Operating Book for Mud Pump 2

HHF-1300/1600 HHF-1300/1600 Mud Pump

USER M MANUAL GH3131/3161-SM

SICHUAN HONGHUA PETROLEUM EQUIPMENT CO., LTD

October ，2007

CONTENTS 1

Introduction …………………………………… …………………………………………………………………….. ………………………………..……..….……3 ……..….……3

2

Technical Technical specification and performance performance parameters ……………………………………….... 4

3

Installation of new pump…………………………………… pump……………………………………………………………………..…6 ………………………………..…6 Requirements for suction system ……………………………………………………………11 ……………………………………………………………11

5

Preparation of power end …………………………… ………………………………………………………………..……1 …………………………………..……12 2

6

Spray pump assembly ………………………………………………… …………………………………………………………...…………... ………...…………... 14

7

Assembly of fluid end parts ……………………………………… …………………………………………………………………. …………………………. 18

8

Lubrication ………………………………………… …………………………………………………………………………………. ………………………………………. .23

9

Maintenance ………………………………… …………………………………………………………………… ……………………………………………..…29 …………..…29

10

Daily maintenances of Pump ………………………………………… ………………………………………………………………..48 ……………………..48

11

Possible failures and how how to eliminate eliminate them……………………………… them…………………………………………………51 …………………51

12

Attentions for mothballs………………………… mothballs………………………………………………………..…… ……………………………..…………...52 ……...52

13

Special Tools Tools List For For HHF-1300 / 1600 Mud Pump, delivered delivered together with the pump…...52 pump…...52

14

Spare Parts Lift For HHF— HHF—1300 / 1600 Mud Pump, delivered together with the pump….. 53

15

Recommended spare parts ……………………………………… …………………………………………………………………. …………………………. 55

CONTENTS 1

Introduction …………………………………… …………………………………………………………………….. ………………………………..……..….……3 ……..….……3

2

Technical Technical specification and performance performance parameters ……………………………………….... 4

3

Installation of new pump…………………………………… pump……………………………………………………………………..…6 ………………………………..…6 Requirements for suction system ……………………………………………………………11 ……………………………………………………………11

5

Preparation of power end …………………………… ………………………………………………………………..……1 …………………………………..……12 2

6

Spray pump assembly ………………………………………………… …………………………………………………………...…………... ………...…………... 14

7

Assembly of fluid end parts ……………………………………… …………………………………………………………………. …………………………. 18

8

Lubrication ………………………………………… …………………………………………………………………………………. ………………………………………. .23

9

Maintenance ………………………………… …………………………………………………………………… ……………………………………………..…29 …………..…29

10

Daily maintenances of Pump ………………………………………… ………………………………………………………………..48 ……………………..48

11

Possible failures and how how to eliminate eliminate them……………………………… them…………………………………………………51 …………………51

12

Attentions for mothballs………………………… mothballs………………………………………………………..…… ……………………………..…………...52 ……...52

13

Special Tools Tools List For For HHF-1300 / 1600 Mud Pump, delivered delivered together with the pump…...52 pump…...52

14

Spare Parts Lift For HHF— HHF—1300 / 1600 Mud Pump, delivered together with the pump….. 53

15

Recommended spare parts ……………………………………… …………………………………………………………………. …………………………. 55

USER MANUAL OF HHF-1300/1600 MUD PUMP


1

Introduction

HHF-1300/1600 Mud Pumps are horizontal, triplex single acting reciprocating pumps. It feeds high-pressure circulated drilling fluid to bottom hole, which flushes the bore-hole bottom and crushes rocks; furthermore, cools and lubricates drill- bits and carries the cuttings (rock chips) to the surface. The Pump mainly consists of two components, power and fluid ends. The power end includes the assemblies of frame, pinion shaft ， crankshaft ， crossheads etc.

The fluid fluid end includes the

assemblies of hydraulic cylinder ，valves, cylinder liner, piston, suction and discharge manifolds and so on. It is designed and manufactured that all parts and components of the pump conform with the requirements specified by the “Specification for Drilling and Well Servicing Servicing Equipment” (API Spec 7K). All easily worn parts at the fluid end such as cylinder liner, piston and valve assemblies etc are universal and interchangeable and could be replaced with the same type parts and components in conformity to the above-said API Specification. To avoid ‘air hammer’ and reduce outlet pressure fluctuation， fluctuation，a suction stabilizer and discharge pulsation dampener were respectively respectively installed at the suction pipes and one side of pump outlet. At the other side of pump outlet, a reset

safety valve valve is

installed to guarantee that the pump pressure would not excess the rated working pressure. Each mud pump is equipped with a charging pump to ensure good suction performances for the pump while operating at high strokes. A combination of splash and forced lubrication systems has been used to lubricate all gears, bearings and crossheads in the power end. The cylinder liners and pistons in the fluid end will be lubricated, cleaned and cooled by water supplied from a spray pump. For conveniences of daily maintenance, a set of special removers/tools will be delivered together with the pump. Except for differences in the gears and bearings at the power end of the pumps., Frame, fluid end and so on for pump HHF— HHF—1300 are the same as

pump HHF— HHF—1600.

For convenience convenien ce of users’

understanding and use, the two pumps are introduced simultaneously in the following texts.

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2

Technical specification and performance parameters

2.1 Technical specifications: The Technical Technical specifications for pump HHF— HHF—1300/1600 are shown in the following table 1: TableⅠ TableⅠ

Technical Technical specifications for pump HHF— HHF—1300/1600

N0

Model

HHF-1300

HHF-1600

1

Type

Horizontal, Horizontal , single acting, triplex piston

2

Input power rated

3

Maximum cylinder liner diameter

7″（177.8mm）

4

Length of stroke

12″（304.8mm）

5

Rated number of stroke

6

Type of gears

7

Gear ratio

4.206:1

8

Dimensions of valve pot

API

9

Weight

1300hp （969kW）

1600hp（1193kW ）

120SPM Herringbone tooth

25850kg

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7# 26100kg


2.2 Performance parameters The performance parameters for pump HHF— HHF —1300/1600 are shown in the following table II: Table II Performance parameters for pump HHF —1300/1600 Diameter of cylinder liner and rated pressure Stroke numbers

HHF-1300

7″178mm

6-3/4 171mm

6-1/2 165mm

6″152mm

5-1/2 140mm

5″127mm

2786 19.2

2998 20.6

3230 22.2

3792 26.1

4517 31.1

5000 34.5

psi

psi

psi

MPa

3429 23.6

MPa

3689 25.4

MPa

3977 27.4

psi

MPa

4667 32.2

psi

MPa

5000 34.5

psi

MPa

5000 34.5

HHF-1600 SPM

psi

MPa

psi

MPa

psi

MPa

psi

MPa

psi

MPa

psi

MPa

Rated power Displacement HHF-1300

HHF-1600

1408 hp

1733 hp

780 GPM

725 GPM

672 GPM

573 GPM

481 GPM

398 GPM

1049 kW

1292 kW

49.19 L/S

45.74 L/S

42.41 L/S

36.14 L/S

30.37 L/S

25.10 L/S

1300 hp

1600 hp

720 GPM

669 GPM

621 GPM

529 GPM

444 GPM

367 GPM

969 kW

1193 kW

45.41 L/S

42.22 L/S

39.15 L/S

33.36 L/S

28.03 L/S

23.17 L/S

1191 hp

1466 hp

660 GPM

613 GPM

569 GPM

484 GPM

407 GPM

337 GPM

888 kW

1091 kW

41.62 L/S

38.70 L/S

35.89 L/S

30.58 L/S

25.70 L/S

21.24 L/S

1083 hp

1333 hp

600 GPM

558 GPM

517 GPM

440 GPM

370 GPM

306 GPM

807 kW

992 kW

37.84 L/S

35.18 L/S

32.63 L/S

27.80 L/S

23.36 L/S

19.31 L/S

975 hp

1200 hp

540 GPM

502 GPM

465 GPM

396 GPM

333 GPM

275 GPM

726 kW

893 kW

34.05 L/S

31.67 L/S

29.36 L/S

25.02 L/S

21.02 L/S

17.37 L/S

867 hp

1066 hp

480 GPM

446 GPM

413 GPM

352 GPM

296 GPM

245 GPM

646 kW

794 kW

30.27 L/S

28.15 L/S

26.10 L/S

22.24 L/S

18.69 L/S

15.44 L/S

758 hp

932 hp

420 GPM

390 GPM

362 GPM

308 GPM

259 GPM

214 GPM

565 kW

695 kW

26.49 L/S

24.63 L/S

22.84 L/S

19.46 L/S

16.35 L/S

13.51 L/S

6.00 GPM

5.58 GPM

5.17 GPM

4.40 GPM

3.70 GPM

3.06 GPM

0.3784L/S

0.3518 L/S

0.3263 L/S

0.2780L/S

0.2336 L/S

0.1931L/S

130

120 ※

110

100

90

80

70

1

Note: Note: a. calculated as per volumetric efficiency (100%) and mechanical efficiency (90%) b. * Shows rated stroke numbers while operating. operating.

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2.3 Overall dimensions The overall dimensions for pump HHF—1300/1600 are shown in the figure 1:

1723

1540

1425

1222 2413

344

8 8 6 2

1858 4 6 4 1

1 6 2 1

1830 2057

215.9 50.8

8 0 0 2

7 0 . 7 8 1

324

15

5 1 6 1

30

0 0 4

12×

1414

2244.7 4426

Figure 1

-6-

0 5 2

28.5

419

8 9 4


3

Installation of new pump

The mud pump HHF-1300/1600, manufactured by our company, has been completely assembled and test-operated under full load and then discharged all lube oils from power end before being delivered to our customers. The pump must be checked and operated according to the following methods and measures before being put into formal services. In order to prevent personal injury during the performance of any checking and maintenance processes, it must be shut down and not operating, all safety and protection facilities installed on the prime mover and drive device should be put in safe positions.

