Professional Documents
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REVISION HISTORY
CHANGE DESCRIPTION
Revisio
01 n Change Descri ption
Initial Release
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1 2.1 Procedures
1 4 Vendor Documentation
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1 2.1 Procedur es
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Technical Specification
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REVISION HISTORY
CHANGE DESCRIPTION
0
1 Initial
Updated Release
Entire Document
02 Added NOV Standard Front Cover & Updated Page Formats
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TABLE OF CONTENTS
1 SCOPE.............................................................................................................................. 4
2 MANUFACTURING PLANT PRESERVATION PRIOR TO PAINT .................................. 4
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 A FTER STORAGE ........................................................................................ 7
8 CONTACT DETAILS FOR NOTED CORROSION PREVENTATIVE MATERIALS ......... 7
9 EXHIBIT 1 ......................................................................................................................... 8
10 EXHIBIT 2 ......................................................................................................................... 9
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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.
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.
9P,
7P, 8P, B or A850-1100PT,
A600PT, FD 500 F/FD 1000, F 800 21Gallons
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).
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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.
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.
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.
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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.
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9 EXHIBIT 1
WARNING
REINSTALL BREATHER BEFORE PUTTING
PUMP INTO SERVICE
NOV PN xxxxxxx
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10 EXHIBIT 2
WARNING
THIS EQUIPMENT IS PROTECTED FOR
SIX MONTHS FROM EX-WORKS DATE OF:
NOV PN XXXXXX
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SELLER INFORMATION
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COMMISSIONING INDEX
Pre-Start Up Requirements.....................................................................................
1. Power End.................................................................................................. 3
2. Main Electric Drive Motors……………………………………………… 3
3. Auxiliary A/C Motors……………………………………………………. 4
4. Instrumentation........................................................................................... 4
5. Liner Wash System..................................................................................... 4
6. Fluid End.................................................................................................... 4
7. Suction Dampener/Desurger....................................................................... 4
8. Pulsation Dampener.................................................................................... 4
9. Pressure Gauge............................................................................................ 5
10. Reset Relief Valve....................................................................................... 5
11. Discharge Strainer………………………………………………………… 5
12. Mud Pump Drive Assembly………………………………………………. 5
a. Belt Drive Units…………………………………………………… 5
b. Chain Drive Units…………………………………………………. 5
1. Pre-Commission Checks………………………………………………….. 6
2. Commissioning Operational Test…………………………………………. 8
3. Inspections/Check-Offs during Test Program…………………………….. 9
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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.
PRE-STARTUP REQUIREMENTS:
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
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.
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9. Pressure Gauge:
Check to assure that the gauge is installed and there is no shut-off valve between it and the
discharge system.
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.
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.
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.
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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:
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.
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5) Visually inspect the mud pump drive assembly for any unusual conditions, i.e. loose bolts,
vibration, noise, etc.
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.
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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.
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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
PRESSURE…………………….. ______ _____ _____ _____ _____
MOTOR AMPS………………… ______ _____ _____ _____ _____
o VOLTS…………………. ______ _____ _____ _____ _____
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START 2 HR 4 HR 6 HR 8 HR
MOTOR AMPS………………… ______ _____ _____ _____ _____
5. LINER/PISTONS (Yes/No):
6. SUPERCHARGING SYSTEM:
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START 2 HR 4 HR 6 HR 8 HR
LOOSE/LEAK OIL LINE…….. ______ _____ _____ _____ _____
8. OTHER:
Comments:
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
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COMMISSIONING ACCEPTANCE:
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Operation Manual
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REVISION HISTORY
CHANGE DESCRIPTION
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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
is taken in part fromandthe maintenance informationmanuals.
various manufacturers’ on equipment
If the other than National
equipment Oilwell issue
manufacturers Varco’s
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.
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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.
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TABLE OF CONTENTS
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
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General Dimensions
(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
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Specifications
Max. Liner Size 6-3/4” (171.45 mm) 6-3/4” (171.45 mm) 6-3/4” (171.45 mm) 7-1/2” (190.5 mm)
and stroke 7-1/2” (191 mm) 9” (228.6 mm) 10” (254 mm) 12” (304.8 mm)
Valve Pots API No. 6 API No. 6 API No. 6 API No. 7
Approx. Wt. 18,657 (8,463 kg) 26,603 (12,067 kg) 33,770 (15,318 kg) 46,820 (21,238 kg)
(Lbs.)
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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.
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.
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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.
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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.
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:
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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.
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)
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.
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
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).
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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.
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:
Since this is an independent system, it will require the same maintenance or service
attention employed on any other piece of machinery, including:
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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.
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.
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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.
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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)
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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.
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.
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
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See sections 5.1 and 5.2 for call out numbers descriptions shown in figure 6.
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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.
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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,floating
material the solids arefluid.
in the allowed to settle out. The filter screen will catch much of the foreign
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.
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.
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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.
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.
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.
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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.
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8 FD-1600
ASSEMBLY OF FLUID END PARTS
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.
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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.
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.
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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.
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.
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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.
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.
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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
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)
* 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.
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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)
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.
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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.
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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
crosshead the crosshead
compartment. Thecompartment manifold block
crosshead compartment (4A) located
manifold above
block (4A) the
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.
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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)
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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:
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)
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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.
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:
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11 MAINTENANCE
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 -
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.
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.
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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:
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.
Check condition of the oil and cleanliness of the oil reservoir. Service oil system as
described in the Lubrication Section of this manual.
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.
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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.
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Chart I
Inches
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.
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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)
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.
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Chart II
Inches
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
Inner Race to Pin H .000 -T.001 T.001 -T.002 T.001 -T.003 T.001 -T.0032
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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
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
gearcrankshaft
with a dialon a set of If
indicator. rollers
total (at main bearing
indicator position).006”,
runout exceeds and check runout
remove gearon face of
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
following the bottom
torque; safetywhen pump is at mid-stroke. Tighten retainer bolts (4) to the
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.
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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 meter kgs.)
FD-1000 30-60 ft. lbs. FD-1600 30-60 ft. lbs.
g. Install the LH eccentric bearing (other than for snap ring) and eccentric strap under the
same procedure outlined in step (f) above.
h. Place main bearings (9) in the main bearing carriers (10 RH and 11 LH) and install
outer race retainer (12) and retainer bolts (15). Tighten bolts to the following torque and
safety wire:
FD-500 30-45 ft. lbs.(4-6 meter kgs.) FD-800 30-60 ft. lbs. (4-8 meter kgs.)
FD-1000 30-60 ft. lbs. FD-1600 30-60 ft. lbs.
NOTE: Even though the main bearing carriers (10 RH and 11 LH) have different
configurations on the OD, they are interchangeable and will fit into the pump frame on
either side. The purpose of the shoulders on the OD of one of the carriers is to locate
and retain the crankshaft in its respective position in the frame.
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i. After installing the two main bearing spacers (16), shrink main bearings (9) on each end
of the shaft. Install inner race retainers (17) and retainer bolts (18). Tighten retainer
bolts to the following torque and safety wire:
FD-500 30-45 ft. lbs.(4-6 meter kgs.) FD-800 30-60 ft. lbs. (4-8 meter kgs.)
FD-1000 30-60 ft. lbs. FD-1600 30-60 ft. lbs.
1. Place piece of wood between eye of eccentric strap and crosshead guide (as shown in
Fig. 18) to protect guide from scoring or gouging as the straps are sliding into position.
2. Rotate the main bearing carrier so that the two flat spots (180° apart) are parallel with
the main bearing bolt holes, and slowly lower the crankshaft into position. (The flat spo
provides clearance for the main bearing bolts.)
3. After placing crankshaft in the frame, and before installing the main bearing caps, check
the rollers in the main bearings to assure that each row of rollers in each bearing is
equally loaded. Equal loading is obtained by positioning the floating bearing carrier so
that the same number of inner and outer rollers supporting the weight of the crankshaft
in each bearing are tight. Because of tolerances, etc., the total number of tight rollers
could vary slightly between individual bearings.
4. Install and shim main bearing caps to obtain .003” (.076 mm) clamp or preload on the
main bearing carrier. This preload is obtained by placing the correct amount of shims
under the main bearing cap. The required amount of shims is determined as follows:
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a. Install .020” (.51 mm) shims under both ends of the main bearing cap.
c. Remove main bearing cap and determine clearance between bore of cap and OD of
bearing carrier by either mikeing thickness of lead or measuring compressed
dimension of Plastigage.
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Example:
.020 Original shims (0.51mm)
Less .004 Lead Thickness Less (0.102mm)
.016 (.408mm)
Less .003 Clamp Fit Less (.076mm)
.013 Correct Shim Thickness (.332mm)
requirements for each (right hand and left hand) main bearing cap.
e. Install main bearing caps with the correct amount of shims as determined above,
and tighten main bearing bolts to torque values shown in Chart III.
f. Again check inner and outer row of rollers on each bearing as previously outlined to
assure equal loading is still present on each bearing.
Chart III
1. Thoroughly clean all dirt or contamination and remove all burrs or rough edges from
both sides of the guides and the frame bore where the guides fit.
2. If old guides are to be reused, inspect the wearing surfaces for wear and scoring
streaks. Pumps with serial numbers below those shown have identical upper and lower
crosshead guides which may be reversed to provide a smooth surface for the lower
guide. Worn guides may be used at the top as forces on the crosshead are always
downward.
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The upper and lower crosshead guides are NOT interchangeable. The guides are
machined so that the lower guide places the crosshead frame centerline, and upper
guides are machined to afford proper crosshead to guide clearance. The guides are
marked “UPPER” and “LOWER.”
3. Install upper and lower guides. Torque guide screws to 150 - 200 ft. lbs. (20.84 - 27.60
meter kgs.) Install lock pins by bending in the middle until the ends of lock pin fit into
counterbore. Align ends of lock pin with pin holes in guide and straighten pin guiding
the ends into the holes.
4. Check between frame and guide at points A, Fig. 19, with .002” (.051mm) feeler gauge
to make sure guides fit into frame bore. NO gap should be present.
2. Position “eye” of eccentric strap at the opening in the side of the crosshead guide.
Block eccentric strap so that crosshead will clear the “eye” as it is sliding into position to
where the crosshead pin holes are in alignment.
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NOTE: Less running clearance at center of crosshead can be cause by “swelling” from
overtightening the crosshead pin retainer bolts (4). If present, loosen pin and retighten
into place by using the make-up torques shown in paragraph 4.
1. Remove diaphragm stuffing box from the diaphragm plate, (fig. 19). Do not remove the
plate.
2. Position crosshead at mid point of stroke. With inside calipers or telescoping gauges
and a micrometer, accurately measure the distance from the diaphragm plate bore to
the crosshead extension rod at the top and bottom. Compare the two measurements to
determine the position of the rod relative to the centerline of the bore.
3. If the top reading is more than .030” (.76mm) greater than the bottom measurement,
shims should be inserted under the lower crosshead guide to bring the extension rod
back to center, provided there is ample clearance between the top of crosshead and
upper guide. Cut shims from steel shim stock long enough to reach completely across
the guides. Cut tabs on the sides to bend down over frame supports to hold shims in
place. Refer to items 3 and 4 under Installation of Crosshead guides.
4. Some older pumps were manufactured with large crosshead clearance which will cause
a loud knocking noise under poor suction conditions. Specifications have been revised
to .020” - .030” (.51 - .76 mm) clearance. After proper alignment has been obtained, the
top guide should be shimmed down to provide the specified clearance.
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a. Make sure all valves on the discharge side of pump are opened before pump is put
into operation. Kicking pump in against a closed valve can often be the start of a
fatigue crack. An open crack may not necessarily occur at the precise moment,
however a small crack could occur and start the process of “corrosion fatigue
failure”.
b. Do not engage pump clutch when prime mover is running at a high rate of speed.
To do so can cause undesirable shock loads against both power end and fluid end.
c. Properly maintain pressure relief valve to assure it is set for the pressure rating on
the liner size being used.
d. Do not operate the pump for an extended period of time if a severe fluid knock is
present. The additional stress cycle, although of a lesser magnitude than normal
operating loads, must be added to the total number of cycles when considering the
fatigue life of the equipment.
e. Properly prepare fluid end for storage. When pump is to be shut down or not
operated for a period of ten days or more, it is recommended that the fluid end parts
such as liners, pistons, rods, etc., be removed from the pump and the fluid end
flushed out completely with fresh water. After a thorough flushing, apply grease or a
rust preventative to all of the machined surfaces such as valve pot cover threads,
valve pot cover gasket surfaces, valve seats, liner bores, etc. The parts removed
from the pump including liners, piston rods, etc., should of course be protected from
the elements.
corrosion, Thisalso
but will willprotect
not only extend
the the
usable lifelife of left
still theinfluid
theend through resistance
expendable parts and to
maintain them in good condition for installation in the pump at the next start-up
period.
Maintenance and repairs should be made on the fluid end assembly by observing the
following precautions. Refer to Figure 20.
The fluid end assembly for these triplex pumps consists of three forged cylinder blocks,
complete with valve pot covers and cylinder heads, a suction manifold, and a discharge
manifold.
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However, to obtain accurate alignment, all nicks or burrs must be removed from “pilot” boss
and frame bore and all dirt and foreign matter cleaned form the mating surfaces; otherwise
cylinder blocks could make up in a “cocked” or misaligned position.
The fit between “pilot” boss and frame bore (Position A) is as follows:
(L.05mm) (L.20mm)
Pilot Boss to Frame L.002 - L.008
Install the three cylinder block nuts to the torque values shown in Chart V.
Start all suction manifold bolts (5) in the three cylinder blocks before tightening. Tighten to
torque values shown in Chart V.
Start all discharge manifold bolts (8) in the three cylinder blocks before tightening. Tighten
to torque values shown in Chart V. Tighten cylinder block to power frame stud nuts to
torque values shown in Chart V.
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NOTE: Install thread ring so that the “bleed hole” is in the down position. Tighten the
cylinder head thread ring stud nuts (10) to the torque values shown in Chart V.
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Chart V
POSITION ITEM FD-500 FD-800 & FD-1000 FD-500 FD-800 & FD-1000
TORQUE TORQUE FT. LBS. TORQUE TORQUE METER-KG
FT-LBS. METER-KG
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Chart VI
G 2” 4” 50.8 101.6
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FD-1600
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Chart VIII
Inches Millimeters
A 8.250-8.255 209.55-209.68
B 7.125-7.130 180.97-181.10
C 8.252-8.255 209.60-209.68
D 14.499-14.501 368.27-368.32
F 2.995-3.000 76.07-76.20
G .625-.630 15.87-16.00
H 1.120-1.130 28.45-28.70
J 5.870-5.880 149.10-149.35
K 6.247-6.252 158.67-158.80
L 6.630-6.635 168.40-168.53
M 7.375-7.380 187.32-187.45
N .495-.505 12.57-12.83
Cracks: - Grind out all of crack. Any attempt to burn out a crack will only result in the
crack progressing faster than the material can be burned.
- Follow the same welding procedure as above.
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Preheating: - The purpose of preheating is to expand the area being repaired so that as
the cooling process takes place, the welded area and the preheated area will
cool more uniformly. Preheating also prevents hard spots from forming
between the base metal and the welding by eliminating a thermal shock as
the weld is being applied. This hard spot will, of course, be a good place for
fatigue cracks to occur.
The high or low spot can also cause valve covers to make up in a “cocked” position and
result in severe thread damage (cracks) due to the axis of the two mating threads being out
of square.
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Pinion Shaft 718 326 1,630 740 1,709 775 2,373 1,077
Crankshaft Assy. 5,185 2,352 7,458 3,383 10,479 4,744 15,179 6,885
Gear Case Cover 341 155 262 119 340 154 379 172
Suction Manifold 258 117 429 195 704 319 704 319
Discharge Manifold 390 177 696 316 717 325 740 336
One-third Fluid end 1,527 693 1,140 517 1,140 517 1,865 846
section-studded
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REVISION HISTORY
CHANGE DESCRIPTION
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PRESSURE
RELIEF
VALVES
! Notice !
Our
mustTechnical Publications
be installed relativesystems
in the discharge to reciprocating pumps,
from these units.state
Thisthat pressure isrelief
supplement valves
issued to
emphasize the importance of relieving the discharge system of all pressure which exceeds
the rated working pressure applied by the manufacturer to the specific pistons and liners (
or plungers and packing) in any particular unit.
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TABLE OF CONTENTS
1 WARNING......................................................................................................................... 5
1.1 The Pressure Relief Valve ...................................................................................... 5
1.2 Rupture Disc or Burst Disc ..................................................................................... 5
1.3 Location of the Relief Valve .................................................................................... 6
1.4 The Relief Valve Discharge Line............................................................................. 6
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1 WARNING
For the protection of persons and properly the discharge system form each Reciprocating
Pump must be equipped with a device which relives the system of all pressures which
exceed the pressure rating applied by the manufacturer to each particular piston or plunger
diameter. Allowances will be made for pressure surges which are inherent with the
reciprocating action of piston and plunger pumps. The percentage of pressure allowance
appears later in this publication and the “Standards of the Hydraulic Institute” (13 th Edition)
The relieving device must provide for instantaneous pressure relief, it may be a valve
designed for automatic or manual resetting; however, if preferred, rupture discs or burst
may be installed.
Failure to comply with the procedures outlined in the Warning may result in damage to the
pump and related equipment and more importantly may cause serious bodily injury or
death!
2. It must have a working pressure rating, equal to or greater than, the maximum
working pressure of the pump.
3. The through capacity of the valve, when fully opened, must be sufficient to relieve
the full capacity of the pump without excessive overpressure.
2. These discs must have a rupture of burst pressure rating consistent with the
specifications tabulated later in this publication.
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2. The relief valve must be on the pump side of any discharge strainer.
3. The relief valve must be between the pump fluid end and any valve in the discharge
system.
4. There must be no restricting device(s) between the relief valve and the pump fluid
end.
4. The line must be the same pipe size as, or may be larger than, the discharge
connection on the relief valve.
5. If the line is of great length, this must be taken into consideration in sizing the relief
valve.
Note: Follow the foregoing instructions if rupture discs or burst discs are installed.
Note: The above set pressures are to be observed when installing rupture discs or burst
discs.
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Page 2 of 3
impact loading encountered in oilfield drilling operations. The results of not
using the recommended gear oil may permit metal-to-metal contact of the
gear teeth, which will be noticeable in the form of excessive pitting and wear
on the load side of the gear teeth. Excessive pitting and wear can result in an
increased risk of mud pump damage. National Oilwell Varco recommends
that an ISO visco sity g rade 460 oil be used during t he “ wear-in” period
After the “ wear-in” period has been acc om pl ished, the lubric ating oil
shoul d be selected from the appropri ate temperature range in Table 1
below:
The Mud Pump bull gears may develop corrective pitting during the early
stages of the product life. This corrective pitting process can be exaggerated
by operating a Mud Pump for extended periods at high load, especially if the
lube oil temperature exceeds 140°F (60°C). As a result of the corrective
pitting process, small metal particles will be present in the lubrication oil.
These metal particles normally accumulate on the power end magnets, in the
lube oil filter, in the settling chamber and in the main sump. National Oilwell
Varco recommends that the magnets, filter and sumps be checked regularly
and maintained/cleaned as needed.
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PROCEDURE
CLIENT PO NUMBER
ASP00019 A
CLIENT DOCUMENT NUMBER
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REVISION HISTORY
CHANGE DESCRIPTION
-
A First
SEE Issue
ECN
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TABLE OF CONTENTS
1 SCOPE.............................................................................................................................. 3
2 APPLICABLE DOCUMENTS ........................................................................................... 4
3 REQUIREMENTS ............................................................................................................. 4
3.1 MATERIAL AND SIZE ............................................................................................ 4
3.2 GENERAL REQUIREMENTS ................................................................................. 5
3.3 LOCK-WIRING METHODS .................................................................................... 6
3.4 OTHER APPLICATIONS ........................................................................................ 7
3.5 ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION .................................. 8
4 QA PROVISIONS.............................................................................................................. 9
5 NOTES.............................................................................................................................. 9
1 SCOPE
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This procedure establishes the method for the selection and application of safety wire.
Lock wiring is the application of wire to prevent relative movement of structure or other
critical components subject to vibration, tension, torque, etc.
Bolts, Nuts and Screws are the common type of fasteners used on NOV
equipment. They need to be locked (secondary retention) against loss of torque / pre-
tension.
Note that the secondary retention will work onl y if the primary retention m ethod is
properly in p lace, i.e. bolts and screws are tightened and torqued as per specifications,
and there is no play between the mating elements. Secondary retention methods aim in
preventing any compromise in primary retention, loss of pre-tension in assembled
fasteners, loosening and backing out.
Definitions:
2 APPLICABLE DOCUMENTS
3 REQUIREMENTS
3.1.1 Material
Lock wire must be aircraft quality stainless steel 302/304 condition A.
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3.2.2 Parts shall be lockwired in such a manner that the lockwire shall be put in tension
when the part tends to loosen.
3.2.3 The lockwire should always be installed and twisted so that the loop around the
head stays down and does not tend to come up over bolt head and leave a slack loop.
3.2.4 Care shall be exercised when installing lockwire to ensure that it is tight but not
over stressed.
3.2.5 Properly twisted lockwire will have 7-12 twists per inch for .032 wire and 6-8 turns
for .052 wire. More twists will over stress the wire and cause fatigue and breakage.
3.2.6 A pigtail should be ½” to 5/8” in length (4-8 twists) at the end of the wiring. This
pigtail shall be bent back or under to prevent it from becoming a snag.
3.2.7 As per the Machinery’s Handbook 27 th edition the following rules apply:
The larger wire may be used in smaller bolts in cases of convenience, but smaller
wire must not be used in larger fastener sizes.
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3.3.1 The method involves threading a wire through holes in the fastener to lock it
against being rotated loose. The wire is twisted before being threaded and is locked to
next bolt. Safety wire should be placed in and around bolt head to maintain the pre-load.
The use of safety wire ties is illustrated in figure 1 above. The illustrations assume the
use of right-hand threaded fasteners.
CAUTION: screws in closely spaced geometric which secure hydraulic or air seals, hold
hydraulic pressure, or used in critical areas of clutch mechanism should use double twist
method of lock-wiring. Make sure that the wire is so installed that it can easily be broken
when required in an emergency situation.
3.3.3 Lock-wiring widely spaced multiple groups by the double twist method.
a) When the multiple fasteners are from 4-6 inches apart, three (3) fasteners
shall be the maximum number in a series that can be safety wired
together.
b) When the multiple fasteners are spaced more than 6 inches apart, the
multiple fastener application specified in Figure 1 shall not be used unless
tie points are provided on adjacent parts to shorten the span of the wire to
less than 6 inches.
c) One end of the safety wire shall be inserted through one set of lockwire
holes in the head of the bolt. The other end of the safety wire shall be
looped around the bolt head in the tightening direction.
