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Manual Operación Bomba de Lodos FD-1600
Manual Operación Bomba de Lodos FD-1600
FINAL DOCUMENTATION
User Manual
Customer
NOV Galena Park
National Oilwell Varco
Rig/Hull
Ideal Rig 135 10000 Richmond Ave.
Project Manager
- Houston, Texas 77042
Sales Order Number
USA
113387
Serial Number Phone: (713) 346-7500
-
Project Number
FAX: (713) 435-2195
TX8912
Document Number Rev
D2G1007002-FDD-001 01
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Document number D2G1007002-FDD-001
Revision 01
Page ii
REVISION HISTORY
CHANGE DESCRIPTION
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Final Documentation Package S.O. Number: 113387
NOV Galena Park - Ideal Rig 135 Page: iii
Table of Contents
This manual may consist of several volumes, chapters and sections and is housed in a number of
different binders as necessary to adequately document the equipment presented.
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FINAL DOCUMENTATION
FD-1600 Mud Pump
Chapter 1.0
FD-1600 Mud Pump
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FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.1
Product Datasheet
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Product Datasheet
FD-1600
Triplex Mud Pump
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Document number FD-1600-DAS-001
Revision 01
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REVISION HISTORY
CHANGE DESCRIPTION
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Document number FD-1600-DAS-001
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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 11⁄16‘’ (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)
M 3’ 2 9⁄16‘’ (979)
N 3’ 6 ⅜’’ (1,076)
P 3’ 11 ½’’ (1,207)
R 3’ ¼’’ (921)
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General Specifications
Type 3 - cylinder Single-Action Piston
Pressure with 7’’ Liner, psi (kg/cm2) 3,423 (240)
Pressure with 5 ½’’ Liner, psi (kg/cm2) 5,000 (352)
Volume with 7’’ Liner @ 120 SPM, gpm (Liters/min) 719 (2,721)
Volume with 5 ½’’ Liner @ 120 SPM, gpm (Liters/min) 444 (1,680)
Nominal HP rating @ 120 SPM, HP (KW) 1600 (1,193)
Type Gear Double Helical
Gear Ratio 4.31:1
Lubrication Pressure and splash to all moving parts
Valve Pots Valve-over-valve, API # 7
Valve Pot Cover Screw Type
Cylinder Head Screw Type
Liner Lock Metal-to-Metal
Crossheard Guide Replaceable
Bearings
Main Shaft Bearings Spherical
Eccentric Bearings Straight Roller
Crosshead bearings Roller, double row,
Pinion Bearings Straight roller
Dimensions and Weight
Size, Bore and Stroke, in (mm) 7” x 12” (178 x 304.8)
Pinion Shaft Size and Keyway, in (mm) 8.5’’ (216) O.D.- 2’’ x 1’’ (51 x 25) keyway
Discharge outlet, in – psi (mm – kg/cm2) 5’’ (127 mm) – 5000 psi (352 kg/cm2) API Flange
Suction inlet, in (mm) 12’’ (305) Flange, Female pipe thread
Approx. Weight, Less fluid end accessories, lbs (kg) 52,478 (23,804)
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FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.2
Operation Manual
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Operation Manual
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Document number EPL- 1911
Revision 01
Page 2
REVISION HISTORY
CHANGE DESCRIPTION
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Document number EPL- 1911
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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 and maintenance information on equipment other than National Oilwell Varco’s
is taken in part from the various manufacturers’ manuals. If the equipment manufacturers issue
later instructions, or in the event of conflict, the manufacturer’s information will take precedence
over that shown in this manual, unless specifically stated otherwise.
Refer to the General Lubrication Bulletin for approved lubricants. If any discrepancy exists
between the recommendations in this manual and the General Lubrication Bulletin, those in the
Lubrication Bulletin will take precedence.
The manual sections follow logical divisions in major components, and cover all standard
production unless otherwise specified. Specifications and components covered are for standard
equipment current at the time this manual was approved for printing.
National Oilwell Varco reserves the right to discontinue models at any time, or change
specifications or design of any model without notice and without incurring any obligation.
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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
8.2 Piston Rod ............................................................................................................ 28
8.3 Piston Rod Clamps ............................................................................................... 29
8.4 Lower Valve Guide and Cylinder Head................................................................. 29
8.5 Discharge Valve Pot Covers ................................................................................. 29
8.6 Discharge Manifold all models .............................................................................. 30
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General Dimensions
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Specifications
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Your National Oilwell Varco pump has been completely assembled and test operated under
pressure before being shipped to the field. Unless otherwise instructed, the lubrication is
drained from the power end and the expendable parts are removed from the fluid end.
Before putting the pump into service, the following precautions and operations must be
performed or checked.
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.
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.
The charging pump can also be belt driven from the triplex pinion shaft charging type of
drive is not as efficient at slow speeds with viscous fluids.
Under some conditions the FD-Series pumps may be operated without a charging pump,
provided the fluid level in mud pits is higher than the top of the liners, fluid being pumped is
low viscosity and suction line must be short, straight and of at least the same diameter as
suction manifold inlet.
The suction lines should be piped with valve arrangements so the charging pump can be
by-passed so operation can be continued in event of charging pump failure or for
maintenance. Operation without a charging pump can be improved by replacing the
suction valve springs with a weaker spring.
Suction desurgers are a very effective aid for complete filling of the liners and dampening
pulsations in the suction line which results in a smoother flow in the discharge line. If your
pump is equipped with a suction desurger it must be pre-charged with compressed air
before operations are begun. See suction desurger manual for charging instructions.
3.1 Caution
Do not pipe the return line from the shear relief valve back into the suction system as a
relief valve operation will cause a sudden pressure rise in the system vastly greater than
the system pressure ratings, resulting in damage to manifold, suction desurger and
centrifugal pump.
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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
installation of the packing assembly.
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Two types of piston and liner cooling systems have been used on National Oilwell Varco
FD-Series Pumps -- the stationary spray type and a moving nozzle type. Ref. Fig. 6. The
manifold (1) for supplying cooling fluid to the piston and liner assemblies is identical on both
systems. Cooling fluid from either a remote source such as a water line, or from a pump
and reservoir system unitized on the pump skids (Ref. Fig. 7) must be piped into the
manifold at the connection located in the pump frame under the crosshead extension rod
section.
CAUTION: The supply line from a remote system should be equipped with a
strainer to prevent stoppage of the spray nozzles. Water should be
cool and free of abrasive solids. Clean strainer screen or trap once
each day, or as required.
The stationary spray cooling system consists of a spray nozzle (2) mounted on a liner
end cover plate (3), which applies cooling fluid in the form of a spray to the piston and
liner area. Adjust cooling water supply to the manifold so that a spray approximately
*12” long is being discharged from each spray nozzle. Inspect spray nozzle operation
VERY OFTEN, making sure the nozzle is pointed directly at the piston.
*(304.8mm)
The moving nozzle system consists of a spray tube (4) mounted on the extension rod
clamp (5), which applies cooling fluid directly to the back face of the piston. The end of
the spray tube is positioned approximately 1” from the back face of the piston, which
causes the cooling fluid to be deflected so that it constantly floods the piston liner area
throughout the full stroke length.
Inspect spray tube very often to assure that ample cooling fluid is being supplied. At
routine intervals, check condition of the hose (6) which connects the spray tube to the
manifold. This hose travels back and forth with the piston rod assembly, therefore must
be installed so that its movement is not restricted.
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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, the solids are allowed to settle out. The filter screen will catch much of the foreign
material floating in the fluid.
Check condition of the cooling fluid at frequent intervals and CLEAN and FLUSH reservoir
as required. Contaminated fluid will cause premature liner and piston wear from abrasion
or stoppage of the spray nozzle or spray tube.
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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THOROUGHLY CLEAN AND DRY the valve seats and install suction and discharge valve
seats into the valve pot bores. Drive seats firmly into place with a bar and hammer.
Install valves and springs, etc., by following any special instructions that may have been
outlined by the specific valve and seat manufacturer.
Install fluid baffle (11), fig. 9 and 9B on end of crosshead extension rod.
A cross-section through the fluid end is shown in Fig. 9. With reference to Fig.9, clean and
assemble the fluid end parts in the following manner:
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7.1 Liners
Inspect liner bore again to make sure it is clean and free of foreign particles to assure metal
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 oil
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 the crosshead compartment manifold block (4A) located above the
crosshead compartment. The crosshead compartment manifold block (4A) distributes oil to
the crosshead, crosshead bearings, and extension rods. Pumps which do not have the
crosshead compartment manifold block (4A) do not have the total pressure lubrication
system, and therefore have a minimum rated speed of 40 SPM.
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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.
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.
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. (Center
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.
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.
All inner and outer races are assembled by means of very accurate fits. This accuracy is
necessary; therefore, if the bearings are to be used again, the inner and outer races and
the roller assemblies of each bearing must be kept together, and reinstalled exactly as they
came off.
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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 shaft
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
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 oil
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
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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 crankshaft on a set of rollers (at main bearing position) and check runout on face of
gear with a dial indicator. If total indicator runout exceeds .006”, remove gear and
determine cause of misalignment. (.15mm)
NOTE: If runout on face of gear is checked while crankshaft is mounted in the pump
frame, the running clearance in main bearings will require that a simultaneous set of dial
indicator readings be taken at the end of the shaft and the face of the gear; the actual
face runout at any point being the difference between these readings.
b. Install the outer races of the eccentric bearings (13) and the outer race retainer ring (3)
in the three eccentric straps. Outer race retainer ring must be positioned so that oil
scoop is at the bottom when pump is at mid-stroke. Tighten retainer bolts (4) to the
following torque; safety wire heads.
FD-500 60-90 ft. lbs. (8-12 meter kgs) FD-800 90-120 ft. lbs. (12-17 meter kgs.)
FD-1000 90-120 ft. lbs. FD-1600 90-120 ft. lbs.
NOTE: The inner and outer races of the eccentric bearings are matched and must not
be intermixed.
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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 spot
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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3. Install the left hand crosshead first. Rotate eccentric assembly to move “eye” into
center crosshead and right hand eccentric strap “eye” back, affording clearance to
install center pin through right hand crosshead inspection door. Remove diaphragm
stuffing box plate (1, Fig. 19) and install right hand crosshead through this bore. Slide
into place and install crosshead pin.
* NOTE: If old crossheads are to be reused, inspect the sliding surfaces for wear or
scoring. If necessary, the crossheads may be switched to opposite sides of the
pump and rotated 180° to provide a smooth surface for the bottom of the
crosshead. The center crosshead can be rotated 180° and the crosshead pin
installed from the opposite side of pump.
Slide crosshead pin into bore but do not seat on taper until the crosshead pin retainer
(2) has been installed.
4. Install crosshead pin retainer (2) and retainer bolts (3) and rotate pin until the four
crosshead retainer to crosshead bolt holes (4) are in alignment. Install the crosshead
retainer to crosshead bolts (4) and make up hand tight.
Referring back to fig.12, page B-2, crosshead pin (4) can be installed without regard to
oil holes (5). Two holes are provided so the pin can be rotated 180° in relation to pin to
retainer plate screws (3).
