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User Manual FD-1600 Triplex Mud Pump Customer References: Customer: PT Citra Tubindo Rig / Hull: N/A Tag Number: N/A
User Manual FD-1600 Triplex Mud Pump Customer References: Customer: PT Citra Tubindo Rig / Hull: N/A Tag Number: N/A National Oilwell Varco References: SO Number / Project Number: 188074 Document Number: D2G1008930-FDD-001 Revision: 01 Volume: 1 of 1
CHANGE DESCRIPTION Revision 01 Change Description Initial Release
Chapter/ Section Title Remarks 1 General Information Section Not Applicable 2 Installation, Operation & Maintenance 2.1 Procedures 2.2 Spare Parts List 3 Technical Documents & Drawings 3.1 General / Mechanical Drawings 3.2 System / Process Diagrams Section Not Applicable 3.3 Electrical / Instrument Section Not Applicable 3.4 Performance Data 4 Vendor Documentation
Chapter/ Section Title 1 General Information Chapter Not Applicable
Chapter/ Section Title 2 Installation, Operation & Maintenance 2.1 Procedures 2.2 Spare Parts List
Chapter/ Section Title 2.1 Procedures
Technical Specification Pre-Shipment And Storage Preservation For New-Build NOV Triplex Mud Pumps
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.
CHANGE DESCRIPTION Revision 0 1 02 Change Description Initial Release Updated Entire Document Added NOV Standard Front Cover & Updated Page Formats
1 SCOPE 2 MANUFACTURING PLANT PRESERVATION PRIOR TO PAINT 3 MANUFACTURING PLANT PRESERVATION AFTER PAINT 4 STORAGE AT MANUFACTURING PLANT OR FINAL DESTINATION 5 STORAGE PREPARATIONS FOR MAIN DRIVE MOTORS. 6 PRESERVATION PROCEDURE WHEN STORAGE EXCEEDS SIX (6) MONTHS OF INITIAL PRESERVATION. 7 START-UP AFTER STORAGE 8 CONTACT DETAILS FOR NOTED CORROSION PREVENTATIVE MATERIALS
This specification covers the preservation and storage procedure for shipment of new-build NOV Triplex Mud Pumps shipped from the manufacturing plant. This specification is intended to provide preservation of new-build NOV Triplex Mud Pumps for six (6) months from the shipment of the mud pump from the manufacturing facility. If a pump is to be stored for a period of time exceeding six (6) months, additional precautions should be taken as outlined in this specification. National Oilwell Varco recommends that all pumps are inspected for any signs of corrosion and for proper preservation at a minimum every three (3) months for pumps stored outside and every six (6) months for pumps stored indoors.
Drain all water and clean out liner wash tank. Remove drain plug in bottom of liner wash pump and drain water then reinstall plug. Remove discharge flange from liner wash pump and pour one (1) pint of inhibiting oil-based concentrate (Cortec VpCI 329 Vapor Corrosion Inhibiting oil-based concentrate or equivalent) into liner wash pump. Rotate two (2) revolutions by hand to distribute the product. Re-install discharge flange. Drain all oil from pump power end sump and remove crosshead covers and inspection covers. Clean out oil sump as per National Oilwell PS-3081 (Mud Pump Cleanliness). Spray all internal machined parts of power end and crosshead area with inhibiting oil-based concentrate (Cortec VpCI 329 Vapor Corrosion Inhibiting oil-based concentrate or equivalent). Rotate pump ½ turn and re-spray. Pour quantity of inhibiting oil-based concentrate specified in the table below into power end sump. Mud Pump Models 14P, FC 2200 12P, 10P, HD or A1700/1400PT, FB/FC/FD 1600, FB 1300 9P, 8P, B or A850-1100PT, F/FD 1000, F 800 7P, A600PT, FD 500 Quantity of Inhibitor 5 Gallons 3 Gallons 2 Gallons 1 Gallon For pumps equipped with chain drives, spray internal machined parts inside chain cases with inhibiting oil-based concentrate (Cortec VpCI 329 Vapor Corrosion Inhibiting oil based concentrate or equivalent).