3.1

Setting of pump

The skid under the HHF-1300/1600 pumps is fit for all types of installations, but it is worth to be mentioned that although the frame with box structure at the power end has high resistances to bending, but relatively lower resistances against twist; therefore, the supports under the frame must be level and with enough strength to bear the pump’s dead load and dynamic forces exerted upon during operation. 3.2

Land installation

In land installation, it is suggested that a mat base with, at least，eight pieces of 3″×12″ （76mm ×305mm） boards be placed under the pump skids along the entire length， the positions as shown in the Figure 2. The board under the pump skids must, at least, be 12 ″（305mm）wider than the width of the pump skid runner. More solid foundations are required in case of the installation being located in wet or marshy land.

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A

B

C

D

Figure 2

3.3 Permanent installations While the pump being permanently installed on the structural base or concrete slab on a barge or drilling platform and the pump skid being fixed by bolts, it is essential that the skid be properly shimmed to prevent the power frame from possible distortion or twists. The pump skid must be solidly sat down on all shims when all bolts are tightened. In case of barge installation, the pump skid is usually bolted to T-beam, the positions for installing shims are shown in the Figure 2 and 3. Properly shimming should be noted to avoid possible twist or distortion. All shims must exceed the full width of the skid beam flanges and have a minimum length of 12” (305mm). When integral installations for power unit or electric motor and pump skids are required ， the pump must be fixed on the skids of the T beam, with retention blocks rather than bolts； in this way， the pump could be a bit “floating” so as to reduce greatly the possible deformation of the pump frame caused by the deformation of barge deck or platform.

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Pump skid

Shim

T-beam

Deck

Figure 3

3.3

Installation of drive

Whether to use V- belt or multi-strand chain or universal shaft for the drive between power source and the pump, it must be very careful during the whole installation to ensure the longest service life and minimize the shut- downs caused by failures from the drive. Upon installation of drive sheave or sprocket, make sure all rust preventatives or greases in the hub and on the shaft are removed ；Burs and rough spots on the keys，keyways and shaft must be removed so that all keys fit properly in the keyways on the shaft and drive elements. The shaft of the pinion gear should be coated with light lube oil or anti-seize oil, and then fit the hub of sheave or sprocket, tighten all bolts according to the following requirements: Tightening bolts with wrench or wrench with extension pipe may lead to exceeding torque, therefore, it is imperative to adhere to the torque value given in the following table to tighten all bolts, otherwise, it may damage the hub and the sheave by the exceeding tightening force, which is again multiplied by the wedging action of the tapered surface. In addition, all bolts of hub must be tightened alternately and gradually.

Pump model

HHF-1300/1600

Hub

Wrench torque

Wrench Length

Force exerted on wrench

600ft .lbs

36″

200 lbs

813N.m

900mm

900N

W

3.4.1 V-belt drive -9-


3.4.1.1 Checking sheave groove status Before installation, check that the sheave grooved are not worn out and getting rounded, otherwise, the V-belt will be damaged quickly. The groove sidewall must be level and straight and there are no dusts, rusts. 3.4.1.2 Checking sheave alignment Having installed all sheaves and tightened them to working status check their alignment. If the distances from one side of the two sheaves to the centerline of sheave groove are equal, check the alignment with two tightened strings (for fishing or better for piano) along one side of the two sheaves; one is put above the sheave center and another below the center, and then move one of two sheaves until the strings have touched 4 points of the sheave rim; in this way determining the two centerlines of the drive sheaves are parallel and their side face be vertical with their axle line. 3.4.1.3 adjustment of V-belt pretension force To adjust the belt tension, change/increase the central distance between two sheaves until no sag to be found on the tightening belt side, and the slack side is also tightened but has a bit of sags. And then increase a certain of central distance again, for example, if the center distance is 100” (2540mm), 1/2” (13mm) is to be increased after completion of adjustment of the central distance; again if the center distance is 150” (3810mm), 3/4” (19mm) is to be increased. Note: Don’t obtain belt tension by lifting the pump or by lowing the pump below ground level to allow the belt to be tensioned by pump’s weight. 3.4.2 Chain drive 3.4.2.1 Installation Installation and maintenances correctly are important means to extend the service life of chain drive and chains and sprockets themselves. Many factors such as the width of chain, center distance, speed and load etc. are to be considered when determining the allowable alignment tolerance of sprockets; since there is no perfect “operating method” to be applied, therefore, what we can do is to make the chain alignment as exactly as possible. As mentioned above in 3.4.1.2, a more precise alignment can be made with two stretching steel wires (better for piano) along one side of the both sprockets; one is put above the centerline and another below the centerline, and then move one of two sprockets until the strings have touched 4 points of the sprocket rim; in this way, to determine

- 10 -


the two centerlines of sprockets are parallel and their end face be vertical with their axle line. 3.4.2.2 Lubrication of chain drive The lubrication system used for all chain drive in HHF series pumps is an independent one, which has its own lube oil pump, reservoir and drive. Filling the lube oil into the chain case must be up to the indicated height. The lube oil to be used are as follows: Ambient temperature above 32 F （0°C）

SAE-30/N100

Ambient temperature below 32 F （0°C）

SAE-20/N68

If Ambient temperature below 0°F（-18°C）, Please consult a reputable lube oil dealer for recommendations. As for those approved lube-oil specifications and their supplements, references might be made to the reports/bulletins usually used on lube oil, which are written and published by oil-manufacturer. If there is any discrepancy between manual and the reports/bulletins, the suggestion from the reports/bulletins shall be prevailed. Owing to the chain lube system being an independent system, the maintenance must be carried out based on equipment’s special requirements, which include: n

Daily checking oil level

n

Daily checking oil status

n

Daily checking oil pressure

n

Supplying some oils to chain

n

Checking nozzle’s working status on the spray tube

n

Checking the working conditions of the oil pump’s drive (V-belts, or chain)

(（5～15psi）（ 0.035～0.103MPa）

Note: a. There is a pressure relief adjusting screw on the rear of the pump housing to adjust the oil pressure. b. When oil pressure is too high or too low, which indicate that the suction and discharge filter screens need cleaning.

4

Requirements for suction system

The design of pump suction system has been considered to install the system independently. To obtain a satisfied suction performance, the HHF series pumps must have positive head (pressure);

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the optimum pressure for suction manifold is 20～30psi （0.14～0.21Mpa）. Under this pressure, the pump could have the maximum volumetric efficiency and the longest service life for consumable parts.

This pressure can be obtained by 5×6 charging pump with a 40 hp, 1150-rpm

electric motor. A special kind of device is necessary to keep the charging pump and the triplex pump automatically and synchronously turned on and off. For drilling rigs driven by DC motor, usually a signal sending out from DC control panel actuates the electromagnetic starter; at this time, the air line of drilling pump clutch can provide a group of contactors when clutch is engaged, through which supply power to the electromagnetic starter. The suction pipeline should be arranged with a by pass for the charging pump, to facilitate the drilling pump’s continuous operation when the charging pump is in maintenance or failure. When the drilling pump is operated without charging pump, usually replace a softer suction valve spring to improve suction performances. Suction stabilizer is a very efficient supplementary device, which can fully charge the fluid into cylinder liner and greatly eliminate the fluid fluctuations in suction pipes resulting in a smoother flow in the discharge line. Note: Don’t connect the discharge pipe of the safety valve to the suction pipeline, since when the safety valve opens it causes a sudden rise to the system internal pressure; if the pressure is higher than the rated pressure of the system, it will damage the manifold, suction stabilizer and centrifugal pump etc.

5 Preparation of power end Before being shipped to the users, the HHF series pump manufactured by our company has been completely assembled and test operated. All lube oils have been drained. Before operating the pump, the following operations and checks must be carried out. 5.1 Power end lubrication Before filling lubricant, open inspection window on cover and check power end oil reservoir for possible accumulation of condensation, and drain and flush the inner chamber by removing the pipe plugs on each side of the pump (see item 2, Fig.7). Fill in the proper brand and quantity of lubrication oil in the power end according to the requirements specified on the designation plate of

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pump frame. Recheck oil level after pump has operated for a period of 15 minutes. Shut pump down for about 5 minutes until oil stabilized, check oil level gauge (see item 1, Figure 7). It is usually necessary for a few more gallons (10 liters) of oil to be added due to a certain amount being retained in the crosshead and frame cavities. 5.2 Installation and inspection of Crosshead Extension Rods and Diaphragm Stuffing Box Seals for HHF-1300/1600 Pump As shown in Figure 4, remove the diaphragm stuffing box and splashguard (1) and rotate pump so that crosshead is at the front of the stroke, check bolt-tightening status. If the cleanliness of front part of crosshead and its extension rod and bolt- tightening are not up to the requirements, remove the extension rod and thoroughly clean the crosshead front and the end face of the extension rod; and then insert alignment boss on crosshead extension rod outer circle into the crosshead bore and install the bolts (2) to the torque: 350 ～370 ft.lbs, (475～500N.M), finally lock it with steel wire.

7

12

4

1 11 8

2

A

3

5

6

5

6

7 9 10

Figure 4 Upon assembly， clean the mating face between splash-guard and frame as shown ‘A’in Figure - 13 -


4， and then fix the seal（3）and bolt (10)， the bolt-tightening torque is 90～120ft. lbs (120～ 160N.M). Clean inner bore and end face of splash-guard, and clean the outside surface and flange face of the diaphragm stuffing box; coat the outside surface of the diaphragm stuffing box with light oil and install O-ring seal (4); and then insert the diaphragm stuffing box to the splash-guard and finally install the seal washers and end covers sequentially. Be careful that the backflow hole of the diaphragm stuffing box and the drainage hole of the end cover must be positioned downwards.Tighten bolts up to the torque: 12～18ft.lbs（16～24N.M）. The diaphragm stuffing box assembly has two double lip oil seal (6), oil seal ring (7), “O”- ring (12), O”- ring (8) and lock spring (9) etc. Install the assembly as follows: a.

Remove the spring (5) from the double lip oil seal (6) and place the seal on the outside of the crosshead extension rod, but main lip towards power end. Install spring (5) on the oil seal lip, and then slide the seal into the diaphragm stuffing box. (See the following note).

b.