Seat crosshead pin in tapered bore by bumping large end with a light blow. Tighten
retainer bolts (3 and 4, Fig. 19) to the following torque and safety wire:
FD-500 90-100 ft. lbs. (12.4-13.8 mkg) FD-800 165-175 ft. lbs. (23-24 mkg)
FD-1000 165-175 ft. lbs. (23-24 mkg) FD-1600 165-175 ft. lbs. (23-24 mkg)
NOTE: To pull the crosshead pin, remove the four crosshead retainer to crosshead
bolts (4) and screw two of the bolts into the “jack screw” holes (5). Tighten the two jack
screw bolts until the pin breaks loose. Complete removal of the crosshead pin retainer
plate (2) and slide pin out of bore.
5. Check running clearance of crosshead by sliding long “feeler” gauges between top of
crosshead and crosshead guide bore.
The clearance should not be less than .020” (.508mm). Check with long feeler gauge
over entire surface of crosshead.
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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. This will not only extend the life of the fluid end through resistance to
corrosion, but will also protect the usable life still left in the expendable parts and
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.
Thoroughly clean the O-ring groove, the O-ring sealing surface on face of the cylinder block
before bolting the manifold back into position. The flange connection MUST make up
metal-to-metal to retain the O-ring seal, therefore any nicks, grooves, or washouts on this
sealing surface must be repaired before installation. Ref. Welding and Repair Section in
this manual for repair procedures.
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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Document number EPL- 1911
Revision 01
Page 54
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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Document number EPL- 1911
Revision 01
Page 55
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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Document number EPL- 1911
Revision 01
Page 56
Chart VI
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Document number EPL- 1911
Revision 01
Page 57
FD-1600
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Document number EPL- 1911
Revision 01
Page 58
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
E ¼” x 45° 6.35 x 45°
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
P 2” Taper per ft. on dia. 50.80 Taper per ft. on dia.
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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Document number EPL- 1911
Revision 01
Page 59
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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Document number EPL- 1911
Revision 01
Page 60
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FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.3
Pressure Relief Valves
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Product Information Bulletin
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Document number MP.WARNING
Revision 02
Page 2
REVISION HISTORY
CHANGE DESCRIPTION
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Document number MP.WARNING
Revision 02
Page 3
PRESSURE
RELIEF
VALVES
! Notice !
Our Technical Publications relative to reciprocating pumps, state that pressure relief valves
must be installed in the discharge systems from these units. This supplement is 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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Document number MP.WARNING
Revision 02
Page 4
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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Document number MP.WARNING
Revision 02
Page 5
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” (13th 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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Document number MP.WARNING
Revision 02
Page 6
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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FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.4
Pre-Shipment &
Storage Preservation
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NO: PS-4030
TECHNICAL REV: 1
HOUSTON, TX SPECIFICATION DATE: 8-15-06
PAGE 1 of 7
SUBJECT: Process
│TITLE: Pre-Shipment and Storage Preservation for New-Build NOV Triplex Mud Pumps
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 or equivalent). Rotate pump ½ turn
and re-spray. Pour quantity of inhibiting oil-based concentrate specified in the table below into
power end sump.
PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION, WHICH BELONGS TO NATIONAL OILWELL VARCO. IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL OILWELL VARCO. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF THIS
DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL OILWELL.
THIS DOCUMENT IS TO BE RETURNED TO NATIONAL OILWELL VARCO UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE OF WHICH IT
WAS LOANED.
UNCONTROLLED COPY
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NO: PS-4030
TECHNICAL REV: 1
HOUSTON, TX SPECIFICATION DATE: 8-15-06
PAGE 2 of 7
SUBJECT: Process
Quantity of
Mud Pump Models
Inhibitor
14P, FC 2200 5 Gallons
12P, 10P, HD or A1700/1400PT, FB/FC/FD 1600, FB 1300 3 Gallons
9P, 8P, B or A850-1100PT, F/FD 1000, F 800 2 Gallons
7P, A600PT, FD 500 1 Gallon
For pumps equipped with chain drives, spray internal machined parts inside chain cases with
inhibiting oil-based concentrate (Cortec VpCI 329 Vapor Corrosion Inhibiting oil based
concentrate or equivalent).
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 rust 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. Reinstall 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 breather hole
with a greased solid plug. Affix a warning label near the breather opening (see Exhibit 1).
Spray all external unpainted machined parts of pump with rust preventative (CRC SP400 or
equivalent).
Cover large diameter pipe and other openings with hardboard and protective plastic wrap. Liner
bushing openings shall also be covered and sealed.
PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION, WHICH BELONGS TO NATIONAL OILWELL VARCO. IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL OILWELL VARCO. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF THIS
DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL OILWELL.
THIS DOCUMENT IS TO BE RETURNED TO NATIONAL OILWELL VARCO UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE OF WHICH IT
WAS LOANED.
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NO: PS-4030
TECHNICAL REV: 1
HOUSTON, TX SPECIFICATION DATE: 8-15-06
PAGE 3 of 7
SUBJECT: Process
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 prevent damage.
Affix one (1) warning label (see Exhibit 2) to the power end pump cover and one (1) warning
label on the fluid end assembly of the pump. Affix warning labels on each loose part container.
In cases where the equipment will be boxed at an offsite export packer, a sufficient number of
warning labels will be supplied with the shipment.
Indoor storage is preferred whenever possible; but if outside storage is required, ensure pump is
stored away from salt water spray, sand blast or other adverse conditions. It is highly
recommended that ship loose parts be stored indoors to eliminate conditions that promote
condensation and direct sources of moisture.
It is also recommended to store pump on blocks and cover entire pump with plastic sheeting.
For storage preparations for main drive motors, National Oilwell Varco recommends that the
original manufacturer’s instructions be followed. If space heaters are supplied, the J-box plastic
wrap must be removed and the heaters should be connected throughout the complete storage
period.
PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION, WHICH BELONGS TO NATIONAL OILWELL VARCO. IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL OILWELL VARCO. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF THIS
DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL OILWELL.
THIS DOCUMENT IS TO BE RETURNED TO NATIONAL OILWELL VARCO UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE OF WHICH IT
WAS LOANED.
UNCONTROLLED COPY
8/15/2006 5:01:52 PM
NO: PS-4030
TECHNICAL REV: 1
HOUSTON, TX SPECIFICATION DATE: 8-15-06
PAGE 4 of 7
SUBJECT: Process
Preservation Procedure When Storage Exceeds Six (6) Months of Initial Preservation.
Note: It is recommended that inspections be carried out on six (6) month cycles when pumps
are in indoors and three (3) month cycles when stored outside.
Remove side crosshead covers and top inspection covers and inspect for any internal corrosion.
Correct any adverse conditions.
Inspect for condition of external protection (rust preventative and paint). Correct any adverse
conditions.
Inspect all ship-loose parts for indications of corrosion or damage and recoat with inhibitor.
Any pump that has been in storage will need a thorough inspection prior to start-up to insure it
has not been damaged in any way and that all parts are properly in place. Failure to observe the
following points can result in serious damage. Before servicing the pump, the power end sump
and chain drives housings will need to be drained of any inhibiting additive. The Cortec brand
products used for preservation are compatible with all lubricating oils and need not be totally
removed when putting equipment into service.
To service the Power End after storage and prior to start-up, remove all covers and thoroughly
PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION, WHICH BELONGS TO NATIONAL OILWELL VARCO. IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL OILWELL VARCO. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF THIS
DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL OILWELL.
THIS DOCUMENT IS TO BE RETURNED TO NATIONAL OILWELL VARCO UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE OF WHICH IT
WAS LOANED.
UNCONTROLLED COPY
8/15/2006 5:01:52 PM
NO: PS-4030
TECHNICAL REV: 1
HOUSTON, TX SPECIFICATION DATE: 8-15-06
PAGE 5 of 7
SUBJECT: Process
clean and inspect all of the parts and finished surfaces. Check all of the bearings to make certain
they are clean and in good condition. Fill the power end with clean EP oil of the proper
viscosity to the proper level. Make sure oil is poured into the oil distribution trough and is
worked into all of the bearings. Replace all covers and install breather.
To service the Fluid End after storage and prior to start-up, remove covers and thoroughly clean
and inspect inside of the fluid end cylinders. Properly install valves, pistons, liners and all other
fluid end parts. Carefully tighten all bolts, nuts, studs and working connections to specified
torque requirements.
Exhibit 1
PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION, WHICH BELONGS TO NATIONAL OILWELL VARCO. IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL OILWELL VARCO. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF THIS
DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL OILWELL.
THIS DOCUMENT IS TO BE RETURNED TO NATIONAL OILWELL VARCO UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE OF WHICH IT
WAS LOANED.
UNCONTROLLED COPY
8/15/2006 5:01:52 PM
NO: PS-4030
TECHNICAL REV: 1
HOUSTON, TX SPECIFICATION DATE: 8-15-06
PAGE 6 of 7
SUBJECT: Process
WARNING
REINSTALL BREATHER BEFORE PUTTING
PUMP INTO SERVICE
NOV PN xxxxxxx
Exhibit 2
PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION, WHICH BELONGS TO NATIONAL OILWELL VARCO. IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL OILWELL VARCO. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF THIS
DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL OILWELL.
THIS DOCUMENT IS TO BE RETURNED TO NATIONAL OILWELL VARCO UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE OF WHICH IT
WAS LOANED.
UNCONTROLLED COPY
8/15/2006 5:01:52 PM
NO: PS-4030
TECHNICAL REV: 1
HOUSTON, TX SPECIFICATION DATE: 8-15-06
PAGE 7 of 7
SUBJECT: Process
WARNING
THIS EQUIPMENT IS PROTECTED FOR
SIX MONTHS FROM EX-WORKS DATE OF:
PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION, WHICH BELONGS TO NATIONAL OILWELL VARCO. IT IS LOANED FOR
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL OILWELL VARCO. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF THIS
DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL OILWELL.
THIS DOCUMENT IS TO BE RETURNED TO NATIONAL OILWELL VARCO UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE OF WHICH IT
WAS LOANED.
UNCONTROLLED COPY
8/15/2006 5:01:52 PM
FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.5
General Lubrication Bulletin
www.nov.com
General Lubrication Bulletin
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
www.nov.com
Document number CE-538E
Revision 06
Page 2
REVISION HISTORY
CHANGE DESCRIPTION
www.nov.com
Document number CE-538E
Revision 06
Page 3
TABLE OF CONTENTS
www.nov.com
Document number CE-538E
Revision 06
Page 4
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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Document number CE-538E
Revision 06
Page 5
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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Document number CE-538E
Revision 06
Page 6
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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Document number CE-538E
Revision 06
Page 7
Drawworks
C-1 Type II 105 U.S. Gal. 400 Liters
C-1 Type III 105 U.S. Gal. 400 Liters
C-2 Type II 110 U.S. Gal. 420 Liters
C-2 Type III 110 U.S. Gal. 420 Liters
C-3 Type I 60 U.S. Gal, 230 Liters
C-3 Type II 60 U.S. Gal. 230 Liters
C-3 Type III 60 U.S. Gal. 230 Liters
D-1 78 U.S. Gal. 296 Liters
D-2 115 U.S. Gal. 436 Liters
D-3 85 U.S. Gal. 332 Liters
EH-II 41 U.S. Gal. 155 Liters
EH-III, IV & V See Operation & Maintenance Manual
Type AU= Catworks 45 U.S. Gal. 170 Liters
W/Right Angle Drive 50 U.S. Gal. 190 Liters
Compounds
CT-5 130 U.S. Gal. 493 Liters
CT-7 130 U.S. Gal. 493 Liters
CT-9 148 U.S. Gal. 560 Liters
D-221 W/Separate Lube System 80 U.S. Gal. 303 Liters
D-232 W/Separate Lube System 80 U.S. Gal. 303 Liters
F-Series Triplex Pump
F-350 40 U.S. Gal. 152 Liters
F-500 65 U.S. Gal. 246 Liters
F-650 55 U.S. Gal. 208 Liters
F-750 55 U.S. Gal. 208 Liters
F-800 65 U.S. Gal. 246 Liters
F-1000 75 U.S. Gal. 284 Liters
F, FA, FB & FC-1300 100 U.S. Gal. 380 Liters
F, FA, FB & FC-1600 100 U.S. Gal. 380 Liters
FC-2200 120 U.S. Gal. 454 Liters
Unitized Pump Drive for
Electric Motor, Per Guard 20 U.S. Gal 76 Liters
Type “F” Unitized Pump Chain Drive
F-350 15 U.S. Gal. 57 Liters
F-500 30 U.S. Gal 15 Liters
F-650 30 U.S. Gal. 115 Liters
F-800 30 U.S. Gal. 115 Liters
F-1000 30 U.S. Gal. 115 Liters
www.nov.com
Document number CE-538E
Revision 06
Page 8
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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FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.6
Commissioning Procedure
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DOCUMENT OR DRAWING NO. PAGE
1 of
ENGINEERING EDN-1688
12
SUBJECT COMMISSIONING PROCEDURE, FB/FD-1600 APPROVED REVISED DATE REV.