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d) The strands, while taut, shall be twisted until the twisted part is just short of
the nearest hole in the next bolt. The twisted portion shall be within 1/8” of
the holes in each bolt as shown in figure 1 above.
e) After wiring the last bolt, the wire shall be twisted to form a pigtail of 2-4
twists. The excess wire shall be cut off. The pigtail shall be bent back or
under the part to prevent it from becoming a snag.
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3.4.1 Hollow head bolts are safety wired in the manner prescribed for regular bolts.
3.4.2 Drain plugs and cocks may be wired to a bolt, nut, or other part having a free lock
hole in accordance with the general instructions contained herein.
3.4.3 External snap rings may be locked if necessary in accordance with the general
locking principles contained herein.
3.4.5 Bolts and hardware may be wired using SAFE-T-Cable. Follow procedure
D744000087-PRO-001.
Safe-T-Cable® can be used similar to Safety/Lock wire to secure Fasteners. The safety
cable installation procedure is shown in Figure. The safety cable comes in pre-cut
lengths with stubs on one end. After sewing through the holes in the fasteners they are
tightened and crimped using a ferrule cartridge and crimping tool.
They are more convenient to use and take only a fraction of the time to secure fasteners
as compared to safety wire as no wire twisting is required. However additional tools like
ferrule cartridge and crimping tool are required. For additional information refer Safe-T-
Cable® (website http://www.dmctools.com/Catalog/safe_t_cable.htm ).
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4 QA PROVISIONS
5 NOTES
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DS00008
Design Specification
NOTES
1. Unless noted, all values are based on light machine oil or anti seize lubricated bolts (not high
pressure lubes)
2. NOV does not recommend assembling bolts dry
3. Proof Strength is 92% of minimum yield strength
4. Torque values given represent 70% to 80% of proof strength
5. Clamp force is based on 75% of proof strength
6. These torque values are to be followed unless otherwise specified
7. If torqueing into aluminum, contact engineering for appropriate torque value.
8. After proper torque has been established in accordance with specification, fasteners shall be
immediately identified as being torqued by either:
a) Being safety wired in accordance with ASP00019 and/or
b) Marked with an “X” using either a red or yellow paint marker.
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COARSEPROOF
THREAD STRENGTH = 41,000 PSI
SERIES - UNC
Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 5.7 6.3 1,407 8.6 9.5 2,266
5/16 – 18 11.4 12.6 2,319 18.1 20.0 3,734
3/8 – 16 20.0 22.1 3,429 33.3 36.8 5,522
7/16 – 14 32 36 4,704 52 58 7,574
1/2 – 13 49 55 6,279 80 88 10,110
9/16 – 12 72 80 8,054 116 128 12,968
5/8 – 11 99 109 10,001 160 176 16,103
3/4 – 10 122 134 10,271 282 312 23,798
7/8 – 9 197 217 14,207 456 504 32,918
1–8 295 327 18,635 684 756 43,179
1 1/8 – 7 418 462 23,462 968 1,070 54,364 7
1 1/4 – 7 590 652 29,797 1,366 1,510 69,041 7
1 3/8 – 6 773 855 35,516 1,792 1,980 82,294 7
1 1/2 – 6 1,026 1,134 43,204 2,378 2,628 100,106 7
F593 F593
G or H U
COARSEPROOF
THREAD STRENGTH = 33,000 PSI
SERIES - UNC PROOF STRENGTH = 74,000 PSI
Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 4.3 4.7 1,320 5.7 6.3 2,020
5/16 – 18 7.8 8.7 2,160 12.1 13.4 3,340
3/8 – 16 14.3 15.8 3,200 21.4 23.6 4,940
7/16 – 14 21.4 23.6 4,380 36 39 6,800
1/2 – 13 36 39 5,840 53 59 9,050
9/16 – 12 50 55 7,500 78 87 11,600
5/8 – 11 71 79 9,300 107 118 14,400
3/4 – 10 125 138 13,800 185 205 21,300
7/8 – 9 118 130 11,400 306 339 29,400
1–8 178 197 15,000 456 504 38,600
1 1/8 – 7 249 276 18,900 570 630 42,300
1 1/4 – 7 356 394 24,000 798 882 53,800 7
1 3/8 – 6 470 520 28,600 1,040 1,150 64,100 7
1 1/2 – 6 620 685 34,800 1,382 1,528 78,000 7
COARSEPROOF
THREAD STRENGTH = 41,000 PSI
SERIES - UNC
Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 4.3 4.7 1,407 6.4 7.1 2,266
5/16 – 18 8.6 9.5 2,319 13.5 15 3,734
3/8 – 16 15 16.5 3,429 24.9 27.6 5,522
7/16 – 14 24 27 4,704 39 43 7,574
1/2 – 13 37 41 6,279 60 66 10,110
9/16 – 12 54 60 8,054 87 96 12,968
5/8 – 11 74 82 10,001 120 132 16,103
3/4 – 10 91 101 10,271 212 234 23,798
7/8 – 9 147 163 14,207 342 378 32,918
1–8 222 245 18,635 513 567 43,179
1 1/8 – 7 314 347 23,462 726 802 54,364 7
1 1/4 – 7 442 489 29,797 1,025 1,132 69,041 7
1 3/8 – 6 580 641 35,516 1,344 1,485 82,294 7
1 1/2 – 6 770 851 43,204 1,783 1,971 100,106 7
F593 F593
G or H U
4.6 8.8
10.9
12.9
4.6 8.8
10.9
12.9
NL4
NL5 M4
M5 .7
.8 3.0
5.8 944
1,529 2.7
5.2 944
1,529
NL6 M6 1.0 10 2,181 9.1 2,181
NL8 M8 1.25 24 4,047 22 4,047
NL10 M10 1.5 47 6,295 43 6,295
NL12 M12 1.75 82 8,992 74 8,992
NL14 M14 2.0 129 12,364 117 12,364
NL16 M16 2.0 197 16,861 177 16,861
NL18 M18 2.5 276 20,682 249 20,682
NL20 M20 2.5 385 26,527 348 26,527
NL22 M22 2.5 525 32,822 474 32,822
NL24 M24 3.0 664 37,993 599 37,993
NL27 M27 3.0 968 49,683 873 49,683
NL30 M30 3.5 1,322 60,474 1,192 60,474
NL33 M33 3.5 1,779 74,861 1,600 74,861
NL36 M36 4.0 2,295 88,125 2,067 88,125
NL39 M39 4.0 2,960 105,211 2,663 105,211
NL42 M42 4.5 3,663 120,947 3,297 120,947
Washer
Size Bolt Size Pitch
(mm) Torque
(ft-lbf) Clamp
(lb) Torque
(ft-lbf) Clamp
(lb)
NL3 M3 .5 1.7 719 1.5 764
NL4 M4 .7 3.9 1,259 3.5 1,326
NL5 M5 .8 7.8 2,046 6.7 2,158
NL6 M6 1.0 14 2,900 12 3,057
NL8 M8 1.25 33 5,171 29 5,620
NL10 M10 1.5 64 8,318 56 8,768
NL12 M12 1.75 110 12,140 95 12,814
NL14 M14 2.0 175 16,636 151 17,535
NL16 M16 2.0 268 22,481 230 23,830
NL18 M18 2.5 375 27,651 323 29,225
NL20 M20 2.5 524 35,070 451 37,093
NL22 M22 2.5 714 43,613 613 46,086
NL24 M24 3.0 903 50,582 776 53,505
NL27 M27 3.0 1,318 66,094 1,128 69,691
NL30 M30 3.5 1,798 80,482 1,542 84,978
NL33 M33 3.5 2,422 99,590 2,068 105,211
NL36 M36 4.0 3,125 117,350 2,673 123,870
NL39 M39 4.0 4,030 140,281 3,440 148,149
NL42 M42 4.5 4,988 160,963 4,262 170,180
SIZE DWG NO REV
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NL4
NL5 M4
M5 .7
.8 4.4
8.7 1,506
2,450 3.8
7.4 1,596
2,585
NL6 M6 1.0 15 3,462 13 3,664
NL8 M8 1.25 36 6,295 31 6,744
NL10 M10 1.5 72 9,892 61 10,566
NL12 M12 1.75 123 14,613 105 15,287
NL14 M14 2.0 196 20,008 167 21,132
NL16 M16 2.0 298 26,977 252 28,551
NL18 M18 2.5 419 33,272 355 35,070
NL20 M20 2.5 585 42,264 494 44,512
NL22 M22 2.5 797 52,380 670 55,303
NL24 M24 3.0 1,009 60,698 850 64,295
NL27 M27 3.0 1,470 79,133 1,235 83,629
NL30 M30 3.5 2,005 96,668 1,688 102,063
NL33 M33 3.5 2,699 119,598 2,265 126,343
NL36 M36 4.0 3,483 140,730 2,927 148,823
NL39 M39 4.0 4,490 168,157 3,763 177,599
NL42 M42 4.5 5,560 193,336 4,666 204,126
Washer
Size Bolt Size Pitch
(mm) Torque
(ft-lbf) Clamp
(lb) Torque
(ft-lbf) Clamp
(lb)
NL3 M3 .5 0.9 337 1.2 450
NL4 M4 .7 1.9 585 2.6 764
NL5 M5 .8 3.7 922 5.1 1,236
NL6 M6 1.0 7 1,326 9 1,754
NL8 M8 1.25 16 2,473 21 3,147
NL10 M10 1.5 32 3,822 41 5,171
NL12 M12 1.75 54 5,620 72 7,419
NL14 M14 2.0 85 7,644 114 10,116
NL16 M16 2.0 130 10,341 174 13,713
NL18 M18 2.5 183 12,589 244 16,861
NL20 M20 2.5 256 16,186 341 21,357
NL22 M22 2.5 349 20,008 465 26,527
NL24 M24 3.0 441 23,155 588 30,799
NL27 M27 3.0 643 30,124 858 40,241
NL30 M30 3.5 877 36,869 1,170 49,233
NL33 M33 3.5 1,182 45,636 1,576 60,698
NL36 M36 4.0 1,525 53,729 2,034 71,714
NL39 M39 4.0 1,968 64,071 2,624 85,652
NL42 M42 4.5 2,435 73,737 3,247 98,241
SIZE DWG NO REV
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NL3.5
NL4 #6
#8 32
32 2.2
3.8 990
1,500 2.0
3.7 1,050
1,600
NL5 #10 24 5.8 1,900 5.5 2,000
NL1/4” ¼ 20 13 3,400 12 3,700
NL8 5/16 18 26 5,700 23 6,000
NL3/8” 3/8 16 45 8,400 39 8,900
NL11 7/16 14 70 11,500 60 12,200
NL1/2” ½ 13 109 15,400 93 16,300
NL14 9/16 12 148 19,800 141 20,900
NL16 5/8 11 216 24,600 184 26,000
NL3/4” ¾ 10 378 36,400 321 38,400
NL22 7/8 9 607 50,200 514 53,000
NL 1” 1 8 916 65,900 776 69,600
NL30 1 1/8 7 1,300 83,000 1100 87,700
NL33 1¼ 7 1,810 105,000 1530 111,000
NL36 1 3/8 6 2,380 126,000 2020 133,000
NL39 1½ 6 3,140 153,000 2640 161,000
ADDITIONAL CODE SDRL CODE TOTAL PGS This document contains proprietary and confidential information
which is the property of National Oilwell Varco, L.P., its affiliates or
REMARKS subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV. National Oilwell Varco
Reproduction, in whole or in part, or use of this design or
MAIN TAG NUMBER DISCIPLINE distribution of this information to others is not permitted without the
RIG SOLUTIONS
express written consent of NOV. This document is to be returned to 11000 Corporate Centre Drive
CLIENT PO NUMBER NOV upon request or upon completion of the use for which it was Houston, TX 77041
loaned. This document and the information contained and
represented herein is the copyrighted property of NOV.
CLIENT DOCUMENT NUMBER © National Oilwell Varco
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REVISION HISTORY
CHANGE DESCRIPTION
02
03 Updated
Updated to electronic format from pdf to ms word in new template
Logo
04 Spelling changed from Overrruning to Overruning.
05 Spelling changed from Overrruning to Overrunning.
06 Removed Recommended Lubrication Product Chart from the document.
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TABLE OF CONTENTS
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The following information lists the recommended type of lubricant to use. The equipment
user must insure that the lubricant selected meets or exceeds the specifications provided.
1.2 Swivels:
1.2.1 Main reservoir – Use an extreme pressure, non-corrosive, anti-foaming gear lubricant.
Ambient temperatures 0°F to 155°F (-18°C to 68°C) AGMA #6EP
-20°F to 40°F (-29°C to 4°C) AGMA #4EP
1.2.2 Wash pipe packing, oil seals and bail pins – Use a multipurpose lithium bas grease.
Ambient temperatures 0°F to 125°F (-18°C to 52°C) NLGI #2
-20°F to 40°F (-29°C to 4°C) NLGI #0
1.3.1 Main Reservoir – Use an extreme pressure, non-corrosive, anti-foaming gear lubricant.
Ambient temperatures 0°F to 155°F (-18°C to 52°C) AGMA #6EP
-20°F to 40°F (-29°C to 4°C) AGMA #4EP
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1.5 Drawworks, Compound Transmissions, Unitized Rotary Transmissions, ECR Units &
Pump Drives:
Grease lubricated bearings, drum brake centralized lubrication system, and all
miscellaneous grease fittings – Use a multipurpose lithium base grease.
Oil lubricated bearings and roller chains – Use a non-detergent machine oil as follows;
Ambient temperatures 80°F to 125°F (27°C to 52°C) SAE 40
32°F to 100°F (0°C to 38°C) SAE 30
0°F to 40°F (-18°C to 4°C) SAE 20
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1.11 Caution:
Do not mix greases with different bases. Always clean reservoirs thoroughly when
changing to grease with a different base.
This oil will help to polish the gear tooth surfaces to prevent initial pitting which is common
on mud pump gears. This is especially important on the new harder gears as they are
more susceptible to cold welding and scoring during the break-in period. The product will
also provide rust prevention during storage periods. It is strongly recommended that the
End User also use this product for at least the initial filling of the pumps. At the first oil
change it would be at the user’s discretion whether to continue its use or change to another
AGMA EP gear oil that meets the general specifications.
A manufacturer of the above product is made by: Schaeffer Oil & Grease Mfg. C.O.
Phone (800) 325-9962
Fax (314) 865-4107
Website: www.schaefferoil.com
If the operator chooses not to use this oil for the initial filling, then a 5% by volume of a
good Moly product, such as Dow Corning M Gear Guard, should be added to the approved
AGMA EP gear oil.
Implementation of the above recommendations will be well worth the extra cost of the
products by extending the life of the equipment and power savings due to reduction of
friction.
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Duplex Pumps
D-225 25 U.S. Gal. 95 Liters
D-375 53 U.S. Gal. 201 Liters
DB-550 58 U.S. Gal. 220 Liters
DC-700 65 U.S. Gal. 246 Liters
DC-1350 100 U.S. Gal. 379 Liters
DC-1650 100 U.S. Gal. 379 Liters
Rotaries
T-1750 (S/N 181 Only) 6 U.S. Gal. 23 Liters
T-1750 (S/N 182-253) 12 U.S. Gal. 46 Liters
T-1750 (S/N 254-268) 8 U.S. Gal. 31 Liters
T-1750 (S/N 269 & up) 10 U.S. Gal. 38 Liters
T-2050 (S/N 31 Only) 5 U.S. Gal. 19 Liters
T-2050 (S/N 111 & up) 6 U.S. Gal. 23 Liters
T-2750 (S/N 89-94) 9 U.S. Gal. 34 Liters
T-2750 (S/N 95-228) 13 U.S. Gal. 50 Liters
T-2750 (S/N 229 & up) 10 U.S. Gal. 38 Liters
T-3750 15 U.S. Gal. 57 Liters
T-4950 15 U.S. Gal. 57 Liters
T-6050 25 U.S. Gal. 95 Liters
Rotary Transmissions
RT-3A Vertical 21 U.S. Gal. 80 Liters
RT-3A Horizontal 28 U.S. Gal. 106 Liters
Chain Coupling 1 U.S. Gal. 4 Liters
Swivels
LB-140 3-3/4 U.S. Gal. 14 Liters
LA, LB-200 4-3/4 U.S. Gal. 18 Liters
LA, LB-300 6-3/4 U.S. Gal 26 Liters
LA, LB-400 10 U.S. Gal 38 Liters
LB-500 15 U.S. Gal 57 Liters
L, LB & LC-650 19-1/2 U.S. Gal 74 Liters
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FD-1600
RIG/PLANT
REFERENCE REFERENCE DESCRIPTION
D290-6316-1003-01-SPL-001 01
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REVISION HISTORY
CHANGE DESCRIPTION
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2 DEFINITIONS
This section provides definitions for accessibility of spare parts and recommendations of spare parts.
Spares Definition
Category
Area 1 Equipment operating within easy access to a National Oilwell Varco store or customer’s own
regional warehouse and expendable parts anticipated for operation of one year.
Area 2 Equipment operating in remote areas.
Group II Spares to support up to two units operating in the area per year.
2.2 Recommendations
Operations Recommendations
Equipment in 1 Lot of Spares for each unit.
accessible
Area 1
Equipment in 1 Lot of Group I Spares for each unit per year,
accessible
Area 2 OR
1 Lot of Group II Spares for approximately each 2 units
2-3 years Multiply Class A spares by 2.
operations
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TABLE OF CONTENTS
Accessibi li ty Area
Area
Part No. Descri ption Area 2
1
Group Group
I 2
Power End Complete
Parts Drawing 6316-1001-03
0-6316-0028-00 Extension, Crosshead 1 3 3
0-6316-0047-00 Gasket, Crosshead Door 6 6
0-6397-0546-00 Spring, Diaphragm S.B. Lock 3 3
0-7501-1269-00 1”-8 X 2 ½” Soc Hd C.S. 12 12
0-7502-0103-00 Gasket, Inspection Door 1 2 8
0-7602-1610-22 O-Ring (Dia. Stf. Box) 3 9
0-7602-1600-39 O-Ring (Dia. Stf. Box) 9 27
0-7602-2131-47 Seal, Single Lip Oil 3 18 54
0-7602-2132-76 Seal, Double Lip Oil 3 18 54
0-7602-0212-67 Bearing, F-1600 Pinion 2 4
0-7502-0840-00 Gasket, Carrier 2 8
0-7502-0841-00 Gasket, Carrier 2 8
0-7602-2131-18 Seal, Oil 1 2 6
0-7602-0212-68 Bearing, F-1600 Eccentric 3 6
0-7602-0201-37 Bearing, F-1600 Main 2 4
0-6316-0127-00 Gasket, Plate 1 4
0-7602-1610-22 O-Ring (Crosshead) 3 9
0-6316-0081-00 Gasket, Plate 3 12
0-6301-0038-00 Bearing, Crosshead F-1600 3 6
7817600438 O-Ring (Rubber) 3 9
0-6397-0548-00 Spring, Stuffing Box 3 9
0-6397-0546-00
0-7602-1070-03 Spring, Lock
Filter, Oil 3
1 29
0-7502-0581-00 Gasket, Cover 4 16
0-7602-1071-13 Element, Filter 1 1 2
0-7602-5940-00 Gasket, Strip 19 ft. 76 ft.
0-6316-0049-00 Gasket, Cover F-1600 Main Bearing 2 8
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0-6397-0575-00
0-6397-0603-00 Guide, Upper
Retainer, Valve
Upper Valve Guide 12
6 36
18
0-7501-0051-00 Screw, Valve Guide Retainer 24 72
0-7503-0230-49 Assembly, ½” Hose 3 9 27
0-7601-2588-50 Nipple, Pipe 3 9
0-7602-1600-25 O-Ring (Disc Manifold) 3 6 12
0-7602-1600-40 O-Ring (Strainer Cap) 3 9 27
0-7602-1600-44 O-Ring (Liner Lock) 3 6 18
0-7602-1600-52 O-Ring (Suction Flange) 6 18
0-7602-1600-61 O-Ring (Suction Manifold) 6 18
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015180300
015180342 Rubbers,
Rubbers, Pair
Pair 6
7”½” 6
6 18
18 72
72
6308241 Nut, Piston 3 16 64
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Ext. Lube Oil Pump Assembly with Magnetic & Coalescing 1262028-DOS E
Filters
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DISCHARGE ACCESSO
MANIFOLD ASSEMBLY
- - -DOS
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1262028-DOS
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1290448-DOS
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-DOS
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TOOL L ST
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Product Datasheet
FD-1600
Triplex Mud Pump
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REVISION HISTORY
CHANGE DESCRIPTION
01 First issue
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TABLE OF CONTENTS
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1 PERFORMANCE DATA
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2 TECHNICAL SPECIFICATION
Dimension, ft in (mm)
A 6’ 10’’ (2,083)
B 5’ 5 ¾’’ (1,670)
C 6’ 1 ⅜’’ (1,864)
D 7’ 4 ⅜’’ (2,245)
E 2’ 6 ¼” (768)
F 1’ 5 ⁄16‘’ (449)
G 4’ 11 ¾’’ (1,518)
H 1’ 9 ¾’’ (552)
I 1’ 1 ¾’’ (350)
J 1’ 0’’ (311)
K 16’ 0’’ (4,877)
L 8’ 0’’ (2,438)
9
M 3’ 2 ⁄16‘’ (979)
N 3’ 6 ⅜’’ (1,076)
P 3’ 11 ½’’ (1,207)
R 3’ ¼’’ (921)
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General Specifications
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Model CM632UUT
CM Series
Induction Motor Powered by a Variable
Frequency Drive
10876548-201-MAN 01
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Document
number 10876548 -201-MAN
Revision 01
Page ii
Part 2
Drawing and Data Package 10876548-201-DWG
CM SERIES
Induction Motor Powered by a Variable
Frequency Drive
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PART 1
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REVISION HISTORY
CHANGE DESCRIPTION
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TABLE OF CONTENTS
1 INTRODUCTION AND DESCRIPTION ............................................................................. 5
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1.1 Introduction
This manual contains instructions for installing, operating, maintaining and trouble
shooting of the various induction motors built by National Oilwell Varco in Sugar Land,
Texas. This section of the manual is general in scope and designed to be used with
supplementary data and attachments, which provides information that applies to a
specific model or series of motors.
WARNING!
HAZARDOUS VOLTAGE CAN CAUSE SEVERE INJURY AND/OR DEATH.
TURN OFF AND LOCK OUT POWER AT MAJOR ELECTRICAL PANEL
Dangerous voltages are present in the motor and peripheral components which can
cause serious injury, electrocution, and equipment damage. To avoid serious injury
and/or equipment damage – before any other acts requiring physical contact with the
electrical or mechanical working components of this equipment are performed – all
equipment must be de-energized, disconnected and isolated to prevent accidental
contact with live or rotating parts. More than one source of power may be applied to the
motor.