Install the O-ring (12) into oil seal ring (7), put (7) and (12) together over the extension rod and then slide it into the stuffing box bore.

c.

Install the O-ring (8) into the groove of the stuffing box.

d.

Install the double lip oil seal at right side (6) in Figure 4, the method is the same as a.

Note: The double lip oil seal (6), near to the power end, can be replaced by single lip oil seal, but the outer one (hydraulic end) cad not. e.

Install lock spring (9), its opening must be just downwards.

Note: Caution must be taken to assure the pressure spring (5) will not slip out of groove of the oil seal lip when the extension rod is heavily scored. The extension rod must be coated with light oil, which facilitates installation of all parts in the stuffing box assembly.

6 Spray pump assembly The spray pump assembly consists of spray pump, water tank and spray pipe with nozzles etc. The function of spray pump is to supply water in the form of spray to the cylinder liner and piston to flush, lubricate and cool them to extend the service life of the cylinder liner and piston.

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The spray pump is a centrifugal pump, which is electric motor driven and uses water as cooling and lubrication fluid. Attention must be paid to assure the cooling fluid is supplied to the cylinder liner and piston, otherwise immediate damage of piston rubber parts and cylinder liner will occur. The HHF series mud-pumps manufactured by our company use a stationary spray pipe, as shown in Figure 5, which consists of a fixture (1), connecting pipe (2) and spray nozzle pipe (3). It sprays the cooling fluid to inner holes of cylinder liner and piston. The spray nozzle pipe should be checked often as the pump works. Through adjustment of water supply to the manifold, to assure enough cooling fluid to be sprayed directly to piston.

1

2 3

Figure 5 Cooling fluid will be transfused by pump (item3, Figure 7), and sucked from water tank (item 5, Fig.7), to the manifold located in the left (right) wall plate of the frame. By regulating the ball valve (item 4, Fig.7), the pump will supply water to the inside of the cylinder liner without splashing back on the crosshead extension rod. Water should not splash on the extension rod otherwise some of water will spray into the power end contaminating the lube oil. The cooling fluid is returned from frame drainage hole to water tank’s setting chamber, and as the fluid flows through the filter screen, the solids settle as shown in Fig. 6.

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It is important to check condition of the cooling fluid at frequent intervals and clean and flush the water tank as well as replace the cooling fluid as required, otherwise the contaminated fluid will cause early wear of liner and piston or block the spray nozzle pipe.

frame drain

filter screen

setting chamber

to spray pump suction pipe

Figure 6

- 16 -

drain


5

4

图 e r 3

2

1

- 17 -

u g i F


7 Assembly of fluid end parts The cross-section of the fluid end is shown in Figure 8, clean and install all parts of the fluid end must follow the methods as follows. Note: The parts in the fluid end are designed for ‘metal to metal’ installations to reduce wear caused by high-pressure fluid which is used in modern high-pressure-pump operations. Based on this consideration, in order to ensure a reliable sealing between parts in the fluid end, it is required to clean all parts thoroughly and have no burs, scores or rusty spots etc 7.1 Valves and seats Remove all three valves pot cover (18), three cylinder heads (16) and plugs (15), 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 additives etc.), and remove all burs and nicks with a fine emery cloth. Clean and dry thoroughly the valve seats and install suction and discharge valve seats into the valve cavity bores and then install the valve body; knock the upper part of the guidepost with a copper hammer to drive the valve seats in place, finally install valve springs and other parts. 7.2 Cylinder liner Insert liner- seal- rings (1) into the counter-bore of the cylinder. Install the wear plate (2) in place with stud bolt, and then install liner flange (3), be sure that the liner lock starting point is at the 5 o’clock position; and coat the inner bore of nut with Locktite gelatin 277, and finally tighten the nut to torque Note:

470～510ft.lbs（640～690N.m）.

the purpose of putting the thread start point at the position of 5 o’clock is to keep the liner

lock threads from being damaged. Insert liner seal rings (1) into the counter-bore of the wear plate (2). Coat inner surface of cylinder liner lock (4) with grease and then put the two-half liner-latching ring on the liner and hold them with the O-ring. Lift the cylinder liner and coat cylinder liner lock threads with grease and put the lead thread start point at the position equivalent to 7 O’ clock and push while turning the liner into the liner flange (3). Tighten the liner lock (4) and press the liner end face into position and knock the liner lock tightly with a hammer.

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5

6

7

8

9 10

17

18

11 12 13 14 15 16

19

4

1

3

2

1

Figure 8

7.3 Piston rod Clean piston rod (7) and piston (8); make sure they are free of burs and nicks. Install O-ring (9) in groove of piston and slide piston (8) on the rod (7) and watching that the O-ring is not dislocated out of the groove. Tighten piston rod nut (10) to a torque: 1200～1600ft.1bs（1625～2165N.m）. Coat liner I.D and piston O.D with grease; check and make sure the ends of piston rod and extension rod are clean and free of burs and nicks. Insert piston rod into the liner and make it centered at the liner rear part. Drive the piston into the liner with a piece of hardwood or special tool. Be careful that while driving and approaching the crosshead extension rod you do not damage the positioning dowel of the piston rod end. The piston rod must be supported and guided into the extension-rod positioning bore.

7.4 Piston rod clamps The piston rod clamps are machined as one piece and then cut into two halves; and the two pieces are stenciled with matching numbers and linked together with a chain. They must be used in pairs with the same matching numbers. Before installation of the clamps, the splashguard (19) - 19 -


must be installed on the end of extension rod and the clamps clip on the end flange chamfer of the piston rod and extension rod. Tighten bolts to the torque: HHF-1300/1600 ,245ft.lbs（330N.m）. When the rods and clamps are new, there is a gap of about 1/2 ″（13mm） between the two halves of the clamp to ensure that the end faces of rods form a good ‘metal-to–metal’ connection. As wear occurs, the two halves will be pulled closer; if no gap exists, the clamping force will be lost and the clamps need to be replaced. Finally, install the liner end cover on the rear part of the cylinder liner.

7.5 Lower valve rod guide and cylinder head Install the lower valve rod guide (12) and slip it on valve body, through flashboard (13) press down the valve rod guide and press the valve spring simultaneously. Install the locating disk (11) into the cylinder bore; install cylinder head O-ring (14) on the cylinder head plug (15). Coat the O-ring and outer circle of the cylinder head plug with lightweight oil. And push the cylinder head plug and knock the end lightly into the cylinder front-end inner bore. Coat the threads of the cylinder head with grease; rotate the cylinder head (16) in against and on the plug (15), and then tighten the cylinder head with a force-multiplier tool and hammer provided together with the pump. If the fluid is leaking through the bleeder holes it indicates that the O-rings are damaged or the cylinder head is loose. Never block the bleeder. Once the O-ring fails it will cause the head threads and other parts be ‘washed out” and damaged.

7.6 Valve pot cover (valve pot cover) Install the valve pot cover seal ring (17) into the bore; coat the sealing parts and threads of the valve pot cover with grease and then tighten the valve pot cover in place with the force-multiplier tool and hammer.

7.7 Discharge manifold 5″(127mm)5000psi flange is used for discharge manifold. Having removed the flange and the ring gasket, weld the flange to the discharge line (types of welding will be selected by user). Tighten the flange connection bolts and nuts alternately to the torque: 1200 ～1600ft.lbs（1625～2165N.m）. If the other end of the manifold will not be pipeline-connected, a blind flange can be installed and

- 20 -


tighten the bolts and nuts as the way mentioned above.

7.8 Suction flange The suction flange is a 12” (305mm) bore flange, which is custom-made and connected and matched with the inlet flange of the suction line. O-rings seal the flange connection. Before connecting, clean the O-ring grooves and flange end faces and then tighten the bolts to the torque: 360～490ft.lbs（490～665N.m）

3 1 I 2 ZG112

NPT3 I 6 4

5

Figure 9 7.9 Accessory manifold The accessory manifold is shown in the figure 9. It may be installed on the discharge manifold and opposite to the discharge filter screen assembly. This accessory manifold is connected with pulsation dampener (1) through the discharge bend- tube assembly; and installed a 3-8NPT and a 2-11 1/2NPT, the two outlets are connected with reset relief valve (3) and pressure gauge (2) respectively. Note: a bushing will be used when the pressure gauge interface threads are R1 1/2. The accessory and discharge manifolds are connected by flanges; before installation, clean thoroughly the flange seal ring grooves and then insert the ring gaskets (4), and tighten the connection nuts (5) to the torque: 1200～1600ft.lbs（1625～2165N.m）. To ensure a uniform force is exerted on the seal gaskets connections, tightening the nuts should be done cross-alternately.

- 21 -

7


The reset relief valve (3) is installed on the accessory manifold for the purpose of protecting the pump from pressure exceeded the rated value and discharge all the fluids to guarantee safety of the mud pump. The reset relief valve must be installed to be able to contact directly to the mud tanks; and no valves may be installed between the relief valve and the discharge line. Pipe the outlet of the relief valve directly to the mud tank by seamless steel pipe and with as few turns in this line as possible. If a turn is necessary, the elbow bend should be > 120°. It is not allowed to pipe the outlet of the relief valve to the suction pipes of the pump. The flange on the bottom of the KB-75 pulsation dampener (1) is supplied together with

R39 ring

gasket(6); before installation of pulsation dampener , clean the ring gasket and groove thoroughly and after installation, tighten the nuts (7) to the torque: 750 ～850ft.lbs（1020～1150N.m）. To ensure balanced forces to be exerted, all nuts should be tightened alternately cross ways. Before starting the pump, pre-charge the pulsation dampener to not be more than 2/3 of the pump discharge pressure. Maximum pressure is not to exceed 650 psi (4.5 Mpa). The pulsation dampener will be charged with nitrogen only. Do not charge with air, oxygen, hydrogen or other easily-burnt and explosion gases. The charging will be conducted with a set of charging equipment (pulsation dampener charging hoses assembly) provided together with the pump, as shown in Figure 10 and the operation sequences are as follows:

Nitrogen cylinder switch

Dampener stop valve

Figure 10 1. Nut 3/4-16UNF-2B 2. Seal joint 3. Joint 4. Seal 5. Plug 6. Hose joint 6I-2500

- 22 -


a.