SELLER INFORMATION
COMMISSIONING INDEX
SUBJECT PAGE NO.
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
DOCUMENT OR DRAWING NO. PAGE
3 of
ENGINEERING EDN-1688
12
SUBJECT COMMISSIONING PROCEDURE, FB/FD-1600 APPROVED REVISED DATE REV.
The initial startup procedures are written to assist the operator in preparing the pump packages for normal
operation. The startup procedures are separated into two categories: Part I: Pre-Commissioning, and Part
II: Commissioning Procedures. It is suggested that a copy of these pages be made for each pump to be
used as a check-off sheet.
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.
Check to assure that all instrumentation has been properly hooked up. Check the calibration
test sheets for validity and recalibrate if necessary.
Clean liner wash tank, if needed, and fill with fresh clean water.
Ensure that supply hoses and spray nipples are installed correctly.
Start pump and adjust regulating valve to maximum flow without splash onto the extension
rods.
6. Fluid End:
Check to assure that all liners, valves, and pistons are installed properly in accordance with
the installation instructions.
Ensure that the liner end covers are installed on the rear end of the liners.
Ensure that the baffle discs are installed on the end of the crosshead extension rods.
Clean grease and paint from the exposed parts of the extension rods, checking for burrs.
Coat rods with a light oil.
7. Suction Dampener/Desurger
NOTE: When charging the bladder, make sure that the mud pump suction line valve has been
closed and that all pressure has been bled off of the suction manifold surrounding the suction
desurger
If a dampener is used, charge dampener with a hand-operated air pump to 10 PSI (0.7 bar).
Once pump operations have been started, check the operation of the suction dampener by
inspecting the sight glass. Add or release air pressure through the Shraeder valve to keep the
diaphragm between the midpoint and the bottom of the sight glass.
8. Pulsation Dampener:
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.
DOCUMENT OR DRAWING NO. PAGE
6 of
ENGINEERING EDN-1688
12
SUBJECT COMMISSIONING PROCEDURE, FB/FD-1600 APPROVED REVISED DATE REV.
GENERAL:
The power end and the fluid end have gone through rigorous tests prior to being shipped from the
manufacturing site; therefore, the following recommendations for the commissioning test are made
for the purpose of checking the overall unitization functions, including instrumentation, and to
assure that there are no problems which may have occurred during transportation and storage.
Operation of the pump in parallel to check the SCR-Motor assignments and controls, volumetric
displacement and mudline systems are at the option of the purchaser.
A. PRE-COMMISSIONING CHECKS:
Prior to starting the unitized pump package, review the previously outlined Pre-Commissioning
Requirements in Part I.
Check the discharge mudline to assure that all necessary valves are open. Ensure that the mud tanks
are full of test fluid (mud/water) prior to startup.
Make the desired assignment of the SCR-Motor Control System to the pump motors, and open the
throttle slightly. Check to ensure that charge pump and liner wash motors have started.
If no immediate problems are encountered, slowly throttle the pump to approximately 60 SPM and
continue operating the mud pump while making the following inspections to assure that all systems
are working properly:
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.
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.
DOCUMENT OR DRAWING NO. PAGE
8 of
ENGINEERING EDN-1688
12
SUBJECT COMMISSIONING PROCEDURE, FB/FD-1600 APPROVED REVISED DATE REV.
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.
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
START 2 HR 4 HR 6 HR 8 HR
5. LINER/PISTONS (Yes/No):
6. SUPERCHARGING SYSTEM:
START 2 HR 4 HR 6 HR 8 HR
8. OTHER:
Comments:
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
DOCUMENT OR DRAWING NO. PAGE
12 of
ENGINEERING EDN-1688
12
SUBJECT COMMISSIONING PROCEDURE, FB/FD-1600 APPROVED REVISED DATE REV.
COMMISSIONING ACCEPTANCE:
Section 1.7
Safety Wire Procedure
www.nov.com
PROCEDURE
CLIENT PO NUMBER
ASP00019 A
CLIENT DOCUMENT NUMBER
REVISION HISTORY
CHANGE DESCRIPTION
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
Document number ASP00019
Revision A
Page 4
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 only if the primary retention method is
properly in place, 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.
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 27th 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.
Document number ASP00019
Revision A
Page 6
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.
Document number ASP00019
Revision A
Page 7
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.
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).
4 QA PROVISIONS
5 NOTES
FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.8
Design Specification –
Design Torque Standard
www.nov.com
DS00008
Design Specification
Design Torque Standard
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.
9. Stainless socket head cap screws shall be torqued using the same values as the F593 G or H
stainless hex head cap screws.
A DS00008 G
SCALE NONE WT LBS SHEET 2 OF 16
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
GRADE 2 GRADE 5
T.S. = 74,000 PSI to ¾” DIA T.S. = 120,000 PSI to 1” DIA
PROOF STRENGTH = 55,000 PSI PROOF STRENGTH = 85,00 PSI
T.S. = 60,000 PSI 7/8” to 1-1/2” DIA T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA
PROOF STRENGTH = 33,000 PSI PROOF STRENGTH = 74,000 PSI
COARSE THREAD 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 1,320 7.6 8.4 2,020
5/16 – 18 10.5 11.6 2,160 16 18 3,340
3/8 – 16 19 21 3,200 29 32 4,940
7/16 – 14 29 32 4,380 48 53 6,800
1/2 – 13 48 53 5,840 71 79 9,050
9/16 – 12 67 74 7,500 105 116 11,600
5/8 – 11 95 105 9,300 143 158 14,400
3/4 – 10 166 184 13,800 247 273 21,300
7/8 – 9 157 173 11,400 409 452 29,400
1–8 238 263 15,000 608 672 38,600
1 1/8 – 7 333 368 18,900 760 840 42,300
1 1/4 – 7 475 525 24,000 1,064 1,176 53,800 7
1 3/8 – 6 627 639 28,600 1,387 1,533 64,100 7
1 1/2 – 6 827 914 34,800 1,843 2,037 78,000 7
A DS00008 G
SCALE NONE WT LBS SHEET 3 OF 16
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
GRADE 8 HOLO-KROME
TENSILE STRENGTH = 150,000 PSI TENSILE STRENGTH = 170,000 PSI
PROOF STRENGTH = 120,000 PSI PROOF STRENGTH = 136,000 PSI
9.
A DS00008 G
SCALE NONE WT LBS SHEET 4 OF 16
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
STAINLESS ASTM F593G & F593H STAINLESS ASTM F593U
T.S. = 100,000 PSI to 5/8” DIA TENSILE STRENGTH = 135,000 PSI
PROOF STRENGTH = 59,000 PSI PROOF STRENGTH = 95,000 PSI
T.S. = 85,000 PSI 3/4” to 1-1/2” DIA
PROOF STRENGTH = 41,000 PSI
COARSE THREAD 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
A DS00008 G
SCALE NONE WT LBS SHEET 5 OF 16
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
GRADE 2 GRADE 5
T.S. = 74,000 PSI to ¾” DIA T.S. = 120,000 PSI to 1” DIA
PROOF STRENGTH = 55,000 PSI PROOF STRENGTH = 85,00 PSI
T.S. = 60,000 PSI 7/8” to 1-1/2” DIA T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA
PROOF STRENGTH = 33,000 PSI PROOF STRENGTH = 74,000 PSI
COARSE THREAD 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 1,320 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
A DS00008 G
SCALE NONE WT LBS SHEET 6 OF 16
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
GRADE 8 HOLO-KROME
TENSILE STRENGTH = 150,000 PSI TENSILE STRENGTH = 170,000 PSI
PROOF STRENGTH = 120,000 PSI PROOF STRENGTH = 136,000 PSI
9.
A DS00008 G
SCALE NONE WT LBS SHEET 7 OF 16
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
STAINLESS ASTM F593G & F593H STAINLESS ASTM F593U
T.S. = 100,000 PSI to 5/8” DIA TENSILE STRENGTH = 135,000 PSI
PROOF STRENGTH = 59,000 PSI PROOF STRENGTH = 95,000 PSI
T.S. = 85,000 PSI 3/4” to 1-1/2” DIA
PROOF STRENGTH = 41,000 PSI
COARSE THREAD 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
A DS00008 G
SCALE NONE WT LBS SHEET 8 OF 16
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
CLASS 4.6 CLASS 8.8
T.S. = 400 MPa T.S. = 830 MPa
PROOF STRENGTH = 225 MPa PROOF STRENGTH = 600 MPa
T.S. is for all dia. T.S. is for all dia
*Metric socket head screws*
METRIC SERIES
Max. Clamp Min. Max. Clamp
Min. Torque
Diameter - pitch Torque Force Torque Torque Force
(ft-Ibf)
(ft-Ibf) (Ib) (ft-Ibf) (ft-Ibf) (lb)
M3 - .5 .4 .5 183 .9 1.2 489
M3.5 - .6 .6 .73 247 1.5 1.9 659
M4 - .7 .9 1.1 320 2.1 2.9 854
M5 - .8 1.7 2.1 516 4.3 5.8 1,378
M6 - 1 2.9 3.7 732 7.2 9.9 1,954
M8 - 1.25 6.9 8.9 1,331 17 23 3,550
M10 - 1.5 14 17 2,106 33 47 5,617
M12 - 1.75 24 31 3,055 57 81 8,148
M14 - 2 38 48 4,177 91 129 11,141
M16 - 2 57 74 5,664 141 199 15,106
M18 – 2.5 81 104 6,975 195 278 18,600
M20 – 2.5 112 145 8,851 274 388 23,604
M22 – 2.5 151 196 10,940 372 524 29,174
M24 - 3 193 251 12,746 472 671 33,989
M27 – 3 280 365 16,570 690 974 44,186
M30 - 3.5 381 496 20,216 934 1,325 53,911 7
M33 – 3.5 514 670 24,961 1,267 1,787 66,563 7
M36 – 3.5 656 857 29,422 1,627 2,285 78,460 7
M39 - 4 852 1112 35,122 2,102 2,966 93,661 7
M42 - 4.5 1,059 1380 40,363 2,599 3,681 107,634 7
M48 - 5 1,586 2069 53,038 7 3,899 5,518 141,435 7
M56 - 5.5 2,535 3310 73,007 7 6,253 8,828 194,686 7
4.6 8.8
A DS00008 G
SCALE NONE WT LBS SHEET 9 OF 16
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
CLASS 10.9 CLASS 12.9
T.S. = 1040 MPa T.S. = 1220 MPa
PROOF STRENGTH = 830 MPa PROOF STRENGTH = 970 MPa
T.S. is for all dia T.S. is for all dia.
