Drilling Pumps

1. Use of New Pump

BOMCO F-500/800/1000 Drilling Pumps are important equipment of oil rigs. They are used to

convey drilling fluid via pressure manifold in the circulating system to bottom holes so as to cool

drilling bits, clean bottom holes, crush rocks, carry rock debris and balance formation pressure etc.

Design and manufacture of F Series Drilling Pumps conform to the requirements of API Spec 7K

Specification for Drilling and Well Servicing Equipment. The Specification of hydraulic cylinders at

hydraulic end conforms to API Spec 7.

1.1 Technical Specifications and Performance Parameters

1.1.1 Technical Specifications

1.1.2 Performance Parameters

The performance parameters of BOMCO F-500/800/1000 drilling pumps are shown as in Table 1, 2

and 3, respectively. When inch cylinder liners are used, their performance parameters are referred to

Table 4, 5 and 6.

Notes: 1. Calculated as per 100% volumetric efficiency and 90% mechanical efficiency.

2. The performance parameters in the form of bold font-style are those under rated

strokes per minute.

1.1.3 Overall Size

1.2 Installation of New Pump

The F-500/800/1000 drilling pump is already assembled at ex-factory, tested by loaded running and

the lubrication is discharged from the power end. Before the pump is put into use, precautions

should be taken to operate and inspect. To prevent any personal accident during the maintenance

and inspection, make sure the equipment is shut and stopped running, all the safety protective

devices on the original movers and drive devices are at the safety positions.

The substructure under the BOMCO F-500/800/1000 is subject to all forms of installation but the

supporting substructure under the pump should be horizontal with sufficient intensity to support

both the pump weight and the forces generated during the pump work.

Fig.2 Installation of new pump

1.2.1 Installation on ground

At least 8 soleplates of 76×305mm are to be used when making ground installation with the length

under the pump substructure upward at positions shown in Figure 2. The foundation under the

soleplates should be 300mm wider than the pump substructure beam. Firmer foundation is required

for damp or wetland areas.

1.2.2 Permanent installation

Mount the pump on the structure substrate of drilling boat or drilling platform or cement foundation,

fix the pump substructure with bolts. Lay the soleplates under the substructure properly to prevent

any possible twisting or beveling of the power end bracket so that the pump substructure is able to

seat on all the soleplates firmly when the bolts are loosed.

When installed on the ship, the pump substructure is usually connected to the T-beam with bolts

with soleplates fixed at the points shown in Figure 2 and Figure 3. Make sure the substructure is

underlaid properly and avoid any twisting or beveling. All the soleplates should be wider than the

substructure beam flange with the minimum width of 305mm.

When the prime mover and drive devices are installed with the pump substructure as an integrity, fix

the pump unit on the T-beam substructure supported by stoppers but don’t fasten them with bolts so

that the pump can be “fluctuating” which will greatly mitigate the possibility of deformation to the

bracket due to the deformation of the berth or platform.

7Operation and Maintenance Manual for F-500/800/1000 Drilling Pumps

8

Figure 3 Installation foundation of new pump

1.2.3 Installation of drive devices

Triangle belts or multi-row chains are used to drive between the pump and the prime movers which

should be precisely installed to ensure the maximum service life and the minimum shutoff due to

drive failures.

When installing the drive belt pulleys or chain pulleys, make sure the mated holes and shaft head

are clear of any antirust or grease. Remove any burr or extruding matters on the key, key groove

and shaft head so that the key is closely attached in the key groove on the shaft and drive unit.

Apply light grease or anti-glutinous oil onto the small gear shaft head, fix the belt wheel hub or chain

wheel hub and tighten the bolts in the following way.

As tightening the bolts with a wrench or extension rod may cause an excessive torque, we insist

tightening the bolts to the given torque value shown below as this is very important since the fasten

bolts force will multiply during the wheel hub installation due the conical face which will force the

wheel hub to clamp the shaft head tightly in which case a great expansion force will be generated

when the fasten bolts are exerting excessive force. Thus the wheel hub bolts should be tightened

symmetrically, intersectionally, evenly and gradually

1.2.3.1 Triangle belt drive

1) Check the state of belt pulley groove

Before installation, check if the belt pulley groove is worn or rounded for the worn groove will

quickly damages the triangle belt. Make sure the groove wall is straight and smooth without any

dirt or extruding in it.

2) Check the alignment of the belt pulley

3) Regulate the pre-tension of the triangle belt.

