User Manual of HHF-1600 Direct-Drive Utilized Pump

HHF-1600 Direct-Drive Utilized Pump

BZ178-SC
August, 2012

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 User Manual of HHF-1600 Direct-Drive Utilized Pump

Contents
1. Safety warnings ........................................................................................................................... 1
2. Description of direct-drive utilized pump ................................................................................... 1
2.1. Purposes and applicability ................................................................................................. 1
2.2. Main technical parameters ................................................................................................ 2
2.3. Drive principle and pump stroke regulation ...................................................................... 3
2.4. Main components .............................................................................................................. 3
3. Structure description.................................................................................................................... 4
3.1. Discharge manifold ........................................................................................................... 5
3.2. Pinion shaft assembly ........................................................................................................ 5
3.3. Main motor bracket ........................................................................................................... 6
4. Installation and commissioning ................................................................................................... 7
4.1. Installation ......................................................................................................................... 7
4.2. Commissioning.................................................................................................................. 7
5. Lubrication .................................................................................................................................. 8
6. Maintenance of equipment .......................................................................................................... 8
6.1. Routine maintenance before running ................................................................................ 8
6.2. Routine maintenance in operation ..................................................................................... 8
6.3. Operation and maintenance of HHF-1600 drilling pump ................................................. 9
6.4. Operation and maintenance of motor ................................................................................ 9
6.5. Maintenance of safety valve .............................................................................................. 9
7. Transportation and storage .......................................................................................................... 9
7.1. Transportation.................................................................................................................... 9
7.2. Storage ............................................................................................................................... 9
8. Recommended spare parts list ................................................................................................... 10
9. Attached drawings ..................................................................................................................... 10

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 User Manual of HHF-1600 Direct-Drive Utilized Pump

Foreword

HHF-1600 direct-drive utilized pump is one of the main supporting

components of drilling rig. The parts and components of the drilling pump are

designed and manufactured in conformity with API Spec 7K Specification for

drilling and well servicing equipment, the fifth edition.

This manual generally describes the technical parameters, main structure,

installation, commissioning and maintenance etc of the direct-drive utilized pump.

Operators must read this manual carefully before installation and operation.

Improper installation, operation or repair may cause personal injury or equipment

damage if operators do not know relevant contents.

There is a recommended spare parts list attached to the user manual as a

reference for users ordering spare parts. If the spare parts needed by the users are

not included in the list, please refer to its parts list.

 User Manual of HHF-1600 Direct-Drive Utilized Pump

User Manual of HHF-1600 Direct-Drive Utilized Pump

1. Safety warnings
1.1 Only trained and qualified persons can install, operate and maintain equipment with
qualification certificates.
1.2 The main personnel engaged in installation, operation and repair shall have
corresponding experiences and experience.
1.3 In the operation process, strictly execute operation specifications and follow technical
safety rules of all equipment.
1.4 Make sure to release pressure to zero in disconnection of any pipelines or hoses. Ensure
to cut off power supply before the repair of electric appliances.
1.5 It is forbidden to maintain and repair equipment during its operation.
1.6 Do not overload equipment.

2. Description of direct-drive utilized pump

2.1. Purposes and applicability
The HHF-1600 direct-drive utilized pump mainly supports AC VF electric drilling rigs. It
has the effect that the VF motor drives the drilling pumps to input the mud of the mud tank into
the drilling fluid circulating manifolds with a certain flow and pressure, so as to meet the
requirements on drilling fluid displacement and pressure in the drilling process. Its appearance
and main dimensions refer to Fig. 1.

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 User Manual of HHF-1600 Direct-Drive Utilized Pump

Fig. 1 HHF-1600 direct-drive utilized pump

2.2. Main technical parameters
2.2.1 Ambient temperature -20℃ to +55℃
2.2.2 Mud pump
Model: HHF-1600
Rated power 1193kW
Rated strokes 120s/min
Rated stroke 305 mm (12'')
Maximum displacement 45.42 L/s (7'' liner)
Maximum working pressure 35 MPa (4 1/2'' liner)
2.2.3 AC VF motor
Model HTB12A
Rated power 1200 kW

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Rated speed 500 r/min

2.2.4 Total weight 33872 kg
2.2.5 Overall dimensions (L×W×H) 6400×3030×3087 mm
2.3. Drive principle and pump stroke regulation
2.3.1. Drive principle
The rotor of the variable-frequency motor is directly connected with the pinion shaft, and
the mud pump is directly driven to work when the motor rotates. The schematic diagram of the
drive system is as follows:

Fig. 2 Drive system drawing

2.3.2 Pump stroke regulation
The pump stroke can be regulated freely in the range of 0-120s/min by regulating the speed
of the main motor.
Reduction formula for pump stroke: stroke s=motor speed n (r/min.)/4.206, referring to the
following table:
Motor speed r/min 21 42 84 126 168 252 337 421 463 505
Pump stroke s/min 5 10 20 30 40 60 80 100 110 120

