BH800III Operation Manual[1]

INSTRUCTION MANUAL

FOR BH-800Ⅲ TRIPLEX MUD PUMP

XI’AN BAODA HAIYOU NEW TECHNOLOGY CO., LTD.

JUNE 2007

INSTRUCTION MANUAL FOR BH-800III MUDP

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Foreword

This manual is provided for guidance of those who wish to install, adjust and maintain BH-800III mud pump, operators should thoroughly read the manual before running the mud pump.

The manual introduces the pump specification, main components structure, routine maintenance, trouble search and shooting as well as operation procedures, it gives you some information to operate the pump correctly.

The manufacturer reserves the right to modify the product design and drawing on the existing basis without notice, if you have any special requirements, keep in touch with us at any time.

The suggestion and advice put forward by the readers will be highly appreciated.


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Content

1. General.................................................................................................................................4 2. Technical parameters......................................................................................................4 3. Structural features ..............................................................................................................6

3.1 Power end (see Figure 2)...........................................................................................6 3.2 Fluid end (see Figure 6) .........................................................................................8 3.3 Lubrication system of power end (see Figure 8)................................................13 3.4 Lubrication system of fluid end (see Figure 9) .....................................................15

4. Installation of new pump ..................................................................................................17 5. Pump application ..............................................................................................................18 6. Pump maintenance............................................................................................................19

6.1 Maintenance of power end .....................................................................................19 6.2 Fluid end maintenance............................................................................................28

7. Periodic maintenance regulations....................................................................................30 8. Troubleshooting.................................................................................................................33 9. Expendables list.................................................................................................................35 10. Special tool list...........................................................................................................36

Affixture:BH-800Ⅲ TRIPLEX MUD PUMP PARTS LIST


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1. General

BH-800III triplex single acting mud pump is the new model one developed by

our company. It takes the advantages of high efficiency, light weight and novelty

construction, being ideal equipment for drilling, workover and completion

operations.

2. Technical parameters Type: Triplex single acting piston pump

Max. horsepower: 800HP (588kW)

Rated strokes: 175r/min

Stroke length: 8 1/2¡± (216mm)

Max. working pressure: 5000psi(35MPa )

Gear ratio: 4:1

Valve pot size: API 7#

Inlet diameter: 8¡± (203mm)

Outlet diameter: 4¡± (102mm)

Weight: 22000Lbs (10000kg)

Overall dimensions: L145.5¡± W98.5¡± H88.5¡±(3700x2500 x2250mm)

Performance data: Power Liner Dia & Pressure Mpa (PSI)

7¡± 6 ½¡± 6¡± 5 ½¡± 5¡± 4 ½¡± 4¡±

12.4 14.4 16.9 20.1 24.3 30.0 35

1771 2057 2414 2871 3471 4286 5000

Strokes/m

in

kW HP

Displacement (L/S)

175 648 880 46.90 40.43 34.48 29.05 23.98 19.43 15.49

160※ 592 805 42.88 36.96 31.52 26.56 21.92 17.76 14.16

150 555 755 40.20 34.65 29.55 24.90 20.55 16.65 13.28

140 518 705 37.52 32.34 27.58 23.24 19.18 15.54 12.39

130 481 654 38.84 30.03 25.61 21.58 17.81 14.43 11.44

120 444 604 32.16 27.72 23.64 19.92 16.44 13.32 10.56

110 407 554 29.48 25.42 21.67 18.26 15.07 12.21 9.68

1 0.268 0.231 0.197 0.166 0.137 0.111 0.088


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Note：Based on 100% volumetric efficiency and 90% Mechanical efficiency.


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3. Structural features

3.1 Power end (see Figure 2)

The power end consists of frame, pinion shaft assy., crankshaft assy. and

crosshead assy., etc.. It has the features of novelty structure, high strength and

rigidity, light weight and long service life.

3.1.1 Frame

Box-type frame is made of steel plates by welding and stress-relieving treated to

provide the optimum rigidity and the high strength as well as bend resistance

capacity. Frame, where other components are all mounted, is the foundation of the

pump. Necessary oil bath and oil line are provided on the frame for cooling and

lubricating. The oil reservoir lies below to lower the pump gravity center, which

improves pump stability. The sleeve type main bearing carrier can largely better the

stress state of the frame.

3.1.2 Pinion shaft assy.

Pinion shaft is through shaft , one end with the pinion for transmitting the torque,

and the other end is the secondary shaft for driving the lube oil pump. The

cylindrical roller bearings are used. The pinion is herringbone gear and the teeth

surfaces are specially heat-treated (ion treatment). It has the features of smooth

running, high strength and long service life.

3.1.3 Crankshaft assy. (see Figure 4)

Crankshaft combines casting shaft with eccentric cam, the casting shaft is

forged from alloy steel and the eccentric cam cast from alloy steel. It can withstand

higher load. The ring gear, connecting rods and bearings are mounted on the

crankshaft.


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3.1.4 Crankshaft assy. (see Figure 5) Crankshaft combines casting shaft with eccentric cam, the casting shaft is

forged from alloy steel and the eccentric cam cast from alloy steel. It can withstand

higher load. The ring gear, connecting rods and bearings are mounted on the

crankshaft.