Move the belt pulley center distance to adjust the tension of the belt until the tension side of the

belt is not drooping and the belt on the loose side is strained too before adding certain center

distance. For example: when the center distance is 2540mm (100″), add a 13mm (1/2″) when

the center distance is adjusted. When the center distance is 3810mm (150″), add a 19mm (3/4″)

when the center distance is adjusted.

Don’t try to obtain belt tension by underlaying the pump end or to strain the belt with the pump

weight by lowering the pump end to lower than the ground.

1.2.3.2 Chain drive

1) Installation

Proper installation and maintenance is the necessary way to obtain good service life of the chain

drive and chain drive device. As many of the factors like chain width, center distance, speed and

load should be considered in determining the neutral tolerance of chain pulley while no perfect

“practical rule” is available for application, the alignment of chains should be as close to accurate

as possible. One fairly precise way of alignment is to strain two steel wires (steel strings) along a

plan of the two chain pulleys with one under the center line and the other above it. Move one of

the chain pulleys so that the two wires contact the four points of the pulleys by which you can

decide that the two chain drives are aligned, their centerlines are parallel and are vertical to the

axis.

2) Lubrication of drive chains

As the chain lubrication system in the F serial pump chain drive device is an independent one with

its won lubrication pump, oil tank and drive, you need to fill the lubrication into the chain box to the

specified liquid surface level. Please refer to Selection Guide of BOMCO Product Lubrications for

selection of lubrication brand.

Consult the lubrication supplier for advice when temperature is lower than -18℃ (0°F).

The lubrication used should conform to rules concerning lubrication and manuals for lubrication

according to such rules.

As the chain lubrication system is an independent one, it should be repaired and maintained like

other mechanical equipment including:

——Check the oil level every day;

——Check the lubrication state every day;

——Check oil pressure(5～15PSI，namely 0.035～0.103Mpa);

——Supply certain oil to the chains;

——Check the working state of the oil nozzle on the sprinkler pipe;

——Check the working state of the oil pump drive (triangle belt or chains).

Note:

① There is a pressure discharge adjustable bolt behind the pump substructure for oil pressure

adjustment.

② Reduced or a higher oil pressure shows that the filter net of the suction and exhaust filters

needs cleaning.

1.3 Requirement on suction pump

The pump suction system is designed to be installed separately where necessary. The F serial

pump should be provided with positive pressure head (positive pressure) to obtain satisfactory

suction performances and the suction manifold best pressure is 0.14～0.21MPa (20～30psi) under

which the pump is able to provide the maximum cubage efficiency and the longest service life of the

damageable members. This pressure head can be obtained with a 5×6 injection pump (with 30Kw,

1450rpm motor) or a 6×8 injection pump (with 45Kw, 1450rpm motor). The injection pump is

automatically started or stopped synchronically with the drilling pump while on a DC motor driven

driller; a signal is usually obtained from the DC control disc to activate the electromagnetic starter.

The injection pump can also be driven by belt with the drive force from the small gear shaft of the

drilling pump.

The suction tube should be arranged so that the injection pump bypasses are connected to ensure

uninterrupted pump work when the injection pumps fails or is being repaired. To improve the suction

performances when the drilling pump works without the injection pump, some softer suction valve

springs can be replaced.

The suction pulsation dampener is a very effective auxiliary device which improves the suction

performances and eliminates the fluid flow ripple of the suction tube so that the exhaust fluid flow is

more stable.

Note: Don’t try to connect the return tube of the shear pin valve to the suction tube as the pressure in

the system will be suddenly raised when the shear pin safety valve is opened which will cause

damage to the manifold, the suction pulsation dampener and the eccentric pump when the pressure

is higher than the rated pressure value of the suction system.

1.4 Preparation for power end

The F serial pump is already completely assembled and tested under bench operation and all the

lubrication at the power end is discharged. The following operation and inspection is required

before starting the pump into operation.

1.4.1 Lubrication of power end

Before filling in the lubrication, open the check door on the cover and check for any possible

deterioration in the lubrication in the power end inner chest. Remove the pipe plugs on both sides of

the pump (No.2 Figure 7) and exhaust all the retained oil and wash it. Fill the lubrication of the

specified brand and quantity (frame nameplate) into the power end.

Check the oil face again when the pump has worked 15 minutes. Check the oil leveler (No.1 Figure

7) when the oil is stable 5 minutes after the pump is stopped. As some oil will stay in the crosshead

and the bracket empty chest, it is often necessary to charge another 10 liters (3 gal) of lubrication.

