F-1000 Operation Manual Kerui Package

F-1000 Mud Pump Skid
Operation Manual
Shandong Kerui Petroleum Equipment Co.,Ltd

山东科瑞石油装备有限公司
Shandong Kerui Petroleum Equipment Co.,Ltd.
Preface
F-1000 Mud pump skid is used for drilling operation’s mud circulation which is widely
used in oil ＆ gas’ exploration and development. It is an vital component of drilling rig or
workover rig. Its design meets industrial standard of oil ＆ gas and related standard of
API.
The pump’s installation, use, maintenance are detailed described in this operation manual.
This operation manual is suitable for the people who have a certain understanding and who
are familiar with related operation. Due to limited space, this manual just covers most part,
not all the part.
Part of equipment operation and maintenance material are taken from the manual which
written by the other manufacturers. If the manufacturers issue new manuals or there is
discrepancy, unless in special occasions, please subject to the manufacturer’s manual.
The manual includes components of pump skid, structure and operation requirements, main
parts’ dimension, main parameters, daily maintenance, trouble shooting and so on.
We reserve the right of abolishing (or modify) product type, design at any time and without
noticing the user, also not take any responsibility and obligation for it.
Before you install, use this pump, please read this operation manual carefully.
If this manual has any shortcomings, please put forward your valuable comments and
suggestions.
Contents
1. Summary ........................................................................................................ 1
1.1. Structural Composition ......................................................................... 1
1.2. Main Technical Parameters................................................................... 3
2. F-1000 Main Pump Skid................................................................................ 4
2.1. Power System ....................................................................................... 6
2.1.1. Summary .................................................................................... 10
2.1.2. Main Parameters ........................................................................ 10
2.2. Transmission System .......................................................................... 14
2.2.1. Cross-axle Type of Universal Drive Shaft................................. 15
2.2.2. Drive Chain Case ....................................................................... 17
2.3. Mud Pump System.............................................................................. 26
2.3.1. Mud Pump Set ........................................................................... 28
2.3.2. Safety Manifold ......................................................................... 32
2.3.3. Discharge Manifold ................................................................... 34
2.3.4. Assembly of Mud Pump System ............................................... 35
2.4. Fuel System ........................................................................................ 37
2.4.1. Fuel Tank Assembly .................................................................. 37
2.4.2. Fuel Tube ................................................................................... 38
2.5. Control System ................................................................................... 39
2.5.1. Composition of Electrically Controlled System ........................ 40
I
2.5.2. Pneumatic Control System ........................................................ 47
3. Injection Skid System .................................................................................. 48
3.1. Structural Type .................................................................................... 48
3.2. Pipeline Assembly .............................................................................. 49
3.3. Charge pump Skid Performance Parameters ...................................... 50
3.4. Charge Pump Skid Operation Instruction........................................... 51
3.4.1. Notes .......................................................................................... 52
3.4.2. Preparation Before Startup ........................................................ 52
3.5. Charge Pump Skid Connection........................................................... 53
3.6. Charge Pump Skid Maintenance ........................................................ 53
4. Installation and Debugging .......................................................................... 54
4.1. Installation Adjustment of Transmission Gear ................................... 54
4.2. Connection of High and Low Pressure Manifold ............................... 54
4.3. Start of Pump Skid .............................................................................. 55
4.3.1. Preparation before Startup ......................................................... 55
4.3.2. Start of Pump Skid ..................................................................... 55
5. Troubles Shooting ........................................................................................ 57
5.1. Trouble and Troubleshooting of F-1000 Mud Pump Skid ................. 57
5.2. Trouble and Troubleshooting of Hydraulic Transmission Box .......... 57
6. Package and Transportation ......................................................................... 59
6.1. Package ............................................................................................... 59
6.2. Transportation ..................................................................................... 59
II
6.2.1. Transportation of Main Pump Skid ........................................... 59
6.2.2. Transportation of Mud Pump Set .............................................. 61
6.2.3. Transportation of Perfusion Skid ............................................... 62
7. Attachment ................................................................................................... 63
III
1. Summary
1.1. Structural Composition
F-1000 mud pump skid(like Fig1, Fig2, Fig3) consists of main pump skid and injection
system. There are hinge bars connected between the two main pump skids, the main pump
skid and injection skid. It adopts flexible hose to connect the suction tube of main pump
skid and outlet of injection skid. The unions are used to connect the outlet of main pump
skid and high pressure manifold.
Fig1 F-1000 Mud Pump Skid（NJBQ10.00）
1
List of F-1000 mud pump skid assembly(Table 1) :
Part drawing number