Remove dampener pressure gauge cover, rotate vent valve handle about 1/4 –1/2 of a circle to release the remaining pressure and make the pressure gauge reading return zero; remove vent valve capping and plug.

b.

Connect the nitrogen cylinder valve to the dampener vent valve by a hose

c.

Open the shut-off valve of the dampener

d.

Open the nitrogen cylinder valve slowly and adjust the airflow into the dampener

e.

Close the nitrogen cylinder valve when the reading of dampener pressure gauge is up to the pressure required

f.

Close the dampener shut-off valve

g.

Remove hose and install the vent valve cap and plug.Install the pressure gauge cover;

h.

To achieve the best results, the dampener pre-charging pressure must not be more than 2/3 of the pump discharge pressure, and the maximum charging pressure is 650 psi (4.5 Mpa).

Warnings: a.

The pulsation dampener must be charged only with compressed nitrogen and not with oxygen, hydrogen or other easily-burnt and explosive gases.

b.

For maintenance of the dampener, the pressure in the dampener must be zero and the pump pressure also is zero.

Be careful that don’t fully rely on the pressure gauge

readings. The vent valve cap must be open to release pressure, the remaining pressure may be low and the pressure gauge may not read correctly. This low pressure may still cause an accident.

8

Lubrication

It is very important to lubricate properly all moving parts, which directly affects the service life of the parts. To obtain the longest service life without failures for all parts of the power end, regular maintenances and inspections must be done to ensure proper and clean lubrication oils flow to all moving parts. 8.1 Minimum operating speed To lubricate whole power end, a combination lubrication system of oil bath splash and pressure

- 23 -


systems is adopted for HHF series pumps. When a gear oil pump is driven mechanically (except driven by a electric motor), the types of pressure system adopted, in fact, govern the minimum SPM, at which the pump being operated. As for the pressure lubrication systems adopted for HHF series pumps, they could operate at a minimum 25 SPM; at this time, the lowest oil pressure is 5 psi (0.035 Mpa). Big gear rim

Pinion shaft

Oil pump gear

Figure 11 Note: The pressure lube oil pump could be installed outside of mud- pump and driven by v-belt or installed inside of mud- pump and driven by big gear rim. When the later installation is used, the rotating direction of the pinion gear should be as shown in figure 11.

8.2 Flow- controlled splash lubrication system The flow- controlled splash lubrication systems are the same for all HHF series pumps, regardless of the types of oil pump provided for the lubrication system. In the flow-controlled splash system, the big gear rim brings up the oil from the sump; and when its teeth mesh with the pinion, the oil is squeezed out and splashed to various oil troughs and oil cavities in the frame. With reference to figure 13, the oils are thrown into the trough (7) and flow through pipe (8), to the bearings on the two sides of the pinion shaft. The passage that oil flow from the top of the crosshead guide into the crosshead bearings is shown in figure 12. The oils accumulated in oil chamber above the crossheads flow through oil nozzle (1), into the crosshead pin baffle, and then to oil passages (5) to lubricate crosshead bearing. There are

- 24 -


two oil passages (5) symmetrical to axial line and machined on the crosshead pin, which enable its oil bores to be aligned even if the crosshead rotates 180 °. This permits the installation of crosshead being possible from either direction of the frame’s two sides.

1

2

4

3 5

Figure 12

8.3 Pressure lubrication system The pressure lubrication systems used for HHF series mud- pumps have installed a lube oil pump, as shown in Figure 13; in this system, the filtered oil is sucked in, through the suction filter (1), by the pump, and then through the block II (2), distributed to the pinion shaft nozzle (3A), main bearing oil-pipe (4) and the block I (4A) in crosshead chamber again through the block I (4A), distribute oil to the crosshead, its bearing and extension rod.

- 25 -


4 1

3A

2

8

6 9

3

3A 8

5

7

4A

4

2 9

Figure 13 A pressure gauge (5) is mounted on the back base plate of the frame to show oil pressure in the block oil-distributor, which is obviously changing with the speed of the pump. However, if a sudden pressure drop or increase occurs, the reasons caused must be found according to the section on Maintenance of lubrication system. A pressure relief valve (6) is mounted on the block II (2) to prevent the pump and its drive from possible damage caused by excessive pressure. The relief valve is preset to 80 psi (0.55 Mpa) and then locked down to avoid the preset pressure changing.

- 26 -

USER MANUAL OF HHF-1300/1600 MUD PUMP 3

2

1

Figure 14

Upon built-in installation of the lube oil pump, as shown item 9 in Figure 13, the pump must be well positioned according to the requirements as shown in the Figure. The side face of the oil pump gear must be flush and parallel with the side edge of the mud pump main gear rim, and the gear teeth have 0.024”-0.0355” (0.60-0.90 mm) backlash. A typical layout for oil pump driven by pinion shaft is shown in Figure 14. The oil pump (1) is pipe-connected to the lube oil pipes system through the suction and discharge adapters mounted on the bottom inside walls of the power end. Don’t over-tighten the V-belt (2) to prevent the pump from premature damage. To avoid possible injury, the V-belt guard, as shown item 3 in Figure 14, must be installed before the pump being operated.

8.4 Maintenance of lubrication system Sufficient lubrication of all moving parts is the most important factor to extend the service life of the pump; being meticulous in maintenance of the lube oil system is a duty for all operators. In fact, a good or poor maintenance of the lube oil system determines a long or short trouble-free service life of the pump. The recommended lubrication oil is as follows; and also shown on nameplate fixed on the pump side. All data recommended are the results of long-period tests in the oil field; therefore, any substitution of oil recommended could only be used for emergency conditions.

- 27 -


Lubrication specification: Using extreme- pressure (EP), non-corrosive and anti-foaming gear lubrication oil is specified as follows: Ambient temperature:

+30°F～+ 155°F （-1°C～+ 68°C） AGMA 250.04EP（6EP）or ISO VG320

Ambient temperature:

0°F～+ 80°F （-18°C～+ 27°C） AGMA 250.04EP（5EP）or ISO VG220

Ambient temperature:

-20°F～+ 40°F

（-29°C～+ 4°C）

AGMA 250.04EP（4EP）or ISO VG150 Oil reservoir capacity:

HHF-1300/1600

100 US gal（379L）

Every shift should make their rounds to check the oil level and maintain the level at the FULL position; in view of oil level compensation, it is allowed to drive the pump for 5 minutes at a slow speed and make sure the oil level at the specified position. Check once every 6-month if the oil has any sand and corrosive compounds in it or not; it should be drained. Drain all the oil and flush the oil reservoir before adding new oil. The oil drains are located on either side of the pump frame. During flushing, thoroughly clean the oil troughs and the chambers under the crosshead guides, and also clean or replace the filter element in the suction oil filter, and clean the suction filter screens. Before filling new oil remove the drain cover from setting chamber and clean out contaminants. Regularly check the condition of the lube oil and replace if contaminated ;moisture in the air, ingress of water and mud, and dirt may enter and contaminate the oil. The settling chamber (deposit chamber) is located in the crosshead guide area of power end; the contamination in the oil splashed into this area is allowed to settle and be drained out by removing the drain cover that located on the two sides of the frame under crosshead inspection cover. Check once every month. Remove drain covers at pump two sides to drain out the contaminated oil from the settling chamber. This will lose about 15-gallons of oil and must be compensated by adding the same amount of oil to the main reservoir. Check once every week. Remove the 2 1/2” plugs below the frame and drain out the accumulated

- 28 -


water. Every shift makes their round of inspection of oil level once and keep the level to the full position. In case of oil pressure drop occurs; check the following items: --- Suction filter screen may be blocked --- Oil level may be too low --- V-belt slipped --- Connections or joints may be broken or loosen --- Oil pump may be worn or damaged --- Relief valve may be failed In case of oil pressure increase occurs; check the following items: --- Oil pass-way may be blocked --- Contaminations may make the oil be viscous --- Relief valve may be inoperative --- Pressure gauge may be defective --- Other abnormal conditions

9

Maintenance

9.1 Power end Regular inspection of the power end is the most important way to conduct preventive maintenance; it could find various failures in time, small or big and enable the mud pump to be repaired according to plan or in the normal shutdown time. a.

Check tightness of the main bearing bolts to the torque: 9750ft.ibs (13210 N.M)

b.

Locking wire Check all bolts including main bearing cover bolts, and check all locking wires on the bolt head of all crankshaft-bearing baffles; after retightening bolts, the locking wires must be replaced. Refer to crankshaft assembly section for bolt torques required.

c.

Oil pipe-line Check all oil pipelines and make sure that they are complete and free of obstructions. Check the pump suction pipelines are free of damage.

- 29 -


d.

Suction filter Check suction filter status, clean or replace it if necessary.

e.

Main bearing cover Remove the main bearing cover; check tightness of main bearing bolts and condition of the bearing rollers. Clean and remove any sludge, dirt or foreign objects, as they might be accumulated in the bottom of the bearing area.

f.

Teeth of main and pinion gear Check the condition of the main and pinion gear teeth for any abnormal wear. During the running-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 gears; however, during the regular check if the pitting is expanding, immediately contact the pump manufacturer to inspect the gears thoroughly.

g.

Crosshead pin bolts and crosshead guide Remove cover and check condition of the crosshead pin bolts and locking wires. (The back cover can be removed and the link (connecting rod) be rotated to outer dead center, while checking middle crosshead pin). Tighten the crosshead bolts (item 3 in Figure 12) to the torque: 165～175ft.lbs（225～240N.m） While tightening use a torque wrench and do not exceed the above-mentioned torque value. If the crosshead or guide shows abnormal wear, replace it immediately as it may cause damage to the bearings and other parts and speed up the wear to the piston and cylinder liner by the excess wear.

h.

Lube oil and oil reservoir Check condition of oil and cleanness of the oil reservoir; service the oil lubrication system as specified in the section on Lubrication of this manual.