1.4.2 Installation of the middle pull bar and stuffing-box packing

1.4.2.1 Installation of middle pull bar and stuffing box for F-500 pump

Remove the stuffing box (1) and turn the pump so that its crosshead is at the front of the journey.

Clean the front part of the crosshead and the end face of the middle pull bar before fixing the

location boss of the middle pull bar in the crosshead hole, tightening the bolt (2) to the torque below

and locking it with iron wires.

67.5-81NM (50-60ft.lbs)

Clan the duct (3) surface and stuffing box (1) thoroughly, fix the O-ring (4) and the stuffing box while

connecting the joint (5) on the oil return pipe. Tighten the stuffing box to the torque below and

connect the oil return pipe (6).

16-19N.M(12-14ft.lbs)

The stuffing box assembly shown in Figure 4A includes: double-lip oil seal (7), oil seal cup (8),

O-ring (9), lock spring (10) and O-ring (11) as follows:

1) Take the double-lip oil seal (7) off the pressure spring (7a) and fix it on the middle pull bar with the

main lip part toward the power end before fixing the pressure spring (7a) to the seal lip and sliding

them into the stuffing box.

2) Fix the oil seal ring (8) and O-ring (11) on the middle pull bar and put them in the stuffing box.

3) Fix the O-ring (9) in the stuffing box groove.

4) Fix the lock spring (10).

Note: Make sure the pressure spring (7a) does not slip off when the middle pull bar is seriously cut.

Apply light oil over the middle pull bar surface for easy installation of the stuffing box assembly.

1.4.2.2 Installation of middle pull bar and stuffing-box packing for F-800/1000 pump

Take off the stuffing box (1), rotate the pump so that the crosshead is at the front of the journey.

Clean the crosshead front part and end face of the middle pull bar before fixing the location boss on

the middle pull bar into the crosshead. Tighten the bolt (2) to the torque 475 ～500N.m (350 ～

370ft.lbs) and lock it with iron wires. Clean the mud block tray and the bracket end faces. Fix a

gasket (3) and bolt (10) at A in figure 4, tighten the bolt to the torque 120～160N.m (90～120ft.lbs).

Clean the mud block tray hole and end face, clean the outer surface of the stuffing box and flange

face and apply light oil onto the outer face of the stuffing box and fix the stuffing box assembly

including: double-lip oil seal (6), oil seal ring (7) and 0-ring (12), O-ring (8) and lock snap spring (9)

in the following ways:

Method 1

1) Take the spring (5) off the double-lip oil seal (6) and fix it on the outer side of the crosshead pull

bar with the main lip part toward the power end. Fix the spring (5) to the oil seal lip and slide

them into the stuffing box as shown in the Note below.

2) Fix the O-ring (12) into the oil seal ring (7) and fix them on the pull bar before putting them into

the stuffing box hole.

3) Fix the O-ring (8) into the stuffing box groove.

4) Fix the double-lip oil seal (6) on the left and right shown in Figure 4 in the same way as step 1.

Notice: The double-lip oil seal (6) at the power end can be replaced with a single-lip oil seal but

no single-lip oil seal can be used at the outside (hydraulic end).

5) Fix locking spring (9).

Figure 4B Installation of middle pull bar and stuffing box packing of F-800/1000 pump

Method 2

1)Take the stuffing box (1) off the bracket and fix the double oil seal (6), oil seal ring (7) and

O-ring (12), O-ring (8) and lock snap spring (9) into the stuffing box (1) before fixing the O-ring (4)

on the outer cylinder face of the stuffing box (1).

Fix the guide bush (attached tool) on the front end of the middle pull bar as shown in Figure 4 and

apply light lubrication over the outer surface of the middle pull bar and guide bush.

Fix the stuffing box assembly on the middle pull bar through the guide bush and pull it to place by

hand before fixing stuffing box (1) on the mud block tray with a spring gasket and bolt (11).

Note: Make sure the pressure spring (5) will not slip off the oil seal lip groove when the

crosshead is seriously cut. Apply light oil over the pull bar for easy installation of the stuffing

box assembly.

1.5 Spray pump assembly

The sprinkler pump consists of the sprinkler pump, water tank and sprinkler pipe which washes and

cools the cylinder liner and piston while the pump is working.

Make sure at all times of use that the cooling fluid is sufficiently supplied to the cylinder liner and

piston as the interrupted supply may cause damage to the piston rubber member and the cylinder

liner.