F-1000 mud pump skid
NJBQ10.00
NO. Code Name Qty. Remarks
Main Pump Skid

1 NJBQ10. 16.00 2
Assembly
2 NJBQ10. 03.00 Injection Skid Assembly 1
Discharge Manifold
3 NJBQ10.03.02.00 2
Assembly
Suction Connecting Pipe
4 NJBQ10.03.02.00 2 Flexible Hose
of Pump
5 NJBQ10.11.20.00 Hinge Bar of Pump Skid 2 Adjustable
Hinge Bar of injection

6 NJBQ10.11.30.00 2 Adjustable
Skid
High Pressure
7 NJBQ10.02.05.00 2 None
Connecting Pipe
Table 1 F-1000 list of mud pump skid assembly
2
Main pump skid consists of power system, transmission system, mud pump set, fuel system,
control system, lubricating system and so on. All the systems and injection system will be
detailed described on section 2 and section 3.
1.2. Main Technical Parameters
The main technical parameters of F-1000 mud pump skid as follows:

Max. input power of main pump skid: 2×1000 HP
Max. discharge flow: 2×147.6 m3/h (6.75″ cylinder sleeve)
Max. output stroke of mud pump: 140 SPM
Mud pump stroke: 254mm（10″）
Max. output pressure of mud pump: 34.5 Mpa（4.5″ cylinder sleeve）
Suction manifold dimension of mud pump: 12″
Discharge manifold dimension of mud pump: 4 1/16″ 5000psi, the flange with 4″ Fig union
Max. input power of injection skid: 2×55 KW
Max. discharge flow of injection skid: 2×200 m3/h
Sand pump lift of injection skid: 36 m
Connection of mud pump and injection pump: flexible hose(One end is flange connection,
the other end is Fig200FxM union connection.)
Dimension of F-1000 mud pump skid: about 12501×10705×3125mm
Weight of F-1000 mud pump skid: about 80000 Kg
3
2. F-1000 Main Pump Skid

The main skid consists of power system, transmission system, mud pump set, fuel system,
control system, lubricating system and so on.
Fig 4 Main Pump Skid(NJBQ10. 16.00)
4
List of mud pump skid assembly（NJBQ10.16.00）(Table 2)
Part drawing number

F-1000 main pump skid assembly
NJBQ10.16.00
1 NJBQ10.11.00 Base Assembly 1
Transmission
2 NJBQ10.10.00 1
System
3 NJBQ10.02.00 Mud Pump System 1
4 NJBQ10.06.00 Control System 1
5 NJBQ10.04.00 Fuel System 1
6 NJBQ10.01.00 Power System 1
Table 2 List of Main Pump Assembly(NJBQ10.16.00)

5
2.1. Power System
Power system consists of C32 engine, Winstar hydraulic transmission box, as it is shown in
Fig 7, Fig 8, Fig9.
Fig 7 Power System Assembly Drawing（NJBQ10.01.00）
6
List of power system assembly（NJBQ10.01.00）(Table 3)
Part drawing number

F-1000 power system
assembly
NJBQ10.01.00
1 CAT C32-C Engine 1 C Calibrated
Hydraulic Transmission
2 BY920B 1 Guizhou Winstar
Box
Hexagonal Head Bolt
3 M18×70 10 Standard Parts
GB/T5783-2000
Standard
4 Nut GB/T6170-2000 M18 10
Spring Washer Standard

5 18 10
GB/T 93-1987
Flat Washer Standard
6 18 10
GB/T 97.1—2002
7 NJBQ10.01.02 Damping Rubber 2 Cutting on site
Hexagonal Head Bolt Standard