The herringbone gear which meshes with the pinion is of interference fit with

the crankshaft, and fastened with bolts and lock nuts.

The big ends of the connecting rods are mounted on the crankshaft via

single-row cylindrical roller bearings while the small ends of them are mounted on

crosshead pins via double-row cylindrical roller bearing.

The crankshaft is mounted on the frame via double-row radial spherical roller

bearings and a bearing sleeve is mounted to protect the bore of the bearing carrier

on the frame. The bearing bore is taper 1:12 for easy assembly and disassembly.

3.2 Fluid End (see Figure 6)

The fluid end consists of three interchangeable fluid cylinders. The suction

valve and discharge valve are separately installed in every cylinder block. Loose

the thread ring(15)bore, remove cylinder(11)head and spring(14),the discharge

valve assy. can be removed. Loose the thread ring, cylinder head, and bolt of

locating ring, turn to 90°the locating ring the suction valve assy. can be removed.


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The three bottom cylinders are connected to the suction manifold by the bolts, the

top cylinders to the discharge cross where there are two outlets, one is used for

connecting discharge screen and pressure gauge, the other for KB45 pulsation

dampener, shear relief valve.


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3.2.1 Cylinder block The cylinder block is ¡°I¡± type and made of forged alloy steel. The fluid flows at the same rate in each cylinder block, which can make the valve assembly avoid the effect of orthogonal fluid drained from the adjacent cylinder block. The dimension of valve pots conforms to API specification and the cylinder blocks are interchangeable.

3.2.2 Liner, piston, coupling

Bi-metal liners and common liners are both available, of which bi-metal liner

sleeve is made of wear-resisting casting iron, the surface hardness is HRC 60~65.

Therefore, the liners are wear resistant and corrosion resistant. The liners are


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made in different sizes form 4¡åto 7¡ådifferent drilling conditions. They are installed

from the top of frame and fixed by compression plate and bolts. The seal of the liner

put on groove of end liner.


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The piston consists of piston hub, rubber cup, plate and snap ring. There are

totally 8 sizes of pistons ranging from 4¡åto 7¡å. The piston is fitted with piston rod and

sealed with the seal ring, and tightened with locknuts. After fastening lock nuts, it

not only can prevent the nuts from loosing, but also can seal.

Coupling is used for connecting extension rod to piston rod. The pin hole fit

ensures the concentricity of extension rod and piston rod. The coupling is easy to

assemble and disassemble.

3.2.3 Thread ring, flange and cylinder head

The thread ring and flange are bolted to the cylinder block while thread ring

connects flange by the saw-toothed thread, tightly compressing the cylinder head

and guide sleeve. For disassemble the liner the cylinder head have the bore. With

tightly plate design for guide sleeve(lower),loose the tightly bolt (stainless steel)

turn to 90°the locating ring, the suction valve assy. can be removed.

3.2.4 Valve assy.

API 7¡± valve is used in the valve assy.. The sizes of valve seat and valve pot are

all in compliance with API 7K Spec, and the suction valve and the discharge valve

are interchangeable.

3.2.5 Suction manifold and pulsation dampener

The suction manifold is welded by seamless tube; the desurger is furnished in

it. The pulsation dampener is cast by alloy-steel, built-in diaphragm. It should be

charged with nitrogen effectively to reduce the pulsation of discharge fluid.

3.2.6 Shear relief valve (see Figure 7)

The body of shear relief valve is of alloy-steel casting. The shear relief valve

can assure the safety of the equipment when the working pressure exceeds the

specified pressure. The shear pins are in the same diameter, when regulating

pressure, the shear pin should be inserted to the hole corresponding with the liner

size.


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3.3 Lubrication system of power end (see Figure 8)

The lubrication system utilizes the combination of splash lubrication and forced

lubrication. The splash lubrication is used to lubricate gear, extension rod and

crosshead, the oil carried by gear and connecting rod is transmitted into the oil

chamber of the frame, then flows to the extension rod surfaces and the oil pan of

crosshead baffle for lubricating crosshead pins and crosshead bearings. The

forced lubrication is used for input bearing, crank bearing and crosshead guide, i.e.

an independence oil pump is placed outside and driven by the input shaft,

secondary shaft belt pulley. the lubrication oil is, through oil filter, pumped into gear

oil pump and oil distributor so as to go into all the lubricating branch lines. An,


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shock resistant pressure gauge are mounted on the outlet of the oil pump, The oil

filter is self-sealed construction. So long as the filter screen is removed, the oil

reservoir will be automatically sealed off inside. Therefore it does not need to

release the oil when cleaning the filter screen, the inside of oil reservoir will open

automatically after finishing the wash and installing the filter element in position.

The lube oil pump are designed as a pump that can install in double ended,

installing in the opposite of the power input shaft, the direction of installing see


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figure 8 A-A. The rack both sides all have the motherboard for installing the gear oil

pump, but please attention both sides of the oil pump belts are different. The left

belt pulley position is outboard and the right one is inboard. When changing the oil

pump the direction, you need to change the oil filter head, liquidometer, pump

assembly, guard, suction and flowing lines, and so on..