2.4. Main components

No. Description Qty Remarks
1 HHF-1600 drilling pump 1 set API Spec7K ▲
2 Discharge manifold 1 set
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 User Manual of HHF-1600 Direct-Drive Utilized Pump

3 Spring safety valve 1 set ▲

Three-phase asynchronous AC VF motor
4 1 set ▲
HTB12A
5 Pinion shaft assembly 1 set
6 Main motor bracket 1 set
7 Mounting seat for fan 1 set
8 Charge manifold 1 set
9 Charge pump SB 6''×8''J-13'' 1 set ▲
Lubrication oil pump KCB55 2.2KW 380V 1 set
10 ▲
50HZ
11 Electric spray pump 32PL 380V, 50HZ 1 set ▲
Dual-scale shockproof pressure gauge YK-150 1 pc
12 ▲
2''-1502 union 0-60MPa
Note: the items marked by ▲ in the table are additionally provided with a separate user
manual or operation manual.

3. Structure description
The direct-drive utilized pump mainly comprises drilling pump, three-phase asynchronous
AC VF motor, discharge manifold, pinion shaft assembly, main motor bracket and mounting seat
for blower, referring to Fig. 3.

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1. Drilling pump 2. AC VF motor 3. Discharge manifold

4. Main motor bracket 5. Mounting seat for fan
Fig. 3 Direct-drive utilized pump
3.1. Discharge manifold
The discharge manifold comprises spring safety valve, gate valve, high pressure pipeline
and return pipeline etc, and the pipelines are connected with the valves by unions. One end of
discharge manifold is connected to discharge six-way block of the drilling pump, and its other
end is connected to the mud tank, and its main function is to open the safety valve and release
pressure for drilling pump mud pump when discharge pressure is excessive. Before overhauling
the drilling pump, open the gate valve first to release pressure for drilling pump, so as to rotate
the drilling pump manually. The structure of the discharge manifold refers to Fig. 4.

1. Spring safety valve 2. Return pipeline 3. Support assembly 4. Gate valve 5. Bracket assembly
Fig. 4 Discharge manifold
Notice: the outlet of the return pipeline of the discharge manifold can be only
connected back to the mud tank and cannot be connected with suction manifold.
3.2. Pinion shaft assembly
The rotor of three-phase asynchronous AC VF motor is connected directly to pinion shaft by

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 User Manual of HHF-1600 Direct-Drive Utilized Pump

the expansion sleeve of the motor, the rotor is fixed with the frame by connecting disc. The
structure refers to Fig. 5.

1. Pinion shaft 2. Connecting disc 3. Shaft sleeve 4. Oil return pipe

Fig. 5 Pinion shaft assembly

3.3. Main motor bracket
The main motor bracket is installed on the frame of drilling pump, there is a 5mm gap
between the connecting plate and main motor base, and gaskets shall be used for adjustment and
fixation during installation, referring to Fig. 6.

1. Bracket 2. Gasket
Fig. 6 Main motor bracket

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4. Installation and commissioning

4.1. Installation
First, install drilling pump, and then fix connecting disc with pump frame well, fix rotor of
main motor on pinion shaft by expansion sleeve, and finally, fix the stator of main motor with
connecting disc well, regulate the gap between the main motor bracket and the main motor base,
fix it by bolt; and install fan part and discharge manifold etc.
Installation requirements:
1) The allowable error of coaxiality between stator and rotor of main motor is Φ 0.12mm;
2) The allowable offset value between stator of main motor and end surface of iron core of
rotor is ±0.5mm;
4.1.1 The components which are disassembled necessarily during routine transportation are
discharge manifold, hoisting frame, small crane and discharge filter screen assembly of mud
pump. Reinstall these components on well site, then connect main motor, air blower, cables of
spray pump motor, and feed oil to drilling pump.
4.1.2 Check the pretension torque for the connection of all main stressed bolts by torque wrench,
and the pretension torques of the bolts refer to the following table.
Bolt nominal diameter/mm
Bolt strength
12 16 20 24 30 36
grade
Pretension torque/N.m
8.8 76-102 189-252 369-492 638-850 1267-1689 2214-2952
10.9 108-127 274-323 529-637 921-1098 1566-1960 2744-3283

Notice: all exposed connecting bolts must be coated with antirust lubricating grease
(oil) before installation each time to prevent threads from rusting. Before all connecting
unions are installed each time, the seal surface must be besmeared with the antirust
lubricating grease (oil) to prevent rusting.
4.2. Commissioning
Commission all functions after the drilling rig is installed each time (or execute as per
relevant rules and regulations of the system and user's department), and commission safety
functions each shift.
Commission the drilling pump and motor to working status as per the requirements of
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operation manuals or user manuals of drilling pump and electric drive system.
Adjust the opening pressure of the safety valve as per the liner diameter of the drilling
pump, its corresponding maximum working pressure and drilling process requirements.
Check the following items during commissioning:
The operating parameters of the electric drive system shall meet requirements and all
protection functions are complete and valid.
All drive devices cannot have abnormal vibration, abnormal noise, oil leakage and overheat
etc.