A fixed sprinkler pipe is used in the F serial drilling pumps as shown in Figure 5 including: a fixing

support (1), a steel pipe (2) and a sprinkler pipe which sprinkles the cooling fluid onto the cylinder

liner and the piston. Regulate the water supply amount of the manifold and check the sprinkler pipe

on regular basis to that the fluid flow is directly sprinkled onto the piston.

The cooling fluid is carried to the manifold on the left (right) wall plate of the bracket through the

sprinkler pump (No.3 of Figure 7) from the water tank (No.5 Figure 7). The regulation valve (No.4

Figure 7) supplies the most possible water to be sprinkled onto the cylinder liner piston to the extent

that the water is not sprinkled on the crosshead pull bar in case some water may return to the

power end and pollute the lubrication.

The cooling fluid returns to the settlement chest. When the cooling fluid overflows through the filter

net, water and other solid state objects are deposited and foreign matters are blocked by the filter

net as shown in Figure 6.

Check the cooling fluid cleanness regularly and clean or wash the water tank and replace cooling

fluid where necessary as the polluted fluid may cause premature wears to the piston and cylinder

liner or jam in the sprinkler pipe due to the increased sand.

1.6 Assembly of accessories for hydraulic end

The F-500/800/1000 hydraulic end cross section is shown in Figure 8. The accessories of the

hydraulic end are cleaned and assembled in the following way

Note: Most of the accessories of the hydraulic end are designed to be installed metal to metal which

mitigates the possible wears in modern high-pressure pump operation due to the high-pressure fluid

flow. As a result, it is necessary that all accessories are cleaned and cleared of any burrs, cut or rusts

that may affect the product quality before they are assembled to ensure reliable sealing of the

hydraulic end.

1.6.1 Valve and valve seat

Take off the three valve covers (1), the three cylinder covers (2) and the plug (10). See Figure 8.

Clean each of the mechanical milling faces (with quality solvent) thoroughly.

Make sure all the valve seat holes are clean and dry (without any dirt, grease or antirust).

Clean and dry valve seat thoroughly, fix the suction and exhaust valve seats into the valve chest

hole and install the valve body. Knock the guide rod on the valve body with a copper bar to place

the valve seat in place and ensure contact before fixing the valve body spring and other

accessories.

1.6.2 Piston rod

Clean the piston and piston rod and make sure there are no burrs or cuts. Fix the O-ring (20) to the

seal groove of piston and mount the piston lightly onto the piston rod while taking care the O-ring

does not slip off the groove. Tighten the piston rod nut (21) to the following torque:

F-500

500N.m (368.lbs)

F-800/1000 1625～2165N.m(1200～1600ft.lbs)

Apply grease to the cylinder liner inner hole and the piston outer surface. Check that the pull bar

and piston rod end are clean and buss free. Push the piston rod into the cylinder liner and keep the

piston rod aligned to the rear part of the cylinder liner. Knock the piston into the cylinder liner with

hard wood or a special tool. Take care the location boss at the piston rod end is not damaged when

the piston rod approaches the middle pull bar and the piston rod is supporting so that it can come

into the location hole.

1.6.3 Piston rod clamp

The clamp is divided into two pieces after milled as a whole. Both pieces are marked with mating

numbers and are connected together with chains. The two pieces marked with the same mating

number should be used in pairs to clamp the flange at the end of the piston rod. Tighten the bolt to

the torque as follows:

F-500

135N.m

(100ft.lbs)

F-800

135N.m

(100ft.lbs)

F-1000 215N.m

(160ft.lbs)

If both the piston and clamp are new, the openings of the two semi-clamps of the clamp has a

spacing of more than 5.5mm to provide good metal to metal connection at the end face of the piston

rod. After wearing, the two semi-clamps will be more closed. If no spacing comes out, the clamp is

not working and you need a new one.

1.6.4 Cylinder jack and lower valve guider

Fix the seal ring (5) behind the cylinder liner and assemble the cylinder liner in place as shown in

Figure 8. Push the cylinder prop (6) into the hydraulic end and make sure the lower hole of the

cylinder prop is aligned to the lower valve chest hole. Fix the guider ○8 on the lower valve rod

through the cylinder prop lower hole and turn the wing on the guider back and forth. Press down the

guider and press the spring (7) until the guider is able to turn 1/4 circles to seat it under the cylinder

prop. Fix the stop clip (9) of the lower valve guider through the lower valve guider hole and turn the

clip (9) to the right so that the clip will clamp the guider tightly when the clip handle is fixed in the

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