Remove breather and pack with loose parts for later shipment with pump. Seal breather hole with a greased solid plug. Affix a warning label near the breather opening (see Exhibit 1). Spray all external unpainted machined parts of pump with rust preventative (CRC SP400 or equivalent). Cover large diameter pipe and other openings with hardboard and protective plastic wrap. Liner bushing openings shall also be covered and sealed. Seal all other pipe work (air, water, and electrical) with plastic caps of the correct size and style. Electrical J-boxes are to be encased in protective plastic wrap. Place two (2) onepound bags of desiccant inside each J-box before sealing with tape. Wrap pressure gauges with bubble paper and plastic. Tape or band down loose hinged guards and inspection covers. Spray all machined unpainted loose parts and expendables to be shipped with pump with rust preventative (CRC SP400 or equivalent). All parts will be wrapped or boxed to prevent damage. Affix one (1) warning label (see Exhibit 2) to the power end pump cover and one (1) warning label on the fluid end assembly of the pump. Affix warning labels on each loose part container. In cases where the equipment will be boxed at an offsite export packer, a sufficient number of warning labels will be supplied with the shipment.
Indoor storage is preferred whenever possible; but if outside storage is required, ensure pump is stored away from salt water spray, sand blast or other adverse conditions. It is highly recommended that ship loose parts be stored indoors to eliminate conditions that promote condensation and direct sources of moisture. It is also recommended to store pump on blocks and cover entire pump with plastic sheeting.
For storage preparations for main drive motors, National Oilwell Varco recommends that the original manufacturer’s instructions be followed. If space heaters are supplied, the Jbox plastic wrap must be removed and the heaters should be connected throughout the complete storage period.
Note: It is recommended that inspections be carried out on six (6) month cycles when pumps are in indoors and three (3) month cycles when stored outside. Remove plastic sheeting. Remove side crosshead covers and top inspection covers and inspect for any internal corrosion. Correct any adverse conditions. Replenish rust inhibitor to quantities previously listed. Rotate pinion shaft five (5) revolutions using supplied tool. Inspect for condition of external protection (rust preventative and paint). Correct any adverse conditions. Replace plastic sheeting. Inspect all ship-loose parts for indications of corrosion or damage and recoat with inhibitor.
Any pump that has been in storage will need a thorough inspection prior to start-up to insure it has not been damaged in any way and that all parts are properly in place. Failure to observe the following points can result in serious damage. Before servicing the pump, the power end sump and chain drives housings will need to be drained of any inhibiting additive. The Cortec brand products used for preservation are compatible with all lubricating oils and need not be totally removed when putting equipment into service. To service the Power End after storage and prior to start-up, remove all covers and thoroughly clean and inspect all of the parts and finished surfaces. Check all of the bearings to make certain they are clean and in good condition. Fill the power end with clean EP oil of the proper viscosity to the proper level. Make sure oil is poured into the oil distribution trough and is worked into all of the bearings. Replace all covers and install breather. To service the Fluid End after storage and prior to start-up, remove covers and thoroughly clean and inspect inside of the fluid end cylinders. Properly install valves, pistons, liners and all other fluid end parts. Carefully tighten all bolts, nuts, studs and working connections to specified torque requirements.
Product Name Cortec VpCI 329 CRC Industries Inc. SP400 KOPR-KOTE Company Gulf Corrosion Control Fastenal Drago Supply Co. Contact Number (713)681-7500 (713)983-7715 (800)553-2363
WARNING REINSTALL BREATHER BEFORE PUTTING PUMP INTO SERVICE NOV PN xxxxxxx
WARNING THIS EQUIPMENT IS PROTECTED FOR SIX MONTHS FROM EX-WORKS DATE OF: MONTH DAY YEAR ADDITIONAL SERVICING INFORMATION IS AVAILABLE IN NOV MUD PUMP OPERATIONAL MANUAL NOV PN XXXXXX
SELLER INFORMATION COMPANY NAME: National Oilwell Varco ADDRESS: 11000 Corporate Centre Drive Houston, TX 77041 TELEPHONE: (281) 854-0400 TELEFAX: (281) 854-0505 DOCUMENT NUMBER: EDN-1688 DOCUMENT TITLE: Commissioning Procedure, FB/FD-1600 Triplex Mud Pump
SUBJECT PAGE NO. Part I. Pre-Commissioning Procedures Pre-Start Up Requirements 3 1. Power End 3 2. Main Electric Drive Motors 4 3. Auxiliary A/C Motors 4 4. Instrumentation 4 5. Liner Wash System 4 6. Fluid End 4 7. Suction Dampener/Desurger 4 8. Pulsation Dampener 5 9. Pressure Gauge 5 10. Reset Relief Valve 5 11. Discharge Strainer 5 12. Mud Pump Drive Assembly 5 a. Belt Drive Units 5 b. Chain Drive Units 5 Part II. Commissioning Procedures 1. Pre-Commission Checks 6 2. Commissioning Operational Test 8 3. Inspections/Check-Offs during Test Program 9
GENERAL: The initial startup procedures are written to assist the operator in preparing the pump packages for normal operation. The startup procedures are separated into two categories: Part I: Pre-Commissioning, and Part II: Commissioning Procedures. It is suggested that a copy of these pages be made for each pump to be used as a check-off sheet. PART I. PRE-COMMISSIONING PROCEDURES: PRE-STARTUP REQUIREMENTS: 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.