* Metric socket head screws*
Max. Clamp Min. Max. Clamp
Min. Torque
Diameter - pitch Torque Force Torque Torque Force
(ft-Ibf)
(ft-Ibf) (Ib) (ft-Ibf) (ft-Ibf) (lb)
M3 - .5 1.3 1.7 676 1.5 2.0 790
M3.5 - .6 2.1 2.7 911 2.5 3.1 1,065
M4 - .7 3.1 4.0 1,182 3.7 4.7 1,381
M5 - .8 6.2 8.0 1,906 7.3 9.4 2,228
M6 - 1 10.6 13.7 2,703 12 16 3,159
M8 - 1.25 25 33 4,910 29 38 5,739
M10 - 1.5 50 65 7,771 58 76 9,082
M12 - 1.75 87 112 11,271 101 131 13,172
M14 - 2 138 179 15,411 162 210 18,011
M16 - 2 212 275 20,897 247 321 24,422
M18 – 2.5 297 384 25,730 347 449 30,070
M20 – 2.5 414 537 53,911 483 628 38,159
M22 – 2.5 557 726 40,358 651 848 47,165 7
M24 – 3 715 929 47,019 7 836 1,086 54,950 7
M27 – 3 1,034 1,347 61,125 7 1,209 1,574 71,435 7
M30 - 3.5 1,408 1,833 74,577 7 1,646 2,142 87,157 7
M33 – 3.5 1,896 2,473 92,079 7 2,216 2,890 107,611 7
M36 – 4 2,421 3,161 108,536 7 2,829 3,695 126,843 7
M39 – 4 3,145 4,103 129,564 7 3,675 4,795 151,418 7
M42 - 4.5 3,907 5,093 148,894 7 4,566 5,952 174,009 7
M48 - 5 5,853 7,633 195,652 7 6,840 8,921 228,654 7
M56 – 5.5 9,352 12,212 269,316 7 10,930 14,272 314,743 7
10.9
12.9
A DS00008 G
SCALE NONE WT LBS SHEET 10 OF 16
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND
CLASS 4.6 CLASS 8.8
T.S. = 400 MPa T.S. = 830 MPa
PROOF STRENGTH = 225 MPa PROOF STRENGTH = 600 MPa
T.S. is for all dia. T.S. is for all dia
*Metric socket head screws*
METRIC SERIES
Max. Clamp Min. Max. Clamp
Min. Torque
Diameter - pitch Torque Force Torque Torque Force
(ft-Ibf)
(ft-Ibf) (Ib) (ft-Ibf) (ft-Ibf) (lb)
M3 - .5 0.3 0.4 183 0.7 0.9 489
M3.5 - .6 0.5 0.6 247 1.1 1.5 659
M4 - .7 0.7 0.9 320 1.6 2.0 854
M5 - .8 1.3 1.7 516 3.2 4.2 1,378
M6 - 1 2.2 2.8 732 5.4 7.0 1,954
M8 - 1.25 5 7 1,331 13 17 3,550
M10 - 1.5 11 14 2,106 25 32 5,617
M12 - 1.75 18 23 3,055 43 56 8,148
M14 - 2 29 37 4,177 68 89 11,141
M16 - 2 43 56 5,664 106 137 15,106
M18 – 2.5 61 79 6,975 146 190 18,600
M20 – 2.5 84 109 8,851 206 267 23,604
M22 – 2.5 113 147 10,940 279 363 29,174
M24 - 3 145 188 12,746 354 460 33,989
M27 – 3 210 273 16,570 518 673 44,186
M30 - 3.5 286 371 20,216 701 911 53,911 7
M33 – 3.5 386 501 24,961 950 1235 66,563 7
M36 – 3.5 492 640 29,422 1220 1586 78,460 7
M39 - 4 639 831 35,122 1577 2049 93,661 7
M42 - 4.5 794 1033 40,363 1949 2534 107,634 7
M48 - 5 1190 1546 53,038 7 2924 3802 141,435 7
M56 - 5.5 1901 2472 73,007 7 4690 6097 194,686 7
4.6 8.8
A DS00008 G
SCALE NONE WT LBS SHEET 11 OF 16
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND
CLASS 10.9 CLASS 12.9
T.S. = 1040 MPa T.S. = 1220 MPa
PROOF STRENGTH = 830 MPa PROOF STRENGTH = 970 MPa
T.S. is for all dia T.S. is for all dia.
* Metric socket head screws*
Max. Clamp Min. Max. Clamp
Min. Torque
Diameter - pitch Torque Force Torque Torque Force
(ft-Ibf)
(ft-Ibf) (Ib) (ft-Ibf) (ft-Ibf) (lb)
M3 - .5 1.0 1.3 676 1.1 1.5 790
M3.5 - .6 1.6 2.0 911 1.9 2.4 1,065
M4 - .7 2.3 3.0 1,182 2.8 3.6 1,381
M5 - .8 4.7 6.0 1,906 5.5 7.1 2,228
M6 - 1 8.0 10.3 2,703 9.0 11.7 3,159
M8 - 1.25 19 24 4,910 22 28 5,739
M10 - 1.5 38 49 7,771 44 57 9,082
M12 - 1.75 65 85 11,271 76 98 13,172
M14 - 2 104 135 15,411 122 158 18,011
M16 - 2 159 207 20,897 185 241 24,422
M18 – 2.5 223 290 25,730 260 338 30,070
M20 – 2.5 311 404 32,652 362 471 38,159
M22 – 2.5 418 543 40,358 488 635 47,165 7
M24 – 3 536 697 47,019 7 627 815 54,950 7
M27 – 3 776 1008 61,125 7 907 1179 71,435 7
M30 - 3.5 1056 1373 74,577 7 1235 1605 87,157 7
M33 – 3.5 1422 1849 92,079 7 1662 2161 107,611 7
M36 – 4 1816 2360 108,536 7 2122 2758 126,843 7
M39 – 4 2359 3066 129,564 7 2756 3583 151,418 7
M42 - 4.5 2930 3809 148,894 7 3425 4452 174,009 7
M48 - 5 4390 5707 195,652 7 5130 6669 228,654 7
M56 – 5.5 7014 9118 269,316 7 8198 10657 314,743 7
10.9
12.9
A DS00008 G
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DCF0045 (REV B)
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 8.8
Oil Graphite
Pitch Torque Clamp Torque Clamp
Washer Size Bolt Size
(mm) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 M3 .5 1.2 540 1.2 540
NL4 M4 .7 3.0 944 2.7 944
NL5 M5 .8 5.8 1,529 5.2 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
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NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 12.9
Oil Graphite
Washer Pitch Torque Clamp Torque Clamp
Bolt Size
Size (mm) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 M3 .5 1.9 877 1.6 922
NL4 M4 .7 4.4 1,506 3.8 1,596
NL5 M5 .8 8.7 2,450 7.4 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
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DCF0045 (REV B)
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 5
Oil Graphite
Washer Bolt Pitch Torque Clamp Torque Clamp
Size Size (TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.1 550 1.0 550
NL3.5 #6 32 1.4 630 1.3 630
NL4 #8 32 2.7 970 2.4 970
NL5 #10 24 3.9 1,200 3.5 1,200
NL1/4” ¼ 20 9.1 2,200 8.3 2,200
NL8 5/16 18 18 3,600 16 3,600
NL3/8” 3/8 16 30 5,400 28 5,400
NL11 7/16 14 47 7,300 42 7,300
NL1/2” ½ 13 73 9,800 66 9,800
NL14 9/16 12 104 12,600 94 12,600
NL16 5/8 11 145 15,600 131 15,600
NL3/4” ¾ 10 254 23,100 230 23,100
NL22 7/8 9 408 31,900 369 31,900
NL 1” 1 8 617 41,800 557 41,800
NL30 1 1/8 7 771 46,400 697 46,400
NL33 1¼ 7 1075 58,900 969 58,900
NL36 1 3/8 6 1410 70,200 1,270 70,200
NL39 1½ 6 1860 85,500 1,670 85,500
A DS00008 G
SCALE NONE WT LBS SHEET 15 OF 16
DCF0045 (REV B)
NORD-LOCK Stainless Steel with ASTM A574 Bolt
Oil Graphite
Pitch Torque Clamp Torque Clamp
Washer Size Bolt Size
(TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.7 870 1.6 910
NL3.5 #6 32 2.2 990 2.0 1,050
NL4 #8 32 3.8 1,500 3.7 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
A DS00008 G
SCALE NONE WT LBS SHEET 16 OF 16
DCF0045 (REV B)
FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.9
Recommended Lubricants &
Hydraulic Fluids
www.nov.com
Recommended
Lubricants and
Hydraulic Fluids
NOV Drilling System Products
Top Drive Systems
Power Swivel Systems
Iron Roughneck Systems
Hoisting Systems
Mud Pump Systems
Pipe Handling Systems
Rotating Systems
BOP Transporter Systems
D811000719-PRO-001 04
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D811000719-PRO-001
Revision 04
Revision History
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D811000719-PRO-001
Revision 04
Change Description
01 First Issue
1. Moved Motor Bearings Lubricating Greases section from page 11 to page 12.
2. Moved External Pinion & Gear Set Lubricating Greases section from page 12 to page 13.
3. Moved Air Lubricator Misting Oil section from page 13 to page 17.
04
4. Add Wire Rope Lubricant section with recommended wire rope lubricant information (Titled:
Inspection, Lubricating, and Rope Lubricants) to page 14 through page 16.
5. Added Wire Rope reference information to Lubricants and Fluids Reference Chart to page 20.
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Table of Contents
i
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D811000719-PRO-001
Revision 04 Lubricants and Hydraulic Fluids
Page 1 of 20
General Recommendations
The lubrication intervals for NOV derrick-mounted equipment are based on lubricant
supplier recommendations, original equipment manufacturer instructions, and engineering
design criteria. Severe conditions such as extreme loads, extreme temperatures, or o
i
Hydraulic fluids must pour freely at the minimum operating
temperature. The Pour Point temperature of Hydraulic
Fluid should be at least 17°C or (30°F) lower than the
expected minimum ambient temperature. If the ambient
temperature approaches the Hydraulic Fluid Pour Point,
you may need to use a heater to get the fluid flowing and to
ensure proper lubrication of components.
i
Gear lubricant must pour freely at the minimum operating
temperature. The Pour Point temperature of Gear
Lubricant should be at least 6°C or (10°F) lower than the
expected minimum ambient temperature. If the ambient
temperature approaches the Gear Lubricant Pour Point,
you may need to use a heater to get the fluid flowing and to
ensure proper lubrication of components.
i
Clean or replace filters whenever lubricants and fluids are
replaced.
!