The successful and safe operation of motors is dependent upon proper handling,
installation, operation, and maintenance. Failure to follow certain fundamental
installation and maintenance requirements may lead to personal injury, failure or loss of
the machine, as well as damage to other property.
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CAUTION!
MECHANICAL RISKS: Entanglement, Drawing-in, Friction, and abrasion
of upper limbs or entanglement of clothes exist by the shaft: Motors are
to be incorporated within a system. The final installer of the system
must guard the shaft extension in accordance with the requirements of
the machinery directive.
Only qualified personnel should be involved in the inspection, maintenance, and repair
A qualified person is one who is familiar with the installation, construction and operation
of the equipment, and the hazards involved. In addition, they have the following
qualifications.
a. Is trained and authorized to energize, de-energize, clear, ground, and tag circuits
and equipment in accordance with established safety practices.
b. Is trained in the proper care and use of protective equipment such as rubber
gloves, hard hat, safety glasses or face shields, flash clothing, etc., in
accordance with established safety practices.
c. Is trained in rendering first aid.
Motor should be installed and grounded per local and national codes to reduce
the potential hazard of shock from incidental contact. Insure motor is properly
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High Voltage: The warning label shown below in Figure 2 is used to alert the user of
the high voltage running in the machine. The system should be turned off and locked
out before servicing.
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1.2.3 Safe Lifting and Handling Information appears on the Outline Drawing
contained in this Instruction Manual. Consult the weight of the motor and locations and
method to lift the motor. Confirm the lifting apparatus are suitable for the motor weight
shown.
1.2.4 Amperes for Sizing the Power Supply Cable appears on the Outline Drawing
and Data Sheets contained in the Drawing and Data Package. The size and insulation
requirement of the supply cabling (feeding the motor) is dependent on the location and
application of the motor. All supply cables feeding the motor shall be installed and
grounded in accordance with Local, National or Agency codes governing the
application.
1. The End User must provide the protection for the motor in accordance with the
instructions in this Manual provided by National Oilwell Varco and the motor starter
and emergency button in accordance with the requirements of the Machinery
Directive.
product with this directive has been established with regard to all local safety and
installation rules.
1.2.6 The Noise Level of the Motor appears on the Data Sheets. When the sound
level exceeds 85 dB(A), ear protection must be wore in the vicinity of the motor.
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1.2.7 Grounding
Grounding motor frames is required to safeguard personnel from electric shock and to
protect the machine itself in the event of an insulation failure in the machine or installation.
WARNING!
FAILURE TO PROPERLY GROUND ELECTRICAL EQUIPMENT MAY EXPOSE
PERSONNEL TO A POTENTIALLY HAZARDOUS CONDITION IN WHICH SERIOUS
OR FATAL INJURY FROM ELECTRICAL SHOCK IS POSSIBLE.
The motor is an alternating current squirrel cage induction motor of forced ventilated
construction designed for use with Variable Frequency Drives only. The construction of
this motor results in a totally enclosed, forced air-cooled machine (IP45) with IP54
minimum terminal boxes. *Please refer to the ATEX Certificate for proper air flow
requirement of motor rating. The motor requires a minimum of 3400 SCFM to be
provided to the inlet of the motor. The motor is provided with openings for duct
connections for air inlet and exhaust. Ducting must remain in place for certification.
The stator and coil assembly is an integral part of the frame with the stator laminations
welded directly to the frame structure. The motor frame is equipped with removable end
frames which provide support for the bearings.
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rotor (2). The rotor is separated from the stator by an air gap (5). The stator consists of
a steel frame (3) that encloses and secures the laminated stator core (4). The stator
core is made from thin laminations stacked to form a hollow cylinder. At the air gap,
along the inner circumference of the laminations, the stator laminations have evenly
spaced slots that contain the stator winding.
The rotor is also made up of punched laminations carefully stacked to create openings
(slots) along the air gap. Copper rotor bars (6) are inserted into the slots and connected
(short circuited) at each end by copper end rings (7). Bars are swaged to the slot to
avoid movement as a counter-measure against sparking and vibration. The rotor forms
a cage and is referred to as “squirrel cage” rotor.
The entire rotor assembly, consisting of stacked laminations, bars, and end rings, is
secured onto the shaft (8). The shaft rotates between bearings at each end (9) and
(10).
The motor stator core is constructed from thin electrical steel laminations and coated
insulated to minimize hot spots and stack losses. The steel laminations are assembled
under pressure to form the stator core. The stator core is welded to the frame structure.
Insulated stator coils constructed of copper magnet wire are inserted in the stator slots.
The stator coils and core slots are insulated with electrical insulating material. The
stator assembly is vacuum and pressure impregnated with electrical grade varnish and
baked to insure proper bonding qualities, to give high dielectric strength and maximum
moisture resistance. Stator leads are routed to the appropriate location on the motor
frame for terminal termination.
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The stator winding is a series of copper coils placed in the laminated stator slots core.
The winding is connected so that a 3-phase power source produces a rotating magnetic
field. This magnetic field in turn induces a rotor field that interacts with the stator field to
produce torque in the rotor.
The copper in the stator winding is insulated with materials suitable for operation at
(Class H) temperature. The thickness and strength of the insulating material are
suitable for the voltage stresses applied to the winding during the Variable Frequency
Drive Operation.
The rotor is also made up of punched laminations carefully stacked to create openings
(slots) along the air gap. Copper rotor bars are inserted into the slots and connected
(short circuited) at each end by copper end rings. Bars are swaged into the rotor slot to
avoid movement and as a counter-measure against sparking and vibration. The rotor
forms a cage and is referred to as a “squirrel cage” rotor.
The entire rotor assembly consists of stacked laminations, bars and end rings. All
components are secured onto the shaft. The shaft along with the rotor assembly rotates
and is supported by bearings mounted at each end. The shaft has a tapered shaft
extension for ease hub installation for coupling. For detailed information, see the
Outline and Mounting drawing included in the Drawing and Data Package.
1.4.4 Bearings
National Oilwell Varco motors are constructed with a two bearing configuration system.
The two types of bearing styles are ball/ball or ball/cylindrical (roller bearing) which is
grease lubricated and equipped with specially constructed seals. The non drive end is
insulated and the rotating shaft assembly is supported by a deep groove ball bearing.
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The drive end of the rotating shaft assembly is supported by a fixed ball bearing or a
cylindrical roller bearing - see motor outline for specific bearing application.
1.4.5 Frame
The frame is fabricated of steel members welded to plate end rings and press plates.
Steel foot plates are welded to the frame assembly to provide rigid support of the motor
and maintain its alignment with the driven load. Lifting provisions are installed on the
frame to facilitate lifting the complete motor with a conventional overhead hoist. A steel
cover is welded to the frame structure to provide additional stiffness to the frame.
1.4.6 Accessories
National Oilwell Varco motors are available with accessories such as speed encoders
and other components required for motor application. The motors require a forced-air
ventilation system. Refer to the motor accessory description provided in the Drawing
and Data Package of this manual for specific information regarding the accessories and
configuration of the motor. (Motor Certification does not include accessories.)
If speed encoders are mounted on the NDE side of shaft, special precaution should
be taken to avoid circulating currents using appropriate insulated
hardware for installation.
All accessories must have certification ratings matching or more severe to maintain
motor certification.
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This motor is to be operated with (powered by) a Variable Frequency Drive. This motor
is designed to be operated with (powered by) a Variable Frequency Drive. The list of
approved drives is listed in the current ATEX Certificate. If there is any concerns about
any approved Variable Frequency Drive please contact the manufacture, National
Oilwell Varco, Sugar Land, Texas.
DRIVE-TYPE CAUTION
In order to maintain temperature in compliance with the
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SECTION 2
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2 INSTALLATION
2.1 Receiving
The motor is skidded and secured prepared for shipment and can withstand most shocks
and rough handling incurred during transit. Before accepting shipment from the transportation
company, examine the motor carefully to determine if any damage has occurred during
shipment. Unpack the unit and carefully examine the frame and sheet metal for damage.
Inspect for the presence of moisture and make certain no foreign material such as packing,
loose fasteners or dirt have fallen into the motor during transportation and unpacking. If
transportation damage is noted, determine the extent of the damage, and immediately notify
the transportation company claims office and National Oilwell Varco in Sugar Land, Texas.
Be sure to provide complete and accurate details when reporting damage.
If the motor is received during cold weather, allow the unit to stabilize to room temperature
before removing the protective covering and packing material. This precaution will minimize
the condensation of moisture on the cold surfaces and the possibility of early malfunctions
2.2.1 Unpacking
Unpack the motor with care to avoid damage to the unit. Connect an overhead crane to a
minimum of (4) lifting points provided on the motor, lift the unit from the shipping skid and
place it in its mounting location.
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CAUTION!
Failure to use lifting points and extreme care when moving the motor can result in
damage to the motor, other objects, or personal injury.
Avoid manhandling the motor and never apply a lifting force to structural points other than
those provided for that purpose.
2.2.2 Storage
If the motor is not to be installed in its operating location as soon as received, it should be
stored in a clean, dry area not subject to sudden changes in temperature and humidity.
Storage at normal room temperature is recommended. The motor should be covered to
protect it against dust, dirt, moisture and other airborne material while in storage. Consult
with National Oilwell Varco for storage recommendations when the motor cannot be stored
in a temperature and humidity controlled area or storage for a period of more than six
months is anticipated.
Space heaters, when provided in the motor frame, should be energized continuously
during storage of motor, but should be de-energized at time of installation and start-up.
Details of space heater power and connections may appear in the Drawing and Data
Package.
2.3 Inspection
Before installing the motor it is recommended that the unit be thoroughly inspected for
indications of damage or potential malfunctions. Carefully examine the exterior surfaces
of the motor for deep scratches, dents, damaged guards, loose or missing bolts, screws
and other attaching parts. Remove the screened or louvered covers from the ends of
the motor and inspect the rotor and stator and other internal components for loose or
damaged windings and lead wires, loosely mounted components, and the presence of
moisture or other foreign material.
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Remove all shipping materials such as blocks, straps, tapes, rubber packing, paper or
other material used to restrict movement of the rotor during shipment. Use low pressure
compressed air, 25 PSI maximum, to blow out all packing residue and dust from the
interior of the motor. Turn the rotor by hand to make certain it rotates smoothly and
without binding.
2.4 Location
The motor can be installed in any clean, dry, well ventilated area which allows a sufficient
unobstructed flow of coolant air and provides sufficient accessibility for operation and
maintenance of the unit. Avoid locations which would subject the motor to excessive
moisture, dust, steam, or fumes from acids, alkalies or other corrosive chemicals. If such
exposure cannot be avoided, a strict periodic inspection and maintenance schedule must
be established.
2.5 Foundation
The foundation or support for the motor must be rigid, level and of ample size and strength
to support the weight of the motor and withstand the motor foundation reaction loads. The
foundation must also be adequately designed to maintain coupling alignment between the
motor and driven load. It is very important that the foundation is designed in such a
manner as to not have any resonant operating frequencies at or near the operating speed,
or at a multiple of the operating speed of the unit.
2.6 Alignment
There are three basic types of alignment: parallel, angular, and axial. Misalignment can
be parallel, angular, axial, or any combination of the three. An explanation of each type
of misalignment follows.
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2.6.3 Axial
Axial misalignment, Figure 6, is the relationship of the motor rotor to the motor stator.
There are several methods to measure the alignment of two connected shafts. Two
methods are:
The motor and driven-load should be located and leveled on the mounting base. Care
should be taken to eliminate “Soft Foot Condition”.
Soft Foot is the condition where the motor does not sit flat on its’ base and only three of
the four mounting points support the motor. When the fourth point is clamped down the
motor frame or mounting skid is distorted causing possible vibration or erroneous
alignment information. Soft Foot can be corrected by loosening each mounting point
one at a time, measuring the relative movement with a dial indicator, and shimming
under the foot to eliminate that relative movement.
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The relative movement should not exceed 0.005 inch. Shims with burrs on the edges
can contribute to the soft foot condition.
Rotate the indicators so that they are at the top location. It is suggested to zero the dial
indicator when at the top location for convenience. The coupling hub should be marked
at 0, 90, 180, and 270 degrees and a stationary reference mark placed or identified on
the equipment so that when the shafts are rotated, they can be indexed through 90
degree increments. Both shafts should be rotated together.
An easy way to record the measurements is to draw two circles on paper, one for
parallel and one for angular measurements. Also, record the radius of the measurement
point for the angular (face) measurement.
Figure 7 shows a typical dial indicator setup. Rotate the shafts one-quarter turn and
record the dial indicator measurements. Take measurements at; 90, 180, 270 and 360
(0) degrees locations. The dial indicators should read zero when returning to the top
(starting or 0 degree) location. If the indicators do not read zero, disregard the
measurements and repeat the procedure. Figure 8 and 9 shows a typical set of
measurements and their corresponding Total Indicator Readings (TIR). Once these
measurements are recorded, the relationship of the measurements to the allowable
misalignment in Table 1 can be determined by subtracting measurements in each plane
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Table 1 lists maximum allowable parallel and angular misalignment for two bearing
NATIONAL OILWELL VARCO motors. After the initial measurements are taken, the
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Allowable Misalignment
Speed Axial
(RPM)
(inch)
measurement point
It is a good practice to first correct the parallel and angular misalignment in the
horizontal plane. Jack screws attached to the skid can be used to adjust the location in
the horizontal plane. Once corrections are made, a new set of alignment measurements
should be taken. If the alignment in the horizontal plane is within limits, then proceed
with correction in the vertical plane. The proper corrections can be determined through
careful evaluations of the measurements. Corrections for parallel and angular
misalignment may be made together. After any corrections are made in the alignment,
new measurements must be taken for all three forms of misalignment.
2.6.5 Coupling
The machine must be connected to the driven equipment with flexible couplings. (pin
coupling, gear coupling)
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CAUTION!
Careful alignment of machines, when using either solid (rigid) or flexible couplings, is
essential to prevent excessive vibration, hot bearings, or shaft failures.
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After the motor and control equipment is completely installed and wired, but before
operating the unit for the first time, perform the following inspections.
1. Check all interconnecting wiring against the connection diagrams supplied with
the motor.
2. Make certain no foreign objects are lodged in the motor, all guards and safety
devices are securely in place. Remove all materials not required for operation
from the vicinity of all rotating equipment.
3. Ensure that mounting hardware, covers and guards are properly installed and
securely in place.
4. Be sure that the bearings are appropriately lubricated per the bearing lubrication
instructions provided in Paragraph 4.8.
5. If the motor has been subjected to extreme dampness during shipment or
storage, it may be necessary to dry out the winding prior to placing the unit into
Visually inspect the motor for evidence of any damage that would interfere with
protective devices or rotation of motor. Check to ensure tightness of the motor
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The following connections to the motor should be made and checked out prior to
startup.
Machine maximum amperes for sizing the power supply cables appear on the outline
drawing and data sheets contained in this manual. The size and insulation
requirements of the cables depend on the location and application of the motor. The
power supply cables to the motor must be installed and grounded to the local electric
codes requirements.
Check the connections of the main power leads from the variable frequency drive to the
terminal leads at the motor. Proper spacing must be maintained. Motor leads are
marked T1-T2-T3 for a three (3) lead machine and (EU Nomenclature U, V, W).
Normally, motors are supplied as three (3) lead machines with neutral leads connected
together internally to the motor. Outline drawings and connection diagrams in this
manual will indicate how the connections are to be made. For motors fed by Variable
Frequency Drives, the neutral if present is not grounded. Ensure that the line voltage
and frequency correspond to that shown on the motor nameplate.
Particular care must be exercised connecting the starting device phase leads to the
motor. The leads must have the proper sequence applied by the Variable Frequency
Drive to obtain the desired motor rotation. (For example, phase sequence L1-L2-L3 of
the power supply connected to motor terminals T1-T2-T3 will give clockwise rotation
facing the non-drive end of the motor). Reversing (L1) & (L3) of the power supply leads
will produce rotation in the opposite direction.
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Connections of main power supply cables to the motor must be in accordance with IEC
60034-8.
NOTE!
If there is any doubt about rotation and phasing, the motor can be “bumped” to
indicate the direction of rotation by momentarily energizing the motor. A
minimum of two people should check this, one at the motor and one at the
starting device with good visual/oral communication via radio. For the purpose of
“bumping” the motor to determine rotation, the starting device should energize
the motor only as long as it takes to cause the motor to “break-away” and begin
to rotate. If the rotation is incorrect, remove power from motor and allow motor to
coast to a stop. Reverse L1 & L3 of the power supply connections to the motor to
correct the rotation.
Space Heaters are provided in the motor frame and should be energized continuously
during motor storage. (Note: During start-up and operation of the motor, the
heaters should be de-energized.) See motor outline drawing for space heater wire
diagram and power information.
The bearing housings are equipped with seals and includes provisions for re-lubrication
during operation. Each bearing is equipped with one 100 ohm platinum resistive
temperature device for monitoring temperature. The temperature of the bearings should
be monitored during operation. The alarm point should be set at 90°C and shut down
initiated at 100°C.
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The stator of the motor is equipped with six 100 ohm platinum resistive temperature
devices (embedded between the coils of the stator) two per phase. The stator coils
embedded in the laminated core receive a Global VPI of non-hygroscopic resin. The
stator insulation system is Class H. For proper insulation protection, the RTD relays
should be set for alarm at 185°C max, and shutdown at 190°C max. The winding RTD
leads are internally shielded in the terminal block of motor terminal box.
Grounding motor frames is required to safeguard personnel from electric shock and to
protect the machine itself in the event of an insulation failure in the machine or installation.
WARNING!
FAILURE TO PROPERLY GROUND ELECTRICAL EQUIPMENT MAY EXPOSE
PERSONNEL TO A POTENTIALLY HAZARDOUS CONDITION IN WHICH SERIOUS
OR FATAL INJURY FROM ELECTRICAL SHOCK IS POSSIBLE.
Grounding conductors must be provided between the machine frame and the supporting
structure. The purpose for this is to avoid hazardous potential voltage difference between
the machine frame and the adjacent surface on which a person may be standing while
contacting the machine surface.
Grounding of the motor and its auxiliary equipment or boxes are compulsory and must
be performed in accordance with current regulations. The motor frame provides a
grounding pad as provision for a connection with 3/8 – 16 bolting.
Main connection box and auxiliary boxes provided with motor are tested and grounded,
and must not be removed.
Before installing the terminal lug on the ground cable, remove paint, rust, and oil from all
surfaces to which the cables are attached. Bolt lug securely to the surfaces and torque
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the bolt or nut to 20 lb. ft. (27.12 Nm). After installation, protect the ground pad bolt,
washer, and cable lug connection from corrosion by applying a rust inhibitor on the
exposed components.
3.3 Start-Up Procedure (Uncoupled)
1. Verify correct shaft rotation; to change rotation reverse power leads as indicated in
Section 3.2.
2. Energize machine using the Variable Frequency Drive, run standard ID run and save
data, run machine for at least one hour and make sure unusual noise or vibration are
present in the machine.
3. Verify that all instrumentation are functional (Bearing and Winding RTD’s, encoders
if applies, and any other instrument device provided with this unit.)
1. After rotation is verified to be correct, the motor can be started using the Variable
Frequency Drive.
2. Check the motor drive parameters full load amperes (AC amps) and confirm with the
full load current values listed in this manual. The phase currents should be balanced
within +/- 5%.
4. Check the motor frame and enclosures for evidence of any excessive vibration. If
the motor frame or enclosures are vibrating excessively, the motor should be shut
down and the cause of vibration located and corrected.
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5. Once the motor is started, it will remain at approximately to pre-set speed, unless
voltage is lost to the main machine terminals. The machine will trip the drive
protection if the load applied to the shaft is increased to a value outside of the
normal operating limits or the torque of the load exceeds the break down torque for
which the motor is designed.
Normally, Variable Frequency Drive will contain relays to protect the motor from
overcurrent, overtemperature, stall, and excessive torque. These relays will open,
and disconnect the motor from the electric drive when abnormal conditions occur.
Vibration detection devices may also be used to disconnect the motor during
excessive vibration.
6. If after starting the motor, a shut down and attempt to restart is required; the
Instruction Manual should be followed for the number of allowable successive starts
per hour.
Motor is designed to operate with a Variable Frequency Drive. Consult the Variable
Frequency Operation Section supplied with this motor that appears in Section 5 of this
manual.
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4 MAINTENANCE
Prior to beginning the inspection, the following items should be available: Inspection
light, basic hand tools and wrenches, overhead lifting equipment, electric/pneumatic
wire brush suitable for the area classification, roughing/sanding pads, safety solvent,
personal protective equipment, etc. Inspections should be conducted by qualified
personnel.
Step 1: Inspect exterior bolting – all bolts should be present, tight and free of rust and
dirt. Bolts should not show evidence of sparking (pitting, burned, or
blackened areas or paint powdering would be evidence of sparking). Clean
and reinspect.
Step 2: Remove end covers and side panels – inspect all mating surfaces, flange
overlaps, and areas where covers are adjacent to metal parts on motor
exterior for indications of sparking or localized heating. Clean and reinspect.
Step 3: Inspect interior – look for evidence of sparking on interior joints, bearing
brackets, bearing bolts, etc. Clean and reinspect.
Step 4: Inspect rotor – look for evidence of sparking at rotor bar to shorting ring bolts
and rotor bolts and between the rotor bars and the laminations at the edges of
the slots at the end of the core and at each air duct. Clean and reinspect.
Step 5: Inspect gaskets – look for evidence of damage to gaskets, replace them if
missing, broken, deformed or hardened.
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Cleaning the motor is essential to long-term motor life. When the drilling motor is
removed from its machinery, accumulated dirt and oil buildup can be removed. The
external motor surfaces can be cleaned by steam cleaning. The internal motor
components should not be sprayed with a steam cleaner. To clean the motor:
1. Clean the external motor surfaces only when the drilling motor is removed from its
machinery and power is removed from the motor.
WARNING!
PERSONNEL PERFORMING CLEANING PROCEDURES MUST WEAR
PROTECTIVE CLOTHING, GLOVES, AND EYE PROTECTION. FOLLOW LOCAL
PRACTICES AND PROCEDURES FOR CLEANING. FAILURE TO DO SO MAY
RESULT IN INJURY OR DEATH.
WARNING!
ALKALI AND CHLORINATED HYDROCARBON CLEANING SOLUTIONS SHOULD
NOT BE USED FOR CLEANING DRILL MOTORS DUE TO THE ADVERSE AFFECTS
ON MOTOR INSULATION. USE OF THESE SOLUTIONS MAY CAUSE MOTOR
FAILURE OR REDUCED MOTOR LIFE.
WARNING!
DO NOT SPRAY THE INTERNAL COMPONENTS OF THE MOTOR WITH A STEAM
CLEANER. MOISTURE CONTAMINATION MAY CAUSE MOTOR FAILURE OR
REDUCED MOTOR LIFE.