Lubricant for power end:

Ambient Temperature: -1℃---+68℃ Use N320# mid-extremely pressure gear

oil (6#EP)


oil (4#EP)


oil (1#EP)

Note: The gear oil is sulfur-phosphorus type with 10% 4# compound anti-rust agent

Lubricant capacity: 250L

3.4 Lubrication system of fluid end (see Figure 9)

The lubrication system of fluid end mainly makes fresh water use of washing and cooling the liner and piston to ensure the piston of normal reciprocation and to prolong the service life.

The lubrication system consists of independent centrifugal pump,

explosive-proof motor, pipe and water tank. The cooling water is recycling, it is

necessary to clean the water tank and change the water timely.


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4. Installation of New Pump

BH-800III mud pump has been completely assembled and load-tested under

pressure before being shipped to the oilfield, unless otherwise instructed, the lube


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oil has been drained from the power end. Before putting the pump into service, the

following precautions and operations must be performed or checked.

In order to prevent personal injury during maintenance or inspection, this pump

MUST BE SHUT DOWN AND NOT OPERATING, and all the protection devices on

prime movers and drives MUST BE IN SAFE POSITION.

4.1 The base of the BH-800III mud pump is suitable for variety of installations. It

should be noted, however, that the box type construction of the power frame has

high resistance to bending but relatively less resistance against twist. Therefore,

the support under the pump must be level and solid to support the weight and

operating forces exerted by the pump. Additionally, trying to install the coupling,

cardan shaft and chain drive for the input shaft from.

4.2 Suction system requirements

Suction of BH-800III mud pump must have positive pressure for obtaining

satisfactory suction effect, the optimum suction pressure is 0.14MPa to 0.21MPa

(20psi to 30psi) for maximum volumetric efficiency and the longest service life of

the expendable. The positive pressure is supplied from charging pump.

Under some conditions, BH-800III mud pump may work without charging pump,

provided that the fluid level in mud pit is higher than the top of the liner, the viscosity

of the fluid conveyed by the pump is low, suction pipe is short, straight and of at

least the same diameter as suction manifold inlet.

The suction manifold should be piped with valve arrangements so that the

charging pump can be by-passed. So the operation of this mud pump can be

continued in event of charging pump failure which can be improved by replacing the

suction valve spring with a softer spring.

4.3 Caution

Do not pipe the return blow line from the shear relief valve back into the suction

system because the operation of shear relief valve may cause a sudden pressure

rise in the system, resulting in the damage of manifold, suction desurger and

centrifugal pump.


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4.4 Before BH-800III mud pump leaves the factory, the lube oil has been empty

in the pump. So it should be filled with new lube oil before the pump starts, the oil

level is subject to the oil scale, and the first filling should be near the top level. After

running 10 to 15 minutes, stop the pump and add some certain amount of lube oil

again for proper compensation as soon as the oil level is still.

5. Pump application

5.1 Preparation before startup

5.1.1 Fill in the pump with lube oil, the water tank of spay pump with fresh water.

5.1.2 Charge nitrogen in the pulsation dampener at the pressure of 2.5-4.5MPa

(it is not allowed to exceed 2/3 discharge pressure, maximum charging pressure is

4.5MPa).

5.1.3 Plug the shear pin of relief valve in the hole corresponding with the liner

size.

5.1.4 Barring-rotate the crankshaft 3 to 5 turns and check all parts for normal.

5.1.5 Connecting power components.

5.1.6 If the independent lube oil pump is used, first start it for running several

minutes and make sure the system is in good condition, then start the mud pump.

5.1.7 When first running the pump it should be opened the cover and filled lube

oil to guide crosshead pin.

5.1.8 Start up the spay pump and observed the efficiency.

5.2 Pump startup

After being sure everything gets ready, turn on the prime mover and drive the

pump running.

5.3 Pump running

5.3.1 Idle-run the pump 20 to 30 minutes (gradually enhance the strokes and

open idle circulation valve), after the pump has run normally, increase to the

working pressure gradually.

5.3.2 During running, check the pressure of lubrication system for being within

0.1MPa and 0.6 MPa.


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5.3.3 During running, observe pump stroke gauge and make sure the pump

strokes should not be higher than 175 r/min.

5.3.4 During running, observe pump pressure and make sure the pump pressure

should not exceed the pressure of corresponding to the liner size.

5.3.5 During running, observe the operation state of the pump and all the

components. If find any problem, stop the pump and shoot the trouble according to

the instruction. It is prohibited to repair the pump during running.

5.3.6 BH-800III mud pump combines splash lubrication with forced lubrication.

When the input shaft is used to drive the gear oil pump for lubrication, the pump

strokes should not be lower than 30r/min, otherwise the pump lubrication will not be

adequate.

5.4 Stopping the pump

5.4.1 After finishing the operation, slowly reduce the pump pressure value to

zero, then pump the fresh water to wash the discharge manifold until the drained

water become clean when the mud pump can be shut down.

5.4.2 If the pump stops running more than 10 days, you should wash and seal

the fluid end with grease.