8 M22×80 4
GB/T5783-2000
7

9 22 8
GB/T 97.1—2002
10 22 4
GB/T 93-1987
Standard
11 Nut GB/T6170-2000 M22 4
Hexagonal Head Bolt Standard

12 M30*165 4
GB/T5783-2000
Standard
13 NJBQ10.01.01 Cushion Clamp 4
Standard
14 Cushion δ30×Φ120 8

15 30 4
GB/T 97.1—2002
16 30 4
GB/T 93-1987
Standard
17 Nut GB/T6170-2000 M30 4
Self-locking Nut Standard

18 M30 4
GB/T 3098.9-2002
Hexagonal Bolt Standard
19 M10×50 12
GB/T5783-2000
Standard
20 Nut GB/T6170-2000 M10 12

21 10 12
GB/T 93-1987
22 10 12
GB/T 97.1—2002
Hexagonal Bolt Standard
23 M12*55 16
GB/T5783-2000
Standard
24 Nut GB/T6170-2000 M12 16

25 12 16
GB/T 93-1987
26 12 16
GB/T 97.1—2002
Standard
27 Bolt of British System 5/8″-11UNC-2B*50 12

28 16 12
GB/T 97.1—2002
8

29 16 12
GB/T 93-1987
30 NJBQ10.05.00 Radiator Assembly 1 C32-1350HP
31 NJBQ10.01.02.00 Air Filter Bracket 1
32 EL-25 Silencer 1
33 308-3424 Air Filter 2
Connecting Line of
34 NJBQ10.01.05.00 1
Silencer
Fixed Seat of Air Filter
35 NJBQ10.01.09.00 2
Bracket
36 NJBQ10.01.12.00 Lower Silencer Bracket 1
37 NJBQ10.01.08.00 Upper Silencer Bracket 1
Intermediate Silencer
38 NJBQ10.01.10.00 1
Bracket
39 NJBQ10.01.11.00 Air Cooling Inlet Line 2
40 NJBQ10.01.13.00 Water Cooling Inlet Line 1
Right Support of Water

41 NJBQ10.11.02.00 1
Tank
42 NJBQ10.01.12.00 Air Cooling Return Line 2
Water Line of Cylinder

43 NJBQ10.01.14.00 1
Sleeve
Connecting Line of Air
44 NJBQ10.01.06.00 2
Filter
45 NJBQ10.11.03.00 Front Support of Engine 1
46 NJBQ10.11.06.00 Band and Beam（Right） 1
47 NJBQ10.11.05.00 Band and Beam（Left） 1
Left Support of Water

48 NJBQ10.11.01.00 1
Tank
Table 3 List of Power System Assembly(NJBQ10.01.00)
9
2.1.1. Summary
Engine C32 provides power which passes through hydraulic transmission box, universal
drive shaft, drive chain case successively to mud pump. Engine C32 can realize the
functions of throttle speed control, failure warning, four parameters display, emergency stop
and so on. Winstar transmission box is connected with engine directly. After speed changed,
it transmit the power to universal coupling. The transmission box can realize the functions
of upshift and downshift, gear show, shutting indication, overpressure protection and so on.
The radiator cools the engine fluid, external diesel oil, transmission box oil, lubricating oil
so that it can ensure the system runs reliable and safe.
2.1.2. Main Parameters
2.1.2.1. Engine C32 Main Parameters
Engine shape as shown in Fig 10:
Fig 10 C32-C Outline Drawing
Main technical parameters as follows:

Manufacturer: Caterpillar
Model: C32-C, 12 cylinders
10
Rated Power: 1125 HP

Rated Speed: 2100 rpm
Starting Model: Electrical Starting
Control Model: ELEC
Turbine Quantity: 2
Weight(Dry weight): 2946 Kg
2.1.2.2. Engine Structure, Precautions for Use
Please refer to C32 industrial engine parts manual.
2.1.2.3. Main Parameters of Transmission Box
Outline drawing of hydraulic transmission box as shown in Fig 11, Fig 12.
Fig 11 Hydraulic Transmission Box(BY920B)
11
Fig 12 Hydraulic Transmission Box(BY920B)
Main parameters of BY920B transmission box:

Manufacturer: Guizhou Winstar
Model: BY920B
Max. Input power: 1250 HP
Max. Input Speed: 2300 rpm
Max. Input Torque: 5880 N.m
Gear Shift Type: Hand air control gear shift
Type of Power Takeoff: Power takeoff from left and below direction
PTO Type: DM20C
Gear Set: Gear 1 4.24:1 Gear 2 2.84:1 Gear 3 2.32:1
Gear 4 1.56:1(Lock) Gear 5 1.00:1 (Lock)
Gear 6 0.67:1(Lock) Neutral Position 0
Total Weight: 1760 Kg
12
2.1.2.4.Structure of hydraulic structure, precautions for use,
maintenance
Please refer to product operation introductions and maintenance manual of Winstar

BY920B series.
13
2.2. Transmission System
Transmission system consists of cross-axle type of universal drive shaft, drive shaft shield,
drive chain case and so on. The universal drive shaft meets national standard and operating
condition requirements. Drive shaft shield with smart design, with lubricating grease
adding and jigger window hole. Drive chain case is our own developed case and it can meet
customer’s requirements, operating conditions’ requirements of transmission system. It is
with compact structure, operate easy, low failure rate. Assembly drawing of transmission
system as shown in Fig 13:
Fig 13 Assembly of Transmission System(NJBQ10.10.00)
List of transmission system assembly（NJBQ10.10.00）(Table 4) :
Part drawing number

Assembly of Transmission System
NJBQ10.10.00
Assembly of hydraulic
1 NJBQ10.09.00 1
transmission box
14
Hexagonal Bolt
2 M18*75 16
GB/T5783-2000
3 Nut GB/T41-2000 M18 16
SWC250DH
4 NJBQ10.12.00 Drive shaft assembly 1
1
5 NJBQ10.12.01.00 Drive shaft shield 1
Drive chain case

6 NJBQ10.10.00 1
assembly
RSF-1000
7 NJBQ10.02.00 Mud pump assembly 1
mud pump
8 NJBQ10.11.00 Base assembly 1
9 Nut GB/T6170-2000 M12 8
Flat washer
10 12 8
GB/T 97.1—2002
Hexagonal Bolt
11 M12*55 8
GB/T5783-2000
Table 4 List of Power System Assembly(NJBQ10.10.00)
2.2.1. Cross-axle Type of Universal Drive Shaft
Cross-axle type of universal drive shaft adopt the drive shaft which meets national
standard(JB/T 5513-2006). With the advantage of big transmission torque, high adaptive
speed, good dynamic balance, big axle angle and so on. It can meet operating requirements
completely.
2.2.1.1. Dimensions of Universal Drive Shaft
Dimensions of Universal drive shaft as shown in Fig 14:
15
Fig 14 Dimensions for Cross-axle Type of Universal Drive Shaft（SWC Series）
Dimensions of drive shaft as shown in Fig 5:

Dimensions
mm Weight
Model
Lmi D1 D2 b Kg
D3 Lm n×φd K t g
n (js11）（H7） (h9)
SWC250DH
735 218 150 168 140 8×φ19 25 5 32 9 136
1
Table 5 SWC250DH1 Dimensions Table of Universal Drive Shaft
2.2.1.2. Performance Parameters of Universal Drive Shaft
Model: Overall jaw cross-axle universal coupling-SWC250DH1

National Standard: JB/T 5513-2006
Turning Radius: 250mm
Nominal Torque: 80KN.m
Fatigue Torque: 40KN.m
Curve Angle: 10°
Expansion Amount: 70mm
Minimum Length: 735mm
16
Use Length: 760mm