2. Cover the motor air inlet and outlet with heavy plastic and tape in place. Ensure
the interior motor components are protected from spray during cleaning.
3. Steam clean the external surfaces of the motor. Do not direct the spray at motor
openings or the plastic covers.
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4. When steam cleaning is complete, let excess fluid drain from the motor.
5. Remove plastic covers or protective covers and tape from the motor. Clean the
inside of the motor by using a vacuum cleaner or dry low pressure compressed
air, 25 PSI maximum, to remove any accumulation of dirt, dust or other gritty
particles. Stubborn deposits of grease, oil or similar substances on the metal
components that are located away and clear of the windings and insulating
components may be cleaned using a clean cloth moistened with a nonflammable
solvent.
WARNING!
UNDER NO CIRCUMSTANCES SHOULD THE SOLVENT OR SOLVENT
MOISTENED CLOTH BE ALLOWED TO CONTACT THE WINDINGS OR
INSULATING COMPONENTS.
to an extent where wiping with a cloth will not remove the contaminants. See Drying
Procedure.
If the motor has been subjected to extreme dampness during shipment, storage, or
cleaning, a procedure may be required to thoroughly dry all windings.
If the stator insulation resistance measures less than 2 megohms, the machine must be
dried out until at least the minimum recommended resistance value is obtained. The
drying-out process can be accomplished by applying either external or internal heat as
necessary to obtain an end-winding temperature of 167 F (75 C) by thermometer.
° °
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The easiest and most convenient method of drying out a motor consists of placing the
CAUTION!
The temperature of the motor should be raised slowly to avoid building up
excessive vapor or gas pressure, which could prove harmful to the insulation. Do
not exceed a temperature rise of 18 F (10 C) per hour.
CAUTION!
Do not hurry the drying-out process. Never permit the temperature of the motor
to exceed the maximum allowable temperature rise marked on the name plate.
4.8.1 Application
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A high quality NGLI #3 grease is recommended, with the following physical properties:
Soap Base…………………………………………………………………………..........Lithium
Dropping Point…………………………………………………………………….............383oF
Worked Penetration Per ASTM D217…………………………………………...238 NGLI #3
Operating Temperature Range………………………………………………...-40oF to 275oF
Oxidation Inhibited…………………………………………………………………………..YES
Corrosion Inhibited…………………………………………………………………………..YES
Flash Point………………………………………………………………………………….415°F
frequency and amount of grease added to a bearing for each application is dependent
on the bearing size, speed, operating temperature, the grease used, seal condition,
ambient conditions etc.
The motor is factory furnished with the bearing properly prepared with the correct
amount of grease for initial operation. The bearing housing is equipped with provisions
for a grease zerk and a grease vent to facilitate the addition of grease to the bearing. At
each lubrication interval and during preventive maintenance inspections, the grease
seal area and adjacent shaft area should be inspected for signs of excessive leakage.
If excessive leakage is present the seals should be replaced and the shaft and seal
sleeves repaired or replaced as necessary.
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The recommendations for typical installations may need to be adjusted for specific
applications. In applications for standby use, the amount of grease may need to be
Please consult with National Oilwell Varco in Sugar Land, Texas if you have
questions concerning over greasing or temperature fluctuations in the bearings.
Should it become necessary to remove the bearing from the motor, it should be
thoroughly inspected for wear or damage prior to re-installation, and replaced if
necessary. The seals of the bearing housing should also be inspected for wear or
damage and replaced if necessary. When re-installing the bearing, the bearing should
be hand packed with grease and the bearing housings should be packed to 1/2 to 2/3
full with grease. Care should be taken to insure that no foreign material is allowed into
the grease, bearing or bearing housing.
It is recommended that the following relubrication interval and amount be adhered to for
proper bearing operation and life.
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1030-20-0076 6330M 100 - 105 grams* Every 3000 hours of operation or 3 months
1030-14-0004 BC1-1330 100 - 105 grams* Every 3000 hours of operation or 3 months
*A typical industrial grease gun pumps approximately one gram of grease for every
stroke of the gun. Therefore 50 grams is approximately 50 shots from a standard
grease gun. This should be checked with each individual grease gun to assure the
proper amount of grease is used.
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4.9 Troubleshooting
The most important item to keep a unit running with very little down time is to set up a
program for intelligently analyzing the malfunctions, and making the necessary
corrections. Although regular preventive maintenance inspections are conducted, be
alert between inspections for any signs of motor trouble. When a minor problem is
located, correct it immediately. Minor defects can result in costly repairs and down time.
Some of the more common symptoms, along with probable causes and helpful
remedies, are found in the following chart.
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TROUBLESHOOTING CHART
Note: Always disc onnect the machi ne fr om the Power Source before
investig ating a fault or perfor ming any work on th e motor.
Over-voltage,
devices trippedunder-voltage, or overload
(when protective devices Check
Correct for
anycause of abnormal
deficiencies. Resetcondition
devices
incorporated in circuit) Check Motor Data Plate for nomina
operating values.
High motor Cooling air is too hot Adjust for sufficient ventilation for the
temp. Ambient Temperature is too hot motor.
overload.
Motor fan rotating in the wrong direction Fan motor or fan must be corrected.
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SECTION 5
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National Oilwell Varco’s CM632 Series induction motors are specifically designed for Rig
Applications and Variable Frequency Drives. The loss distribution and performance has
been optimized for operation with Variable Frequency Drives. The motor’s capability is
described on the nameplate and in published curves. This section of the Instruction
Manual explains the significance of the descriptions that define the capability of the motor
under variable frequency operation.
The following diagram shows GENERAL capability ranges of a motor under variable
frequency operation. The SPECIFIC ranges are marked on the nameplate. Data sheets
and curves detailing the motor’s performance under Variable Frequency operation also
appear in the Drawing and Data Package.
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Figure 10 shows a typical Speed-Torque Curve for rating values, please refer to data
sheets and curves for specific model number.
HORIZONTAL AXIS – Speed of the motor controlled by a Variable Frequency Drive (VFD)
in RPM.
The intersection of 100% (full torque) and based speed, Point 1 Figure10 gives the rated
torque of the motor and its base speed.
Constant TORQUE SPEED RANGE (Line 2 Figure 10): The motor is capable of
continuously producing the torque equal to its rated. In this speed range, the motor flux is
kept constant by the drive; therefore, motor draws almost the same amount of current for
the same torque request at any speed.
Constant HP SPEED RANGE (Line 3 Figure 10): The motor is capable of continuously
producing the power equal to its rated. At base speed, motor voltage reaches its
maximum. Beyond the base speed, motor voltage stays at its maximum; consequently,
motor flux decreases as the motor speed increases. The decreases of motor flux and the
thermal limitation defined by the rated current results the constant HP Speed Range, in
which the decreases of the torque is inversely proportional to the increase of the speed.
The speed range of constant HP is defined on the nameplate.
Reduced HP SPEED RANGE (Line 4 Figure 10): The motor can’t hold the rated power
anymore, as the break down torque falls off by the square of the reduced flux. Instead, it
produces a reduced power, determined based on the breakdown torque (pull out) of the
motor at each corresponding speed.
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The magnetizing amps provide amp-turns to develop the magnetic flux in the motor.
Uncoupled or at no-load, the motor should draw the same magnetizing current to
the harmonic content and losses within the motor and result in lower temperatures. If a
carrier frequency is specified the value is a minimum.
Other parameters of the Drive program can be set with consideration for factors of the
Drive and the application. Limiting the motor current, torque, and power less than the
rated values will affect motor output.
5.3.1 General
Motors should be properly selected with respect to their service and operating
conditions. CM632 Series induction motors are designed for operation in accordance
with their ratings (as marked) under usual service conditions. While the motor may be
capable of operating under one or more unusual service condition a SPECIAL motor
may be required for some unusual conditions. Usual and unusual conditions are listed
below as the basis for evaluating proper application of the motor.
Applying a motor with service conditions other than those specified as usual may
involve some degree of hazard. The additional hazard depends upon the degree of
departure from the usual condition and the severity of the environment to which the
motor is exposed. The conditions of hazard could result from overheating, mechanical
failure, premature insulation deterioration, corrosion, fire, and explosion.
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Unless otherwise marked, the following conditions are the basis for defining the
motor’s capability.
1. Grease lubricated bearings lowest ambient temperature: -20°C
(minus)
2. Water cooling lowest ambient temperature: 5°C
National Oilwell Varco should be consulted if any of the following unusual service
conditions exist.
A. Exposure to:
4. Nuclear radiation
B Unusual Operation where motor voltage is unbalanced by more than one percent
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C. Unusual Operation at speeds above the rated speed or speed marked on the
nameplate
1. The settings of the Drive do not provide optimum flux levels as marked.
2. The air flow does not provide the required CFM at the motor as marked.
4. The voltage to the motor is low from low input into the drive or a drop in
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SECTION 6
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WARNING!
MOTORS FOR HAZARDOUS AREAS ARE SPECIALLY DESIGNED TO
COMPLY WITH OFFICIAL REGULATIONS CONCERNING THE RISK OF
EXPLOSION. IF IMPROPERLY USED, BADLY CONNECTED, OR
ALTERED, NO MATTER HOW MINOR, THEIR RELIABILITY COULD BE
IN DOUBT. STANDARDS RELATING TO THE CONNECTION AND USE
OF ELECTRICAL APPARATUS IN HAZARDOUS AREAS MUST BE
TAKEN INTO CONSIDERATION, ESPECIALLY NATIONAL STANDARDS
FOR INSTALLATION. ONLY TRAINED PERSONNEL FAMILIAR WITH
THESE STANDARDS SHOULD HANDLE THIS TYPE OF APPARATUS.
WARNING!
MOTORS OPERATED FROM INVERTERS SHOULD NOT BE USED IN
ANY HAZARDOUS (CLASSIFIED) LOCATIONS UNLESS THE MOTOR IS
IDENTIFIED ON THE NAMEPLATE AS ACCEPTABLE FOR SUCH
OPERATION. FAILURE TO COMPLY WITH THIS WARNING COULD
RESULT IN AN UNSAFE INSTALLATION THAT COULD CAUSE
DAMAGE TO PROPERTY OR SERIOUS INJURY OR DEATH TO
PERSONNEL, OR BOTH.
All external wiring to power motor or accessories mounted on the motor must be in
compliance with EN 60079-14, Explosive Atmospheres – Part 14: Electrical Installation
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1. This motor requires the following two measures to maintain the safe
temperatures of Increase Safety “e” protection for a maximum of 200°C surface
temperature.
a) Motor requires Thermal protection.
b) Motor requires forced air during operation providing a minimum of
3400 SCFM.
2. Do not open when energized. All components, including anti condensate heaters
must be de-energized before opening access covers or enclosure covers.
3. Use only with Variable Frequency Drive designated on ATEX Certificate. Not
intended for across-the-line start.
4. The responsibility for insuring safe operation lies with the end user and special
conditions for safe use on the ATEX Certificate must be followed.
5. This is a standard motor that may require additional wiring, modifications and
accessories to be added prior to installation and use. These additional elements
are not included in this certification and the user of the certificate must ensure
that the final installation conforms to the relevant ATEX requirements.
6.1 Construction
National Oilwell Varco’s CM632 Series of motors is specifically designed for Rig
Applications involving Variable Frequency Drives.
When the motor is marked with a nameplate reading Increased Safety “e”, the motor is
provided with a type of protection in which additional measures are applied so as to give
increased security against the possibility of excessive temperatures and of the
occurrence of arcs and sparks inside and on external parts of electrical apparatus in
normal service. The type of protection is denoted by “e” and the additional measures
are those required by Standard EN60079-7 Electrical Apparatus for Potentially
Explosive Atmospheres – Increased Safety “e”.
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6.2 Standards
This motor has been designed manufactured to the applicable requirements of NEMA
MG1.
This motor has been designed manufactured to the applicable requirements of IEC/EN
60034-1. (Rotating Electrical Machines, Part 1: Rating and Performance)
The performance and features of construction are in accordance with the requirements
set forth in the following Standards for use in a potentially explosive atmosphere.
The following other standards are incorporated into the performance and features of
construction not related to the specifics of – Increased Safety “e”.
IEEE Standard 303 Recommended Practice for Auxiliary Devices for Motors in Class I,
Groups A, B, C, and D Division 2 locations.
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“e” also enables the motor to be applied in North American areas designated Division 2.
This motor designated as Increased Safety “e” conforms to the guidelines listed in IEEE
Standard 1349 Guide for Application of Electric Motors in Class I, Division 2 and Class I,
Zone 2 Hazardous (Classified) Locations, also conforms guidelines and codes listed on
NFPA 70 (NEC) Article 500 for Class I, Division 2 and Class I, Zone 2 Location.
National Oilwell Varco’s CM632 Series Motor has nameplates that are marked with the
agency that certifies compliance with the standards listed. When shown on the
nameplate the motor design and performance is certified to comply with the standards
listed on the nameplate. The certifying agency may be a Third Party organization with a
listing-file or certification may be from testing performed by National Oilwell Varco.
Certification requires the motor to be tested with the specific drive type used in the final
application. The following two pages are the Declaration of Conformity that ships with
the motor and lists specific motor serial numbers.
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Manufacturer: National Oilwell (Or after March 2005, National Oilwell Varco) is located
at 500 Industrial Blvd., Sugar Land, Texas 77478, USA.
MODEL: Each motor has a Model Number identification that defines the features and
performance. Duplicate motors share the same Model Number.
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SERIAL No.: Each motor has a unique number that identifies a specific motor. No two
motors have the same Serial Number. Complete traceability of manufacturing is
This nameplate is for a motor designed and tested to be Increased Safety “e” defined
from EN 60079-7: Increased Safety “e”.
The following information is shown on the Hazardous Location Nameplate for induction
motors.
When a mark does not appear in the field on the nameplate, the information Does Not
Apply.
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MODEL: Each motor has a Model Number identification that defines the features and
performance. Duplicate motors would share the same Model Number. This is the same
Model Number that appears on the Main Motor Nameplate.
SERIAL NO.: Each motor has a unique number that identifies a specific motor. No two
motors have the same Serial Number. Complete traceability of manufacturing is
maintained with this identifier. This is the same Serial Number that appears on the Main
Motor Nameplate.
CERTIFICATION LISTING:
FILE NUMBER: The Identification number from a Certifying Agency regarding the
motor’s compliance to the standards of construction and performance listed.
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shown regarding compliance with the standards or temperature limits. Note: The motor
is a passive device that depends on proper energization and removal of power to
maintain safe temperatures. Proper application of a motor in a hazardous-location
requires proper system parameters such as pre-start purging, adequate cooling-air,
drive-programming, and overload and stall protection.
AGENCY: The Certifying Agency that has reviewed compliance with the standards of
construction and performance listed.
NOMINAL SPEED: The speed of the motor at full-load in RPM. The Slip R.P.M. is
determined from this marking by the difference in full-load RPM and the synchronous
RPM.
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NOMINAL CURRENT: The amp-draw of the motor at full-load in amps R.M.S. The
amps shown are when rated voltage is applied at the motor terminals. This is the
CURRENT RATIO (IA/IN): This is the ratio of the stall current IA (at rated conditions)
divided by Nominal full-load amps IN. This ratio defines the motor current in a locked-
rotor (stall) condition. This marking is required by Standard EN 60079-7 for Increased
Safety “e” motors. This marking is used with time (tE) to set over temperature
Protection of the motor. The drive must be set to limit the motor to this value of current
overload.
inrush is not represented. The drive must be set to limit the motor to this value during a
stall.
SAFE STALL TIME (tE): The time in seconds for an AC winding when carrying starting
current IA, to be heated up from the temperature reached in rated service and at
maximum ambient temperature to a temperature that does not exceed the limiting
(maximum surface) temperature. At the current level IA at stall, power must be
removed from the motor before time (t E).
MAG. (NL) AMPS: The current drawn by the motor at rated voltage and rated
frequency at the no-load (uncoupled shaft) conditions. This is the magnetization amps
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of the magnetic circuit that is dependent on the voltage and frequency settings of the
Variable Frequency Drive.
POWER FACTOR: The Cosine of the angle between voltage applied and the amps
drawn by the motor. The Power Factor can be multiplied by 100 and represented by a
percentage.
TIME TO THERMAL STABILITY: (t1): The time in hours for the motor’s stator winding to
reach thermal stability at rated conditions. The total temperature shown is the allowable
temperature for a Class H insulation system.
The drive must be set to limit the amps into the motor at stall to the value IA. At the
current limit IA. Power must be removed from the motor before time (tE).
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The total temperature allowed for the Hazardous Location maximum surface
temperature is marked on the nameplate at the top of the graph as LIMITING
Intermittent Duty:
The CM632 Series motor is capable of short time overloads indicated as the
Intermittent Duty on the motor’s published data. The motor is suitable for high load
excursions without exceeding the surface temperatures of the rated conditions if limited
to the Duty Cycle listed.
The temperatures of the rated condition will not be exceeded if the r.m.s. current of the
Duty Cycle does not exceed rated current.
Intermittent Duty Cycles may require higher current outputs from the Variable
Frequency Drive than shown as the motor’s IA/IN stall ratio. To obtain higher current
levels, the allowable stall time must be reduced by the square of the higher current.
The allowable stall time is less at higher amps by the square of the ratio.
For example, if the IA/IN ratio of the motor is 1.2 PU current and the time (tE) is 30
seconds, the rotor temperature is capable of 1.8 PU current for 13 seconds.
The shorter allowable stall time of 13 seconds was calculated by the square of the ratio
1.2/1.8 times the original 30 seconds.
CE Marking: The CE marking is legally required (mandatory) for products intended for
sale or placed into service in Europe. The marking applies to all manufacturers,
whether located within or outside of the E.U.
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The impetus behind the CE Marking of products is to allow free movement and sales of
goods within the Union, and to eliminate country specific requirements.
Directives (laws) contain the requirements that a product must meet to be sold in the
E.U. For this motor, special documentation requirements and test requirements have
been met for compliance with E.U. Directive on Machinery Safety 98/37/EC.
Compliance is demonstrated with the marking affixed to the product, in this case, the
CE Marking appearing on the motor nameplate. Specifically, conformity with EHSR
1.5.1 has been demonstrated by compliance with the requirements of EN 60204-1
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the hazardous material involved. The hazardous area classification defines the
requirements of the motor and the space heaters to be suitable for operation in that
area. The Area Classification marked on the motor’s nameplate must agree with the
area where it is to be operated. If the Area Classification marking on the motor
nameplate is BLANK, the motor is not suitable for hazardous locations. It is suitable for
an area that is NOT CLASSIFIED as hazardous.
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Per EN 60079-7 it is required that motors supplied with varying frequency and voltage
by a Drive (converter) be tested with the Variable Frequency Drive and certified for the
duty marked on the nameplate. Testing of the protective devices provided for the motor
are also required to be tested at final installation.
The quantity of cooling-air at the motor is marked on the nameplate as air volume in
SCFM (Standard Cubic Feet per Minute). This is the air required into the motor opening
to maintain the maximum surface temperature listed. The density of the cooling-air is
defined to be less than an altitude of 3300 feet (1000 meters). The maximum
temperature of the cooling-air is defined to be less than the ambient temperature listed
on the Main Motor Nameplate.
Motor cooling is dependent on the air supplied to the motor. The cooling air is a System
requirement for proper application of the motor.
WARNING!
IN ORDER TO MAINTAIN COMPLIANCE WITH THE INCREASED SAFETY “ e”
APPLICATION OF THIS MOTOR, THE DUCTED AIR FLOW PROVIDED AT THE
MOTOR MUST BE EQUAL OR GREATER THAN SHOWN ON THE NAMEPLATE.
A DIFFERENTIAL PRESSURE SWITCH OR OTHER MEANS TO ENSURE
REQUIRED AIR FLOW IS RECOMMENDED.
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The motor fed by a Variable Frequency Drive power source will exhibit increased
temperature as compared to a motor operated on a sine-wave due to the affects of the
harmonic frequencies produced by the drive. The amount of increase in losses and
increase in motor temperatures is dependent on the harmonic characteristics of the
drive feeding the motor and the design of the motor.
This motor has been specially designed and tested for operation with the Variable
Frequency Drive type(s) listed on the motor nameplate. The operating program of the
drive affects the temperature of the motor if it is not done properly. The parameters for
programming the Variable Frequency Drive are provided with this manual.
WARNING!
ANY CHANGES TO THE PROGRAMMING OF THE VARIABLE
FREQUENCY DRIVE COULD ADVERSELY AFFECT THE TEMPERATURE
AND PROTECTION OF THE MOTOR AND INVALIDATE THE SUITABILITY
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SECTION 7
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7.1.5 Ventilation
This motor is designed for ducted ventilation. This type of ventilation requires external
air-flow. Air is blown into the motor through the NDE openings in the frame. Hot air is
exhausted through the drive openings. The blower must be operational and providing
the required amount of air (3400 SCFM) in order for the motor to provide rated output at
the temperatures required.
7.1.6 Bearings
This motor is of two bearing construction. The non drive end of the rotating shaft
assembly is supported by deep grove ball bearing. The drive end of the rotating field
and shaft assembly is supported by a fixed ball bearing or cylindrical bearing. The drive
end bearings are grease lubricated, BCI-1330 Type or 6330. Depending on the model
one or both of the bearings DE and NDE are electrically insulated. The bearing
housing’s are furnished with seals and includes provisions for refilling during operation.
Each bearing is equipped with one 100 ohm platinum resistive temperature device.
Refer to Bearing Lubrication Instructions provided in Paragraph 4.8 of this manual for
specific lubrication details.
The stator and coils assembly consists of coil groups embedded in slots within the
laminated steel core of the stator. The lamination material is coated with a non-organic
coating. The stator coils are of form wound construction and interconnected on the non
drive end of the stator. The stator connections are located in a side-mounted connection
box. Labeled lead cables are provided in the connection box for the customer
connections to the power source. The stator of the motor is equipped with six 100 ohm
platinum resistive temperature devices embedded between the coils of the stator.
RTD’s are shielded internally to the motor.
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This motor has been provided with space heaters to prevent moisture absorption when
the machine is out of service. The space heaters are specially designed to limit surface
temperatures for suitability with the Hazardous Area application. A wide range of
voltages can be applied to the Space Heaters as marked. The range is 120 to 240
Volts AC or DC. The motor requires 200 watts, single phase, 120 / 240 volt AC power.
The space heaters should be energized whenever the motor is not in use. This includes
motor storage and all other cases when the motor is not operating. If the motor is in a
humidity controlled environment, then the space heaters do not need to be energized.
When the motor is in storage, provision shall be made to allow adequate air circulation
for moisture removal and prevention of overheating.