5.4.3 If the climate is cold at the temperature of about 0℃, you should drain the

seep in fluid end away to prevent the cylinder from freeze-cracking.

6. Pump maintenance

6.1 Maintenance of power end

Routine inspection of the power end is the most important form of preventive

maintenance and will result in considerable savings by detecting any major trouble

that might be developing and allowing the necessary repairs to be made on a

planned or normal rig-down time.

6.1.1 Bolts and safety wires

Check safety wires and all the bolts including the crankshaft bearing baffle bolts,

connecting bolts, gear hold-down bolts and guide bolts for tightness, replace any

broken wires with new ones after tightening the bolts.


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6.1.2 Oil lines

Check all oil lines to insure that they are intact and free of obstructions. Check oil

pump suction hose for damage or flat areas. Check the clips of the oil lines for

reliability, and the joints for loose. If find any problem, should solve it timely.

6.1.3 Suction filter

Check the condition of suction filter. Clean and replace as required.

6.1.3.1 Oil filter cleaning method

Self sealing magnetism oil filter(CXL-100X80L)is mounted on the left side of the

lower oil tank in BH-800IIImud pump.

Features:

1) During the disassembly of the oil filter, the automatic valve can be

automatically closed to prevent discharging of lubricant oil. It’s not necessary to

drain the oil in the oil tank for easy operation.

2) Permanent magnet is installed in the oil filter to absorb the metal substance.

3) A by-pass valve is equipped and can be open automatically to protect the


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pump from damage when the oil filter is blocked.

6.1.3.2 Disassembly operation of the oil filter

6.1.3.2.1 Remove the center screw(1),mandrel(5).Pull the filter screen out. (6)

The self sealing valve will seal the oil in the oil tank.

Remove the press cap. It will be normal that some oil in the drainer flow out.

Disassemble the strainer and the mandrel.

6.1.3.2.2 Wash and clean the drainer and the permanent magnet to remove the

sticking feculence by pure gasoline or diesel.

6.1.3.2.3 Assemble the mandrel (pay attention to the direction), filter screen,

spring in turn. Tighten the press cap. The assembly will be done after screwing on

the center screw.

Note: During the assembling of the mandrel, the end with shoulder should be

installed inside and the round end should be installed outside. Make sure the

sealing element should be assembled in right way (See Fig. 10)

6.1.3.3 Caution

Performance test of BH-800III mud pump have be done before the delivery. The

oil filter has been cleaned couples of times.

The initial period of the operation is running-in period to the mud pump. It is

unavoidable that the filter screen will be jammed by the feculence.

Make sure to pay attention to the change of oil pressure gauge frequently. If the

pressure is lower than 0.05MPa, the oil filter should be cleaned as soon as

possible.

During the initial period of the operation, the filter should be washed and cleaned

at least one time per week. The cleaning period will be prolonged accordingly after

above mentioned period.

In the meantime ,the lubrication oil should be replaced periodically.

For the first time, the lubrication oil should be replaced within one week.

For the second time, the lubrication oil should be replaced within one week.

The lubrication oil should be replaced in accordance with Instruction Manual after


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two times replacement. The lubrication oil should be replaced no later than six

months.

Before replacement of lubrication oil, the operator should wash and clean the oil

tank and the guide cavity. Pump the oil by the filter. Inspect the oil pipelines and

make sure there’s no any block in the oil pipelines.

6.1.4 Main bearing cover

Remove the main bearing cover to clean and get rid of any sludge or foreign

materials that might have accumulated at the bottom of the bearing area.

6.1.5 Gear and pinion

Inspect the condition of the gear and pinion teeth for any indications of abnormal

wear. During the initial break-in period there will be some pitting on the gear tooth

surfaces. This is referred to as ¡°initial pitting¡± and is not harmful to the life of the

gear. However, if routine inspection indicates that the degree of pitting continues to

increase, immediately contact the pump manufacturer for a more thorough

inspection of the gear.

6.1.6 Lube oil and oil reservoir

Check the lube oil quality and cleanliness of the oil reservoir. If necessary,

replace the lube oil and maintain the lubrication system as described in the manual.

6.1.7 Maintenance of roller bearings

The roller bearings are used in BH-800III mud pump, they are of precise

machinery parts. Therefore careful maintenance is required in order to obtain the

long service life and high load characteristics.

The main bearings are double-row spherical roller bearings. The pinion shaft is

mounted on the long roller bearings without inner race shoulder. The eccentric

bearings are cylindrical roller bearings with thrust plates on each side to keep the

connecting rod in center line, and the crosshead pin bearings are double-row long

roller bearings.

The inner and outer races of all bearings are assembled by means of very

accurate fits. This accuracy is necessary, for the bearings are to be used again, the


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inner and outer races and the roller assembly of each bearing must be kept

together, and reinstalled exactly as they came off.

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.