9.2 Roller bearing Roller bearings are used for all HHF series mud- pumps. As very precise mechanical parts, all roller bearings must be carefully maintained to ensure that higher load capacity and longer service life to be obtained.

- 30 -


Spherical self-alignment roller bearings are used for crankshaft main bearings. The pinion shaft is mounted on short-column roller bearings. The eccentric bearings are single-row short-column with detent ring roller type to facilitate removing. The crosshead pin bearings are double-row long-column roller type. None of the bearings require special adjustments. All inner and outer rings are assembled and fitted very accurately as the fit clearance of bearings are very small; therefore, they must be used in sets. If one element of a bearing failed (inner or outer rings, rollers or retainer), it must be replaced in sets. If excessive tolerance clearance, groove or wear in socket ring and spot corrosion or scaling on parts occur; which indicate that these bearings are already failed and must be replaced as soon as possible. All roller bearings are assembled to shafts by shrink fit (refer to every bearing assembly for the bearing fit data). Damaged or worn bearing or socket ring can be removed by driving them off the shaft with a copper rod and hammer or by gas cutting but must be very careful don’t hurt the shaft. Bearings assembling usually use the way heating in an oil bath; but the temperature should be below 300℉（149℃）.

Make sure that both the oil and tank must be very clean; if the oil were

directly heated by open fire under the oil tank, the bearing inner ring must be supported while putting it in the oil tank and don’t leave the bearings in the tank longer than 3 minutes. Don’t heat the bearings with a torch unless it is the only possible means available. When heating by torch, it must be only operated by an experienced gas-welder; the torch and the bearing must be at least be 6” (150mm) apart. Use a tempil-stick to measure the temperature; don’t overheat the bearings; otherwise, the bearing will become soft by tempering of metal. Once the heated bearing is in place on the shaft, it should be naturally cooled, never use water or other liquid to cool the hot bearing. Rapid cooling will cause the bearing’s inner and outer rings as well as rollers to be ‘thermal-cracked’ and damaged. Never strike bearing with a steel hammer, upon installation a wood hammer might be used to drive lightly the bearing in place. Usually coat the shaft neck and fixing bores by grease before installation of bearing; the best one for this purpose is called as ‘white lead oil’, i.e. a kind of anti-seize compound oil. Before installation, open the packaging box and take out the bearings; be sure that prevent any dirt and other foreign objects enter into the bearings; and remove packaging antirust grease and clean

- 31 -


all bearings thoroughly with kerosene or other solvents.

9.3 Pinion shaft assembly

11 16 15

C

B

B

C

14 13 12 11

17 19 18

Fluid end

1

2

3

4

5

A

A

10

9 8

6

7

Figure 15 The fittings between parts on the pinion shaft assembly and bearings are shown in table III

Table Ⅲ Matching location

Marked by

Numerical value T0.002 ″～T0.0043″

Bearing inner ring to shaft neck

A T0.050mm～T0.109mm L0.0007″～L0.0045 ″

Bearing outer ring to bore

B L0.018mm～L0.115mm L0.003″～L0.008″

Bearing carrier to frame bore

C L0.076mm～L0.203mm

In this table, T indicates interference and L indicates clearance. The gear and shaft are machined as an integrated unit; the fit tolerances of the bearings are determined by their precision fit with the shaft and the bearing carrier. When performing maintenance or overhaul, make sure the requirements in Table III are obtained. Having installed the inner ring and seal sleeve. (15° bevel edge towards outside) of bearing by shrink fit on the pinion shaft neck, the installation of pinion shaft assembly is completed, and then the pinion shaft assembly can be installed in frame bores at any end into the frame assembly (see Figure 15). - 32 -


When installing the pinion components in the frame assembly, the following points should be noted: a.

Ensure the seal washers (6) of bearing carrier and the end cover seal washers (5) are correctly in place.

b.

When installing the bearing carrier (7) and end cover (4), make sure the oil groove is positioned downwards and aligned with the drain hole; moreover, the oil-accumulating box on the bearing carrier should also be installed downwards.

c.

Remove burs, dents and gouges from outside surface of the seal sleeve (3), and then install end cover (4) in place. Take care when sliding the seal lip over the keyway on the end of shaft as the lip may be damaged by the sharp edge of the keyway; when sliding seal into the seal sleeve the seal lip is not allowed to be turned over the carrier edge.

d. e.

Tighten bearing carrier bolts (12) to the torque: 140～165ft.lbs (190～225 N.m) Check condition of the pinion bearing inner and outer rings and roller, if there is any wear, galling, scaling and grooving or radial clearance exceeds 0.012” (0.30mm), it is recommended a new one replace the bearing damaged.

9.4 Crankshaft assembly The crankshaft assembly consists of crankshaft, link (connecting rod) (including bearings), and main gear rim and main bearings. The fit tolerances of the bearings are determined by their precision fit with the crankshaft and the bores related to. When performing any maintenance or overhaul, make sure the requirements in Table IV are obtained. Table Ⅳ Matching location

Marked by

Numerical value T0.0022″～T0.0048″

Main bearing inner ring to shaft neck

A T0.056mm～T0.123mm 0″～L0.0043 ″

Main bearing outer ring to carrier bore

B 0mm～L0.108mm T0.0069″～T0.0118″

Bearing inner ring in link(connecting rod) big C

T0.175mm～T0.300mm

end to eccentric outside ring

- 33 -

USER MANUAL OF HHF-1300/1600 MUD PUMP L0.0019 ″～T0.004 ″

Bearing outer ring in link big end to bore in link D

L0.049mm～T0.102mm

big end

T0.005 ″～T0.0093 ″ Inner bore of big rear rim to hub outside round

E T0.126mm～T0.236mm L0.002″～T0.002″

Main bearing carrier outside round to frame bore

F L0.05mm～T0.05mm T0.0006 ″～T0.003 ″

Crosshead bearing outside ring to link bore in G small end

T0.016mm～T0.076mm

Crosshead bearing inner ring to crosshead pin

T0.0012″～T0.0035″ H T0.031mm～T0.09mm

outer round

In this table, T indicates interference and L indicates clearance. The crankshaft assembly is installed as follows: (refer to Figure 16) 9.4.1 Assembly of big gear rim Clean the aligning and mating faces of the big gear rim and outside of the crankshaft hub and heat the big gear rim to the temperature 176°F～248°F（80°C～120°C）and keep thermal insulation for one hour, and then mount on the crankshaft by shrink fit. When the temperature dropped down to room temperature, tighten the nuts (19) and bolts (11) cross-alternately to the torque: 1810 ft.lbs （2455N. m.Check the diameter and end plane run-out of the big gear rim after installation by the ways as follows: first mount the crankshaft into the frame assembly, and then rotate the big gear rim and measure its diameter run-out on gear rim circle directly by a dial indicator. While measuring the gear rim end plane run-out since it also affects the running clearance the of main bearings, it must be measured simultaneously at the shaft end and gear end face by two dial indicators; therefore, the actual run-out at any point is a difference of the two readings. 9.4.2 Install the inner ring of the eccentric bearing on the crankshaft eccentric shaft neck by shrink fit and mark the matching bearing pair well; first install the bearing in middle and then at both sides, while installing the inner ring of the right eccentric bearing, the locating ring (7) should be first installed. Tighten the allen screws (28) to the torque: 44～66ft.lbs（ 60～90N.m）and lock them with steel wires. 9.4.3 Heat the link big end to the teperature 176°F～248°F（80°C～120°C）and install outer ring of

- 34 -


the eccentric bearing, and mark the the matching bearing pair well; When the temperature dropped down to room temperature, install the outer detent ring (5) and keep its scoop positioned at the bottom and tighten the bolts (20) uniformly to the torque: 44～66ft.lbs（ 60～90N.m）and lock them with steel wire. 9.4.4 Heat the link small end to the teperature 176°F～248°F（80°C～120°C）, install the outer ring of the crosshead bearing into the link small end bore according to the matching marks. 9.4.5 Install the link on the inner ring of the eccentric bearings and install the inner detent ring (4); tighten bolts (20) uniformly to the torque: 44～66 ft .lbs（60～90 N. m）and lock them with steel wire. 9.4.6 Install first main bearings on the bearing carrier by shrink fit and then together be installed on the crankshaft also by shrink fit; when the temperature dropped down to room temperature, install detent ring (14) and baffle plate (15). Tighten uniformly the bolts (20) to the torque: 44 ～66ft.lbs （ 60～90N.m）and lock them with steel wire. Before shrink- fitting, the bearing remember to install the spacers (12).

- 35 -


Flu id end

Figure 16

- 36 -


9.5 Installing crankshaft assembly in frame assembly In order to obtain a more precise fit between the main bearing carriers (sleeve) (right and left) and the frame bore; the following steps should be followed. 9.5.1

Before lifting crankshaft assembly, put a piece of woodblock between the link small end

and crosshead guide (see Figure 18), to prevent the guide from possible gouging as sliding the link in place. 9.5.2

Rotate the main bearing carrier so that its two symmetry planes are parallel with the main

bearing boltholes and provide clearance for the main bearing bolts to ensure the main bearing bolts to pass in; and slowly lower the crankshaft into position. 9.5.3

After installing the crankshaft in the frame and before installing the main bearing caps,

check the bearing rollers of each row at each side are equally loaded. Tighten the main bearing bolts only when the numbers of inner and outer rollers supporting the dead weight of the crankshaft are equal. Owing to the affects of manufacturing tolerances etc, the total number of the rollers may vary slightly.