Nozzle Quantity: 3
Oil Injection Period: Once a week (Proposed)
Grease Type: 2# Industrial lithium base grease or 2# molybdenum disulfide
calcium base grease
2.2.2. Drive Chain Case
Drive chain case is designed and manufactured ourselves according to integrated design
requirements. It has been through long time running-in test. The drive chain case with the
functions of compact structure, operate easy, low failure rate and so on.
2.2.2.1. Dimensions of Drive Chain Case
Assembly drawing of drive chain case as shown in Fig 15, Fig 16, Fig 17, Fig 18, Fig 19:
Fig 15 Assembly Drawing of Drive Chain Case(LTXF1000)
17
Fig 16 Assembly Drawing of Drive Chain Case（LTXF1000）
18
19
List of drive chain case assembly(Table 6):
Part drawing number

Drive Chain Case Assembly
LTXF1000
NO. Code Name Qty.
1 NJBQ10.10.01.00 Drive Chain Case Support 1
2 GB/T5782-2000 Bolt M24x100 8
3 GB/T97.1-2002 Washer 24 8
4 GB/T93-1987 Spring Washer 24 8
5 GB/T6170-2000 Nut M24 8
6 NJBQ10.10.05 Observation Hole Cover Board 1

Cushion of Observation Hole
7 NJBQ10.10.06 1
Cover Board Cover Board
8 NJBQ10.10.07 Right-side Plate Cover Board 1
Cushion of Right-side Plate
9 NJBQ10.10.08 1
Cover Board
10 EF3-40 Air Filter 1
11 NJBQ10.10.09 Upper Seal Plate 1
12 NJBQ10.10.10 Cushion of Upper Seal Plate 1
13 GB/T5783-2000 Bolt M10x30 35
14 GB/T97.1-2002 Washer 10 35
16 NJBQ10.10.04.00 Right Cover Plate 1
17 NJBQ10.10.23 Left Bearing Pedestal 1
18 GB/T5783-2000 Bolt M12x40 29
19 GB/T97.1-2002 Washer 12 29
21 GB/T5782-2000 Bolt M16x50 18
22 GB/T97.1-2002 Washer 16 21
24 NJBQ10.10.11 Locating Sleevw 1
25 NJBQ10.10.01 Big Sprocket 1
20
26 NJBQ10.10.12 Pump Shaft Damper 1
27 NJBQ10.10.13 Bolt 5/8-11UNCx40 3
28 GB/T5595-2007 Chain 120-6*100 1
29 NJBQ10.10.14 Input Flange 1
30 NJBQ10.10.15 Clamp 1
31 NJBQ10.10.03 Sprocket Shaft 1

Oil Seal Pedestal of Sprocket
32 NJBQ10.10.16 1
Shaft
Oil Seal Seat Cushion of
33 NJBQ10.10.17 1
Sprocket Shaft
34 GB/T288-1994 Self-aligning Roller Bearing 2
35 NJBQ10.10.02 Small Sprocket 1
36 NJBQ10.10.18 Spacer Bush 1
37 NJBQ10.10.19 Left Bearing End Plate 1
38 NJBQ10.10.20 Left Bearing End Plate Sealing 1
39 NJBQ10.10.21 Enclosed Fitting Sealing Strip 1
40 NJBQ10.10.22 Right Cover Board Sealing Strip 1
41 NJBQ10.10.34 Sprocket Shaft Oil Sealing 1
42 TF-250x100F Self-sealing Suction Filter 1
43 YWZ-250T Liquid Level Meter 1
44 NJBQ10.10.05.00 Enclosed Fitting Assembly 1
45 NJBQ10.10.03.00 Cab 1
46 NJBQ10.03.04 Flat Key 1
47 NJBQ10.10.24 Left Bearing Pedestal Sealing 1
48 NJBQ10.10.28 Liquid Level Meter Shield 1
49 NJBQ10.10.26 Pump Sealing Gasket 1
50 NJBQ10.10.27 Breather Branch Drum 1
51 NJBQ10.10.29 Enter Key 1
52 NJBQ10.10.25 Bearing Pressing Plate 1
53 NJBQ10.10.31 Filter Flange Welding Pipe 1
54 NJBQ10.10.32 Drain Outlet Plug 1
21
55 NJBQ10.10.30 Drive Chain Case Nameplate 1
56 NJBQ10.10.33 Adjusting Shim Unit 1
Table 6 List of Drive Chain Case Assembly（LTXF1000）
2.2.2.2. Drive Chain Case Performance Parameters
Model: LTXF1000
Max. Input Speed: 1050 r/min
Max. Input Power: 1200HP （882KW）
Speed Reducing Ratio: 1.32:1（41:31）
Chain Section Number: 100
Chain Line Number: 6
Chain Type: 120-6×100（GB/T 5595-2007）
Lubricating Method: Forced lubrication
Lubrication Oil Type: 32# wear-resistant lubrication oil
Dimensions: 2010×935.5×1963.2 mm
Total Weight: 2191Kg
2.2.2.3. Drive Chain Case Lubricating System
Drive chain case lubricating system consists of cab, filter, oil pump, cooler, overflow valve,
pressure gauge, liquid level thermometer and so on. The working principle as shown in Fig
20.
22
Fig 20 Lubricating System Schematic Diagram(NJBQ10.10.06.00)
Part list of drive chain case lubricating system（NJBQ10.10.06.00）(Table 7):
Drive Chain Case Lubricating Part drawing number