° °
NDE Bearing RTD 90 C 100 C
RTD Winding 185 C ° 190 C
°
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Models: CM632UUT-
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10876548-201-DWG 01
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REVISION HISTORY
CHANGE DESCRIPTION
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TABLE OF CONTENTS
Section Page
1 DATA SHEETS
Induction Motor Data 1-5
Hazardous Location Information 2-5
Torque - Speed Performance Curve, 600 Volts 3-5
Torque - Speed Performance Curve, 690 Volts 4-5
Torque - Current Performance Curve, 600 Volts 5-5
Torque - Current Performance Curve, 690 Volts 5-5
2 DRAWINGS
3 ATEX CERTIFICATION
ii
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SECTION 1
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1600 600 560 9659 870 1570 S1, Continuous -40°C to +55°C
1600 690 640 9659 870 1500 S1, Continuous -40°C to +55°C
1850 600 560 11168 870 1735 S9, 120 Sec ON, 60 Off -40°C to +55°C
2000 600 560 12074 870 1912 S9, 120 Sec ON, 90 Off -40°C to +55°C
Note: The sound level will exceed 85 dB(A) - ear protection must be worn while in the vicinity of the motor
when running.
TITLE:
DATA SHEET
AC INDUCTION DRILLING MOTOR
02 5/20/2013 M. Carter C. Wade
MODEL NUMBER: CM632UUT
REV. DATE BY APPVL. 1600 HP RATING
DWN. BY: 03/22/12 CHK. BY: 03/22/12 APVD BY: 03/22/12 DWG. NO. REV.
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MOTOR CONSTRUCTION: Increased Safety “e” in normal operation does not produce sparks,
arcs, or dangerous temperatures.
Comply with : CE Marking on the rating plate per ATEX Directive 94/9/EC
: IEC/EN 60079-7: Electrical Apparatus for Potentially Explosive
Atmospheres – Increased Safety ‘e’ and IEC/EN 60079-0:
Electrical Apparatus for Potentially Explosive Atmospheres – General
Requirements.
Certified By: : Trac EMC & Safety. Under certification files: TRL05ATEX31082X
Important Note:
1) Standard ID run is required prior to starting up the motor.
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690 V OPERATION
Co ntinuous: 1600HP
Constant Torque (*) : 0 to 870 RPM
Constant Horsepower (*) : 870 to 1400 RPM
Reduce Power : 1400 to 2400 RPM
(*) Above points are witnessed and certified by the ATEX notifying body on page 2 of 5
12000
11000
10000
9000
)t 8000
‐
F
b 7000
L
(
E 6000
U
Q
R 5000
O
T 4000
3000
2000
1000
0
0 2 00 4 00 6 00 8 00 1 00 0 12 00 1 40 0 16 00 1 80 0 20 00 2 20 0 24 00 2 60 0 28 00 3 00 0 32 00
SPEED (RPM)
600V OPERATION
Motor Perform ance Curve
Torque versus Current @ 870 RPM
14000
12000
) 10000
t
F
‐
b
L
( 8000
E
U 6000
Q
R
O 4000
T
2000
0
0 250 500 750 1000 1250 1500 1750 2000 2250
CURRENT (Amps)
690V OPERATION
14000
12000
)t 10000
f‐
b
L( 8000
E
U 6000
Q
R
O 4000
T
2000
CURRENT (Amps)
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2 DRAWINGS – 10876548-201-DWG
Nameplate, Heater……………………………………………………………………….G25313
2-1
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Installation, Exhaust…………………….……………………………….....................G97125
Bill of Material……………………………………………10010372-001 (B/M G97125)
Installation, Blower………………………………………………………………10746842-ASM
Bill of Material………………………………………………………..B/M 10746842-001
2-2
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Description: 1600 HP, 690V, CM632UUT Motor equipped with 100W heater 120/240V, six
100 ohm platinum stator RTDs, One 100 ohm platinum RTD for each bearing,
max rated speed 2400RPM, ambient temperature -40°C to 55°C, and furnished
with the following:
Accessories:
1) Connection Box: Stainless steel mounted right side, (viewed from NDE)
IP56
2) Pressure Switch: United Electric J120K - 455
3) Blower Assembly: Furnished; see detail below.
4) Shaft / Hub: 5.65 inch tapered shaft with 10.470 inch Hub
5) Encoder: None
6) Exhaust Hood: Top mounted drive end exhaust.
Blower Description: 4200 CFM Blower assembly with a 20HP 440\480V 3 phase 60Hz motor.
Blower assembly has weather louvers installed on air intake.
Blower Installation NOV # 10746842-001, Blower Assy. Part # 10700335-301
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C Number: 10876548-201-SPC Printed REV: 01 Latest REV
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Description: 1600 HP, 690V, CM632UUT Motor equipped with 100W heater 120/240V, six
100 ohm platinum stator RTDs, One 100 ohm platinum RTD for each bearing,
max rated speed 2400RPM, ambient temperature -40°C to 55°C, and furnished
with the following:
Accessories:
1) Connection Box: Stainless steel mounted left side, (viewed from NDE)
IP56
2) Pressure Switch: United Electric J120K - 455
3) Blower Assembly: Furnished; see detail below.
4) Shaft / Hub: 5.65 inch tapered shaft with 10.470 inch Hub
5) Encoder: None
6) Exhaust Hood: Top mounted drive end exhaust.
Blower Description: 4200 CFM Blower assembly with a 20HP 440\480V 3 phase 60Hz motor.
Blower assembly has weather louvers installed on air intake.
Blower Installation NOV # 10746842-001, Blower Assy. Part # 10700335-301
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C Number: 10876549-201-SPC Printed REV: 01 Latest REV
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irezrl Printed On: Wed Aug
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B . M O A T S O I L W E L L , L . P . U P O N R E Q U E S T A N D I N A N Y E V E N T
U P O N C O M P L E T I O N O F T H E U S E F O R W H I C H I T W A S A C I N D U C T I O N M O T O R
A P P V L 9 / 2 7 / 2 0 1 0 L O A N E D . T H I S D O C U M E N T A N D T H E I N F O R M A T I O N
C O N T A I N E D A N D R E P R E S E N T E D H E R E I N I S T H E
F R A C T I O N A L C . W A D E C O P Y R I G H T E D P R O P E R T Y O F N A T I O N A L - O I L W E L L , L . P . C M 6 3 2 U U T - 1 3 0 / 1 3 8
± 1 / 1 6
F S C M N o . S C A L E : P R O J E C T I O N : S I Z E :
T I R . 0 1 0 A P P V L
A N G U L A R 52142
P O W E R S O L U T I O N S G R O U P 3 / 1 6
5 0 0 I N D U S T R I A L B L V D .
D O C U M E N T N U M B E R :
± 1 / 2 E S T I M A T E D W E I G H T N E X T A S S Y .
S U G A R L A N D , T E X A S 7 7 4 7 8
D O N O T S C A L E D W G . 1 0 5 0 6 6 8 9 - G A D
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[1340.70] 66 9/16
MAY VARY DEPENDING [1690.81]
ON THE BLOWER MANUFACTURER O P T I O N A L B L O W E R
O P I O N A L B L O W E R
A N D F I L T E R
A N D F I L T E R
P T I O N A L O P T I O N A L E X H A U S T H O O D
E X H A U S T H O O D
O P T I O N A L B L O W E
E X T E N S I O N A D A P
70 3/4
[1797.71]
AY VARY DEPENDING
E BLOWER MANUFACTURER O P T I O N A L H E A T E R
P R E S S U R E S W I T C H
O P T I O N A L H U B
S E E S H E E T 2
O P T I O N A L E N C O
NON
DRIVE END DRIVE END
D E C I M A L J . K R O B O T N A T I O N A L - O I L W E L L , L . P . . I T I S L O A N E D F O R L I M I T E D
P U R P O S E S O N L Y A N D R E M A I N S T H E P R O P E R T Y O F
. X X X ± . 0 0 5 N A T I O N A L - O I L WE L L , L . P . . R E P R O D U C T I O N, I N W H O L E
9 / 2 7 / 2 0 1 0 O R I N P A R T , O R U S E O F T H I S D E S I G N O R
. X X ± . 0 2 0 T I T L E :
H . T O R R E S D I S T R I B U T I O N O F T H I S I N F O R M A T I O N T O O T H E R S I S
N O T P E R M I T T E D W I T H O U T T H E E X P R E S S W R I T T E N
. X ± . 0 6 0
A P P V L
F I N I S H 1 2 5
9 / 2 7 / 2 0 1 0 C O N S E N T O F N A T I O N A L - O I L W E L L ,
D O C U M E N T I S T O B E R E T U R N E D
L . P . . T H I S
T O N A T I O N A L
O U T L I N E A N D M O U N T I N
B . M O A T S O I L W E L L , L . P . U P O N R E Q U E S T A N D I N A N Y E V E N T
U P O N C O M P L E T I O N O F T H E U S E F O R W H I C H I T W A S A C I N D U C T I O N M O T O R
A P P V L 9 / 2 7 / 2 0 1 0 L O A N E D . T H I S D O C U M E N T A N D T H E I N F O R M A T I O N
C O N T A I N E D A N D R E P R E S E N T E D H E R E I N I S T H E
F R A C T I O N A L C . W A D E C O P Y R I G H T E D P R O P E R T Y O F N A T I O N A L - O I L W E L L , L . P . C M 6 3 2 U U T - 1 3 0 / 1 3 8
± 1 / 1 6
F S C M N o . S C A L E : P R O J E C T I O N : S I Z E :
T I R . 0 1 0 A P P V L
A N G U L A R 52142
P O W E R S O L U T I O N S G R O U P 3 / 1 6
5 0 0 I N D U S T R I A L B L V D .
D O C U M E N T N U M B E R :
± 1 / 2 E S T I M A T E D W E I G H T N E X T A S S Y .
S U G A R L A N D , T E X A S 7 7 4 7 8
D O N O T S C A L E D W G . 1 0 5 0 6 6 8 9 - G A D
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7
5.
1
2
Ø
1 3
9. 6.
5 6
n n
4 9 8 8 8 R R - R
4. 4. 0. 6. 1. R A- T
6 E 6 E 9 F E
8 3 7 5 3 0. O T 9. T 7. T
5 5 4 4 4 T E A
0 N 9 N 9 H N
3 O E 2 E NI 2 E
R L S
C C C
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1 of 1
11/11/2013
Bill of Material-Engineering
NOV Sugar Land
Instl, End Frame DE 320Fr
Part Number: 10503856- 001
Legacy Number: 10503856-001
Revision: 01
Reference
Item No. Oracle No. Legacy No. Description UOM Quantity Designator
1 10008336-001 G58175 END FRAME, MACH DE CM632 Each 1
2 10504089-001 10504089-001 Cap, Bearing Outer Each 1
3 10004813-001 G45660 CAP, BEARING INNER DE/NDE Each 1
4 10009471-001 G21806 GASKET, CAP INNER DE/NDE 626FR Each 1
5 10009478-001 G21814 GASKET, CAP OUTER DE/NDE 626FR Each 1
6 10032517-016 1030-14-0004 BEARING, ROLLER CYLINDERICAL Each 1
7 10009669-001 1885-05-0013 GREASE, SHELL-CYPRINA Pound 1
9 10090179-001 1555-10-0019 SEAL, LIP PTF SKFE SKF Each 1
9 10090179-001 1555-10-0019 SEAL, LIP PTF SKFE SKF Each 1
9 10090179-001 1555-10-0019 SEAL, LIP PTF SKFE SKF Each 1
10 10001220-001 G56491-3 OIL DEFLECTOR DM626 Each 1
11 10032557-034 7612022 WASHER, HI-COLLAR SPG LOCK 3/4 Each 6
12 10032444-208 3929-05-0014 SCRW,CAP;HD HEX;THRD SZ 3/4-10IN Each 6
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1 of 1
11/11/2013
Bill of Material-Engineering
NOV Sugar Land
Instl, End Frame NDE 320Fr
Part Number: 10504249- 001
Legacy Number: 10504249-001
Revision: 01
Reference
Item No. Oracle No. Legacy No. Description UOM Quantity Designator
1 10008338-001 G58177 END FRAME, MACH NDE CM632 Each 1
2 10504297-001 10504297-001 Cap, Bearing Outer Each 1
3 10004814-001 G45660-2 CAP, BRG INNER DE/NDE Each 1
4 10009471-001 G21806 GASKET, CAP INNER DE/NDE 626FR Each 1
5 10009478-001 G21814 GASKET, CAP OUTER DE/NDE 626FR Each 1
6 10032508-009 1030-20-0076 BEARING,BALL;150MM ID;320 MM OD; Each 1
7 10009669-001 1885-05-0013 GREASE, SHELL-CYPRINA Pound 1
9 10090179-001 1555-10-0019 SEAL, LIP PTF SKFE SKF Each 1
9 10090179-001 1555-10-0019 SEAL, LIP PTF SKFE SKF Each 1
9 10090179-001 1555-10-0019 SEAL, LIP PTF SKFE SKF Each 1
10 10001220-001 G56491-3 OIL DEFLECTOR DM626 Each 1
11 10032557-034 7612022 WASHER, HI-COLLAR SPG LOCK 3/4 Each 6
12 10032444-212 3929-05-0022 SCRW,CAP;HD HEX;THRD SZ 3/4-10IN Each 6
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39
42
8 7
(3)
5 3/4 (1/2)
3 TYP
41 40
4 9 12 4 9 12
2 (6) (3) (3) (6) (3) (3)
ISOMETRIC
REF ONLY
44
SUB ASSEMBLY 2
SUB ASSEMBLY 1
ALL DIMENSIONS ARE IN INCHES, UNLESS OT
TOLERANCE (U.N.) DWN 4/23/2013 THIS DOC
NOTES: DECIMAL
.XXX ` .005
J. VARGAS
CONFIDE
NATIONA
SUBSIDIA
CHK 5/6/2013
1. NUMBERS IN ( ) DESIGNATE QUANTITY. .XX ` .020
04 7/10/2014 HAB BCM
HEREINA
PURPOSE
.X ` .060 H. TORRES NOV. REP
2. DIMENSIONS IN ( ) REFERENCE. FINISH 125 APPVL 5/7/2013
USE OF T
INFORMA
3a. POSITION BUS BARS (ITEM 39) IN BUS SUPPORT (ITEM 2)TO 03 3/13/2014 HAB SR
K. HARWOOD
OUT THE
DOCUME
DIMENSION SHOWN. SEAL IN PLACE USING RESIN EPOXY FRACTIONAL APPVL 5/7/2013
REQUEST
WHICH IT
02 1/3/2014 HAB BCM THE INFO
(ITEM 40 AND ITEM 41) WITH A 50/50 MIX. BUILD UP APPROXIMATELY ` 1/16"
TIR .010
B. MOATS HEREIN IS
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22 15
(12) (12)
33 32 30
(2) (2) (2)
31
A
SECTION A-A
NON DRIVE END FRONT VIEW
W/ COVERS REMOVED FO
RIGHT CONNECTION POSIT
5. ROUTE RTD LEADS THRU CHANNEL ON BOTTOM AND CONNECT FINISH 125 APPVL 5/7/2013
USE OF T
INFORMA
03 3/13/2014 HAB SR OUT THE
TO TERMINAL BLOCKS (ITEM 20). K. HARWOOD DOCUME
REQUEST
6. CHASE ALL THREADED HOLES PRIOR TO MOUNTING COVERS, ETC. FRACTIONAL
02 1/3/2014 HAB BCM
APPVL 5/7/2013 WHICH IT
THE INFO
` 1/16"
B. MOATS
APPLY THREAD SEALANT (ITEM 3) TO STEEL FASTENERS. TIR .010
HEREIN IS
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RTD1-R
RTD, STATOR 18 17 19 20 43
RTD1-W
PHASE A (2) (2) (35) (2)
RTD1-W
RTD2-R
RTD, STATOR SEE
RTD2-W DETAIL E
PHASE B
RTD2-W
RTD3-R
RTD3-W RTD, STATOR
PHASE C
RTD3-W
RTD4-R
RTD4-W RTD, STATOR
PHASE A
RTD4-W
RTD5-R
RTD, STATOR
RTD5-W
PHASE B
RTD5-W
RTD6-R
RTD, STATOR
RTD6-W
PHASE C
RTD6-W
NON DRIVE END
RTD7-R
BEARING 21 16 DETAIL D 15 22
RTD7-W (BEARING AND STATOR RTD'S) (2)
RTD NDE (2)
RTD7-W
RTD WIRE
RTD8-R 50
BEARING SEE NOTE 10
RTD8-W
RTD DE
RTD8-W ALL DIMENSIONS ARE IN INCHES, UNLESS OT
SCHEMATIC TOLERANCE (U.N.) DWN 4/23/2013 THIS DOC
DETAIL E
DECIMAL CONFIDE
`
.020
.060
04 7/10/2014 HAB BCM PURPOSE
H. TORRES NOV. REP
NOTES: TYP (24) PLCS FINISH 125 APPVL 5/7/2013
USE OF T
INFORMA
03 3/13/2014 HAB SR OUT THE
8. LEAVE A 2 FOOT SERVICE LOOP FOR RTD LEAD CABLE. K. HARWOOD DOCUME
REQUEST
FRACTIONAL APPVL 5/7/2013
9. APPLY PUTTY TO ALL BOLTED JOINTS AND HALF LAP BUS BARS ` 1/16" 02 1/3/2014 HAB BCM
WHICH IT
THE INFO
B. MOATS HEREIN IS
WITH TAPE; THEN APPLY DRY VARNISH. THIS IS TO BE DONE TIR .010
FSCM No.
ANGULAR
ONCE ALL CONNECTIONS HAVE BEEN MADE TO THE MOTORS ` 1/2
REV DATE BY APPVL
52142 NAT
INTERNAL BUS BARS. ESTIMATED WEIGHT NEXT ASSY 5
SUG
10. CRIMP FERRULE (ITEM 50) PER MP1272. DO NOT SCALE DRAWING 293 LBS
FORM No. 137-D
2
Number: 10738912-ASM Printed REV: 04
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34
29 4
(3)
(36) (36)
35
(3)
28 27
(2) (2)
TOP VIEW
TYP TOP AND BOTTOM
29 4
(22) (22) 25
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ISOMETRIC VIEWS
W/ COVERS REMOVED FOR CLARITY
.XXX ` .005
J. VARGAS NATIONA
SUBSIDIA
.XX ` .020 CHK 5/6/2013 HEREINA
04 7/10/2014 HAB BCM PURPOSE
.X ` .060 H. TORRES NOV. REP
USE OF T
FINISH 125 APPVL 5/7/2013 INFORMA
03 3/13/2014 HAB SR OUT THE
K. HARWOOD DOCUME
REQUEST
FRACTIONAL APPVL 5/7/2013 WHICH IT
` 1/16" 02 1/3/2014 HAB BCM THE INFO
B. MOATS HEREIN IS
TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL
` 1/2 52142 NAT
ESTIMATED WEIGHT NEXT ASSY 5
SUG
DO NOT SCALE DRAWING 293 LBS
FORM No. 137-D
2
Number: 10738912-ASM Printed REV: 04
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.XXX ` .005
J. VARGAS NATIONA
SUBSIDIA
.XX ` .020 CHK 5/6/2013 HEREINA
04 7/10/2014 HAB BCM PURPOSE
.X ` .060 H. TORRES NOV. REP
USE OF T
FINISH 125 APPVL 5/7/2013 INFORMA
03 3/13/2014 HAB SR OUT THE
K. HARWOOD DOCUME
REQUEST
FRACTIONAL APPVL 5/7/2013 WHICH IT
` 1/16" 02 1/3/2014 HAB BCM THE INFO
B. MOATS HEREIN IS
TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL
` 1/2 52142 NAT
ESTIMATED WEIGHT NEXT ASSY 5
SUG
DO NOT SCALE DRAWING 293 LBS
FORM No. 137-D
2
Number: 10738912-ASM Printed REV: 04
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10312001
10312001
04
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10312001
10312001
04
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10 11 12
(10) (10)
(2 3/4)
SEE NOTE 7
SEE DETAIL A
SEE NOTE 11
ISOMETRIC 6
REF ONLY 5
REF
NOTES:
1. SLEEVE HEATER CABLE WITH 0.387 I.D. SLEEVING
6 PRE ASSEMBLE
(ITEM 9) FROM HEATER CABLE GLAND TO PLATE (ITEM 2).
SEE NOTE 5
2. ROUTE HEATER LEADS AS SHOWN INTO
HEATER AUXILIARY BOX.
3. FULLY TIGHTEN ALL SCREWS TERMINALS AND
TERMINALTION POINTS INCLUDED WITH HEATER. 8 7
4. TORQUE ALL STEEL FASTENERS PER TABLE ON
SHEET 4.
5. PRE-ASSEMBLE (ITEMS 5,6 & 7) AS SHOWN ON DETAIL A. DETAIL A
SCALE 7/16
6. FILL WITH HEATER
RUNNING PACKINGWIRES
FIBERTHROUGH.
(COMES WITH ITEM 8) AFTER ALL DIMENSIONS ARE IN INCHES, UNLESS OT
TOLERANCE (U.N.) DWN 12/5/2007 THIS DOCUMENT CONTAINS PR
7. TIGHTEN ELBOW PIPE (ITEM 7) INTO NIPPLE ON PLATE DECIMAL CONFIDENTIAL INFORMATION W
NATIONAL OILWELL VARCO, L.P
Seitz Mike
(ITEM 6) UNTIL DISTANCE FROM COVER (ITEM 2) .XXX .005 `
CHK 12/13/2007
SUBSIDIARIES (ALL COLLECTIV
HEREINAFTER AS "NOV"). IT IS
C 11/26/2013
TO CENTER OF HUB (ITEM 5) AND ELBOW (ITEM 7) .XX .020 ` HAT RIH
B.KROBOT
PURPOSES ONLY AND REMAIN
NOV. REPRODUCTION, IN WHO
.X .060 USE OF THIS DESIGN OR DISTR
IS 2-3/4 INCHES. `
APPVL 12/13/2007 INFORMATION TO OTHERS IS N
FINISH 125 B 1/20/2011 JCD BCM OUT THE EXPRESS WRITTEN C
8. APPLY THREAD SEALANT (ITEM 12) TO BOLTS H.PHAM DOCUMENT IS TO BE RETURNE
REQUEST OR UPON COMPLETI
PRIOR TO MOUNTING COVER PLATE TO FRAME. FRACTIONAL
A 10/17/2010 JK HT
APPVL 12/13/2007 WHICH IT WAS LOANED. THIS D
THE INFORMATION CONTAINED
1/16" `
9. SEE OUTLINE FOR HEATER LOCATION. TIR .010
B.ISOM HEREIN IS THE COPYRIGHTED
FSCM No.
ANGULAR REV DATE BY APPVL NATIONAL OILW
` 1/2 52142
ESTIMATED WEIGHT
500 INDUSTR
NEXT ASSY
SUGAR LAND, T
DO NOT SCALE DRAWING 17.66 LBS
FORM No. 137-D
2
Number: G97546:37 Printed REV: C
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6 9
SEE NOTE 5 SEE NOTE 1
ISOMETRIC
REF ONLY HEATER MOUNTING
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NOTES:
10. BROWN AND BLUE LEADS TO BE CONNECTED ON
OPPOSITE SIDE FROM TERMINAL BLOCK LABELS. DETAIL B
BROWN INLINE LABEL 1, BLUE INLINE LABEL 2.