5. Lubrication
The lubrication of the drilling pump is executed with reference to the User Manual of
Drilling Pump.
Grease lubrication is adopted for motor bearing. The oil brand and the oil-feeding cycle
refer to the operation manual of motor.

6. Maintenance of equipment
6.1. Routine maintenance before running
6.1.1 Before the direct-drive utilized pump runs, check following items:
1) All connection must be firm and reliable without looseness.
2) Pinion shaft should run flexibly without blockage.
3) Check lubrication oil passage for smoothness.
4) All protection functions of the main motor are normal.
5) The main motor which does not run for a long time or stops working in a wet
environment for more than 1 hour shall be checked for insulation before running, dry it if
necessary. (If insulation resistance of stator winding and casing is lower than 0.5MΩ, it must be
dried.)
6.1.2 Check of safety valve
The opening pressure of the safety valve must be set in conformity with the requirement of
liner diameter and its maximum pressure.
6.2. Routine maintenance in operation
Check the following items in the running of the direct-driven utilized pump:

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 User Manual of HHF-1600 Direct-Drive Utilized Pump

1) Fill lubricating grease or oil periodically as per lubrication and maintenance regulations.
2) The temperature rise of the bearing shall not be more than 45℃ or the actually measured
temperature shall not be more than 95℃, otherwise, find out reasons and treat.
3) Check the running of rotating parts for abnormal phenomena such as abnormal vibration
and abnormal sound etc.
4) Check fastener for looseness.
5) All protection functions of the main motor are normal.
6) Check the setting of the opening pressure for safety valve for conformity with
requirements.
6.3. Operation and maintenance of HHF-1600 drilling pump
Refer to the operation manual or user manual of HHF-1600 drilling pump.
6.4. Operation and maintenance of motor
Refer to the operation manual or user manual of HTB12A AC VF motor.
6.5. Maintenance of safety valve
Refer to the operation manual or user manual of safety valve.

7. Transportation and storage

7.1. Transportation
Determine parts and components needing dismounted AS PER the requirements of vehicles.
The parts and components which need to be disassembled in routine transportation include: the
discharge manifold, the lifting frame of the drilling pump, and small crane, and its transportation
overall dimensions are: 6400x3085x2771mm.
Notice: when the temperature in transportation area is lower than 0℃, drain mud in valve
and pipeline completely.
7.2. Storage
During storage, clean the surfaces of the product, coat the surfaces which are not painted
with antirust oil, and cover the whole utilized drilling pump with waterproof oilcloth or plastic
film.
The utilized drilling pump should be stored in dry and ventilating places without corrosive
gas, 100mm above the ground.
During the long-term storage, discharge the lubricating oil in the oil tank completely,
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 User Manual of HHF-1600 Direct-Drive Utilized Pump

discharge mud in the valve bodies completely, and rinse the inside of the suction system and the
discharge system of the drilling pump clearly with clear water.

8. Recommended spare parts list

No. Code Description Qty Unit Remarks
Dual-scale pressure gauge (0-60MPa 2''- 1502
1 YK-150 1 set
union)
2 Spring safety valve: 3''-1502 union (0-5000psi) 1 set OTECO

3 FIG 1502 Welded union (sleeve) 2″-1502 2 set

4 FIG 1502 Welded union (sleeve) 3″-1502 2 set

5 Z23Y-35/50 Welded metal hard sealing mud valve 2'' 1 set

9. Attached drawings

Attached drawing 1 Direct-drive utilized pump

Attached drawing 2 Pinion shaft assembly
Attached drawing 3 Discharge manifold
Attached drawing 4 External lubrication system

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 User Manual of HHF-1600 Direct-Drive Utilized Pump

Attached drawing 1 HHF-1600 direct-drive utilized pump BZ178.00

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 User Manual of HHF-1600 Direct-Drive Utilized Pump

Attached drawing 2 Pinion shaft assembly BZ121.01.00

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 User Manual of HHF-1600 Direct-Drive Utilized Pump

Attached drawing 3 Discharge manifold ZJ407.20.00

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 User Manual of HHF-1600 Direct-Drive Utilized Pump

Attached drawing 4 External lubrication system BZ131.02.00

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