Bearing bolt

Main bearing

Bearing sleeve

Lead wire

(～0.60mm)

Bearing cap

crankshaf

shims

(0.50mm)

Figure 17 9.5.4

Install and shim main bearing; and make the main bearing carrier have a interference of 0.0024″～0.004″（0.06mm～0.10mm）to obtain a pretension through adjusting the

- 37 -


thickness of the shims. There are two ways to decide the thickness of shims: a. Calculate: 1) Measuring the outer diameter of main bearing carrier A 2) Measuring the inner bore diameter of main bearing pedestal B, or read directly from frame main bearing pedestal end face. 3)Actual shim-thickness needed =0.25-〔0.10-（A-B）〕mm； 4) Tighten main bearing bolts 3-8UN-3A to torque 9750 ft.lbf （13210N.m） b. Trial-adjusting method, as shown in Figure 17 1)

Put steel shims with thickness of 0.5mm in main bearing cap matching face

2)

Add a piece of lead wire (fuse) in the middle of matching area between main bearing cap inner hole and bearing carrier

3)

Tighten all main bearing bolts to torque mentioned above.

4)

Remove the main bearing cap and measuring the thickness of the lead wire.

5)

Pretension of the main bearing cap is 0.10 mm

6)

Actual shim-thickness needed = shims thickness 0.50 –lead wire thickness pressed – bearing pretension 0.10mm.

Note: Different matching tolerances for right and left sides make it necessary to measure and determine the shim-thickness for both sides separately.

And then place the shims under the main

bearing cap according to the thickness above-determined separately, tighten all main bearing bolts to the torque: 9750 ft.lbs（13210N.m）. Recheck the load condition of inner and outer two-row roller at both ends as mentioned above, to ensure that each bearing has the same load.

9.6 Installation of crosshead guide 9.6.1Clean thoroughly the surfaces of the guide and frame bore used for installation of the guide and remove all burs or rough edges. 9.6.2If an old guide is to be reused, check the friction surface for wear and scoring etc. If it is not up to the requirements, replace it. Note: As for HHF –1300/1600-mud pumps, the upper and lower crosshead guides are not interchangeable. The guides are differently machined so that the lower one places the crosshead on

- 38 -


frame centerline, but the upper guide is machined to afford a certain clearances between the crosshead and guide. The upper guide is thinner and has a big bevel edge at the back part and oil hole in the middle. 9.6.3 When installing upper and lower guides, tighten the guide screws to the torque:

150～200ft.

lbs (200 N.m～270N.m). 9.6.4Check tightness between frame and guide at point A as shown in Figure 19A with 0.002 “(0.05mm) feeler gauge to make sure guides fit into frame bore properly.

9.7 Installation of crosshead The crosshead can be installed from the front end (fluid end) or guide back end (power end), refer to Figure 19 and follow the following steps:

Upper guide

link

Woodsuppor t

Lower guide

Figure 18

- 39 -

crosshead


9.7.1Thoroughly clean all dirt or contaminations and remove all burs or rough edges from OD, pinhole of the crosshead and guide inner bore etc. Wipe and dry crosshead pinhole so that the connection with the pin taper bore is made up as ‘metal to metal’ one. See following note. 9.7.2 Position the small end of the link at the side hole of the crosshead guides. Support the link with a piece of wood so that the crosshead pin can pass through the bore of link small end while sliding the crosshead into the pinhole at the aligned positions. See Figure 18. 9.7.3 Install the left side crosshead first and then rotate the crankshaft assembly to make the middle link hole into the middle crosshead; at this time the right link hole backs, remove the splash guard disk (see item1, Figure 19); push the right crosshead to the middle extension rod chamber so that enough clearances are provided for installation of middle crosshead, and then install the right crosshead. Note: If an old guide is to be reused, check the wearing surface for wear and scoring etc. The crosshead might be installed to opposite side of the pump if necessary i.e. the left and right crosshead could be exchange- installed into the bores. However, don’t install the pin into the taper hole until the crosshead pin baffle (2) is mounted. 9.7.4 Install crosshead pin baffle (2) and bolts (3), (4); align the taper hole of crosshead with the link small end hole, and push the pin by hand or knock the big end of the pin lightly by a hammer to install the pin into the taper bore. Put the adjusting shims between crosshead pins and baffle (note: as to a set of pin and its hole, the thickness of shims needed are determined and not exchangeable with other shims, otherwise, failures may occur); rotate crosshead pin until the 8 boltholes on the pin baffle align with the holes below and install 6 bolts (4) and 2 bolts (3) separately and tighten them by hand (refer to Figure 19 and 19A). The oil catcher of crosshead pin baffle should be upwards.

- 40 -


5

4

2

1

A

3 5 4 2

A 7

A

6

3

Figure 19

Figure 19A

Tighten all bolts evenly to torque: 165～175ft.lbs（225～240N.m）and lock them with steel wire. Use torque wrench and don’t exceed the torque specified above. Note: Steps used for pulling out the crosshead pin: Remove 6 bolts (4) and rotating two of them into the “jack screw” holes (5); tighten the two bolts until the pins become loose. Remove crosshead baffle (2) and bolts (3), and then take out the pins from the holes. 9.7.5Insert long feeler gauges in between crosshead top surface and upper guide (8) to check running clearance that should not be less than 0.02” (0.508mm). Check with the long feeler gauges over entire surface of crosshead. Note: Over- tightening the bolts (4) of crosshead pin baffle will cause deformations of crosshead outer contact arc-face and thus increase eccentrically-worn; at this time, the bolts (4) of the crosshead pin baffle must be loosen and retighten them according to the requirements in 9.7.4 above-mentioned.

9.8 Check crosshead alignment In order to let the piston move correctly in the liner, the crosshead must travel horizontally along the centerline of the frame hole. To check and align the crosshead as follows: 9.8.1 Remove the diaphragm stuffing box from the splashguard disk but don’t remove the disk, (See Figure 19). 9.8.2 Position the crosshead at the extreme front of i ts stroke. Carefully measure the distance from

- 41 -


the extension rod to the splashguard disk hole at the top and bottom with inside calipers or telescoping gauges; compare these two measurements to determine the position of the extension rod relative to the centerline of the bore. Rotate pump to extreme rear of stroke and take measurements again at the same place as

9.8.3

9.8.2; compare these measurements with those taken at the front of the stroke to determine if the crosshead is running horizontally. If radial clearance difference of the extension rod under the splashguard disk hole exceeds

9.8.4

0.015” (0.381mm), shims should be inserted under the lower guide to make the extension rod move just towards the aligned center. In the meantime, enough clearance between the upper and lower guides should be ensured; in general, the lower guide is loaded heavily and a bigger force is exerted at the back part since the angle of link, thus the lower guide is fast worn; therefore, it is permissible to shim the guides a bit skewed to take up the wear.. During shimming, the clearance between the upper guide and crosshead upper surface must not be less that 0.020” (0.5mm). Larger clearances are acceptable since the characteristics of triplex pump operation and the crosshead pressure is always exerted on the lower guide when clockwiserotating. Note:

When the pump must be driven anti-clockwise the crosshead pressure is exerted on the

upper guide, therefore, the guide clearance must be controlled between 0.01 ″～0.016″（0.25～ 0.40mm）. 9.8.5 Cut shims being long enough to make them completely pass through the guide; and cut tabs on the shim side and exceeding over the frame supports (refer to installation of crosshead guide, 9.6.3 and 9.6.4).

9.9

Maintenance of fluid end

With the increase of pressure used for drilling equipment, the damage to the fluid end often occurs. However, good maintenances for all parts and components of the fluid end will make them have a longer and more proper service life. The points requiring attention are as follows: 9.9.1

Before starting the pump, make sure all valves installed on the high-pressure discharge

- 42 -


manifold must be open. While the valve are closed, the pump starting will exert an impact stress to the pump and may cause fatigue cracks; and finally the pump head would be damaged by fatigue failure if the situation continued. 9.9.2

Don’t engage the clutch when the prime mover (diesel engine, electrical motor and their

drives) is running at a high speed, otherwise, it will cause some additional and undesirable shock loads against both power and fluid ends. 9.9.3

Properly maintain high-pressure relief valves and reset pressure according to the

cylinder liner installed to ensure that the working pressure is not exceeded. 9.9.4

Don’t operate the pump for a long time if a severe fluid knock is present.

Properly maintain the fluid ends for storage. When a pump will not be used for 10 days more, it is suggested to remove the pistons. piston rods, liner etc and flush thoroughly the fluid end with clean water and then wiping them clean after flushing; grease all parts removed and all machined surfaces. This will not only extend the life of the fluid end parts but also protects them in good condition to be installed when the pump will be operated again. The fluid end assembly for triplex pumps consists of 3 forged fluid cylinder blocks, liner, valve pot cover and cylinder head cover, suction and discharge manifold etc. a.

Cylinder blocks

The structure of the cylinder blocks is shown in Figure 20, Dimensions in Table 5. The 3 independent blocks (3) are connected to the frame of power end through stud-bolts (5); and guided by wear plate outer boss (shoulder or flange) on the cylinder block and aligned by fitting with the power end frame bores. Upon installation, all burs, dirt and dents etc should be removed from wear-resistance disk outer boss on the cylinder block and all frame inner holes’ mating faces, otherwise there will be warping. TableⅤ Position

Dimension

Position

8.250″～8.255″ A

Dimension 1.120″～1.130 ″

H 209.55mm ～209.68mm

28.45mm～28.70mm

7.125″～7.130 ″

5.870″～5.880 ″

B

J 180.97mm ～181.10mm

149.10mm ～149.35mm

- 43 -

USER MANUAL OF HHF-1300/1600 MUD PUMP 8.252″～8.255″

6.247″～6.252 ″

C

K 209.60mm ～209.68mm

158.67mm ～158.80mm

14.499 ″～14.501 ″

6.630″～6.635″

D

L 368.27mm ～368.32mm

168.40mm ～168.53mm

1/4″×45°

7.375″～7.380 ″

E

M 6.35mm×45°

187.32mm ～187.45mm

2.995″～3″

0.495″～0.505″

F

N 76.07mm～76.20mm

12.57mm～12.83mm

0.625″～0.630 ″ G

P

1:6

15.87mm～16.00mm

M

10 11

N

9

L K

8

P J D C

B

G

K

E F

A

7

H P

6 3 4

5 2 1 Figure 20 b.