When adding or changing fluids (gear oil or hydraulic fluid),
take every precaution to prevent fluid contamination.
Do not mix different types of fluids. Do not mix the same
type of fluid from different manufacturers.
1
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General Recommendations
!
Always use NOV recommended lubricants in your NOV
equipment.
i
Contact an NOV Service Center for additional instructions
if none of the recommended lubricants have the correct
properties for ambient and operating temperatures ranges
at your location.
2
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Revision 04 Lubricants and Hydraulic Fluids
Page 3 of 20
General Recommendations
Precautions
Make sure to read and understand the following prior to adding or changing lubricants.
!
Do not over-lubricate parts. Over-lubricating a fitting can
cause a bearing seal to pop out. Over-lubricated parts may
also drip, creating a slipping hazard.
i
Careful handling of all lubricants should always be
practiced. Avoid prolonged contact to skin, splashing into
eyes, ingestion or inhaling of vapor or mist. Refer to the
MSDS (Material Safety Data Sheet) for additional
information.
3
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General Recommendations
Additional Information
Refer to the following for related information.
The design notes provided on the assembly drawing in the Technical Drawing
Package (TDP) may list lubrication product information and instructions. The TDP is
located in the NOV equipment Owner’s Manual.
There may be a nameplate on the equipment that provides lubrication product
information and instructions.
The original equipment manufacturer’s (vendor) documentation may contain specific
lubrication and hydraulic fluid requirements. Vendor-supplied documentation is
located in the NOV equipment Owner’s Manual.
The Maintenance chapter in the NOV equipment User Manual provides the specific
component lubrication instructions.
The Long-Term Storage section provides lubrication instructions associated with
putting NOV equipment back into service after prolonged storage. This section is
located in the NOV equipment User Manual.
4
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Hydraulic Fluid
NOV recommends anti-wear (AW) hydraulic fluid of the proper viscosity grade. AW
hydraulic fluid is typically mineral-based and contains anti-wear additives, along with rust
and oxidation inhibitors.
The hydraulic oil viscosity should be adjusted based on expected ambient conditions, refer
to the recommended hydraulic fluid tables for specific hydraulic fluids for start-up and
operating in non-arctic and arctic environments.
Change Interval
The hydraulic fluid should be changed after the first initial start-up or if returning the
equipment to service after prolonged storage.
Change all hydraulic fluids yearly or as frequently as operating conditions require.
Fill all hydraulic fluid systems to correct levels with specified lubricants. Refer to the
recommended hydraulic fluid tables for specific hydraulic fluids.
!
Do not mix different types of fluids. Do not mix the same
type of fluid from different manufacturers.
Filters
Filters should always be replaced when changing hydraulic fluid. Refer to the Maintenance
chapter (in the NOV equipment User Manual) for filter descriptions and details.
Replace filters every three (3) months or whenever the lubricants are changed.
5
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Hydraulic Fluid
Inspection
Check the hydraulic fluid level daily.
i
Keep the hydraulic reservoir full at all times. The oil level
should be visible in the sight gauge.
6
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Hydraulic Fluid
Non-Arctic Service Fluids
The recommended hydraulic fluid to use for start-up and operating in non-arctic
environments are provide in the following table.
i
All temperatures are in degrees of Celsius. The Fahrenheit
temperature is the reference temperature.
Kinematic
6.9 cSt @ 100°C (49 SUS @ 210°F)
Viscosity
ISO/ASTM
46
Viscosity Grade
Kinematic
6.9 cSt @ 100°C (49 SUS @ 210°F)
Viscosity
ISO/ASTM
46
Viscosity Grade
i
Contact an NOV Service Center for additional instructions
if none of the recommended hydraulic fluids have the
correct properties for the ambient and operating
temperature ranges at your location.
7
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Hydraulic Fluid
Arctic Service Fluids
The recommended hydraulic fluid to use for start-up and operating in arctic environments
are provide in the following table.
Recommended Hydraulic Fluids for Arctic Service
Kinematic
5.5 cSt @ 100°C (44 SUS @ 210°F)
Viscosity
Best Choice
Viscosity Index 377
ISO/ASTM
15
Viscosity Grade
Kinematic
3.72 cSt @ 100°C (39 SUS @ 210°F)
Viscosity
Alternative
Viscosity Index 140
ISO/ASTM
15
Viscosity Grade
Kinematic
6.4 cSt @ 100°C (47.5 SUS @ 210°F)
Viscosity
Alternative
Viscosity Index 155
ISO/ASTM
32
Viscosity Grade
i
Contact an NOV Service Center for additional instructions
if none of the recommended hydraulic fluids have the
correct properties for the ambient and operating
temperature ranges at your location.
8
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Gear Oil
You should select gear oil based on the minimum ambient temperature expected before
the next oil change.
!
Using an oil with a viscosity greater than what is required
could reduce oil flow and damage the gearbox. Higher
viscosity oils may also damage the oil pump with excessive
load.
You should use an extreme pressure (EP) gear oil. EP gear oils are typically mineral oils
that contain sulfur-phosphorous additives. Most EP gear oils meet American Gear
Manufacturers Association (AGMA) extreme pressure performance requirements.
i
Check the gearbox oil level daily.
i
Change oil whenever it becomes contaminated. Oil
contamination depends on operating conditions and
temperature. Continuous operation at 180°F (82°C), or
above, will require more frequent oil changes.
Inspection
Inspect the oil level and check for leaks every 250 operating hours.
Examine oil for changes in its appearance and odor.
Change Interval
The gear oil should be thoroughly drained after 500 operating hours or after the first
(1) month of operation, following the initial start-up or if returning the equipment to
service after prolonged storage.
Under normal operating conditions, the gear oil should be changed every six (6)
months, and oil viscosity should be adjusted based on expected ambient conditions
for the next six (6) months.
The gear oil should be drained when at normal operating temperatures. Refer to
table on page 9.
9
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Lubricants and Hydraulic Fluids Revision 04
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Gear Oil
Low-Temperature Operation
Equipment operating in cold areas must be provided with gear oil that circulates freely and
does not cause high torque at start-up. Lubrication viscosity must be low enough to allow
the oil to flow freely at start-up, but high enough to carry the load at operating temperature.
Gearbox Lubricants
The recommended gear oil grades for ambient and operating temperature ranges are
provided in the following table.
i
All temperatures are in degrees of Celsius. The Fahrenheit
temperature is the reference temperature.
10°C to 52°C
16°C (60°F) AGMA No. 7 EP, ISO/ASTM VG 460
(50°F to 125°F)
9°C to 16°C
4°C (25°F) AGMA No. 6 EP, ISO/ASTM VG 320
(15°F to 60°F)
-29°C to 4°C
-23°C (-10°F) AGMA No. 4 EP, ISO/ASTM VG 150
(-20°F to 25°F)
-46°C to -18°C
-40°F (-40°C) AGMA No. 4 EP, ISO/ASTM VG 100
(-50°F to 0°F)
i
Contact an NOV Service Center for additional instructions
if none of the recommended gear oils have the correct
properties for the ambient and operating temperature
ranges at your location.
10
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Grease
General Lubrication
The recommended grease for general preventative maintenance is provide in the following
table.
General Lubricant Recommendation
i
Contact an NOV Service Center for additional instructions
if none of the recommended greases have the correct
properties for the ambient and operating temperature
ranges at your location.
11
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Grease
Motor Bearings Lubricating Greases
Some motors are equipped with greased bearings, which must be lubricated at
manufacturer-recommended intervals.
Generally, drilling motors and blower motors are vendor-supplied equipment. The motor
housing may have a nameplate attached to it that provides the recommended lubrication
product, amount to use, and lubrication intervals.
If there is no nameplate, refer to the vendor-supplied documentation in the Owner’s
Manual. If no vendor reference information is supplied, contact an NOV Service Center.
Lubricate the drilling motor and blower motor bearings every six (6) months or as
specified by the original equipment manufacturer, refer to your User Manual or to the
vendor-supplied documentation in the Owner’s Manual.
!
Always use the recommended lubrication product specified
by the original equipment manufacturer.
!
Always use the recommended lubrication product specified
by the original equipment manufacturer.
12
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Revision 04 Lubricants and Hydraulic Fluids
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Grease
External Pinion & Gear Set Lubricating
Greases
Lubricate all external pinion and gear sets, such as the following:
Handling Ring Assembly
Repositioner Assembly
Crown Tooth Gear Coupling
Lubricate external pinion and gear sets weekly with a light coating to the entire pinion and
gear set.
The recommended external pinion and gear set grease for general preventative
maintenance is provide in the following tables.
Handling Ring Pinion & Gear Set Lubricant Recommendations
Coat the gear teeth with an extreme pressure lubricant such as NOV "Copper Top", Jet Lube Inc.
"Kopr-Kote" compound, or equivalent.
Coat the gear teeth with an extreme pressure lubricant such as NOV "Copper Top", Jet Lube Inc.
"Kopr-Kote" compound, or equivalent.
13
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Inspection
Periodically inspect the wire rope and determine the condition of the strand and the
condition of the lubricant coating, and if there is question on either the strand or lubricant
coating the following procedures should be followed:
When performing wire rope lubrication inspection, use appropriate tools, dry clean
rags, and wear protective hand and eye safety equipment when examining or
cleaning the rope. Never use detergents or solvents to clean rope; the use of
solvents can effect or diminish the rope’s lubricant.
Visually inspect the entire length of wire rope for bare rope surface, lubricant build
up, lubrication appearance, and contamination. Refer to the applicable OEM
literature in the User Manual for lubrication and inspection schedules for wire rope
equipment.
Visually and physically examine the entire length of wire rope and determine if its
acceptable for service or requires replacement before re-dressing with rope
lubricant. Refer to the applicable OEM literature in the User Manual for additional
information for wire rope equipment.
i
Always follow all federal, state and local rules, code and
rig-specific wire rope guidelines for inspection and
maintenance of wire rope equipment. Inspection and
lubrication recommendations provided in this supplement
do not take precedence over local rules and regulations,
OSHA regulation, or instructions issued by the
manufactures of wire rope.
14
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Revision 04 Lubricants and Hydraulic Fluids
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i
The lubricant used must be compatible with the initial
lubricant applied by the wire rope manufacture.
Follow recommendations concerning the temperature of
the wire rope and atmosphere required when applying
lubricant.
The recommended wire rope lubricant for general
preventative wire rope maintenance is provide in the table
titled "Recommended Lubricant for Wire Rope" on page 1-
16. See OEM literature for additional maintenance
information or contact your NOV representative.
15
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Color Blue
Texture Smooth/Creamy
4-Weld, kg 250
1. Coat the wire rope products with a lubricant designed for wire rope lubrication having the recom-
mended properties in the above table such as “Dynagard Blue”, or equivalent.
16
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Misting Oil
Air Lubricator Misting Oil
Use misting type oil, 29-35 cSt @ 38°C (136-165 SUS @ 100°F), ISO Viscosity
Grade 32.