Roller bearings are generally assembled to their shafts by means of shrink fits

(Exception of the main bearings which are taper fit, the moving clearance may be

adjustable). Damaged or worn bearings and raceways can be removed by driving

them off the shaft with a copper bar or 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 149℃

(300oF), being certain that both the oil and the container are very clean. If an

electric heater is used for heating, place a rack into the oil container so that the

bearings will not rest on the bottom. Do not leave the bearings in the oil bath longer

than 10 minutes to avoid the bearing from tempering and softening, shortening the

service life.

The heated bearing should be placed on the shaft immediately and held in

position, and it must be cooled naturally. NEVER USE WATER OR ANY OTHER

LIQUID TO COOL A HOT BEARING. Rapid cooling will cause the bearing

heat-cracking and the bearing will fail immediately.

Before installation, the bearing should be protected from dirt and other foreign

materials at all times. It will be allowed to install only after the bearing is cleaned

with clean kerosene or other solvent and coated with grease.

6.1.8 Installation of pinion assy. (see Figure 3)

Gear shaft is through shaft construction. It support by three same type

bearings and too end size are same.

The pinion shaft is of two-piece combination construction, the left and right hand


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gear shaft .the shaft left and right gears are assembled on the shaft by key.

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 of the bearings should measure up the precision and specification as

shown in design drawing and process.

When installing the pinion shaft assy. in the pump frame, observe the following

precautions:

1). Thoroughly break burrs, dents or gouges from bearing carrier, bearing cap

and bearing surfaces, and wash them clean.

2). First install the right bearing carrier in the frame, then hoist the left input shaft

assembly horizontally and place it into the frame, finally install the right secondary

shaft assembly in position.

3). When installing the bearing carrier and bearing cap, the oil return hole should

be down.

4). Insure all parts should be installed in right position.

5). Tighten bearing bolts to the torque value shown below:

For bolt M16, torque value is 135~170 N.m (100-125ft. lbs).

Check the condition of the pinion bearing inner and outer races and rollers. If

there is any indication of galling, flaking, or if radial clearance exceeds the range

0.20-0.25mm, it is recommended the entire bearing be replaced.

6.1.9 Installation of Crankshaft assy. (see Figure 4)

The crankshaft assembly consists of the crankshaft, ring gear, connecting rod,

bearings and the bearing carriers.

The running clearances of the bearings are predetermined by their precision fit to

the shafts and the bearing carrier bores. When performing any maintenance or

overhaul, make sure the fits of the bearings should measure up the precision and

specification as shown in design drawing and process.

6.1.9.1 Disassemble the crankshaft in the following manner:


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1). Loosen main bearing bolts and remove the pressure plate

2). Remove the bolts of bearing carrier, two side plates of crankshaft, then press

the bearing carrier by the screws tightly and impose force to the oil hole on the

shaft end by hand-operated pump until the main bearing is taken down.

3). Remove crosshead bolts and eject crosshead pins.

4). Take out crankshaft and connecting rod from the open area by special hoist to

avoid galling the crosshead guide.

6.1.9.2 Assemble the crankshaft in the following manner:

1). Thoroughly clean matching faces of ring gear and flange, and insure the gear

tooth surface is smooth without galling or dent. Tighten the flange by bolts sized

M27 at the torque of 747 Nm (551ft.lbs).

Check the end face and the run-out of the ring gear. If the run-out exceeds

0.15mm, remove the ring gear and find out the cause of misalignment.

2). Install the outer races of the eccentric bearings in the big end eyes of three

connecting rods and the outer race retainer must be positioned. Tighten retainer

bolts and lock them with safety wire.

3). Install the outer race of the crosshead bearings in the small end eyes of three

connecting rods. It is preferred that the outer race assembly be ¡°pressed¡± into

position through ¡°dry ice¡± (CO2) freezing method. Under emergency circumstances,

the outer race assembly can be installed by using a large torch and heating the eye

of the connecting rod. DO NOT EXEED 149℃ AND COOL THE ROD SLOWLY. A

thermoscope can be used.

4). Install the inner race of the crosshead bearing on the crosshead pin (heating

in oil bath) and mark them according to their respective connecting rod positions. It

is prohibited to make them confused.

Note: The inner and outer races of the eccentric bearings are pair-matched and

must not be intermixed.

5). First install inner race of the center eccentric bearing on the shaft, then the

inner races of the other eccentric bearings, and pair-matched installation is a must.


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Finally slide the center rod and the other rods into position. Clear away the foreign

materials in the thread holes and wash the screws, then apply Lock to the screws

and lock them by safety wires. Pay attention to the direction and retainer during

installing the bearing inner races.

6.1.9.3 Installing crankshaft assembly in frame

1). Place three pieces of wooden blocks on three crosshead guides (lower) to

protect the guides from scoring or gouging as the rods are sliding into position.

2). Lift and put the crankshaft (excluding main bearing) into the frame by a

special hoist and link the crossheads to the small end of the connecting rods.

3). Place the main bearing carriers into the crankshaft ends from two sides.

4). Position the crankshaft correctly and adjust the working play of main bearing

on the left side. As the inner diameter of main bearing is taper 1:12, the working

play is adjusted by the shims and should be between 0.062 and 0.193mm, which

can be inspected by depth micrometer.

