURE THE CARRIERS ARE INSTALLED WITH THIS MARK AT THE TOP to correctly position oil troughs and align drain holes.
c. Remove burrs, dents or gouges from the OD of the oil seal spacer (5) before sliding oil seal carrier (4) into place. Exercise care when sliding lip of seal over end of shaft
to prevent it from being damaged by the sharp edge of the keyway. Also pay particular attention to insure oil seal lip IS NOT TURNED UNDER by edge of spacer when sliding seal onto the spacer.
d. Tighten pinion bearing carrier bolts (6) to the approximate torque shown below:
FD-500 100-125 ft. lbs. (14-17 m/kgs.) FD-800 60-100 ft. lbs. (8-14 m/kgs.) FD-1000 80-160 ft. lbs. (11-22 m/kgs.) FD-1600 80-160 ft. lbs. (11-22 m/kgs.)
e. Check condition of the pinion bearing inner and outer race and rollers. If there is any indication of galling, flaking or grooving, or if diametral clearance exceeds .008-
.010”, it is recommended the entire bearing be replaced. (.20 - .25mm)
11.4 Crankshaft Assembly (Fig. 16)
The crankshaft assembly consists of the crankshaft, eccentric ring gear, eccentric strap with bearings, and the main bearings.
The running clearances of the bearings are predetermined by their precision fit to the shaft and their respective bores. When performing any maintenance or overhaul, make sure the fits shown in Chart II are obtained.
www.nov.com
Inner Race to Shaft A T.002-T.003 T.0022-T.0032 T.0024-T.0048 T.0020-T.0044
Outer Race to Bore B L.015 - T.0003 L.002 - .000 L.0034-T.0004 L.0038- .000
Inner Race to Shaft C T.003 -T.007 T.005 -T.007 T.005 -T.009 T.0060-T.0100
Outer Race to Bore D .000 -T.004 T.002 -T.004 .000 -T.004 .000 -T.0040
Gear to Flange E L.001 -L.005 L.001 -L.005 L.001 -L.005 L.001 -L.005
Carrier to Frame Bore F L.001 -T.005 L.002 -T.002 L.002 -T.002 L.002 -T.002
Outer Race to Bore G T.001-T.0034 T.0022-T.003 .000 -T.003 T.0008-T.004
Inner Race to Pin H .000 -T.001 T.001 -T.002 T.001 -T.003 T.001 -T.0032
www.nov.com
Millimeters
Inner Race to Shaft A T.043 -T.069 T.056 -T.081 T.061 -T.122 T.051 -T.112
Outer Race to Bore B L.049 - T.010 L.051 - .000 L.086 -T.010 L.096 - .000
Inner Race to Shaft C T.076 -T.173 T.127 -T.178 T.127 -T.229 T.152 -T.254
Outer Race to Bore D .000 –T.102 T.127 -T.102 .000 -T.102 .000 -T.102
Gear to Flange E L.025 -L.127 L.025 -L.127 L.025 -L.127 L.025 -L.127
Carrier to Fr. Bore F L.025 -L.127 L.051 -T.051 L.051 -T.051 L.051 -T.051
Outer Race to Bore G T.025 -T.076 T.056 -T.086 .00 -T.076 T.02 -T.10
Inner Race to Pin H .000 -T.025 T.025 -T.051 T.025 -T.076 T.025 -T.081
Assemble the crankshaft in the following manner: (Refer to Fig. 16)
a. Mount gear on flange
Thoroughly 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-800 800-1200 ft. lbs. (110-166 meter kgs) FD-1000 800-1200 ft. lbs. FD-1600 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 and determine cause of misalignment. (.15mm)
NOTE: If runout on face of gear is checked while crankshaft is mounted in the pump frame, the running clearance in main bearings will require that a simultaneous set of dia 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 thefollowing torque; safety wire heads.
FD-500 60-90 ft. lbs. (8-12 meter kgs) FD-800 90-120 ft. lbs. (12-17 meter kgs. FD-1000 90-120 ft. lbs. FD-1600 90-120 ft. lbs.
NOTE: The inner and outer races of the eccentric bearings are matched and must not be intermixed.
www.nov.com
c. Install the outer race of the crosshead bearings (19) in the three eccentric straps. It is
preferred that the outer race assembly be “pressed” into position or frozen in “dry ice” or a 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 of the eccentric strap. DO NOT EXCEED 300°F (149°C) (USE Tempil-Stik) and DO NOT USE WATER to cool the strap.
NOTE: The inner and outer races of the crosshead bearings are matched and should not be intermixed.
d. Install the inner race of the crosshead bearing on the crosshead pin and mark according to their respective eccentric strap positions. Remove all nicks and burrs before shrinking 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 into position and install inner race clamp (5). Tighten socket head screws (8A) in clamp to the following torque:
FD-500 60-90 ft. lbs.(8-12 meter kgs.) FD-800 30-60 ft. lbs. (4-8 meter kgs.) FD-1000 30-60 ft. lbs. FD-1600 30-60 ft. lbs.
f. Install snap ring (7) in the groove on RH eccentric and shrink inner race of eccentric bearing on shaft. After sliding the RH eccentric strap into position, install inner bearing retainer (14).
Tighten inner race retainer bolts (8) to the following torque and safety wire:
FD-500 60-90 ft. lbs.(8-12 meter kgs.) FD-800 30-60 ft. lbs. (4-8

Documents

7. FD-1600 Triplex Mud Pump User Manual