17
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18
Lubricants and Fluids Reference Chart
ASTM/ Kinematic Viscosity
Component Environment Lube Type ISO-VG/SAE NLGI AGMA Viscosity Index Pour Point
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Lubricants and Fluids Reference Chart
Revision 04
ASTM/
Page 19 of 20
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ISO-VG/ Kinematic Viscosity
Component Environment Lube Type SAE NLGI AGMA Viscosity Index Pour Point
D811000719-PRO-001
External Pinion
and Gear Sets,
and Elevator
All EP Grease1 --- #2 --- --- --- ---
and Main Links
contact
surfaces
Metalon
IBOP/Kelly Hi-Tech 1.5
All --- #1.5 --- --- --- ---
Valve Actuator
Grease2
Drilling Motor
Bearings
All EP Grease3 #2 --- --- --- ---
Blower Motor
Bearings
Moderate
Primrose Plus
Operating --- #2 --- --- --- ---
Conventional # 327
Conditions
Washpipe
Packing
Extreme
Grease Primrose Plus
Operating --- #3 --- --- --- ---
# 327 C
Conditions
Lubricants and Hydraulic Fluids
19
20
Lubricants and Fluids Reference Chart
ASTM/
ISO-VG/ Kinematic Viscosity
Component Environment Lube Type SAE NLGI AGMA Viscosity Index Pour Point
Wire Rope
Wire Rope > 6°C (43°F) --- #2 --- --- --- ---
Lubricant1
Lubricants and Hydraulic Fluids
1. Lithium 12 base, containing additives and inhibitors for non sheening, extreme pressure, corrosion, low temperature flexibility, strong adhesion, and low fling off.
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FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.10
Hydraulic Fluid Cleanliness
www.nov.com
Hydraulic
Fluid
Cleanliness
Supplement
SM00081 Rev. C
October 26, 2000
Scope
The purpose of this document is to provide guidance to the installers and users of
Varco’s hydraulically powered equipment and to ensure that each piece of equipment
performs as intended. Prior to connecting Varco equipment to a hydraulic system, the
piping/plumbing/hoses/service loops must be cleaned and the hydraulic fluid filtered to
minimize hydraulic fluid contamination. The following paragraph defines the
hydraulic fluid cleanliness levels required for operating Varco equipment. Failure to
maintain these cleanliness levels could result in premature equipment damage and
nullification of the equipment warranty.
This document outlines fluid cleanliness measurement and analysis criteria and also
describes procedures for filtering and cleaning a hydraulic system.
Each final assembly item from Varco will be function tested with clean hydraulic fluid
maintained at ISO 4406 18/15 (was 9) or better (See Table 1). The hydraulic fluid
cleanliness levels will be recorded on Test Specification document (TS00419) for each
piece of equipment prior to shipment.
Hydraulic fluid
Varco recommends hydraulic fluid levels be maintained at a cleanliness level of ISO
4406 18/15 (was 9) or better prior to the initial connection, startup, and commissioning
of Varco equipment. After initial system operation, Varco recommends that the
hydraulic supply system be capable of continuously maintaining this level of
cleanliness or better to assure that fluid contamination is not a factor in any component
failure during the desired useful life of the hydraulic powered equipment. The final
level of acceptable cleanliness prior to equipment hook up must be determined by a
hydraulic fluid sample and should be analyzed by a qualified laboratory.
Solid contamination
When determining contamination of hydraulic fluids, you must consider the size and
quantity of the solid particle contamination within a representative fluid sample. The
contamination of hydraulic fluids by solid particles is covered by a number of different
classification systems:
CLASSES OF CONTAMINATION
The various classes of contamination define the quantity of particles of a certain size in
a 100 ml sample of fluid.
Above a dirt concentration of about 20 mg per liter, or if the fluid is very turbid, the
contamination can only be ascertained by weight, i.e., by gravimetric analysis.
However, with this method, the individual dirt particles cannot be classified.
ISO DIS Particles ACFTD Mil STD NAS 1638 SAE 749 D
4406 per ml solids 1246 A (1967) (1963)
or >10 µm content (1967)
Cetop RP mg/L
70 H
26/23 140000 1000
25/23 85000 1000
23/20 14000 100 700
21/18 4500 12
20/18 2400 500
20/17 2300 11
20/16 1400 10
19/16 1200 10
18/15 580 9 6
17/14 280 300 8 5
16/13 140 1 7 4
15/12 70 6 3
Acceptable range for Varco equipment
Taking samples
Sampling point: Take the sample within a system that is operating and which contains
turbulent flow. (See ISO 4021.)
Since obtaining a fluid sample can be an input for contamination the following general
measures should be utilized when taking a fluid sample.
❏ Utilize continuous flow monitoring equipment that records a cleanliness level over
a period of time whenever possible.
❏ Take a sample of the circulating fluid of a system that is at operating conditions and
temperature. All fluid samples shall be taken from a system test-port fitting using
a on/off flow sampling device. Never loosen or break a hydraulic fitting to establish
a leak point as a fluid source for fluid contamination sampling.
❏ Before attaching the sampling device, carefully flush out the device and clean the
system test-port fitting.
❏ Open sampling device and allow approximately 2 liters of fluid to flow through the
test port prior to sampling the fluid.
❏ Without shutting the test port, open and fill the sterile sampling bottle by holding
it in the continuous fluid stream. Cap and seal the test bottle.
❏ Label and date the sample bottle to identify the tool and sample hydraulic circuit
location.
e Only properly trained personnel should be allowed to take the fluid samples. Errors in
sampling procedures can greatly affect contamination classes below ISO 18/IS.
To avoid errors in sampling, conduct particle counting off site. Do not allow rig
personnel to attempt to check the samples at the time of sampling. Send the samples to
an appropriate institute for testing.
z Mobile laboratory services can also perform the measurements for customers.
Service loops
Varco service loops are blown clean in the factory and capped prior to shipment. They
are not flushed. All service loops and hoses should be flushed as part of the overall
hydraulic system prior to connecting Varco equipment.
The process for cleaning and preparing hydraulic pipes is dependent on the type of pipe
(carbon or stainless), the condition of the pipe (pickled or not pickled), the types and
levels of contamination, the types and temperatures of the pickling and flushing
solutions in use, and the type of flushing equipment.
REFERENCE DOCUMENTS:
❏ ASTM Standard 5.02 D-4174, standard practice for cleaning, flushing, and
purification of petroleum fluid hydraulic system.
Degrease
Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends
on the nature of any contaminants present. Pipes and fittings with heavy rust, varnish
or other tough soils should be sandblasted prior to pickling.
Rinse
Rinse carbon steel pipe with potable water until all alkaline cleaner is removed.
Acid pickle
Immerse or spray the pipe with a 10-15% inhibited hydrochloric acid solution at
ambient temperature (for at least one hour) until all scale, slag, rust, etc. Is removed.
Rinse with potable water until all alkaline cleaner is removed.
Rinse
Rinse the pipe with potable water until the water reaches a neutral PH (7.0).
Flush
Begin flushing the piping with the hydraulic power unit until the desired state of
cleanliness is met.
Degrease
Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends
on the nature of any contaminants present.
Rinse
Rinse pipe with portable water until all alkaline cleaner is removed.
Acid pickle
Immerse or spray the pipe with a 15-17% nitric acid/3-5% hydrofluoric acid mixture at
ambient temperature (for at least two hours) until all scale, slag, rust, etc. is removed.
Rinse
Rinse the pipe with potable water until the water reaches a neutral PH.
Passivate
Use a 10 - 15% nitric acid/75-80% potable water mixture at ambient temperature for
approximately one-half the time used in acid pickling.
Rinse
Rinse with potable water until the PH of the effluent equals the pH of the influent.
Dry
Dry with oil-free air until all visible traces of moisture are removed.
Final inspection
Use a white light to inspect all pipe and/or fittings for visible contamination. Prior to
hooking up equipment pump clean hydraulic fluid through the plumbing and measure
the contamination of the system per this specification. Additional flushing and cleaning
may be required if contamination levels do not meet the requirements of this
specification.
Section 1.11
Technical Drawing Package
www.nov.com
Technical Drawing Package
RIG/PLANT
REFERENCE REFERENCE DESCRIPTION
10541942-ASM Top Assembly
ADDITIONAL CODE SDRL CODE TOTAL PGS
This document contains proprietary and confidential information
REMARKS which is the property of National Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV. National Oilwell Varco
MAIN TAG NUMBER DISCIPLINE Reproduction, in whole or in part, or use of this design or
distribution of this information to others is not permitted without the RIG SOLUTIONS
CLIENT PO NUMBER express written consent of NOV. This document is to be returned to 11000 Corporate Centre Drive
NOV upon request or upon completion of the use for which it was Houston, TX 77041
loaned. This document and the information contained and
CLIENT DOCUMENT NUMBER represented herein is the copyrighted property of NOV.
© National Oilwell Varco
D811002377-DOS-001 01
www.nov.com
D811000461-GEN-001/04
Document number D811002377-DOS-001
Revision 01
Page 2
REVISION HISTORY
CHANGE DESCRIPTION
www.nov.com
D811000461-GEN-001/04
Document number D811002377-DOS-001
Revision 01
Page 3
Drawings by Assembly
www.nov.com
D811000461-GEN-001/04
DISCHARGE ACCESSORY
MANIFOLD ASSEMBLY
6317-0125-10-DOS B
-DOS
-DOS
1 of 1
-DOS
INSPECTION DOOR ASSEMBLY
PUMPS AND DRAWWORKS
1 1
7510-0202-00-DOS J
-DOS
FLUID END EXPENDABLE
SERVICING CRANE
1
6316-0020-20-DOS C
OS
OS
Document number: 6316-0250-02-DOS
Revision: A
TOOL LIST
FOR F-1600 SERIES TRIPLEX MUD PUMPS
www.nov.com
Technical Drawing Package
RIG/PLANT
REFERENCE REFERENCE DESCRIPTION
10541943-ASM Top Assembly
ADDITIONAL CODE SDRL CODE TOTAL PGS
This document contains proprietary and confidential information
REMARKS which is the property of National Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV. National Oilwell Varco
MAIN TAG NUMBER DISCIPLINE Reproduction, in whole or in part, or use of this design or
distribution of this information to others is not permitted without the RIG SOLUTIONS
CLIENT PO NUMBER express written consent of NOV. This document is to be returned to 11000 Corporate Centre Drive
NOV upon request or upon completion of the use for which it was Houston, TX 77041
loaned. This document and the information contained and
CLIENT DOCUMENT NUMBER represented herein is the copyrighted property of NOV.
© National Oilwell Varco
D811002378-DOS-001 01
www.nov.com
D811000461-GEN-001/04
Document number D811002378-DOS-001
Revision 01
Page 2
REVISION HISTORY
CHANGE DESCRIPTION
www.nov.com
D811000461-GEN-001/04
Document number D811002378-DOS-001
Revision 01
Page 3
Drawings by Assembly
www.nov.com
D811000461-GEN-001/04
DISCHARGE ACCESSORY
MANIFOLD ASSEMBLY
6317-0125-10-DOS B
-DOS
-DOS
1 of 1
-DOS
INSPECTION DOOR ASSEMBLY
PUMPS AND DRAWWORKS
1 1
7510-0202-00-DOS J
-DOS
FLUID END EXPENDABLE
SERVICING CRANE
1
6316-0020-20-DOS C
OS
HP MUD LINE SPOOL ASSY.