5). With the same method as described in above item 4, adjust the working play

of main bearing on the right side and keep the clearance of 1.5mm to 2.5mm

between the bearing cap and bearing.

6). During installation, frequently check the rollers in the main bearings for

tightness, the total number of tight rollers could be equal in each row, ensuring that

each bearing is equally loaded.

6.1.10 Installation of crossheads and guides (see Figure 5)

6.1.10.1 The crossheads are generally installed before the crankshaft, maybe

done from the front opening for easy inspection and repair. For the detailed

installation, observe the following procedure and precautions:

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. The

contact face between the guide and crosshead should also be polished.

2). If old guides are to be reused, inspect the working surfaces for wear and

scoring streaks. If present, the old guides should be replaced by the new ones.


27

3). Install upper and lower guides with the torque value of 200~270N.m

(150~200ft. lbs) and check the fitness between frame and guide to ensure that the

guides fit into frame bore closely, it is inspected with 0.05mm feeler gauge.

4). Push the crosshead in the position by padding the small end of the

connecting rod and rotating the pump. Slide the crosshead pin into its taper bore to

form closest fit by moving the small end of the connecting rod up and down.

5). After the crosshead pin is really put in position, add the adjustable shims

according to the pin protrusion length checked by depth micrometer and apply Lock.

It should be noted that the oil groove opening for crosshead pin baffle is upward.

The screws are tightened with the torque value between 185Nm and 205 Nm.

6). Check running clearance of crosshead by inserting a long feeler gauge

between the crosshead and upper guide. The clearance should be ranged from 0.4

to 0.5 mm. Check with the long feeler gauge over entire surface of crosshead. Less

running clearance can be caused by ¡°swelling¡± from over tightening the crosshead

pin retainer bolts. If present, loosen the crosshead pin and retighten it as per

specified torque value.

7). If the crosshead and lower guide are found slight scoring, the crosshead may

be rotated 180℃ for use. But the scoring area and the taper face between

crosshead pin and crosshead must be ground, and the crosshead pin is not

allowed to change lest the bearing should not be matched.

6.1.10.2 Checking crosshead alignment

The three shaft holes of BH-800III mud pump have been aligned on the basis of

the front wall holes of the frame by the special fixture in the factory. The tolerance

should be ±0.38 mm horizontal, ±0.25 mm vertical. In order for the pistons to

linear-run in the liners, the crosshead alignment should be checked after changing

the guide and crosshead.

1). Take out the piston and check the clamp for precise setting. Based on the

inner bore of the liner, accurately measure the distance from the diaphragm plate

bore to the crosshead extension rod at the top and bottom, front and rear with


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inside calipers or telescoping gauges. Compare these measurements to determine

if crosshead is running horizontally.

2). If the lower piston rod is not in the limited tolerance, steel shims should be

inserted under the lower guide to bring the piston rod back to center. Due to

characteristics of triplex pump operation, the lower guide is largely forced, namely,

the crosshead pressure is always on the lower guide. It is permissible to shim the

guides on a taper, providing firm support for the guide.

3). The shims should be long enough to reach completely across the guides.

After the clearance between crosshead and upper guide reaches 0.4mm ~ 0.5mm,

tighten the bolts of lower guide to the specified torque value.

6.2 Fluid end maintenance

As the drilling technique is developing more and more, pump pressure has

become a major factor to consider in high-speed drilling operation. Therefore the

higher and higher requirements have been imposed to the fluid end.

6.2.1 Attention to following points during application and installation:

1). Make sure all valves on the discharge side of pump are opened before the

pump is put into operation. Kicking pump in against a closed valve can often be the

start of a fatigue crack.

2). Do not engage pump clutch when prime mover is running at a high rate of

speed. To do so can cause undesirable impact loads against both power end and

fluid end.

3). Properly maintain shear relief valve to ensure it can work when exceeding the

pressure rating (the pressure is related with the liner size being used).

4). Do not operate the pump for an extended period of time if a severe fluid knock

is present.

5). The maintenance of fluid end. After the pump is to be shut down or not

operated for some times, the fluid end should be timely flushed out with fresh water

and coated with grease to prevent against rust.

6). Cylinder block. Before connecting cylinder block to the frame, all burrs and


29

dirt must be removed from the mating surfaces or boss, otherwise cylinder block

could make up in a cocked or misaligned position. Place the seal rings in position

and be sure that the connecting bolts are reliably tightened with the torque value of

1900 Nm.

7). Suction manifold. The suction manifold is bolted to each cylinder block.

Before installation, thoroughly clean seal groove, the sealing surface on bottom of

the cylinder block in connection flange, and replace seal before bolting manifold

into position. Any burrs and nicks at the groove edges or on the sealing surface

must be repaired.

8). Discharge manifold. The discharge manifold is bolted to each cylinder block

and sealed through the seal in the connection flange. Thoroughly clean the seal

groove, the 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

seal, tightening the bolts to torque values of 1055Nm (778 ft.lbs).

9). Charging instructions of pulsation dampener (see Figure 11)

A set of charging device (including charging hose assembly) will be supplied with

the pump during delivery, charging procedures should be followed below:

1). Remove dampener gauge cover and bleed off any existing pressure in the

gauge area by turning purge valve cap approximately 1/4 to 1/2 turn. Then remove

purge valve.