LEAD CONNECTIONS
GREEN, TOP OR BOTTOM GROUND CONNECTION.
11. SEAL THE ELBOW (ITEM 7) USING SEALING COMPOUND (ITEM 8) PER MP-1261.
ALL DIMENSIONS ARE IN INCHES, UNLESS OT
TOLERANCE (U.N.) DWN 12/5/2007 THIS DOCUMENT CONTAINS PR
CONFIDENTIAL INFORMATION W
DECIMAL NATIONAL OILWELL VARCO, L.P
Seitz Mike SUBSIDIARIES (ALL COLLECTIV
.XXX ` .005
CHK 12/13/2007 HEREINAFTER AS "NOV"). IT IS
.XX ` .020 C 11/26/2013 HAT RIH PURPOSES ONLY AND REMAIN
B.KROBOT NOV. REPRODUCTION, IN WHO
.X ` .060 USE OF THIS DESIGN OR DISTR
APPVL 12/13/2007 INFORMATION TO OTHERS IS N
FINISH 125 B 1/20/2011 JCD BCM OUT THE EXPRESS WRITTEN C
H.PHAM DOCUMENT IS TO BE RETURNE
REQUEST OR UPON COMPLETI
FRACTIONAL APPVL 12/13/2007 WHICH IT WAS LOANED. THIS D
A 10/17/2010 JK HT THE INFORMATION CONTAINED
` 1/16"
B.ISOM HEREIN IS THE COPYRIGHTED
TIR .010
FSCM No.
ANGULAR REV DATE BY APPVL NATIONAL OILW
` 1/2 52142
ESTIMATED WEIGHT
500 INDUSTR
NEXT ASSY
SUGAR LAND, T
DO NOT SCALE DRAWING 17.66 LBS
FORM No. 137-D
2
Number: G97546:37 Printed REV: C
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A A
SHT 2 SHT 2
2 3
REF REF SEE NOTE 5
4
(4)
3 2
(5) (6)
2
REF
1/4
5. LOCATE MOTOR, ATEX, & HEATER PLATE AS SHOWN. SEE FRACTIONAL APPVL
UPON CO
9/26/2008 LOANED.
A 4/19/2013 HAT BCM CONTAIN
TOP MOTOR BOM TO DETERMINE CORRECT ORIENTATION 1/16"
TIR .010
`
B. MOATS COPYRIG
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PRIOR TO INSTAL
5 3/8 STAMP MODEL, SERIAL N
7/8 TYP
TYP AND YEAR ONTO NAM
PER SALES OR WORK
4
(4)
SEE NOTE 5
4
(4)
REFER TO
TOP LEVEL
BILL OF MATERIAL
IF REQUIRED
3 2 VIEW A-A (TOP VIEW)
REF REF ALL DIMENSIONS ARE IN INC
TOLERANCE (U.N.) DWN 7/13/2008 THIS DOC
DECIMAL D 10/23/2013 HAT BCM CONFIDE
Seitz Mike NATIONAL
NOTES: .XXX
.XX
`
`
.005
.020
C 9/24/2013 HAT BCM
CHK 9/26/2008
PURPOSE
NATIONAL
OR IN PAR
6. LOCATE NAMEPLATE (ITEM 5) CENTERED ABOVE MOTOR & .X ` .060 B. KROBOT DISTRIBU
NOT PER
FINISH 125 APPVL 9/26/2008
ATEX NAMEPLATE. MARK HOLE LOCATIONS & B 5/21/2013 HAT BCM
CONSENT
DOCUMEN
J. MCGUANE OILWELL,
DRILL #37 DIA THRU TYPICAL (2) PLACES & INSTALL FRACTIONAL 9/26/2008
UPON CO
APPVL LOANED.
NAMEPLATE WITH DRIVE SCREWS (ITEM 6). ` 1/16" A 4/19/2013 HAT BCM
B. MOATS
CONTAIN
COPYRIG
TIR .010
7. DIMENSIONS ARE APPROXIMATE. ANGULAR FSCM No.
REV DATE BY APPVL
8. IDENTIFY PART WITH PART NUMBER & REVISION, ` 1/2 52142 POW
ESTIMATED WEIGHT NEXT ASSY 5
(EX:1XXXXXXX-XXX/REVXX) USING THE APPROPRIATE TAG.. SUG
DO NOT SCALE DRAWING N/A = LBS
FORM No. 137-D
2
Number: G97379-3:37 Printed REV: D
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1/2 1/2
7 4
(4)
4 7
(4)
DRIVE END
.XXX ` .005
Seitz Mike NATIONAL
PURPOSE
.XX ` .020 CHK 9/26/2008 NATIONAL
C 9/24/2013 HAT BCM OR IN PAR
.X ` .060 B. KROBOT DISTRIBU
NOT PER
FINISH 125 APPVL 9/26/2008 CONSENT
B 5/21/2013 HAT BCM DOCUMEN
J. MCGUANE OILWELL,
UPON CO
FRACTIONAL APPVL 9/26/2008 LOANED.
` 1/16" A 4/19/2013 HAT BCM CONTAIN
B. MOATS COPYRIG
TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL
` 1/2 52142 POW
ESTIMATED WEIGHT NEXT ASSY 5
SUG
DO NOT SCALE DRAWING N/A = LBS
FORM No. 137-D
2
Number: G97379-3:37 Printed REV: D
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(36.50) (11.18)
(18.25) 2.88
TYP
A (3.63)
A
CONNECTION END
NOTE:
SEE SHT 2 FOR "
SEE SHT 3 FOR "
NOTE:
CONNECTION BO
RIGHT HAND PO
MIRROR IMAGE A
FOR LEFT HAND
NOTES:
1. NUMBERS IN ( ) DESIGNATE QUANTITY. ALL DIMENSIONS ARE IN INCHES, UNLESS OTH
TOLERANCE (U.N.) DWN 3/3/2008 THIS DOC
2. DIMENSIONS IN ( ) ARE REFERENCE. DECIMAL CONFIDE
Seitz Mike NATIONA
3. REMOVE EXCESS VARNISH FROM STATOR CORE AND RTD LEADS. .XXX ` .005
CHK 4/18/2008
SUBSIDIA
HEREINA
.XX ` .020
PRIOR TO INSERTION OF STATOR, INSPECT FRAME STATOR BORE .X ` .060 L. SPANGLE
PURPOSE
NOV. REP
USE OF T
AND O.D. OF STATOR. IF NECESSARY HEAT FRAME PRIOR TO FINISH 125 APPVL 4/18/2008 INFORMA
OUT THE
STATOR INSERTION. B. MOATS DOCUME
REQUEST
FRACTIONAL APPVL 4/17/2008
4. INSERT STATOR CORE (ITEM 2) INTO FRAME (ITEM 1) FROM ` 1/16" 06 12/9/2023 HAT BCM
WHICH IT
THE INFO
B. ISOM HEREIN IS
CONNECTION END AND PRESS TO SHOULDER IN FRAME. TIR .010
FSCM No.
ANGULAR
CENTER LEADS ON STATOR CORE AT 12 O'CLOCK. ` 1/2
REV DATE BY APPVL
52142 NAT
5. TACK WELD STATOR SUPPORT TO FRAME BARS WHERE ACCESSIBLE. ESTIMATED WEIGHT NEXT ASSY 5
SUG
DO NOT SCALE DRAWING 4771 LBS
FORM No. 137-D
2
Number: G93277:37 Printed REV: 06
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SHT 4 SHT 4
16
D D
18 16 15 1
B (2
T3 T2 T1
B
CONNECT LEADS MARKED "1" & "6" TO "
CONNECT LEADS MARKED "3" & "5" TO "
NOTES: (Cont.)
6. MOUNT BUS LINKS (ITEM 13 AND ITEM 14) TO BUS ASSEMBLY USING
HARDWARE (ITEMS 8,11, AND 12), HAND TIGHTEN ONLY. MOUNT BUS ALL DIMENSIONS ARE IN INCHES, UNLESS OTH
TOLERANCE (U.N.) DWN 3/3/2008 THIS DOC
BARS (ITEM 7) TO BUS LINKS USING HARDWARE (ITEMS 8,11, AND 12) DECIMAL CONFIDE
.XXX ` .005
Seitz Mike NATIONA
AND HAND TIGHTEN ONLY. USE COPPER SHIM STOCK IF REQUIRED. .XX ` .020 CHK 4/18/2008
SUBSIDIA
HEREINA
PURPOSE
POSITION AND INSTALL INSULATORS (ITEM 4 AND ITEM 6) USING .X ` .060 L. SPANGLE NOV. REP
USE OF T
HARDWARE (ITEMS 3, 5, 8, AND 9) SEE SHEET #4. FINISH 125 APPVL 4/18/2008 INFORMA
OUT THE
7. CONNECT ALL LEAD LUGS (ITEM 10) TO BUS BARS USING HARDWARE B. MOATS DOCUME
REQUEST
FRACTIONAL APPVL 4/17/2008 WHICH IT
(ITEMS 8, 11, AND 12). ` 1/16" 06 12/9/2023 HAT BCM THE INFO
B. ISOM HEREIN IS
8. TIGHTEN ALL BUS BAR HARDWARE AND APPLY PUTTY (ITEM 15) TO TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL
BOLTED JOINTS. HALF LAP BUS BARS WITH TAPE (ITEM 16) THEN APPLY ` 1/2 52142 NAT
5
AIR VARNISH (ITEM 18). TORQUE BOLTS PER CHART ON SHEET 5. ESTIMATED WEIGHT NEXT ASSY
SUG
DO NOT SCALE DRAWING 4771 LBS
FORM No. 137-D
2
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16 15 12 11
(6) (6)
C 18 16 15 14 12 11 8
(1) (2) (2) (4
T3 T2 T1
C
CONNECT LEADS MARKED "2" & "4" T
.XXX ` .005
Seitz Mike NATIONA
SUBSIDIA
.XX ` .020 CHK 4/18/2008 HEREINA
PURPOSE
.X ` .060 L. SPANGLE NOV. REP
USE OF T
FINISH 125 APPVL 4/18/2008 INFORMA
OUT THE
B. MOATS DOCUME
REQUEST
FRACTIONAL APPVL 4/17/2008 WHICH IT
` 1/16" 06 12/9/2023 HAT BCM THE INFO
B. ISOM HEREIN IS
TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL
` 1/2 52142 NAT
ESTIMATED WEIGHT NEXT ASSY 5
SUG
DO NOT SCALE DRAWING 4771 LBS
FORM No. 137-D
2
Number: G93277:37 Printed REV: 06
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5 6
(2) (2)
9 8
3 4
DETAIL E
CONNECTION END
.XXX ` .005
Seitz Mike NATIONA
SUBSIDIA
.XX ` .020 CHK 4/18/2008 HEREINA
PURPOSE
.X ` .060 L. SPANGLE NOV. REP
USE OF T
FINISH 125 APPVL 4/18/2008 INFORMA
OUT THE
B. MOATS DOCUME
REQUEST
FRACTIONAL APPVL 4/17/2008 WHICH IT
` 1/16" 06 12/9/2023 HAT BCM THE INFO
B. ISOM HEREIN IS
TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL
` 1/2 52142 NAT
ESTIMATED WEIGHT NEXT ASSY 5
SUG
DO NOT SCALE DRAWING 4771 LBS
FORM No. 137-D
2
Number: G93277:37 Printed REV: 06
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.XXX ` .005
Seitz Mike NATIONA
SUBSIDIA
.XX ` .020 CHK 4/18/2008 HEREINA
PURPOSE
.X ` .060 L. SPANGLE NOV. REP
USE OF T
FINISH 125 APPVL 4/18/2008 INFORMA
OUT THE
B. MOATS DOCUME
REQUEST
FRACTIONAL APPVL 4/17/2008 WHICH IT
` 1/16" 06 12/9/2023 HAT BCM THE INFO
B. ISOM HEREIN IS
TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL
` 1/2 52142 NAT
ESTIMATED WEIGHT NEXT ASSY 5
SUG
DO NOT SCALE DRAWING 4771 LBS
FORM No. 137-D
2
Number: G93277:37 Printed REV: 06
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, &
10022001
32
0
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15 7 6 3 1 6 7 12
(10) (10) (14) (14)
DE NDE
14 7 6 5 2 6 7 13
(10) (10) (12) (12)
OPPISITE SIDE OF OPPISITE SIDE OF
AUXILIARY RTD BOX MAIN CONNECTION BOX
4
(2)
DE NDE
.XXX ` .005
DOBROWOLSKI NATIONA
SUBSIDIA
.XX .020 CHK 5/9/2006 HEREINA
NOTES:
`
C 9/20/2010 JK HT PURPOSE
.X ` .060 R. RAMIREZ NOV. REP
USE OF T
FINISH 125 APPVL 5/9/2006 INFORMA
1. APPLY THREAD SEALANT, ITEM 10, TO HARDWARE B 8/13/2010 JCD BCM OUT THE
M. SEITZ DOCUME
BEFORE ASSEMBLY. FRACTIONAL APPVL 5/9/2006
REQUEST
WHICH IT
A 10/24/2006 TB BI
2. TORQUE ALL STEEL FASTENERS PER TABLE ON SHEET 2. ` 1/16"
B. ISOM
THE INFO
HEREIN IS
TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL NAT
` 1/2 52142
ESTIMATED WEIGHT NEXT ASSY 5
SUG
DO NOT SCALE DRAWING
FORM No. 137-D
2
Number: G97331:37 Printed REV: C
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.XXX ` .005
DOBROWOLSKI NATIONA
SUBSIDIA
.XX ` .020 CHK 5/9/2006 HEREINA
C 9/20/2010 JK HT PURPOSE
.X ` .060 R. RAMIREZ NOV. REP
USE OF T
FINISH 125 APPVL 5/9/2006 INFORMA
B 8/13/2010 JCD BCM OUT THE
M. SEITZ DOCUME
REQUEST
FRACTIONAL APPVL 5/9/2006 WHICH IT
` 1/16" A 10/24/2006 TB BI THE INFO
B. ISOM HEREIN IS
TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL NAT
` 1/2 52142
ESTIMATED WEIGHT NEXT ASSY 5
SUG
DO NOT SCALE DRAWING
FORM No. 137-D
2
Number: G97331:37 Printed REV: C
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Bill of Material‐Engineering
NOV Sugar Land
INSTL, COVER ASSY
Part Number: 10010116‐001
Legacy Number: G97331
Revision: C
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(6 11/16)
(1 1/2)
4 1
2 3 5
(REF)
FRAME (10) (10)
NOTES:
FINISH 125 APPVL 1/4/2007 INFORMA
OUT THE
A.CARDIEL DOCUME
REQUEST
1. NUMBER IN ( ) DESIGNATES QUANTITY. FRACTIONAL APPVL 1/4/2007 WHICH IT
` 1/16" A 5/13/2010 JCD N.B. THE INFO
2. DIMENSIONS IN ( ) ARE REFERENCE. TIR .010
B.ISOM HEREIN IS
FSCM No.
3. TORQUE ALL STEEL FASTENERS PER TABLE ON SHEET #2. ANGULAR
REV DATE BY APPVL NAT
` 1/2 52142
4. APPLY SMALL AMOUNT OF SEALANT (ITEM-5) TO ALL SCREW ESTIMATED WEIGHT NEXT ASSY 5
THREADS PRIOR TO INSERTION. SUG
DO NOT SCALE DRAWING LBS
FORM No. 137-D
2
Number: G97125:37 Printed REV: A
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Bill of Material‐Engineering
NOV Sugar Land
INSTL, AIR EXHAUST TOP
Part Number: 10010372‐001
Legacy Number: G97125
Revision: A
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(4.850)
GAGE LINE
1
A
2
REF
n(5.650)
GAGE LINE
A
SECTION A-A
VIEW A
HUB ARRANGEMENT
ALL DIMENSIONS ARE IN INCHES, UNLE
TOLERANCE (U.N.) DWN 5/29/2006 THIS DOC
DECIMAL CONFIDE
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(17 3/8)
SEE NOTE 6
3 4
(14) (14)
1
(19 1/2)
5 6
(14) (14)
7
SEE NOTE
(2)
DRIVE END
NOTES:
1. NUMBERS
2. DIMENSIONSIN (IN) DESIGNATES QUANTITY.
( ) ARE REFERENCE. ALL DIMENSIONS ARE IN INCHES, UNLESS OT
TOLERANCE (U.N.) DWN 5/13/2013 THIS DOC
3. TORQUE ALL STEEL FASTENERS PER TABLE ON SHEET 2. DECIMAL
H. TASSEW
CONFIDE
NATIONA
.XXX ` .005
4. APPLY SMALL AMOUNT OF SEALANT (ITEM 9) TO ALL SCREW .XX ` .020 CHK 5/13/2013
SUBSIDIA
HEREINA
PURPOSE
THREADS PRIOR TO INSERTION. .X ` .060 DOBROWOLSKI NOV. REP
USE OF T
5/13/2013
5. REMOVE TOP COVER, NON DRIVE END (10006561-001) PRIOR TO FINISH 125
03 7/7/2014 HAB BCM
APPVL INFORMA
OUT THE
INSTALLING BLOWER ASSEMBLY. K. HARWOOD DOCUME
REQUEST
FRACTIONAL APPVL 5/13/2013 WHICH IT
6. SEE TOP LEVEL MOTOR SPECIFICATION FOR BLOWER ` 1/16" 02 6/14/2013 HAT BCM THE INFO
B. MOATS HEREIN IS
ASSEMBLY PART NUMBER. TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL
7. IDENTIFY PART WITH PART NUMBER & REVISION, ` 1/2 52142 NAT
5
(EX:1XXXXXXX-XXX/REVXX) USING THE APPROPRIATE TAG. ESTIMATED WEIGHT NEXT ASSY
SUG
DO NOT SCALE DRAWING
FORM No. 137-D
2
Number: 10746842-ASM Printed REV: 03
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.XXX ` .005
H. TASSEW NATIONA
SUBSIDIA
.XX ` .020 CHK 5/13/2013 HEREINA
PURPOSE
.X ` .060 DOBROWOLSKI NOV. REP
USE OF T
FINISH 125 APPVL 5/13/2013 INFORMA
03 7/7/2014 HAB BCM OUT THE
K. HARWOOD DOCUME
REQUEST
FRACTIONAL APPVL 5/13/2013 WHICH IT
` 1/16" 02 6/14/2013 HAT BCM THE INFO
B. MOATS HEREIN IS
TIR .010
ANGULAR FSCM No.
REV DATE BY APPVL
` 1/2 52142 NAT
ESTIMATED WEIGHT NEXT ASSY 5
SUG
DO NOT SCALE DRAWING
FORM No. 137-D
2
Number: 10746842-ASM Printed REV: 03
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SECTION 3
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RIG/PLANT
REMARKS
CLIENT PO NUMBER
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REVISION HISTORY
CHANGE DESCRIPTION
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PREFACE
LS-NOV makes no warranties of any kind, expressed or implied; including any warranty of
mechanical fitness for any particular purpose that the work performed pursuant to this
manual will be free from defects in workmanship or material.
LS-NOV retains for itself all proprietary rights in and to all designs, engineering details, data
and procedures set forth herein. This manual is intended for the sole use of LS-NOV
customers and they shall strictly control copying of same, as this manual and all copies
thereof may be recalled by LS-NOV at any time.
This manual makes recommendations only. The customer is at all times responsible for
actual disassembly, inspection, re-assembly and testing of the pulsation dampener body.
The customer is also solely responsible for providing competent and qualified persons;
equipment and facilities to perform such operations; and for workmanship and safety.
If at any time the customer is unable to understand the recommendations made in this
manual or is unable to follow those recommendations, they should consult the nearest LS-
NOV location.
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Contents
PREFACE.................................................................................................................................... 3
1 INSTALLATION ................................................................................................................ 5
1.1 Mounting ................................................................................................................... 6
1.2 Precharging (NITROGEN ONLY) ........................................................................... 6
2 DISASSEMBLY ................................................................................................................ 8
2.1 Disassembly Procedure.......................................................................................... 8
2.2 Cleaning and Inspection Procedure........................................................................ 9
3 ASSEMBLY .................................................................................................................... 10
3.1 Bottom Plate Gasket Installation........................................................................... 10
3.2 Bottom Plate Installation....................................................................................... 10
3.3 Diaphragm Installation .......................................................................................... 10
3.4 Stabilizer Installation............................................................................................. 10
3.5 Cover Plate Installation......................................................................................... 11
3.6 Installation of Charging Valve ............................................................................... 11
3.7 Installation of Pressure Gauge ............................................................................. 11
3.8 Pressurize Pulsation Dampener ........................................................................... 12
4 MAINTENANCE.............................................................................................................. 13
4.1 Precharge............................................................................................................. 13
4.2 Low Precharge Effects.......................................................................................... 13
4.3 High Precharge Effects......................................................................................... 13
5 PRECHARGE ADJUSTMENTS ..................................................................................... 13
5.1 Precharge Low...................................................................................................... 13
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1 INSTALLATION
CAUTION: Do not attempt to precharge pulsation dampener prior to mounting the unit into
the pump piping system.
The LS-NOV Pulsation Dampener should be mounted in the vertical position (refer to Figure
1-1 for mounting options) with the mating flange connection at the bottom. The discharge
dampener should be mounted as close as possible to the discharge port of the pump. If
possible, it is advantageous that the dampener be mounted in such a way that the fluid
stream is directed towards the fluid opening.
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1.1.3 Install one lubricated nut on each stud and tighten one turn at a time until dampener is
firmly in place. Assure that space between dampener and flange is equal.
1.1.4 Cross tighten nuts to the proper torque (appro. 1012 lb-ft or 1372 N.m).
The correct precharge is vital for maximizing efficiency of the pulsation dampener. Generally,
precharge pressure is based on the average operating pressure of the system, but precharge can
be affected by other system parameters; for these applications, consult qualified LS-NOV
personnel for correct precharging instructions.
WARNING: ALWAYS PRECHARGE WITH ZERO PRESSURE ON THE SYSTEM AND ALWAYS
PRECHARGE WITH NITROGEN.
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1.2.1.1 The pressure gauge is located under the valve guard and is exposed by removing the
valve guard.
1.2.1.2 Before precharging the dampener make sure all cover stud nuts are tightened evenly and
charging valve and pressure gauge seal nuts are firmly seated on the dampener.
1.2.1.3 Precharging is accomplished by connecting one end of the charging hose assembly to a
standard commercially available NITROGEN bottle and the other end to the charging
valve located at the top of the pulsation dampener.
1.2.1.4 Precharge from a standard commercially available nitrogen bottle equipped with a
pressure regulator.