520
IDEAL RIG, FD-1600 PUMP
M291262317-DOS-001 03
Document number: 6316-0250-02-DOS
Revision: A
TOOL LIST
FOR F-1600 SERIES TRIPLEX MUD PUMPS
www.nov.com
FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.12
Recommended Spare Parts
www.nov.com
Recommended Spare Parts
FD-1600
RIG/PLANT
REFERENCE REFERENCE DESCRIPTION
D290-6316-1003-01-SPL-001 01
www.nov.com
D290-6316-1003-01-SPL-001/01
Document number D290-6316-1003-01-SPL-001
Revision 01
Page 2
REVISION HISTORY
CHANGE DESCRIPTION
www.nov.com
D290-6316-1003-01-SPL-001/01
Document number D290-6316-1003-01-SPL-001
Revision 01
Page 3
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 OR
Area 2
1 Lot of Group II Spares for approximately each 2 units
2-3 years Multiply Class A spares by 2.
operations
www.nov.com
D290-6316-1003-01-SPL-001/01
Document number D290-6316-1003-01-SPL-001
Revision 01
Page 4
www.nov.com
D290-6316-1003-01-SPL-001/01
Document number D290-6316-1003-01-SPL-001
Revision 01
Page 5
TABLE OF CONTENTS
Accessibility Area
Area
Part No. Description 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 Spring, Lock 3 9
0-7602-1070-03 Filter, Oil 1 2
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
www.nov.com
D290-6316-1003-01-SPL-001/01
Document number D290-6316-1003-01-SPL-001
Revision 01
Page 6
www.nov.com
D290-6316-1003-01-SPL-001/01
Document number D290-6316-1003-01-SPL-001
Revision 01
Page 7
www.nov.com
D290-6316-1003-01-SPL-001/01
Document number D290-6316-1003-01-SPL-001
Revision 01
Page 8
www.nov.com
D290-6316-1003-01-SPL-001/01
Document number D290-6316-1003-01-SPL-001
Revision 01
Page 9
www.nov.com
D290-6316-1003-01-SPL-001/01
FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 1.13
Service Center Directory
www.nov.com
National Oilwell Varco
Service Center Directory
D811001337-DAS-001 04
www.nov.com
Form D811001123-GEN-001/06
D811001337-DAS-001
Revision 04
Revision History
Change Description
01 First Issue
• Updated/added Brazil, Canada, Colombia, UK contact information (page 2-3 through page 2-8).
• Added North Dakota contact information (page 2-4).
04 • Updated the contact information for the China office (page 2-6).
• Added addresses and contact information for Singapore and India (page 2-6).
• Updated contact information for NOV Dubai and NOV Abu Dhabi. (page 2-8).
www.nov.com
D811001337-DAS-001
Revision 04
The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
http://www.nov.com/ContactUs/24HrEmergencyContacts.aspx
Americas
Brazil
National Oilwell Varco do Brasil
Rodovia Amaral Peixoto, s/n KM164,5 - n° 8.500
Imboassica – Macaé – RJ – Brazil
CEP 27925-290
+55 22 2773 0600 (reception)
+55 22 9882 7591 (after hours)
+55 22 9702 8866 (drilling equipment)
+55 22 9974 7056 (PCE / MoComp equipment)
+55 22 9894 6608 (lifting and handling equipment)
+55 22 2773 0635 (repair shop)
+55 22 2773 0675 (inside sales)
+55 22 2123 2452 (tech college)
Canada
NOV Rig Solutions Aftermarket Service, Repair and Rentals (Leduc)
Varco Canada ULC CO 009
6621 – 45 Street
Leduc, Alberta, Canada
T9E 7E3
+1 780 986 1712 (main)
NOV Rig Solutions Spares (Edmonton)
Varco Canada ULC CO 009
7127 – 56 Ave
Edmonton, Alberta, Canada
T6B 3L2
+1 780 801 1800 (main)
+1 780 619 5579 (24 hour on-call)
Colombia
National Oilwell Varco de Colombia
Bogota, DC
Top Drive Rental and Service
+57 316 875 8748 (mobile)
+57 317 515 3321 (mobile)
3
www.nov.com
Form D811001123-GEN-001/06
D811001337-DAS-001
SC Service Center Directory Revision 04
Page 4 of 10
Americas
USA
Colorado
NOV Service and Repair (Colorado)
420 South Ash St.
Fruita, CO 81521
+1 970 858 4522
+1 281 569 3050 (after hours)
Louisiana
NOV Service and Repair (Covington)
73765 Penn Mill Rd.
Covington, LA 70435
+1 985 892 8216 (direct)
+1 800 722 4425 (toll free)
(Cranes: AmClyde, Unit, OS National, Dreco, Kingpost)
+1 985 871 8609 (service)
+1 985 871 8603 (parts
NOV Service and Repair Center (New Iberia)
5212 Highway 90 Service Road West
New Iberia, Louisiana 70560
(All NOV spare parts; legacy Shaffer, Varco, and NOI equipment)
+1 337 374 1400
Minnesota
NOV Service (St. Paul)
240 East Plato Blvd.
St. Paul, Minnesota 55107
(lifting and handling equipment)
+1 651 293 4745 (service)
+1 651 293 4776 (service)
+1 651 293 4600 (parts)
+1 651 293 4603 (parts)
North Dakota
NOV Service, Repair, and Spare Parts
3201 1st Avenue W.
Williston, ND 58801
+1 307 473 8888
+1 281 569 3050 (after hours)
Oklahoma
NOV Service and Repair (Oklahoma City)
7713 North West 3rd St.
Oklahoma City, Oklahoma 73127
+1 405 495 1000
+1 281 569 3050 (after hours)
4
www.nov.com
D811001337-DAS-001
Revision 04
Page 5 of 10
Service Center Directory SC
Americas
USA
Pennsylvania
NOV Service (Pittsburgh)
1349 Saw Mill Run Blvd.
Pittsburgh, Pennsylvania 15226
+1 412 884 1027
+1 281 569 3050 (after hours)
Texas
NOV Service and Repair (Alice)
2351 Energy Avenue
Alice, Texas 78380
+1 361 668 4154
+1 281 569 3050 (after hours)
NOV Service and Repair (Houston)
5100 North Sam Houston Parkway West
Houston, Texas 77086
+1 281 569 3050 (24/7 technical support)
+1 281 569 3051 (eHawk remote support)
Wyoming
NOV Service and Repair (Casper)
1080 North Robertson Road
Casper, Wyoming 82601
+1 307 473 8888
+1 281 569 3050 (after hours)
Venezuela
NOV Rental and Service (Maturin, Monagas)
Varco International de Venezuela
Top Drive Rental and Service
+58 291 651 6489
+58 414 394 2784 (mobile)
+58 291 651 4384 (fax)
5
www.nov.com
D811001337-DAS-001
SC Service Center Directory Revision 04
Page 6 of 10
Asia
China
NOV Service
18th Floor, Raffles City Beijing Office Tower
No. 1, Dongzhimen South Street, Dongcheng District
Beijing 100007 P. R. China
+86 139 0121 9392
+86 800 810 5109 (24/7 technical support)
India
NOV Service and Repair
R-619, TTC Industrial Area
Rabale, MIDC
Navi Mumbai – 400 701
Maharashtra, India
+91 22 3916 9700
+91 982 009 1322
+91 983 349 6154 (after hours)
NOV Machining Centre (Pressure Control)
11A/2 (NP) Sidco Industrial Estate
Ambattur
Chennai, Tamil Nadu, India 600098
+91 44 4285 8074
+91 95 0008 4149 (after hours)
Singapore
NOV Service and Repair
29 Tuas Bay Drive
Singapore 637429
+65 6594 1000
+65 6594 1222 (24/7 technical support)
NOV Machining Centre (Pressure Control)
22 Jalan Terusan
Singapore 619299
+65 6265 1900
+65 9128 2545 (after hours)
6
www.nov.com
D811001337-DAS-001
Revision 04
Page 7 of 10
Service Center Directory SC
Europe
France
NOV Service
+33 24 068 3600
+33 24 068 3611
+33 24 068 3600 (after hours)
+33 677 790 943 (after hours)
Norway
NOV Service (Asker)
Blakstadmarka 26
1386 Asker – Norway
+47 6400 5000
+47 6400 5001 (after hours)
NOV Service (Kristiansand)
Skibaasen 2
4636 Kristiansand – Norway
+47 3819 2000
+47 3819 2482 (after hours)
NOV Service (Molde)
Granfjaera 24
6415 Molde – Norway
+47 7120 2020
+47 9169 9664 (after hours)
NOV Repair (Stavanger)
Dusavik Base
Notberget 46
4029 Stavanger – Norway
+47 5781 8181
NOV Service (Stavanger)
Lagerveien 8
4069 Stavanger – Norway
+47 5181 8181
+47 4140 0041 (after hours)
+47 9511 8181 (24/7 eHawk remote support)
Russia
NOV Service and Support
Russia, 119071, Moscow
Leninsky prosp., 15A, 7th floor
+7 495 287 2601 (direct)
+7 495 981 3470 (fax)
+7 985 410 5272 (mobile)
7
www.nov.com
D811001337-DAS-001
SC Service Center Directory Revision 04
Page 8 of 10
Europe
UK
NOV Service and Repair (Aberdeen/Montrose)
Forties Road
Montrose
Scotland
DD10 9ET
+44 1674 677222
UK after hours, on-call contacts
+44 (0) 7711 415 485 (mechanical)
+44 (0) 7711 415 484 (electrical)
+44 (0) 7739 170 079 (repair workshop)
+44 (0) 7713 643 012 (spare parts)
+44 (0) 7770 325 333 (distribution)
+44 (0) 7801 078 092 (IMO/MD Totco)
Middle East
UAE
NOV Service and Repair (Abu Dhabi)
Varco Al Mansoori Services LLC
P. O. Box 27011
Abu Dhabi, United Arab Emirates
+971 2 555 2668
+971 2 554 2280 (fax)
+971 2 554 0012 (fax)
+971 50 811 6083 (after hours service)
+971 50 617 1235 (after hours workshop)
NOV Service and Repair (Dubai)
P.O. Box 61490
R/A No.13, Plot MO 0682
Daimler Chrysler Street
Jebel Ali Free Zone
Dubai, United Arab Emirates
+971 4 883 8776
+971 4 883 8795 (fax)
+971 56 686 2184 (after hours service on-call)
North Africa
NOV Service (Algeria)
Overseas Equipment Service Africa
BP 852 Zone Industrielle Algerie
Hassi Messaoud Ouargla
Algeria 30500
+213 29 73 1236
+213 29 75 4105 (fax)
8
www.nov.com
D811001337-DAS-001
Revision 04
Page 9 of 10
Service Center Directory SC
Middle East
North Africa
NOV Service and Repair (Badr City)
IMPEC (Sea Harvest Company)
Part B, 47 Acer Area
Badr City, Cairo, Egypt
+20 2 231 08001
+20 2 231 08002
+20 2 231 08003 (fax)
Saudi Arabia
NOV Service and Repair (Dammam)
P. O. Box 20754, Al-Khobar 31952
Al Khobar, Saudi Arabia
Gate No. 2, Makkah Street (opposite of Saudi Electricity Company)
Dammam Second Industrial City
Dammam, Saudi Arabia
+966 3 835 3061
+966 3 830 2453 (fax)
9
www.nov.com
D811001337-DAS-001
SC Service Center Directory Revision 04
Page 10 of 10
10
www.nov.com
FINAL DOCUMENTATION
FD-1600 Mud Pump
Chapter 2.0
Accessories
www.nov.com
FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 2.1
Motor
www.nov.com
FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 2.2
Pulsation Dampener
www.nov.com
REV. A
107.132.00
OPERATOR’S MANUAL
PULSATION DAMPENER
Page 1
Operator’s Manual
107.132.00 Pulsation Dampener
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
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
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
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.