2). Connect charging hose to dampener charging valve and nitrogen cylinder

valve.

3). Open dampener charging valve.

4). Slowly open the cylinder valve to regulate nitrogen flow to dampener by this

valve.

5). When the dampener pressure gauge shows the desired charging valve

pressure, close nitrogen cylinder valve and dampener valve.

6). Remove the hose from dampener charging valve and install purge valve.

For best results, dampener pre-charge pressure should be not more than 2/3 of


30

pump discharge pressure. Maximum pre-charge pressure is 650 PSI (4.5 MPa).

WARNING:

1). USE ONLY NITROGEN OR COMPRESSED AIR; DO NOT CHARGE WITH

OXYGEN OR OTHER INFLAMMABLE GAS.

2). WHEN MAINTAINING THE DAMPENER, THE PUMP PRESSURE AND

DAMPENER PRESSURE MUST LOWER TO ZERO.

7. Periodic maintenance regulations

To check and maintain BH pump properly and timely is the necessary measure to

assure the normal working and prolong the service life.

7.1 Daily Maintenance items

1). After stopping the pump, check the oil level of power end, at least once a day.

2). Check the working of liner and piston. It is normal that a little mud is taken out

with piston, if there is sound-leakage, the piston should be timely changed. Check

the abrasion of liner inner bore, if the abrasion is severe, the liner should be

changed in time.

3). Check the liner compartments of the frame. The mud and contamination

should be cleaned.

4). Check the water tank of spray pump. The water should be supplied if there is


31

not enough. The polluted water should be changed and the water tank should be

cleaned.

5). Check if the pressure of discharge pulsation dampener meets the

requirements ranged from 2.5 to 4.5 MPa.

6). Check the lube oil pump for the variation of pressure gauge, if the pressure is

very low (lower than 0.035MPa) or no pressure, check if the suction filter screen

are plugged.

7). Check the reliability of shear relief valve, if necessary, they should be

changed.

8). Loose the coupling of piston rod every day, check if the pyramidal face of

coupling and the junction face of piston rod and extension rod are clean, rotate the

piston rod a quarter round and tighten it. The purpose of doing that is to make the

wearing face evenly and prolong the service life of liner and piston.

9). Check the bolt 1/2¡±-13UNC of suction valve (see fig 6 item 20),if it’s loosing

it should be tighten it .before tightening the valve bonnets and cylinder heads, coat

the lubricating grease on the threads and check them for loosing.

10). Check thread ring seal, liner seal and extension rod seal, if the mud

discharges, the relative seal ring should be changed.

7.2 Weekly maintenance

1). Disassemble the valve bonnets and cylinder heads and clean them every

week, meanwhile coat the molybdenum disulfide complex calcium base grease.

Check the inner sleeves (rubber) of valve guide, if there is obvious abrasion, and

the clearance is too big, it should be changed to avoid the guide failing to guide

sleeves the valve motion in the right way and accelerating the abrasion of valve.

2). Check the valve and valve seat change the worn or pierced valve body, valve

rubber and valve seat. Check the valve spring and change the broken or inelastic

spring.

The valve seat puller (see Figure 12) is supplied with the pump to take out the

valve seat. The usage is that the valve seat puller, after putting into the seat, hang


32

up the bottom of the seat. Then screw nut M42 x 3 and strike the top cylinder block

and the end of screw 1 5/8¡±-8UN by a copper bar at the same time, in this case

the valve seat will be pulled out.

3). Check the locknuts of piston. The corrosive or damaged locknuts should be

changed. The seal rings in the locknuts will fail and should be changed after the

locknuts are tightened three or four times.

4). Check and clean the filter screen in the lubrication system.

7.3 Monthly maintenance

1). Check all the stud bolts and nuts of fluid end, for example, bolts and nuts

among cylinders, bolts and nuts connecting the valve bonnet and flange, the bolts

and nuts on discharge manifold. If they are loose, they should be tightened to the

specified torque value.

2). Check the seal rings in the packing box of extension rod. The worn one

should be changed. Usually, change it at least once every three months. Attention

should be taken to the oil seal position when changing (the lip should be inward).

3). Remove and clean the discharge manifold.

4). Change the dirty lube oil in the power end once every six months and clean

the oil pool and fill in new oil at the same time.

7.4 Yearly maintenance

1). Check if the crosshead and guide are loose, if the crosshead running

clearance conforms to requirements. The clearance can be adjusted by adding

shim under the guide, see Clause 6.1.10 Installation of crossheads and guides.

2). Check the whole pump completely every two years, check if the main bearing,

connecting rod bearing, crosshead bearing, input shaft bearing are worn or

damaged. They should be changed if they can not be used any more.

3). Check the wear or pitting of gear, if worn sharply, the ring gear should be

replaced.

7.5 Cares should be taken for the following in maintenance

1). When connecting the extension rod and piston rod, the setting pin bore and


33

the 22° taper face should be cleaned.

2). When changing the liner, the liner seal ring should be changed as well.