3. Auxiliary A/C Electric Motors: Megger test the motors. Check motors for correct rotation. 4. Instrumentation (if equipped): Check to assure that all instrumentation has been properly hooked up. Check the calibration test sheets for validity and recalibrate if necessary. 5. Liner Wash System: Clean liner wash tank, if needed, and fill with fresh clean water. Ensure that supply hoses and spray nipples are installed correctly. Start pump and adjust regulating valve to maximum flow without splash onto the extension rods. 6. Fluid End: Check to assure that all liners, valves, and pistons are installed properly in accordance with the 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. 7. Suction Dampener/Desurger If a desurger is used, charge desurger to 10 PSI (0.7 bar) air pressure. NOTE: When charging the bladder, make sure that the mud pump suction line valve has been closed and that all pressure has been bled off of the suction manifold surrounding the suction desurger If a dampener is used, charge dampener with a hand-operated air pump to 10 PSI (0.7 bar). Once pump operations have been started, check the operation of the suction dampener by inspecting the sight glass. Add or release air pressure through the Shraeder valve to keep the diaphragm between the midpoint and the bottom of the sight glass. 8. Pulsation Dampener: Refer to manufacturers’ instructions for charging the dampener. USE ONLY NITROGEN OR AIR! DO NOT USE OXYGEN.
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.
PART II. COMMISSIONING PROCEDURES: GENERAL: The power end and the fluid end have gone through rigorous tests prior to being shipped from the manufacturing site; therefore, the following recommendations for the commissioning test are made for the purpose of checking the overall unitization functions, including instrumentation, and to assure that there are no problems which may have occurred during transportation and storage. Operation of the pump in parallel to check the SCR-Motor assignments and controls, volumetric displacement and mudline systems are at the option of the purchaser. A. PRE-COMMISSIONING CHECKS: Prior to starting the unitized pump package, review the previously outlined Pre-Commissioning Requirements in Part I. Check the discharge mudline to assure that all necessary valves are open. Ensure that the mud tanks are full of test fluid (mud/water) prior to startup. Make the desired assignment of the SCR-Motor Control System to the pump motors, and open the throttle slightly. Check to ensure that charge pump and liner wash motors have started. If no immediate problems are encountered, slowly throttle the pump to approximately 60 SPM and continue operating the mud pump while making the following inspections to assure that all systems are working properly: 1) Power End Lubrication: Check oil pressure: 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.
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: 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.
B. COMMISSIONING OPERATIONAL TEST: DURATION: EIGHT (8) HOURS TOTAL RUNNING TIME. The following are basic guidelines for conducting of an eight (8) hour operational test. The pump was test run under pressure in the manufacturing plant but with different motors and drives. The discharge pressure can be regulated by temporarily installing an adjustable choke at some point in the discharge line. NOTE: There can be short intervals of shut-down time to fix leaks, make adjustments, etc., without having to restart the test program. 1. LOWER PRESSURE TEST – DURATION: TWO (2) HOURS: TIME START STOP 0-500 PSI (0.34-34.5 bar) 40 min. @ 40 SPM 500-700 PSI (34.5-48.2 bar) 40 min. @ 50 SPM 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.
C. INSPECTIONS/CHECK-OFFS DURING TEST PROGRAM: The overall performance of the unitized pump package should be continuously monitored during the eight hour test program. The following checks should be made and recorded each two hours of operation. START 2 HR 4 HR 6 HR 8 HR 1. POWER END LUBRICATION: PRESSURE TEMPERATURE 2. LINER WASH SYSTEM: MOTOR AMPS REGULATING VALVE ADJUST INLET TEMPERATURE OUTLET TEMPERATURE 3. MAIN DRIVE MOTOR NO. 1: COOLING AIR TEMP BEARING TEMP BLOWER AIRFLOW MOTOR AMPS VOLTS LOAD SHARE (YES/NO)
START 2 HR 4 HR 6 HR 8 HR 4. MAIN DRIVE MOTOR NO. 2: COOLING AIR TEMP BEARING TEMP BLOWER AIRFLOW MOTOR AMPS VOLTS LOAD SHARE (YES/NO) 5. LINER/PISTONS (Yes/No): INDICATIONS OF SCORING.. ABNORMAL BREATHING..… LINER TEMPERATURE..……. 6. SUPERCHARGING SYSTEM: MOTOR AMPS SUCTION MANIFOLD PRESS.