Page 2
Operator’s Manual
107.132.00 Pulsation Dampener
CONTENTS
PAGE
PREFACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Page 3
Operator’s Manual
107.132.00 Pulsation Dampener
1.0 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.
Dampener Dampener
Page 4
Operator’s Manual
107.132.00 Pulsation Dampener
Tee o
A. Mounting
2. Position dampener on gasket and mating flange so that the space between flange and bottom
3. Install one lubricated nut on each stud and tighten one turn at a time until dampener is firmly in
4. Cross tighten nuts to the proper torque (725 - 800 lb-ft or 980 - 1080 N.m).
Page 5
Operator’s Manual
107.132.00 Pulsation Dampener
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
WARNING: ALWAYS PRECHARGE WITH ZERO PRESSURE ON THE SYSTEM AND ALWAYS
1. The pressure gauge is located under the valve guard and is exposed by removing the valve guard.
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.
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
4. Precharge from a standard commercially available nitrogen bottle equipped with a pressure
regulator.
5. For those applications where higher precharge pressures are required, a gas booster pump is
available.
Page 6
Operator’s Manual
107.132.00 Pulsation Dampener
6. Open bottle regulator valve until recommended precharge pressure shows on regulator gauge.
7. Slowly open charging valve on dampener. Allow pressure to increase in the dampener until
8. Close the charging valve and tighen. Then, close regulator valve at nitrogen bottle. Remove
C. Precharge Recommendations
For normal operating conditions, set the precharge pressure at 50 to 70 percent of the average
operating discharge pressure not to exceed 5000 PSI(350kg/cm²). The precharge pressure can be
D. Leak Detection
Apply leak detection fluid at all connections around valve, pressure gauge, cover, body contact
surfaces, and studs. Observe carefully for bubbles that indicate leaks. If any indications are found,
check system for loose connections and retighten. Allow the nitrogen gas in the dampener to come to
ambient conditions (approximately one-half hour) and recheck the precharge pressure.
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.
Page 7
Operator’s Manual
107.132.00 Pulsation Dampener
2.0 DISASSEMBLY
A. Disassembly Procedure
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.
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.
6. After all pressure is removed from dampener, remove nuts from studs.
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.
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
9. If the bottom plate is to be removed for replacement or inspection, follow the procedure below:
Page 8
Operator’s Manual
107.132.00 Pulsation Dampener
c. Remove dampener from flange connection. Set stud nuts and gaskets aside and save for
reinstallation.
e. Remove socket head cap screws that hold bottom plate in place. Set aside and save.
f. Remove bottom plate from dampener. Remove gasket and inspect for damage. Set aside and save
g. Inspect bottom plate for excessive pitting, corrosion or wear. If these conditions exist, consult your
1. Flush diaphragm body, clean and remove scale and other foreign material.
2. Inspect inside of dampener body for excessive pitting. Corrosion or wear. If these conditions exist,
3. Mild pitting or scaling can be removed with application of light duty emery cloth. Inside of dampener
Page 9
Operator’s Manual
107.132.00 Pulsation Dampener
Page 10
Operator’s Manual
107.132.00 Pulsation Dampener
3.0 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.
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 725 - 800 lb-ft or 980 -1080 N.m.
C. Diaphragm Installation
1. Apply a light coat of a general lubricant (castor oil or equivalent) on diaphragm to aid in installation.
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.
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Operator’s Manual
107.132.00 Pulsation Dampener
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).
5. Fold the remainder of the diaphragm into the vessel and allow it to open inside the body.
D. Stabilizer Installation
2. Break vacuum at neck by pulling diaphragm slightly away from sealing area.
5. Fold stabilizer with edge down and insert into diaphragm opening.
6. Assemble stabilizer plate, lock washer, and hex screw through stabilizer and fasten to diaphragm
NOTE: Make certain that the neck portion of the diaphragm and cover plate is clean and free of any
debris, rust, or scale. Coat with a light lubricant prior to installation of cover plate to the body.
Page 12
Operator’s Manual
107.132.00 Pulsation Dampener
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).
1. Back thread seal nut on valve and thread valve into tapped hole.
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
1. Install pressure gauge so that the face is positioned in such a manner that it will be visible through
2. Back thread seal nut on valve and thread valve into tapped hole.
4. If the gauge is not facing in the proper direction, take the following steps:
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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 possible until the gauge is positioned in the proper
Use precharge instructions in Section 1. Attach valve guard, and the pulsation dampener is now
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4.0 MAINTENANCE
A. Precharge
1. When properly installed and pre-charged, the pulsation dampener is virtually maintenance free.
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
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.
2. Additionally, excessive flexing of the diaphragm may cause premature rubber failure at the neck or
1. If the pre-charge is TOO HIGH, the diaphragm insert will rest on the bottom of the dampener,
2. Until the system pressure exceeds the precharge pressure, no dampening will take place.
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.
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A. Precharge Low
b. Tighten loose threads, close valve stem, or replace valve if stem does not close.
b. Tighten stud nuts. If leaks persist, remove cover and clean mating surfaces. Reassemble and
6. Check Diaphragm (if all the above fail to find the leak). If the dampener will not hold precharge
pressure, it may be due to nitrogen leaks through the diaphragm. Check for evidence of fluid at either
charging valve or pressure gauge port hole. CAUTION: Make sure dampener pressure is at zero psig
before removing charging valve or pressure gauge. If fluid is present, replace diaphragm. See
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B. Precharge High
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 shuts 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
ASSEMBLY PROCEDURES.
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6.0 PARTS
1"-8UNC-2A
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M48x3-2A
M48x3-2A
M33x2-2A
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Page 21
FINAL DOCUMENTATION
FD-1600 Mud Pump
Section 2.3
Reset Relief Valve
www.nov.com
Operation, and Maintenance
Manual
M-34000
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.
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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. Any
field advisory or installation support is advisory only. The foregoing warranties are in lieu of all other warranties, whether
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 herein.
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 warnings 1-1
Notes 1-1
Cautions 1-1
Warnings 1-1
Illustrations 1-1
Safety requirements
Personnel training 1-2
Recommended tools 1-2
Genera system safety practices 1-3
Replacing components 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
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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 is likely to result in serious or fatal injury to personnel, significant property loss or significant
equipment damage.
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 training
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 tools
Service operations may require the use of tools designed specifically for the purpose described. When stated, use only
these tools.
Replacing components
Verify that all components are tagged and labeled during disassembly and reassembly of equipment.
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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 manual
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 constant
force exerted by the spring, the valve "trips" open (the piston moves to its fully open position) and allows process fluid to
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. Patent
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” provided
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
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Storage
Recommended procedure for extended storage 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 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.
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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 that
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 inadvertent
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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Note:
Back pressure on the valve (usually due to hydrostatic head pressure from a column of fluid in the discharge line) is
usually undesirable. However, due to the balanced design of the Titan “B”, back pressures less than 100 psig will have
little if any affect on the operational accuracy of the valve
Storage
Recommended procedure for extended storage
Relief Valve should be stored inside a cool, controlled environment.
Valve should be stored in an upright position, protecting the piston and internal parts.
Internal parts should stay lubricated with synthetic grease, Mobil SHC 220, Mobilith or equal.
If the valve is in storage more than 6-15 months, the valve should be disassembled, the bonnet pulled and the piston
cap seal and o-ring inspected and changed. Clear all debris from internal parts, lubricated with recommended lubricant.
For assembly procedures, see Section 6.
If additional information is needed, please contact your sales representative or call the location shown on the cover of
this manual.
Valve “Calibration”
The valve adjusting nut (item 32) should be tightened (rotated clockwise looking at the top of the bonnet) to increase the
compression on the load springs and thus increase the setting indicated by the calibration plate. Likewise, the nut should
be loosened to lower the set pressure. Going from a higher setting to a lower setting with pressure on the valve could
inadvertently cause the valve to “trip”. Increasing the set point with pressure on the valve is generally not a problem.
Although all NOV Reset Relief Valves are calibrated at the factory, because of the variety of mud types, it is important to
verify the operating characteristics of the valve in a particular system and with the mud being used to determine if any
additional adjustments are needed. Please refer to the section on valve calibration in this section.
The valve should be bench tested on a regular basis to verify proper calibration and accuracy. As mentioned, NOV can
provide a complete portable test unit for a modest price. For calibration purposes, an accurate “test” gauge should be
used (usually plus or minus 1/4% of the full scale reading). The gauge should be connected so that it indicates pressure
in the lower end of the valve. If any gauge with a built-in dampening device is used, the line pressure should be built up
slowly to allow for the actual system pressure and gauge pressure to stabilize. If possible, the system pressure should
be built up slowly and gradually with little or no pressure pulsations. Remove the adjusting nut (item 32), upper spring
retainer (item 34), two load springs (item 37), four socket head cap screws (item 50) and the bonnet cover (item 29) so
that the lower spring retainer can be lifted and turned. Drive out the ¼” Spirol Pin (item 40) from the back side (bonnet
side) of the lower spring retainer. Replace the bonnet cover using new NOV socket head cap screws. Replace the
remaining components.
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gauge pressure indicated. If the valve “tripped” before the gauge reached the pressure indicated on the calibration plate,
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 of
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). Once
the “zero” setting is close, it is time to check the “span” or upper setting.
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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 of
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 in
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 a
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 reset
crank. Replace the roller with a new one and install a new pin.
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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
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position during assembly (the pad end of the lower link is to be farthest away from the bonnet flange while both pads are
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, it
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 been
disconnected. If the valve was supplied with 1502 connections (see section 8), the inlet adapter will need to be removed.
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 cap
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 the
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 in
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.
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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.
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Reset Relief Valve –C 34000
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 the
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 basically
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 against
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 outer
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 lower
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” Spirol
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). Align
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, and
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" on
page 16. The valve is now ready for calibrating.
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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 accurately indicate the actual relief pressure. When the valve has been completely torn down and reassembled,
it will be necessary to re-calibrate the valve, even if no new components have been installed. Binding or interference
between parts, any and all moving parts, especially parts associated with the linkage assembly, will cause the valve to
operate improperly.
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Maintenance 7-1
Torque 7-1
Inspection 7-2
Tools Required 7-2
Replacement Seal Kit 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 torque
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 of
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-in
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
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Reset Relief Valve – C 34000
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.
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.
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Bushings
Figure 8-1-1. 1002 - Hammer Union, Part No. 31893 (Flange 1002 Female)
Item Description Part
No.
1 Flange 1002 Male Connector 31891
2 Detachable Nut 31881
3 Nitrile Seal Ring 31884
4 Female Half (Butt Weld Prep 31871
Piece)
5 Retainer Segments (3 ea. 31926
included)
6 Retainer Ring 31927
Figure 8-1-2. 1002 - Hammer Union, Part No. 31894 (Flange 1002 Female)
Figure 8-1-3. 1502 - Hammer Union, Part No. 31885 (Flange 1502 Female)
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Reset Relief Valve – C 34000
Figure 8-1-4. 1502 - Hammer Union, Part No. 31886 (Flange 1502 Female)
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Class Type “C”W/3”-1502 Connection Drawing
Installation and Operation Manual
Reset Relief Valve – C 34000
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Class Type “C”W/3-1502 Connection Parts List (Continue)
Section 2.4
Pressure Gauge
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