3). After stopping the pump in winter, the mud in the valve compartment and liner

should be discharged and cleaned completely, then apply the lubricating grease to

valve and liner.

4). The discharge pulsation dampener is only allowed to charge inert gas (such

as nitrogen) or air. No inflammable and explosive gases are allowed such as

oxygen and hydrogen, etc.


34

8. Troubleshooting

8.1 Trouble and troubleshooting of fluid end Trouble Cause Troubleshooting

1. The pressure readings become

low and the displacement

reduces or no mud discharged.

1.The charging piping is not sealed off and the

air gets in the pump.

2.The suction filter screen is plugged.

1. Tighten the flange bolts of charging piping

or change the shim.

2. Stop the pump and clean the suction filter

screen.

2. Uneven discharge. The

pressure gauge fluctuates. The

charging piping has abnormal

noise.

1. A piston or a valve is worn out or damaged.

2. There is air in the pump cylinder.

1. Change the damaged piston and check if

the valve is damaged or plugged.

2. Check if the charging piping and valve

bonnet are sealed off.

3.There is severe slap in the liner. 1.The piston nuts are loose.

2.The liner cover is loose.

3.The suction is not good to cause water dash.

1.Tighten the piston nuts.

2.Tighten the liner cover.

3.Find out the reason of improper suction.

4.The mud leakage from thread

ring 1, thread ring 2 and liner

seal.

1.The thread ring is not tightened.

2.The seal ring is damaged.

1.Tighten thread ring 1 and thread ring 2.

2.Change the seal ring.

5. The pulsation dampener can’t

be charged or it leaks after

charging.

1.The charging connector is plugged.

2.The diaphragm of the pulsation dampener is

broken.

3.The charging valve is not sealed.

1.Clean the connector.

2.Change the diaphragm.

3.Repair or change the charging valve.

8.2 Trouble and troubleshooting of power end Trouble Cause Troubleshooting

1..Overheat of

bearing

1.The oil pipe or oil port is plugged.

2.The lube oil is too dirty or deteriorated.

3.The roller bearing is worn or damaged.

4.The lube oil is too much or too little.

1. Clean the oil pipe or oil port.

2. Change oil.

3. Repair or change bearing.

4. Add proper amount of oil.

2. There is slap

on the power

end.

1. The crosshead guide is worn out sharply.

2. The bearing is worn out.

3. The bearing is loose.

1. Adjust the clearance or change the

worn guide.

2. Change the bearing.

3. Tighten the bolts of guide.

8.3 Besides the above estimated trouble, if other abnormal phenomenon is

found, the reason should be found out according to the trouble spot. The pump can


35

not run until the trouble is solved.

9. Expendables list ITEM

PART NO. DESCRIPTION QTY PER

PUMP

MOUNTING POSITION

1 JB/ZQ4265-86 D90 Yx seal ring 6 For extension rod

2 R39 Gasket ring 5 For discharge manifold

3 R35 Gasket ring 3 For pulsation dampener manifold

4 NB-02Y-10 Liner seal 3

5 NB-02Y-13 Liner seal 3

6 NB-02Y-18 Valve spring 6

7 NB-02Y-20 O-ring 3 For discharge pipe

8 NB-02Y-28 O-ring 3 For suction pipe flange

9 GB3452.1-92 O-ring 47.5 x 3.55 3 For piston rod

10 NB-02-29-09 Bladder 1 In suction

11 45L Diaphragm 1 In pulsation dampener

12 JA-3 Shear pin 5 In relief valve

13 JA-3 Bumper 1 In relief valve

14 JA-3 Piston 1 In relief valve

15 NB-02Y-08 Liner 3 As per liner size

16 NB-02Y-09 Piston assy. 3 As per liner size

17 NB-02Y-17 Valve assy. 3

18 NB-02Y-26 Valve. guide sleeve 3


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10. Special tool list

ITEM

PART NO. DESCRIPTION QTY PER

PUMP

APPLICATION POSITION

1 NB-07Y- 01-0GJ Valve seat puller 1 Pulling out valve seat

2 NB-07Y-02GJ Socket spanner 37/ 7/8¡å 1 Unscrew nut 7/8¡å

3 NB-07Y-03GJ Thread ring bar 1 1/2¡å 1 For disassembling thread ring

4 NB-07Y-04GJ Socket spanner51/ 1 ¼¡± 1 Unscrew nut 1 1/4¡±

5 NB-07Y-05GJ 24¡± force rod 1 Tightening bolts

6 NB-07Y-06GJ Charging hose assy. 1 For pulsation dampener

7 NB-07Y-07GJ 1 ¡±/ 1 1/8¡± hammer

spanner

1

8 NB-07Y-08GJ 47/ 1 1/8¡± hammer

spanner

1

9 NB-07Y-09GJ 51/ 1 1/4¡± hammer

spanner

1 For hang up liner

10 NB-07Y-10GJ Tools for liner 1

11 NB-07Y-11GJ Cylinder head puller 1

12 Inner hex spanner 1 Disassemble crosshead guide

Date post:	21-Jul-2016
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BH800III Operation Manual[1]

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