1.2.1.5 For those applications where higher precharge pressures are required, a gas booster
pump is available.
1.2.1.6 Open bottle regulator valve until recommended precharge pressure shows on regulator
gauge.
1.2.1.7 Slowly open charging valve on dampener. Allow pressure to increase in the dampener
until dampener pressure gauge reads the specified precharge
1.2.1.8 Close the charging valve and tighten. Then, close regulator valve at nitrogen bottle.
Remove charging hose, replace dust plug in charging valve.
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Adjust the precharge pressure as required. After precharge pressure has stabilized at specified
pressure, close valves, remove charging hose. Dampener is now ready for operation.
2 DISASSEMBLY
2.1.1 Shut down pumps and remove system pressure from dampener.
2.1.2 Open charging valve and bleed off all precharge pressure. CAUTION: System and vessel
pressure must be at zero PSI before removing charging valve and pressure gauge or
loosening cover or flange bolts.
2.1.5 Loosen all cover stud nuts, but do not remove. Make sure the cover plate is not pushing
upwards against nuts. This would indicate that pressure has not been completely removed
from dampener.
2.1.6 After all pressure is removed from dampener, remove nuts from studs.
2.1.7 If dampener is equipped with a stabilizer, remove cap screw, lock washer and stabilizer
plate. Remove stabilizer so the diaphragm may be folded and removed from the body.
2.1.8 Pull neck portion of diaphragm loose from one side of dampener. Push bottom of
diaphragm down, fold diaphragm or place bar between dampener body and diaphragm
below the diaphragm mid-section to assist folding and removal of diaphragm from body.
2.1.9 If the bottom plate is to be removed for replacement or inspection, follow the procedure
below:
a. Verify cover is attached and all stud nuts are snug.
b. Remove all flange and stud nuts at bottom connection.
c. Remove dampener from flange connection. Set stud nuts and gaskets aside and save
for reinstallation.
d. Remove dirt and debris from bottom plate opening.
e. Remove socket head cap screws that hold bottom plate in place. Set aside and
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save.
f. Remove bottom plate from dampener. Remove gasket and inspect for damage.
Set aside and save if reusable. Replace if damaged.
g. Inspect bottom plate for excessive pitting, corrosion or wear. If these conditions
exist, consult your nearest LS-NOV representative for corrective action.
2.2.1 Flush diaphragm body, clean and remove scale and other foreign material.
2.2.2 Inspect inside of dampener body for excessive pitting. Corrosion or wear. If these
conditions exist, consult your nearest LS-NOV representative.
2.2.3 Mild pitting or scaling can be removed with application of light duty emery cloth. Inside of
dampener must be free of burrs and debris.
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3 ASSEMBLY
All metal surfaces of the cover plate, body, and bottom plate which come into contact with the
diaphragm must be cleaned carefully before reassembly. Scrape and wire brush all surfaces and
completely remove any foreign matter, rust or scale. Refer to Figure 3-1 while following the
procedure below.
3.2.1 Insert bottom plate into body taking care not to pinch gasket and align counter bore holes
with tapped holes in body. Install socket head cap screws and tighten evenly until bottom
plate is snug against body. Torque cap screws to appro. 650 lb-ft or 882 N.m.
3.3.1 Apply a light coat of a general lubricant (castor oil or equivalent) on diaphragm to aid in
installation.
3.3.2 Pull up on neck of diaphragm while pushing diaphragm insert area down.
3.3.3 Take the new diaphragm in the at rest position and roll one side toward the other forming a
crude football shape. A thin belt or strap may be helpful in holding this shape.
3.3.4 Apply lubricant to the folded diaphragm and insert it long ways into the body of the
dampener as far as possible (the diaphragm should go over half way into the dampener
body).
3.3.5 Fold the remainder of the diaphragm into the vessel and allow it to open inside the body.
3.4.1 When stabilizer is used, temporarily install hex screw into insert.
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3.4.2 Break vacuum at neck by pulling diaphragm slightly away from sealing area.
3.4.3 Pull up on hex nut so diaphragm bottom moves up near neck opening.
3.4.4 Re-seat diaphragm neck, remove hex screw, and install stabilizer.
3.4.5 Fold stabilizer with edge down and insert into diaphragm opening.
3.4.6 Assemble stabilizer plate, lock washer, and hex screw through stabilizer and fasten to
diaphragm by attaching hex screw to threaded insert.
3.5.1 Install cover plate, studs, and lubricated nuts. Cross tighten by hand or wrench, a few turns
at a time, until cover is firmly seated on the dampener body. Cross tighten to the
appropriate torque (~2000lb-ft or 2700N.m).
3.6.1 Back thread seal nut on valve and thread valve into tapped hole.
3.6.3 If the valve is not facing in the proper direction, take the following steps:
a. Rotate forward if less than a 1/2 turn is required to position valve in proper direction.
b. Rotate backward if the previous step is not possible until the valve is positioned in the
proper direction (. turn maximum).
c. After valve is in position, tighten seal nut to 20 ± 5 lb-ft or 27 ± 7 N.m torque.
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3.7.1 Install pressure gauge so that the face is positioned in such a manner that it will be visible
3.7.4 If the gauge is not facing in the proper direction, take the following steps:
a. Rotate forward if less than a 1/2 turn is required to position gauge in proper direction
b. Rotate backward if the previous step is not possi le until the gauge is positioned in
the proper direction (1/2 turn maximum).
c. After gauge is in position, tighten seal nut to 20 ± 5 lb-ft or 27 ± 7 N.m torque.
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4 MAINTENANCE
4.1 Precharge
4.1.1 When properly installed and pre-charged, the pulsation dampener is virtually maintenance
free.
4.1.2 The vessel should be checked periodically for proper precharge and leaks. Unless
conditions such as ambient temperature, operating conditions, or operating temperatures
change, checking every six months should be sufficient.
4.2.1 If the pre-charge pressure is TOO LOW, the pulsation dampener will fill with excess fluid,
thus losing some of the working volume of the gas and reducing dampener efficiency.
4.2.2 Additionally, excessive flexing of the diaphragm may cause premature rubber failure at the
neck or equator of the diaphragm.
4.3.1 If the pre-charge is TOO HIGH, the diaphragm insert will rest on the bottom of the
dampener, closing off the fluid inlet.
4.3.2 Until the system pressure exceeds the precharge pressure, no dampening will take place.
4.3.3 During the time the precharge pressure is nearly equal with the system pressure, the
diaphragm will bounce on and off the inlet opening which could effect the service life of the
diaphragm.
5 PRECHARGE ADJUSTMENTS
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5.2.3 Diaphragm may be trapping pressure (system fluid) when pump is shut down. This will be
indicated by a higher than normal pressure reading on the gauge, which is usually of a
different value, each time the pump is shut down. This condition usually occurs when the
fluid is highly viscous. Installation of a diaphragm stabilizer should cure this condition.
CAUTION: If it is determined that any items need to be replaced or dampener cover
removed, PLEASE FOLLOW THE DISASSEMBLY AND ASSEMBLY PROCEDURES.
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6 PARTS
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M-34000
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Foreword…
This manual is published as a guide for the normal operation of your NATIONAL OILWELL VARCO equipment.
Because of many factors which contribute to the function or malfunction of this machinery, and not having complete
knowledge of each factor or combination of factors, we cannot detail all facets of this subject. We must therefore
confine the scope of this presentation and when situations encountered are not fully encompassed by complete,
understandable instructions, these situations must be referred to the manufacturer.
The dimension and tolerances specified in this publication are those desirable for the most efficient operations of the
equipment. When components become worn or when new parts are introduced into a worn unit, it may not be possible
or economically feasible to reestablish such strict alignment and correct all dimensional deviations.
Improvements in design, engineering, materials, production methods, etc., may necessitate changes in these
products and result in inconsistencies between the content of this publication and the physical equipment. We reserve
the right to make these changes without incurring any liability or obligation beyond that which is stipulated in the
purchase contract.
The pictures, photographs, charts, diagrams, drawings, verbal contents and specifications are not to be construed
as giving rise to any warranty on the part of NATIONAL OILWELL VARCO. NATIONAL OILWELL VARCO makes no
warranty either expressed or implied beyond that which is stipulated in the purchase contract.
Warranty
National Oilwell Varco (NOV) warrants that, for a period of one year from the date of delivery equipment of manufacture
the Equipment shall be free of defects in materials and workmanship under normal use and service, and provided the
Equipment is used and maintained in accordance with instructions supplied. This is a sole and exclusive warranty. If a
defect in the Equipment appears within one year from the date of shipment, and Purchaser has given written notice of
such defect within thirty days from the discovery thereof, NOV will repair or replace the part, at its option, by shipping a
similar part FOB shipping point or, at its option, refund an equitable portion of the purchase price. NOV may require the
return, to a designated location, of the defective part, transportation prepaid to establish Purchaser's claim. No
allowance will be made for repairs undertaken without NOV’s written consent or approval. This warranty applies only to
equipment manufactured by NOV. Warranties on equipment manufactured by others, if any, are assigned to Purchaser
by NOV (without recourse) at time of delivery. Any description of Equipment, drawings, specifications, and any samples
models, bulletins, or similar material, used in connection with this sale are for the sole purpose of identifying the
Equipment and are not to be construed as an express warranty that the Equipment will conform to such description. An
field advisory or installation support is advisory only. The foregoing warranties are in lieu of all other warranties, whethe
oral, written, express, implied or statutory. Implied warranties or merchantability and fitness for a particular purpose will
not apply. NOV's warranty obligations and purchaser's remedies there under are solely and exclusively as stated herei
Purchaser's sole and exclusive remedy, whether based upon warranty, contract or tort, including negligence, will be to
proceed under this warranty. All liability of NOV shall terminate one year from the date of delivery of the Equipment.
Intended audience
Conventions
Notes, cautions, and w arnings 1-1
Notes 1-1
Cautions 1-1
Warnings 1-1
Illustrations 1-1
Safety requirements
Personnel trainin g 1-2
Recommended too ls 1-2
Genera system safety practices 1-3
Replacing comp onents 1-3
Maintenance 1-3
Proper use of equipment 1-3
Intended audience
This manual is intended for use by field engineering, installation, operation and repair personnel. Every effort has been
made to ensure the accuracy of the information contained herein. National Oilwell Varco company (NOV), will not be
held liable for errors in this material, or for consequences arising from misuse of this material.
Conventions
2
Notes
The note symbol indicates that additional information is provided about the current topic.
Cautions
The caution symbol indicates potential risk of damage to equipment or injury to personnel. Follow instructions explicitly
and take extreme care.
A caution symbol may also indicate a condition that voids your equipment warranty.
Warnings
The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to observe and follow
proper procedures
equipment damage.is likely to result in serious or fatal injury to personnel, significant property loss or significant
Illustrations
Figures provide a graphical representation of equipment components or screen snapshots for use in identifying parts or
establishing nomenclature, and may or may not be drawn to scale. For more specific component information pertinent to
your rig configuration, see the technical drawings included with your National Oilwell Varco documentation.
Safety requirements
Safety requirements
Personnel trainin g
NOV equipment is installed and operated in a controlled drilling rig environment involving hazardous operations and
situations. Proper service and repair is important for safe and reliable operation. Operation and service procedures
provided by NOV manuals are the recommended methods of performing those operations. Figures provide a graphical
representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature,
and may or may not be drawn to scale. For more specific component information pertinent to your rig configuration, see
the technical drawings included with your National Oilwell Varco documentation.
All personnel performing installation, operation, repair or maintenance procedures on the equipment, or those in the
vicinity of the equipment, should be trained on shop safety, tool operation, and maintenance. Contact the NOV Valve
training department for more information about equipment operation and maintenance training.
Recommended tool s
Service operations may require the use of tools designed specifically for the purpose described. When stated, use only
these tools.
Wear proper protective equipment during equipment installation, operation, maintenance, assembly/disassembly or
repair. Local codes may apply. Please consult them prior to performing any operation. The presence of a NOV Valve
representative at the site does not relieve the owner/ operator of responsibility to follow published installation, operation,
and maintenance instructions.
Replace failed or damaged components with NOV genuine certified parts. Failure to do so could result in equipment
damage or personal injury.
Maintenance
Equipment must be maintained on a regular and routine basis. See the Maintenance and Repair chapter of this manua
for maintenance recommendations.
Introduction
Features 2-1
Introduction
A pressure relief valve is a self operating valve that is installed in a process system to protect against over
pressurization of the system. The NOV Reset Relief Valve is designed to keep pressure from exceeding a preset valve
which will in turn protect the liners and other internal components of a typical mud pump.
There are a wide variety of valve designs, but most valves of this type incorporate one or more helical compression
springs which are used to maintain constant force acting on the backside of a piston, causing the valve to be normally
closed. When the force exerted by the process stream (i.e. fluid pressure) against the piston is greater than the consta
force exerted by the spring, the valve "trips" open (the piston moves to its fully open position) and allows process fluid t
exit the valve and pass through a discharge line to a mud tank or pit. This valve actually utilizes a balance beam
whereby the piston force acts on a short moment arm while the spring force acts on a longer moment arm.
The NOV Titan Class "C" Valve utilizes the 34000 series part number. Various dash numbers may be added to indicate
the type of piping adapters supplied with the valve or any other auxiliary items. Please refer to the bill of material and
drawing sections to determine the complete valve assembly number.
Features
Unlike its predecessor, which utilized an elastomeric cushion ring, the Titan Class “C” valve incorporates a pressure
balance chamber, similar to the original RX valve. The opening movements of NOV's patented piston ports (U.S. Paten
5,715,861) are hydraulically cushioned by throttling fluid from the balance chamber to the discharge side of the valve.
The butt weld flanges or 3”-1502 unions provide excellent connection integrity.
There is no load bearing threaded connections exposed to the flow media (such as line pipe threads).
The 4-bolt inlet and discharge flanges allow for easy access to the body and internal parts.
The entire valve can be replaced with all adjacent piping in place.
The valve is 100% adjustable to provide any relief pressure setting within the particular pressure range of the valve.
The relieving pressure set point may be altered easily by turning a single adjusting nut; adjustment may be made while
pressure is in the valve however, is limited to increasing the setting only.
The accuracy of the relief valve is not affected by continuous pressure surges or vibration.
The valve is easily reset by operating a single lever; no replacement shear pins are required and little, if any, down time
is encountered in resetting the valve.
Once properly calibrated, the accuracy of the valve is maintained over numerous valve “trips”.
The valve may be manually discharged at any time, regardless of line pressure, by striking the “release button” provide
on the valve.
The “open” or “set” position of the valve piston is indicated by the position of the “release button”. When the button is
away from the side of the bonnet, the valve is “set”. When the button is adjacent to the side of the bonnet, the valve is
“open”.
The valve’s internal linkage is fully enclosed and protected from debris and corrosion.
The release shaft retainer has been redesigned for greater safety.
Inspection
Installation 3-1
Storage
Recommended pro cedure for extended s torage 3-4
Inspection
Installation
Prior to setting up and operating a new Reset Relief Valve, inspect the goods as received from the shipping company. A
claim for damage or loss should be reported immediately to the carrier and to the Valve Division. Also, check the bill of
lading for any separately shipped items, including manuals and CDs. Once it is confirmed the order has been received
complete in undamaged condition, installation may begin.
The Titan “C” Reset Relief Valve may be installed in any position but it is generally easier to operate and maintain with
the bonnet in a vertical position together with a horizontal discharge line. The valve is outfitted with (A) a pair of 6-bolt
butt weld flanges (one on the inlet and one on the outlet) that have to be fitted, tacked, welded, and stress relieved in
accordance with ASME Section IX and/or ASME B31.1 specifications PRIOR to bolting the valve in place for operation
or (B) adapter flanges which go from a 6-bolt pattern (to match the body) to 3”-1502 male and female union connections.
Material certificates for these components are available and (for the butt weld components) include heat treating times
and temperatures which may be used to write a proper weld procedure for valve installation (WPS or PQR). Due to the
service encountered and pressure rating of this equipment, the integrity of all welding, which may be required for the
installation of this valve, should be volumetrically inspected 100% using appropriate X-ray procedures. Assemblies
including component parts with butt weld ends requiring welding must follow the same procedures described above. The
dimensions of the “window” required for valve installation are shown in the assembly drawing. It is recommended that
the pipe I.D. be no smaller than that of a 3” Schedule XXH pipe (2.300 I.D.) for the upstream and downstream piping.
Figure 3-1 exhibits the correct setup of the upstream and downstream piping. A 3 degree minimum downward slope
must be maintained on piping.
THE VALVE. REPLACE ALL WORN OR DAMAGED UNION COMPONENTS WITH ORIGINAL NOV PARTS.
The dimensions of the “window” required for valve installation are shown in the assembly drawing. It is recommended
that the pipe I.D. be no smaller than that of a 3” Schedule XXH pipe (2.300 I.D.) for the upstream and downstream
piping. Figure 3-1 exhibits the correct setup of the upstream and downstream piping. A 3 degree minimum downward
slope must be maintained on piping.
Note:
Sufficient size piping and schedule are required for operating conditions including containing working pressure, handling
cyclic nature of the pump pressures, and staying within the erosional velocity limits of the pipe for the expected
discharge fluid volumes of drilling mud and the related fluid velocity within the pipe.
The discharge line should slope gradually downwards from the valve outlet to the mud pit or holding tank. This insures
any fluid remaining in the line will self-drain.
Due to thrust loads at the time of discharge, adjacent piping for a relief valve installation requires all piping be properly
braced, anchored and supported to prevent unnecessarily high stresses from damaging the valve or any adjacent
connectors.
Note:
Refer to the Parts and Drawings Section when item numbers are referenced.
Standard butt weld hubs normally supplied with this valve when requested (p/n 31953), are for mating up with 3-1/2”-
SCH. XXH (4.000” O.D. x 2.728” I.D.) piping. Torque the (6) flange bolts (item 50) gradually in a crossing pattern so tha
the adjacent sealing faces of the flange and body remain parallel. This will also prevent flange separation and the
resulting flange-to-body seal failure. The adjusting nut (item 32) moves the upper spring retainer (item 34) thereby
increasing or decreasing the amount of spring compression and thus spring force against the arm of the crank. The
correct position of the adjusting nut is shown by an indicator (item 33) mounted on the upper spring retainer and the
calibration plate (item 36) mounted adjacent to the indicator on the bonnet cover (item 29). It is generally undesirable to
bring a mud pump on-line with the valve at an abnormally low pressure setting. Such a practice could cause inadverten
opening of the valve. Always verify the pressure setting by examining the indicator and calibration plate prior to placing
the valve in service. In some operating conditions, the valve may appear to discharge at a lower (or higher) pressure
than indicated by the valve setting. This phenomenon may sometimes result from (1) a lag between the actual system
pressure and the pressure gauge reading, especially for gauges with dampening devices, (2) pressure pulsations,
especially when inadequate or poorly operating pulsation dampeners are installed, (3) inaccurate or improperly
calibrated gauges, or (4) an improperly maintained valve. The release of drilling mud, especially at high pressures, can
be very destructive to internal valve parts. Operators are advised to always try to isolate and shut down a pump as
quickly as possible when the relief valve for that pump discharges. Doing so can help to increase the life of the valve
and its internal parts.
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gauge pressure indicated. If the valve “tripped” before the gauge reached the pressure indicated on the calibration plat
the valve
“Zero setting” is low (too little initial spring compression). In order to correct the zero setting, the two flats on the lower
end of the load screw (item 38) will be used to change the initial compression on the load springs. If the valve “tripped”
early, more initial spring compression is required and vice versa. Use a 3/8” open end wrench to tighten the load screw
further into the lower spring retainer if the valve “tripped” early. Looking down on the upper face of the lower spring
retainer, a clockwise rotation of the wrench will drive the load screw farther into the lower spring retainer. The amount o
change will vary somewhat between valves but a half turn of the load screw should cause approximately a 50 psig
(higher or lower depending on the direction of rotation) change in the “tripping” pressure of the valve. Because it will be
locked in place by the 1/4” Spirol pin upon successful completion of the calibration procedure, the load screw may only
be adjusted in half-turn increments (with the flats on the load screw left perpendicular to the lower spring retainer). Onc
the “zero” setting is close, it is time to check the “span” or upper setting.
let’s assume
for the “zero” that we and
setting are working with aat
then “tripped” typical 1500-5000
say 4900 PSI forPSI
the valve
“span”assembly.
setting, it Ifisthe valve to
possible initially
bring“tripped” at 1400
both values PSt
closer
the desired setting. In other words, by going back to the “zero” setting and increasing the initial spring compression, the
valve may be made to “trip” at exactly 1500 PSI or plus 100 PSI. As such, we will expect the valve to “trip” at an
additional 100 PSI on the high end (span setting), very close to the desired 5000 PSI. We will rerun the span procedure
to confirm. However, if the valve “trips” at 1700 PSI at the low end and at 5300 PSI at the high end, you can not perform
the basic calibration procedure to make the valve more accurate. If we increase the initial spring compression, when
testing the high setting, to make the valve “trip” right at 1500 PSI we could expect the valve to “trip” at around 8600 PS
which would be totally unacceptable. In short, both settings (low and high) may be either increased or decreased but
they may not be moved closer together or farther apart. Valves which do not calibrate properly may have one or more
faulty load springs, a worn upper link pin (which most often causes erratic valve behavior), excessive seal friction due t
corrosion, a faulty main crank, or binding linkage. If the operator is unable to achieve satisfactory performance from the
valve after following normal calibration procedures, contact the factory. If the valve is within acceptable tolerances at
both the low and high set points, secure the load screw with the Spirol pin (item 40) by driving it into the lower spring
retainer (against the bonnet) until the end is flush with the outboard side of the lower spring retainer. If the valve is not
within acceptable tolerances, replace the load springs or look for mechanical problems. Repeat this entire procedure
after reworking valve.
For Titan Class “C” valves, any in-plant or customer-witness hydrostatic pressure testing will be limited to the following
maximum values: 5000 PSIG WORKING PRESSURE , 7500 PSIG TEST PRESSURE Acceptable Tolerance, Set Point
vs. Actual Valve “Trip” Pressure
Pressure Range 1500-5000, psig Acceptable Tolerance +200 psig
If the valve is within acceptable tolerances at both the low and high set points, secure the load screw with the Spirol pin
(item 40) by driving it into the lower spring retainer (against the bonnet) until the end is flush with the outboard side of
the lower spring retainer. If the valve is not within acceptable tolerances, replace the load springs or look for mechanica
problems. Repeat this entire procedure after reworking valve.
lower pistonnot
valve does seal. This
hold seal can
pressure, be used
check again
piston sealwhen it shrinks
for wear back to
and insure original
links shape
are fully after
reset drying
(the resetfor few minutes.
button should beIf the
extended 3/8 inch). Check piston and body for wear. If the valve calibration has changed, replace the load springs if they
are shorter than 7 inches. Inspect links and link pins for wear or bent. Follow calibration procedures.