Suction manifold The suction manifold (1) is connected with each cylinder blocks by bolts and sealed by O-ring

(2) in the connection faces with flange. Before installation, thoroughly clean O-ring grooves and sealing surfaces in the cylinder block, and then insert O-ring; to ensure good sealing, the flange - 44 -


connection must be made up ‘metal to metal’ to retain the O-ring seal, therefore, any nicks, grooves or galling on the sealing surface must be repaired. Refer to the following section 9.10: Welding and Repair, of this Manual for detailed repairing steps. Before tightening the bolts of suction manifold (4), the four bolts (4) on the three cylinder blocks must be well started in but not tightened, finally tighten them to torques indicated in Table VI with torque wrench (see description below). C.

Discharge manifold

The discharge manifold (8) is fixed on each cylinder block with stud bolts (10) and nuts (11) and sealed by O- rings. Before installation, thoroughly clean O-ring grooves in the cylinder block and sealing surfaces on the discharge manifold; and the connection must be made up ‘metal to metal’ to retain the O-ring seal, therefore, any nicks, grooves or galling on the sealing surface must be repaired. Refer to the following section 9.10: Welding and Repair, of this Manual for details. Before tightening the bolts of discharge manifold (11), the four bolts (11) on the three cylinder blocks must be well started in but not tightened, finally tighten them to torques indicated in Table VI with torque wrench (see description below). D.

Cylinder head flange (cylinder thread ring)

There are threads in cylinder head flange bore to facilitate removing of cylinder head (head); the flange should be replaced if damaged. Before installation, thoroughly clean all burs, cutting edges or foreign objects on the mating faces and install the flange “leakage groove” downwards. To ensure its end-face is perpendicular to the axial-line of the cylinder block, a ‘metal to metal’ connection on the matching faces between cylinder head flange and cylinder must be made up. All nuts (11) must be tightened to the torque as shown in Table VI: Table Ⅵ Position

Item no. in figure.

Torque ft.lbs

Torque N.m

With frame

5

1600

2170

Suction manifold

4

240

325

Discharge manifold

10、11

1000

1355

Cylinder head flange

7

1600

2170

- 45 -


9.10 Welding and repairs When repairing bores, for normal wear or being badly washed in the fluid end, the following welding procedures must be strictly followed and all dimensions of the bores patched up be machined to size specified in the Table V.

In all cases, the bores’ shoulders (for installing

cylinder liner, cylinder head etc.) must be 90°to the axes line of the bores. 9.10.1 Welding procedures Distinction should be made between welding the pricks and cracks; the following are some basic information for welding: a.

Procedure --Welding as per the way used for 30 # carbon steel --Before welding, clean area to be welded by grinding or carbon-arc-air-gouging, be sure the electrodes are dry and free of moisture, and if necessary, put them in an oven to dry before welding. -- Spot-heat the welding area, at least for a surrounding 3” (75mm) area, to 250 °F～ 350 °F（120°C～180°C）. --Use low-hydrogen rod: AWS-ASTM E-60-7018, such as ADAM-Arc7018 --Temperature should be dropped down to 250°F～ 350°F（120°C～180°C）after one welding seam was completed and then start welding the second. After all patches were completed, heat to

250 ° F ～ 350 ° F （ 120 ° C ～ 180 ° C ） again and then start

‘thermal-insulation-cooling’. b.

Cracks: -- Grind out all cracks. It is not recommended that to remove cracks by torch cutting since it will cause the cracks to enlarged. --Preheating: the purpose of preheating is to expand the area to be heated so that when

cooling, the welded area and the preheated area will cool more uniformly, thus to avoid ‘thermal cracking’ and prevent the ‘hard spots’ forming between the base metal and the ‘welding metal’; These hard spots are just the places the fatigue cracks will start. The welding procedures for cracks are the same as above-mentioned.

- 46 -


9.11 Repair to valve pot cover bore When repairing the valve pot bore damaged by washouts keep the valve pot cover seat completely level and 90°to the axis of the threads are most important while turning or boring the valve pot bores. As shown in the Figure 21, the valve pot seal ring (1) seats into the counter-bore at the top of valve pot and forms ‘metal to metal’ contacts; the seal ring was sealed in the lower point machined by turning or boring, otherwise, a gap will be formed between the end faces of valve pot bench and valve pot bore, through which the seal ring will be extruded and damaged under pressure. Any high or low spots could also cause the valve pot to become ‘warped’ and result in severely damaging the threads. .

Metal-to metal connection

Figure 21

9.12 Replacement of the bladder ( air-bag) of dampener While replacing the dampener, the following procedures must be followed: (see KB-75 air dampener assembly): 9.12.1 Make sure the pressure in the system is completely released. (See the above-mentioned) 9.12.2

Remove the cover (5), which can be jacked out by using two removing threaded holes; if

the stud-bolt was rotated out from the shell while removing, first remove the nut (R2), and then clean the bolts and holes, rotate again the stud-bolts into the holes with the stud-bolt spanner or putting two nuts together tightly with a spanner and finally tighten them to torque: 670 ft..lbs（910 N·m）

- 47 -


9.12.3 Remove the dampener: insert a stick in between the shell and bladder and fold the bladder and take it out from the top. 9.12.4 Check the condition of the bladder, good or damaged; if damaged inspect any swell or foreign objects in the damage-related place and the shell inside; and eliminate all factors caused the damage. 9.12.5 Check the condition of the bottom plug and its all edges must be smooth. It must be replaced if damaged by wears, and have a interference of 0.003" ～0.006"（0.076～0.152 mm）. 9.12.6 Install new bladder Roll and coil the bladder as a spiral-shaped until it can be installed from the upper opening and then stretch and adjust the bladder to make it fit closely with the shell, finally push the sealing ring at the dampener neck to the shell opening and coat the inner side of dampener neck with greases. 9.12.7 Install the cover (5) and be sure not extrude or deform the bladder. 9.12.8 Tighten the nut (R2) to torque: 1200～1600 ft.lbs (1625～2165N.m). 9.12.9 Charge the bladder as required and specified by section of accessory manifold 7.9.

10 Daily maintenances of Pump To maintain the pump properly is a necessary measure to ensure the pump is working correctly and extend its service life. Importance should be attached to this key task during operation. 10.1 Daily maintenances 10.1.1 Shut down the pump and check oil level at power end. Check once each day; if the pump is driven by chain transmission the oil level in chain reservoir should also be checked. During operation, the lube-oil pressure changes in the system shown on the oil pressure gauge should be checked. 10.1.2 Observe working status of the cylinder liner and piston; if a little bit mud-leakage is found it is normal, but if mud leaked is excessive the piston needs to be replaced and the cylinder liner wear should also be carefully checked. If excessive wear is found replace the liner. 10.1.3 Check the liner cavity of the frame and wash out the accumulated mud 10.1.4 Check the cooling water quantity in the spray pump water tank. Replenish and replace the contaminated cooling water if necessary

- 48 -


10.1.5 Check the charging pressure of discharge dampener up to the requirement specified. 10.1.6 Periodically test reset safety valve. 10.1.7 Loosen the piston rod clamp everyday and rotate piston about 1/4 turn. and tighten the clamp again. The purpose of this is to move the wear on the piston around and extend the service life of piston and cylinder liner. 10.1.8 Before tightening cylinder head and valve pot cover, first coat the threads with grease, and then check the tightness of the bolts once within 4 hours. 10.1.9 Observe often the seals of valve pot cover, cylinder liner and leakage hole of cylinder liner seal, replace the seal rings in time and accordingly if mad-leakage was found and flowed out.

10.2 Maintenances every week 10.2.1 Remove the valve pot cover, cylinder head once a week, clean them thoroughly, coat with molybdenum disulfide-complex calcium grease, Check the inner sleeve of valve rod guide, if worn out obviously ( the clearance between inner sleeve and valve rod guide ＞ o.11” (3mm), replace immediately. 10.2.2 Check the valves and valve seats and replace those worn. ( Note: when replacing a valve seat, the valve should also be replaced.) 10.2.3 Check the piston locking nuts and replace if washed or damaged. (After the nuts have been tightened three times they should be replaces as the plastic locking insert is worn out. 10.2.4 Drain water from the clean out cover plugs until the oil comes out.

10.3 Maintenances every month 10.3.1 Check all stud-bolts and nuts of fluid end, such as, cylinder head flange (cylinder thread ring) nuts, connecting nuts between cylinder block and frame, bolts and nuts installed for suction and discharge manifolds etc. Retighten them to the torque as specified if any loosening was found. 10.3.2 Check the seal rings in the extension rod diaphragm stuffing box, and replace those worn out. In general, the seal rings should be replaced every three months and while replacing, pay attention to the installing direction as shown in Figure 22)

- 49 -

USER MANUAL OF HHF-1300/1600 MUD PUMP Single oip oil seal

crosshead

Double lip oil seal

Extension rod

Figure 22 Oil seals assembly 10.3.3 Remove and clean the filter element installed in the discharge filter. 10.3.4 Replace the contaminated oils in power end reservoir and crosshead settling chamber (deposit chamber) every 6 months and at the same time, clean all oil grooves and lines.

10.4 Maintenances every year 10.4.1 Check the tightness of the crosshead guide and running clearance up to the requirements or not, if not it could be adjusted by adding shims under the guide. If the crankshaft assembly is removed for any reason it is recommended to rotate the crossheads 180 °for use again. 10.4.2 It is recommended to inspect the pump fully every two or three years; check the wear and damage status of the main bearings, eccentric bearings, crosshead and pinion bearings. Replace with new if excessive wear on the old parts. 10.4.3 Check all gears’ wear, if severely worn out in one face, the crankshaft and pinion shaft may be turned to use the gear’s other unworn face.

10.5 Other points for attention in maintenance 10.5.1 Wipe the 25°taper face clean before installing the piston and extension rod clamps. 10.5.2 While replacing the cylinder liner the liner seal rings must be replaced together. 10.5.3 The pump was shut down or temporarily be shut down for more than 10 d ays. 10.5.4 Close all inspection covers well to prevent the oil from being contaminated by sand or dirt. 10.5.5 The pulsation dampener will be charged only with compressed nitrogen or other inert gases. - 50 -


Do not charge with oxygen or hydrogen or other easily-burnt and explosive gases.