START 2 HR 4 HR 6 HR 8 HR 7. OVERALL VISUAL EXAMINATION (Yes/No): OIL LEAKS………….………… GUARDS DRAGGING..……… LOOSE BOLTS……..…………. LOOSE/LEAK OIL LINE…….. COOLANT LEAKS...…………. 8. OTHER: ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ Comments: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________
Date Complete: ________________________________ Client _______________________ ______________________ _____________________ Name Signature Title Class _______________________ ______________________ _____________________ Name Signature Title Owner _______________________ ______________________ _____________________ Name Signature Title National______________________ ______________________ _____________________ Oilwell Name Signature Title Varco
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.
01 15.08.2006 New Manual
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’s is 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.
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.
PREFACE 3 1 INSTALLATION OF NEW PUMP 11 2 SETTING THE PUMP 11 2.1 Land Installations 11 3 SUCTION SYSTEM REQUIREMENTS 16 3.1 Caution 16 4 PREPARATION OF POWER END 17 4.1 Power End Lubrication 17 4.2 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 ASSEMBLY OF FLUID END PARTS 23 6.1 Valves and Seats 23 7 FD-500, FD-800 & FD-1000 24 7.1 Liners 25 7.2 Piston Rod 25 7.3 Piston Rod Clamps 25 7.4 Liner Cage and Lower Valve Guide 26 7.5 Cylinder head 26 7.6 Discharge Valve Pot Covers 26 8 FD-1600 27 8.1 Liner 28 8.2 Piston Rod 28 8.3 Piston Rod Clamps 29 8.4 Lower Valve Guide and Cylinder Head 29 8.5 Discharge Valve Pot Covers 29 8.6 Discharge Manifold all models 30
8.7 Suction Flange 30 8.8 Accessory Manifold 30 9 LUBRICATION 31 9.1 Minimum Operating Speeds 32 9.2 Controlled Flow Splash System 33 9.3 Total Pressure lubrication System 34 10 MAINTENANCE OF THE LUBRICATION SYSTEM 36 11 MAINTENANCE 38 11.1 Power End 38 11.2 Roller Bearings 39 11.3 Pinion Shaft Assembly 41 11.4 Crankshaft Assembly (Fig. 16) 42 11.5 Installing Crankshaft Assembly in Frame 46 11.6 Installation of Crosshead Guides 48 11.7 Installation of Crossheads 49 11.8 Checking crosshead alignment 51 12 FLUID END MAINTENANCE 51 12.1 Fluid Cylinder Blocks 52 12.2 Suction Manifold 53 12.3 Discharge Manifold 53 12.4 Cylinder Head Thread Ring 54 12.5 Welding and Repairs 54 12.6 Welding Procedures 58 12.7 Repairs to Valve Pot Cover Bore 59
Your National Oilwell Varco pump has been completely assembled and test operated under pressure before being shipped to the field. Unless otherwise instructed, the lubrication is drained from the power end and the expendable parts are removed from the fluid end. Before putting the pump into service, the following precautions and operations must be performed or checked. In order to prevent personal injury during the performance of any maintenance or inspection procedures, this equipment MUST BE SHUT DOWN AND NOT OPERATING, and all safety devices on prime movers, drives, etc., MUST BE IN THE SAFE POSITION.
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.
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.
On permanent installations such as barge, platform, structural base, or concrete slab, where pump skids are bolted down, it is essential that the skids be properly shimmed to prevent possibility of twisting or distorting the power frame. The pump skids must sit solid on all shim points with bolts loose. On barge installations, the pump skids are generally bolted down to T-beams running parallel and in line with the pump skids. Install shims at points shown in Figs. 2 and 4 and observe caution of proper shimming to prevent twist or distortion. The shims on all installations should extend the full width of the skid beam flanges and have a minimum length of 12” (305mm). On installations where the power unit or electric motor is mounted integrally with the pump skids, the preferred installation would be to set the pump package on the T-beam skids and provide retention blocks rather than bolts to hold it in place. This will allow the pump to “float” and minimize the transfer of barge deck or platform distortion into the frame.
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: 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.
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 Vbelts. 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).
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)
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.
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.
Your National Oilwell Varco pump has been completely assembled and test operated before being shipped to the field. Unless otherwise instructed, the
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