If valve is leaking on outside between bonnet and body remove stem bushing seals.
If fluid is leaking through discharge side remove the flange/discharge line on valve outlet side and clean the inside of the
valve from the discharge side. Use a flashlight and check for fluid leaks.
If the fluid is leaking from bottom i.e. between piston cap and insert, turn off the pump and drain all the fluid from the
valve body, push the reset button in and reset the valve 2-3 times. If the valve is still leaking, replace the lower piston
cap seals.
If fluid is leaking from top, remove the bonnet assemble and replace the upper piston – shoulder seal. Before re-
installing the bonnet assembly, check the inner valves of the body for rust, pitting or scarring.
The inner surface where the seal seats must be clean and smooth or the valve will leak. If there is more than
surface/superficial rust proceeds to send the valve body to NOV facility for further evaluation.
If you have any more problems contact NOV service guys or NOV facility for repair.
bushing seal (item 14) has disengaged its respective seal bore in the body. Only then the (4) cap screws may be
completely removed from the body along with the bonnet sub-assembly.
2. Clean the upper bores of the body with a soft cloth. Verify that the seal bores in the upper end of the body are free o
marks, scratches, dings, and corrosion prior to reinstalling a cleaned up or rebuilt bonnet assembly. Also, clean and
inspect the seat insert (item 2) in the lower end of the body. DO NOT attempt to repair a leaking valve by merely
replacing the lower piston seal when the seat insert is also damaged.
3. holding the bonnet firmly loosen and remove the piston cap (item 4) from the piston body (item 3). Remove the
outboard seal retainer (item 8), the lower piston seal (item 7) and the inboard seal retainer (item 8) from the piston body
Inspect the piston cap face seal (item 11) for damage and replace as required.
Replace item 7, (Never reuse the lower piston seal (item 7)) along with two of item 8 if necessary, and reassemble the
lower end of the piston. Note the orientation of all components for correct assembly of the piston.
4. Inspect the outer stem bushing seal (item 14) for damage and replace if required. Verify that the piston slides freely
and out of the stem bushing. If not, there could be damage to the inner stem bushing seal (item 10) or excessive
corrosion on the internal bore of the stem bushing (item 6). Correcting this problem will require complete removal of the
piston sub-assembly from the bonnet. See the "Bonnet & Linkage Disassembly"
5. Verify that the piston shoulder seal (item 9) is in good condition. If not, it will require replacement. Again, correcting
this problem will require complete removal of the piston sub-assembly from the bonnet. See the "Bonnet & Linkage
Disassembly"
6. Using high quality synthetic grease, lubricate the upper end of the body as well as the lower and upper end of the
piston, particularly all sealing elements.
7. Again, contingent upon the inspection performed in step 2, the bonnet sub-assembly may be reinserted into the body
Lubricate the threads and collars of four NEW cap screws (item 54) with a nickel base anti-seize compound and using
crossing pattern, torque the screws to specification, see the "Torque Chart"
1. Completely remove the adjusting nut (item 32) and lift off and remove the upper spring retainer (item 34) and the two
load springs (item 37). Check the load springs for yielding. If either spring is less than 7.00” in overall length, replace
both springs and re-calibrate the valve.
2. If the adjusting stud (item 35) must be replaced, punch out the ¼” Spirol Pin (item 40) in the bonnet cover and
unscrew the stud. Note the amount of stud protruding from the cover so that the replacement part may be reinstalled
properly as before.
3. Remove and discard the four cover cap screws (item 50) from the bonnet cover (item 29), lift off and remove the
cover.
4. If the reset roller (item 31) must be replaced, punch out the 1/8” Spirol Pin (item 44) and slide the roller from the rese
crank. Replace the roller with a new one and install a new pin.
5. If the reset crank (item 30) or the reset handle (item 16) must be replaced, punch out the 5/16” Spirol Pin (item 24).
Slide the reset handle off of the reset crank, remove the shaft seal o-ring (item 43) and pull the reset crank out of the
bonnet cover.
6. If the cover bearing (not ballooned) is damaged, it may be pressed out of the bonnet cover (with the proper tooling)
and replaced with a new one.
7. Remove the spring guide rod (item 28) along with the reset spring (item 23) and the keeper (item 27) from the bonnet.
8. Using a pair of needle nose pliers, carefully remove the two “clock” or linkage springs (item 25). Examine both springs
for damage. The tabs which hold the spring in place (one on the inside and one on the outside) should be in alignment
with each other. If the outer tab is more than 30 degrees out of alignment with the inner tab, replace both springs with
new NOV parts.
9. With the remaining bonnet assembly resting above the piston (item 3) which is to be positioned firmly on a flat
surface, rotate the upper link (item 21) into a horizontal position (as if the valve had “tripped”). Punch out the 1/8” pin
(item 19) in upper link. Note: Pulling back on the release button and locking it in the retracted position with a small block
(or other item which may be used temporarily as a spacer) during this operation will keep the inboard end of the release
shaft (item 45) from interfering with the removal of the pin (item 19). Remove the top crank pin (item 26).
10. If the crank (item 22) must be removed, lift lower spring retainer and turn it so that the ¼” diameter pin can be driven
out from side adjacent to the bonnet. Rotate the load screw (item 38) CCW to remove it from the lower spring retainer
(item 39). Lift the load screw up through the crank for complete removal from the bonnet. Punch out the 1/8” pin (item
44) from the crank to remove the crank pivot pin (item 41). The crank may now be lifted out and completely removed
from the bonnet.
11. If required, the bearing (item 15a) may be removed from bonnet (item 15) with a 19/32 punch. Again, this is a
somewhat tedious task and replacement of the bonnet sub-assembly is generally the better choice.
12. If it is necessary to remove the release shaft (item 45), hold the inboard end from rotating with a drift pin while
rotating the release button (item 47) CCW. With the release button removed, push the release shaft inboard until it
clears the notches in the release shaft retainer (item 46). A large slotted screw driver may be used to loosen and remove
the release shaft retainer (item 46). Now the release shaft and release shaft spring may be easily removed from the
bonnet.
13. The piston along with the linkage may now be carefully pulled out of the lower end of the bonnet.
14. Disassemble upper link and lower links by punching out four 1/8” pins (item 19) and removing the two link pins (item
18).
15. Remove the stem bushing by sliding it off of the small end of the piston. Inspect both the bushing outer seal (item
14) and the bushing inner seal (item 10) for wear or damage. Clean and inspect both glands for damage or corrosion.
16. If required, the bearing (item 21a) may be removed from upper link (item 21) with a 15/32 punch. Again, this is a
somewhat tedious task and replacement of the upper link sub-assembly is generally the better choice.
Note
Usually, while the valve is completely disassembled, it is always a good practice to replace any and all worn, damaged,
or otherwise questionable parts.
17. Check lower links for straightness and/or ovaling of the link pin holes. Check straightness by laying a straight edge
against the end flat on each side of the link. If either link is distorted, always replace both lower links—never just one.
Check the small pads on one side of each lower link for damage from contacting the pad on the main crank. It is
important to note the position and orientation of the pads on both lower links. These pads MUST be placed in the same
11
position during assembly (the pad end of the lower link is to be farthest away from the bonnet flange while both pads ar
to face towards the release shaft button).
18. Check all link pins and crank pins for straightness. If a pin is not straight or shows signs of wear, it should be
replaced. A worn pin may show cracks or dings in the surface or may no longer be perfectly straight and or round.
19. Check all pressed-in bushings. If a bushing is loose, has chipped or otherwise damaged edges, or is wallowed out,
should be replaced with a new NOV part.
20. Check the outside diameter of the piston and all sealing surfaces for signs of wear, corrosion, or other damage that
might impair the effectiveness of a new seal.
2. If the valve was supplied with butt weld flanges and the body is out of the line, the 6-bolt flange will have already bee
disconnected. If the valve was supplied with 1502 connections (see section 8), the inlet adapter will need to be remove
Using a 12-point socket or box end wrench, loosen and remove all 6 flange cap screws from the valve inlet.
3. Carefully remove the inlet flange adapter from the body and set aside. Clean and inspect the union components for
damage. Clean and inspect the face seal groove for damage or corrosion and inspect the seal.
4. It is best to carefully anchor the body when removing the sub. This may be done by using a minimum of 2 bonnet ca
screws to bolt the body to a work table. Holes will have to be drilled in the table to match the bonnet bolt pattern. Flip th
body upside down (bonnet end down) and attach it to the work table using discarded bonnet cap screws or place the
body (in a similar position) securely in a large vice.
5. Insert the lugs of the sub wrench into the sub. Looking at the inlet of the body, rotate the sub counter clockwise to
loosen and remove the sub from the body. In some cases, applying penetrating oil or similar substance to the sub may
help with its removal from the body.
6. Clean the sub (item 5) and inspect it for damage, especially in the threaded area, the radial seal groove, and the
sealing faces on the inboard and outboard ends.
7. Remove the seat insert (item 2) from the body along with the insert face seal (item 13). Carefully clean and inspect
the insert for damage, especially the internal seal surface (I.D.) and the face seal groove.
8. Clean and inspect the lower valve body internals, especially the threads and the seal bore for the sub seal (item 12).
1. If the body (item 1), sub (item 5), seat insert (item 2) are all cleaned and free of damage, they may be reassembled.
Always use new sealing elements when reassembling this valve.
2. Use a nickel base anti-seize compound to lubricate the threads and sealing surfaces of the lower end of the body
prior to assembly. Also lubricate the threads and inboard face and radial sealing surfaces of the sub prior to assembly.
3. Install a new sub seal (item 12) into its groove in the sub. Install a new seat insert face seal (item 13) into its groove
the insert. As mentioned in step 1, with the bonnet side of the valve body facing downwards, place the seat insert into
the lower body cavity, face seal side up. Verify that the insert shoulder is fully seated against the step in the body.
4. Place the sub into the lower body cavity, threaded end last. Make up the sub into the body by hand. If this is not
possible, check the body and sub for thread damage. Continue making up the sub until it bumps against the seat insert.
5. Using the pipe wrench, torque the sub to 800-1000 ft.-lbs. protect the outboard sealing face of the sub when flipping
the body over for bonnet assembly.
2. Assemble the piston body (item 3) with items 4, 7, 8 (2x), 9, and 11. Place the face seal (item 11) into its gland in the
piston cap (item 4). Place the first seal retainer (item 8) over the nose of the lower end of the piston as shown in the
assembly drawing. Carefully place the piston seal (item 7) over the nose of the lower end of the piston and against the
first seat retainer. Place the second seal retainer (item 8) over the piston seal. Screw the piston cap (item 4) into the
lower end of the piston. Be sure that the face seal (item 11) remains fully in its groove during make up. Torque the cap
to 80-100 ft.-lbs. install a (lubricated) shoulder seal (item 9) into its gland on the upper end of the piston. Again,
orientation of this seal is critical. The spring energizer MUST be oriented towards the upper end of the piston as shown.
The piston sub-assembly is now complete. Take care not to damage piston seals (items 7 and 9) during assembly.
3. Slide the stem bushing sub-assembly (from step 1) over the lubricated end of the piston, large end first. Carefully slide
the bushing down towards the big end of the piston, as far as it will go. Do not force.
4. Assemble the two lower links (item 20) to the upper end of the piston with the first link pin (item 18). Orientation of
both links is critical. The links should have side bosses facing the same direction (away from the piston centerline). The
link bosses should also be oriented away from (not adjacent to) the bushing in the piston. Secure links with two 1/8”
Spirol Pins (item 19).
5. Assemble the “thick” end of the upper link (item 21) between the upper end of the lower links with the second link pin
(item 18) and again secure with two 1/8” Spirol pins (item 19). Upper and lower links should fit snugly with the link pins
but both link pins should turn freely in their respective bushings.
6. Slide the release shaft (item 45) into its respective hole in the side of the bonnet (big end first). Slide the release shaft
spring (item 48) over the threaded end of the release shaft. Slide the release shaft retainer (item 46) over the release
shaft, notched end last. Apply several drops of non-permanent thread locking compound to the threads of the release
shaft retainer prior to making it up fully into the bonnet. With no other components yet attached to the bonnet, the
release shaft may be pushed towards the middle of the bonnet to allow for use of a large slotted screw driver to make up
the release shaft retainer.
7. Push the release shaft towards the outboard side of the release shaft hole in the bonnet so that the threaded section
protrudes from the bonnet. Screw the release shaft button on to the release shaft. Use a few drops of non-permanent
thread locking compound to secure the release shaft button. Alternatively, the threaded end of the release shaft may be
pined with a center punch to prevent inadvertent loosening of the release shaft button.
8. Place the crank assembly (item 22), with its two bushings, into the cavity in the top of the bonnet. Slide the middle
section of the crank over the bushing in the top of the bonnet. Align the small end of the crank over the hole for the load
screw. Align the crank assembly hole with the bonnet bushing and insert the crank pivot pin (item 41). Note that the
transverse hole in the crank pivot pin must be oriented with respect to the matching hole in one side of the crank
assembly. Rotate and slide the crank pivot pin so that the transverse hole is in line with its respective hole in the crank
assembly. Drive the Spirol pin (item 44) through the hole to secure the crank assembly. The end of the pin should be
flush with the outer surface of the crank as shown in the assembly drawing.
13
9. Insert the linkage (attached to the piston) through the bottom of the bonnet with side bosses of lower links facing
release shaft hole. Again, orientation of the bosses on the lower links is CRITICAL to proper valve operation. Align the
hole in the upper end of the upper link with its respective hole in the crank assembly. Slide the top crank pin through th
hole.
10. With the lower end of the piston resting on a flat surface, steady the bonnet while rotating the top crank pin with
respect to the upper link. When the transverse slot in the top crank pin is aligned with the hole through the upper link,
place a 7/64 drift through the upper link to hold both members in place. Now allow the bonnet to move downwards and
the upper link to move to the near horizontal position until the parts rest against each other. (The piston is now basicall
in the “tripped” position). Carefully remove the drift and, without disturbing the related parts, drive one 1/8” Spirol pin
through the hole in the upper link. Tap the pin carefully until it passes the top crank pin.
11. Lay the bonnet assembly on its side with the piston extended in the “set” position. Both lower links should be agains
the side of the bonnet. Place one linkage (or “clock”) spring (item 25) over each end of the top crank pin. The inner tab
of the spring should slide into the slot in both ends of the top crank pin. Use a pair of needle nose pliers to grab the out
tab of the spring to wind it “tighter” approximately 90 degrees and slip it into the slot in the crank. The short crook or
bend in the very end of the outer end of the spring should face towards the release shaft button. Press against the
outboard side of the spring to assure that it is fully against the side of the crank and fully engaging both slots.
12. Insert the load screw (item 38), threaded end first, through the hole in the crank assembly and out through the lowe
side of the bonnet.
13. Drive a 1/4” Spirol pin (item 40) about 1/4 to 3/8” into one side of the lower spring retainer (item 39), just to hold it in
place. With the spring guide nubs facing upwards and the Spirol pin facing away from the bonnet, make the load screw
up into the lower spring retainer. The end of the load screw should protrude from the lower side of the lower spring
retainer by about 1/4”.
14. Slide the reset roller (item 31) over the small end of the “Z” or reset crank (item 30) and secure it with one 1/8” Spir
pin (item 44). Insert the large end of the reset crank through its respective hole in the bonnet cover from the inside.
Place the weather seal o-ring (item 43) over the reset crank shaft from outside the bonnet cover.
15. Place the reset handle (item 16) over the reset crank shaft with the large chamfer facing the o-ring (and cover). Alig
the hole in the reset crank with the hole in the handle and secure both parts with a 5/16” spirol pin (item 24).
16. Screw the adjusting stud (item 35) into the bonnet cover (milled notch end first) until the end is flush with inside
surface of the cover. Rotate the stud in or out slightly to allow the notch to align with the hole through the end of the
cover. Secure the stud by driving one ¼” spirol pin (item 40) through the cover until the outer end is flush with the outer
surface of the cover.
17. Place reset spring (item 23) over the spring guide rod (item 28) and insert one end of the rod into the shallow hole
(or divot) inside of the bonnet. Rotate the reset crank to allow the spring keeper (item 27) to be inserted into its hole in
the reset crank (from the outboard side). Position the cover (item 29) over the bonnet, tilt it back to view the keeper, an
guide the keeper over the end of the spring guide rod prior to placing the cover fully against the top of the bonnet.
Secure the bonnet cover using only New NOV cap screws lubricated with a nickel base never seize compound. Tighten
all four screws in a crossing pattern according to the "Torque Chart" on page 16
18. Set both load springs (item 37) on the lower spring retainer (item 39) and place upper spring retainer (item 34) over
the top of the adjusting stud and allow it to move downwards until it engages both springs. Screw the locknut (item 32)
on the adjusting stud until a minimum amount of compression is placed on the springs to hold them in place.
19. Orient the reset handle so that it is opposite the discharge side of the valve body. After lubricating the body bores
and piston seals stab the piston carefully into the upper end of the body. Press downwards on the bonnet until the
bonnet flange mates with the body. Secure the bonnet using only New NOV cap screws lubricated with a nickel base
never seize compound. Tighten all four screws in a crossing pattern according to the torque shown in "Torque Chart" o
page 16. The valve is now ready for calibrating.
2. On assemblies with the 3”-1502 union connections, care must be taken to protect the threads and sealing surfaces of
these unions at all times when the valve is removed from the line. Using worn or damaged union parts can cause
failures which could lead to serious bodily injury. Union hammer nuts should always engage their mating parts using
hand force. Never try to start a thread using a hammer. After the union is mostly made up by hand, it may be tightened
using a hammer. Usually, a 4 to 8 pound hammer is sufficient. Three to four blows on the nut member after initial
rotation has ceased should suffice to achieve the proper preload. Correct calibration - The relief pressure indicator
should
it will beaccurately
necessaryindicate the actual
to re-calibrate therelief
valve,pressure. When
even if no new the valve hashave
components beenbeen
completely tornBinding
installed. down and reassembled,
or interference
between parts, any and all moving parts, especially parts associated with the linkage assembly, will cause the valve to
operate improperly.
15
Maintenance 7-1
Torque 7-1
Inspection 7-2
Tools Required 7-2
Replacement Seal Ki t 7-2
Bushings 7-3
Maintenance
The Titan Class “B” Reset Relief Valve has been designed to require a minimum amount of maintenance. The
recommended maintenance for the valves involves removing the bonnet assembly (refer valve disassembly procedure
every 2-4 weeks and flushing out the valve body and cleaning any debris. Then you would need to apply grease to the
inner walls of the valve body where the upper shoulder seal on the piston seals and also apply grease through the
grease fitting on the bonnet assembly itself until it is completely full of grease (from the factory it should be full of
grease). The grease will act as a rust inhibitor and this will protect against the corrosion. Flange screws, bonnet
retaining screws, and cover retaining screws should be checked for proper torque periodically. Please refer to the torqu
chart.
Note:
Recommended Lubricant P/N 2560 Upper Bonnet Assembly Parts (Top Works): Maxi Glide Teflon Gel Lubricant or
Equal P/N 3015 Piston, Body I.D. and Seals: Synthetic Lubricant Grease or Equal.
Torque Chart
Size. Part No. Quantity Where Used Torque, Ft.-lbs--N-m
Due to the variations in pulsation dampening from rig to rig and the resulting effect on component fatigue life, it is
recommended that the 1/2” and 5/8” socket head cap screws not be reused but rather replaced with new cap screws
when servicing the valve. Verification of the valve accuracy should be done on a regular basis. After all, this is a piece o
safety equipment and it should be operated and maintained accordingly. It is recommended that the valve be calibrated
every 6 months as a minimum. For calibrating the valve in the field, NOV may provide a portable manual pump with a
proper test gauge (1/4% full scale) to aid the operator (reference part number 32590). If a pressure gauge with a built-i
dampening device is used, the line pressure should be built up slowly to allow the actual system pressure and gauge
pressure to stabilize. If possible, the line pressure should be built up slowly and gradually with little or no pressure
pulsations.
Inspection
To inspect visually, with no pressure in the valve, reset button pushed in, remove (4) Bonnet Bolts. Pull Top Work up
vertically; inspect piston seal and the body ID. Wash any debris from the body and re-lube body and piston.
Reassemble. Valve is ready for reset.
Tools Required
1.3/32 to 7/64 inch diameter x 1 inch (min.) long straight shank punch (for items 19 and 44) To perform service work on
the Titan Class “B” Reset Relief Valve, the following tools will be required: To inspect visually, with no pressure in the
valve, reset button pushed in, remove (4) Bonnet Bolts. Pull Top Work up vertically; inspect piston seal and the body ID.
Wash any debris from the body and re-lube body and piston. Reassemble. Valve is ready for reset.
2. 7/32 to 15/64 inch diameter x 1-3/4 inch (min.) long straight shank punch (for item 40)
3. 1/4 to 19/64 inch diameter x 1-3/8 inch (min.) long straight shank punch (for item 24)
4. Small hammer
5. 3/8 inch hex Allen or internal hex wrench (for item 50)
6. 1/2 inch hex Allen or internal hex wrench (for item 54)
7. 3/8 open end wrench (for item 38)
8. Large slotted screwdriver (for item 38)
9. 1-1/4 6pt. or 12 pt. box end or socket wrench (for item 32)
10. Needle nose pliers (for item 25)
11. 1”-12 pt. socket and torque wrench (for item 51)
12. Sub wrench assembly, NOV p/n 31873 (for item 5)
13. Release Shaft Retainer Spanner, use large slotted screw driver (for item 46) 14. 15/16 open end wrench or open
end adjustable wrench (for item 4) 15. O-ring pick
In addition to these tools, a supply of new NOV spare parts should be available and on hand in order to speed the repair
process.
14 1 702640-23-01
43 1 702640-21-01
53 2 702640-23-71
Spirol Pins
The minimum number of Spirol Pins required for complete replacement of all pins in the valve is shown on the bill of
materials and in the chart below:
NOTE
Refer to the Drawings and Parts List at the end of this manual for NOV part numbers and usage.
The bushings shown in the chart below are not specifically “ballooned” on the assembly drawing but they are called out
on the bill of material under the main item in the sub-assembly where they are used.
17
Bushings
Figu re 8-1-1. 1002 - Hammer Unio n, Part No. 31893 (Flange 1002 Female)
Figu re 8-1-2. 1002 - Hammer Unio n, Part No. 31894 (Flange 1002 Female)
Figu re 8-1-3. 1502 - Hammer Unio n, Part No. 31885 (Flange 1502 Female)
1
2 Flange 1002Nut
Detachable Male Connector 31929
31925
3 Nitrile Seal Ring 31884
4 Female Half (Butt Weld Prep Piece) 31932
5 Retainer Segments (3 ea. included) 31926
6 Retainer Ring 31927
Figure 8-1-4. 1502 - Hammer Unio n, Part No . 31886 (Flange 1502 Female)
19
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