11 Possible failures and how to eliminate them 11.1 Failures of fluid end Failures

Caused by 1.Suction

manifold

Methods to eliminate is

not

1. Gauge pressure dropped and

sealed tightly and air entered

output reduced.

into pump.

discharges

Tighten all suction flange bolts or replace gaskets.

2.

2 .Suction filter screen clogged. 2.Fluid

1.

Stop pump and clean the filter screen.

are

non-uniform and pulsations are

1.Replace damaged piston: open valve 1.One piston or one valve

subject to sudden change, gauge

pot cover and check valves. severely worn or damaged.

pressures vary greatly, a wheezy

2. Check suction manifold’s and valve pot 2.Air entered into cylinder.

sound can be heard in suction

cover’s tightness.

manifold. 1.Loose piston nut

1.Tighten piston nuts.

2.Loose cylinder head gland.

2.Tighten cylinder head gland.

3.Poor suction.

3.Check reasons for poor suction.

1.Loose valve pot cover and

1.Tighten valve pot cover and cylinder

ot cover or cylinder head and

cylinder head.

head.

iner sealing places.

2.Seal rings damaged.

2.Replace damaged seal rings.

3. Severe knock could be heard in liner.

. Leak at indicator hole of valve

1.Discharge

connection 1. Remove dirt in connection.

5.Discharge dampener cannot be

blocked. 2.Replace damaged airbag.

charged or leaks down soon after

2.Dampener’s airbag broken. 3.Repair or replace the damaged needle

charging

3.Needle valve was not tightly stop valve. sealed.

6. Motor is heavily-loaded

1.Discharge filter clogged

- 51 -

Remove filter screen, and clean.


11.2 Failures of power end Failures 1 Bearings overheating.

Caused by

Methods to eliminate

1

Oil pipe or holes clogged

1

Clean oil pipe and holes.

2

Lube oil is too dirty.

2

Replace old with new oil.

3

Roller bearings are worn

3

Dismount bearings and find out

out or damaged.

reasons, replace damaged bearings.

2 Some knocks could be heard in power end.

12

1

Crosshead guide worn-out.

1 Adjust clearance or replace guide .

2

Worn bearing.

2 Replace bearing.

3

Loose crosshead guide.

3 Tighten guide screws.

4

Air hammer in fluid end.

4 Improve suction performance.

Long term storage.

12.1 If a mud-pump will not be used for a long period, it should be mothballed. 12.2 Before mothballing, all fluids in the fluid end should be drained out, remove all dirt, wash with water and wipe clean. Coat all machined surfaces of all parts and components in the fluid end with grease. 12.3 Drain out all lube- oils in power end oil reservoir, crosshead guide at two sides, oil-settling chamber and remove all accumulated dirt. 12.4 Coat all machined surfaces on all bearings, crosshead, gears, piston rod, extension rod etc with heavy oil. 12.5 Block all suction and discharge flanges with blind plates. 12.6 Seal all crosshead hole end cover, back cover, inspection-opening cover etc tightly.

13 Special Tools List For HHF

1300 / 1600 Mud Pump, delivered together with

the pump

No.

DWG NO.

Name

- 52 -

Qty


HHF-1300/1600 GH3161-26.00

Special tools

1

1

GH3161-26.01.00

Crowbar, cylinder head

1

2

GH3161-26.02.00

Hoisting tool for liner

1

3

GH3161-26.03

Socket wrench

2 3/8 ″

1

4

GH3161-26.04

Socket wrench

2″

1

5

GH3161-26.05

Socket wrench

3 5/8 ″

1

5

GH3161-26.06

Socket wrench

1 1/2 ″

1

7

GH3161-26.07

Socket wrench

1 5/8 ″

1

8

GH3161-26.08

Extension rod

19 5/8 ″

1

9

GH3161-26.09

Extension rod, 8″

1

10

GH3161-26.10

Joint, 1″

1

11

GH3161-26.11

Extension rod , 24″

1

12

JB/T7334-94

Chain block, SH1/2

1

13

SYB-2

Manual oil pump, 0 ～63 MPa（0～9150psi ）

1

14

GH3161-26.12.00

Hydraulic valve-puller

1

15

GH3161-26.13

Intermediate taper sleeve

1

16

GH3161-26.14

Pressing sleeve

1

17

GH3161-26.15.00

Socket wrench, long

1

18

GH3161-26.16

Bolt, 1-8UNC-2A×160

1

Allen wrench, 5/8″

1

19 20

GH3161-26.17.00

Flashboard puller

1

21

GH3161-26.18

Socket wrench, 1 11/16 ″

1

22

GH3161-27.11.00

Charging hose assembly, dampener

1

14 Spare Parts List For HHF

1300 / 1600 Mud Pump, delivered together with the pump

DWG CODE No.

Name HHF-1300/1600

- 53 -

Qty

USER MANUAL OF HHF-1300/1600 MUD PUMP GH3161-29.00

Spare parts with mud pump

1

GH3161-03.11

Oil seal, 9.125″×10.375 ″×0.625″

2

2

GH3161-04.06

Oil seal ring

3

3

GH3161-04.07

Double lip oil seal, 5″×6.25″×0.625″

6

4

GH3161-05.08

Seal ring, cylinder head

3

5

GH3161-05.11.03

Rubber, valve

6

6

GH3161-05.12

Seal ring, valve pot cover

3

7

GH3161-05.14

Seal ring, liner

6

8

GH3161-05.24.04.02.00

Rubber, 6 1/2 ″

3

9

GH3161-05.31

Seal ring, piston

3

10

GH3161-05.33.01

Rubber cell（suction dampener ）

1

11

GH3161-09

Seal washer

2

12

GH3161-22.04 （A）

Seal ring, R35 (steel)

2

13

GH3161-22.06.12


2

14

GH3161-23


3

15

GH3161-27.01


1

16

GH3161-27.03.00

Air cell (bladder), discharge dampener

1

17

GH3161-28.03.00

Piston assembly, relief valve

1

18

GH3161-28.06

Bumper pad

1

19

GH3161-28.11

Shear pin

10

20

GB/T3452.1-1992

O ring, 190×3.55G

3

21

GB/T3452.1-1992

O ring,95×5.3G

3

22

GB/T3452.1-1992

O ring,125×7.0G

3

23

GB/T3452.1-1992

O ring,160×7.0G

3

24

GB/T3452.1-1992

O ring,165×7.0G

1

25

GB/T3452.1-1992

O ring,190×7.0G

3

26

GB/T3452.1-1992

O ring,200×7.0G

3

27

GB/T3452.1-1992

O ring,345×7.0G

3

- 54 -


Note: 1）When with the five-way discharge assembly, then make use of the Seal ring R35( NO.12), with discharging elbow assembly, use the Seal ring R27 (NO.13). 2） When the HP relief valve is in other structures, the part No.17, 18, and 19 are not necessary.

15 Recommended Spare Parts List

HHF-1300/1600 Mud Pump No.

Dwg. Code

Name

Qty

1

GH3161-03.11

Oil seal 9.125″×10.375 ″×0.625″

2

2

GH3161-04.06

Oil-seal ring

3

3

GH3161-04.07

Double lip seal ring, 5 ″×6.25″×0.625″

6

4

GH3161-04.12

Intermediate extension rod

3

5

GH3161-05.04.00

Flashboard assembly

3

6

GH3161-05.08

Seal ring， cylinder head

6

7

GH3161-05.10

Spring, valve

6

8

GH3161-05.11.00

Valve assembly, API 7 #

24

9

GH3161-05.11.03

Rubber, valve

24

10

GH3161-05.12

Seal ring, valve pot cover

6

11

GH3161-05.14

Seal ring， Liner

12

12

GH3161-05.15

Abrasion proof disc (wear plate)

3

13

GH3161-05.18

Piston rod

3

14

GH3161-05.21

Bi-metal liner 5 1/2 ″

3

15

GH3161-05.21

Bi-metal liner 6″

3

16

GH3161-05.21


3

17

GH3161-05.21


3

18

GH3161-05.21


3

19

GH3161-05.21A

Liner, 7″

3

20

GH3161-05.24.01.00

Piston 5 1/2″

3

- 55 -


GH3161-05.24.01.02.00

Rubber

6

22

GH3161-05.24.02.00

Piston 6″

3

23

GH3161-05.24.02.02.00

Rubber

6

24

GH3161-05.24.03.00

Piston 6 1/4″

3

25

GH3161-05.24.03.02.00

Rubber

6

26

GH3161-05.24.04.00

Piston 6 1/2″

3

27

GH3161-05.24.04.02.00

Rubber

6

28

GH3161-05.24.05.00

Piston 6 3/4″

3

29

GH3161-05.24.05.02.00

Rubber

3

30

GH3161-05.24.06.00

Piston 7″

3

31

GH3161-05.24.06.02.00

Rubber

3

32

GH3161-05.31

Seal ring, Piston

6

33

GH3161-05.32.00

Piston Nut,

3

34

GH3161-05.33.01

Rubber cell（suction dampener ）

1

35

GH3161-27.03.00

Rubber cell（discharge dampener ）

1

36

GH3161-28.03.00

Piston assembly（relief valve）

5

37

GH3161-28.06

Bumper pad （relief valve）

5

38

GH3161-28.11

Shear pin

39

GB/T3452.1-1992

O ring 190×3.55G

6

40

GB/T3452.1-1992

O ring

95×5.3G

6

41

GB/T3452.1-1992

O ring

125×7.0G

6

42

GB/T3452.1-1992

O ring

160×7.0G

6

43

GB/T3452.1-1992

O ring

165×7.0G

2

44

GB/T3452.1-1992

O ring

190×7.0G

6

45

GB/T3452.1-1992

O ring

200×7.0G

6

46

GB/T3452.1-1992

O ring

345×7.0G

6

10

Note: 1） When HHF-1300/1600 mud- pump leaves factory, it is equipped with three(3) set of 6 1/2″ liner and piston. - 56 -

Operating Book for Mud Pump 2

Recommend Documents