System NJBQ10.10.06.00

Lubricating Oil Drive chain case
1 CB-F40 1
Pump pumping oil
Lubrication oil’s
2 GLQ-01 Filter 1
filtering
Oil pressure control
3 YLF-02 Overflow Valve 8
of lubricating oil
4 NJBQ10.10.01 Sprocket 2
5 GB/T288-1994 Bearing 2
Lubrication oil’s
6 YLB-03 Pressure Gauge 1
display
Fig 7 List of Drive Chain Case Lubricating System
2.2.2.4. Setup and Disassembly of Drive Chain Case
During operating and using, the chain and the other parts will cause damage so that the
chain should be changed. The detailed installation and disassembly as follows:(Note: The
23
number 1 of above drawing ‘Drive Chain Case Base’ should be welded on base of
RSF-1000 mud pump set.)
2.2.2.4.1. Installation of Drive Chain Case
1) Install the pump sealing gasket(Number 49) on the outlet shaft sealing base, then fix
the enclosed fitting(Number 49) to the outlet shaft sealing base by bolts and screw up
by bolts so that it can ensure the lubrication oil not leak from this point.
2) Install the locating sleeve(Number 24) to input shaft of the mud pump, please note this
locating sleeve’s direction in accord with key’s installation direction. Then install the
big sprocket(Number 25) to input shaft of the mud pump, please note the left end face
direction of big sprocket stay close to the locating sleeve. If the first assembly, adjust
the length of locating sleeve so that ensure the inner end face of big sprocket 1-2mm
longer than end face of mud pump input shaft.
3) During drive chain case’s installation, install the chain(Number 28) to drive chain case
body(Number 45) and make the chain pass through cab hole so that chain can bypass
the small sprocket.
4) Adopt lifting hook to lift chain cab body and install it to the enclosed fitting
assembly(Number 44). Install the adjusting shim(Number 56) between drive chain case
lower surface and base(Number 1). The installed adjusting shims should ensure the
bolts can be screwed into enclosed fitting and drive chain case cab. Then add torque so
that it can fix drive chain case and base. The torque value of bolts here is 1500N.m.
5) After the cab fixed, make the chain(Number 28) bypass the big sprocket(Number 25)
and the chain dock at the cab above hole. It adopts chain tightener to realize clamping.
Then install hinge pin at the observation port, tighten chain fixed pin(Without drawing
in the drawing).
6) Pure chain lubrication oil(32# lubrication oil) at the air filter point(Number 10) and
make the liquid level to the length of 2/3.
7) Install above sealing plate(Number 11) and above sealing gasket(Number 12),
right-side cover board(Number 8), right-side cover board cushion(Number 9), please
24
coat sealant(Loctite 207) in order to prevent the oil leak from bolts.
8) Connect the input flange(Number 29) and drive shaft. This bolt type is M18×75 and the
adding torque is 350N.m.
9) Install drive chain case cover(Number 5 in the drawing). After the other parts’
debugging, start the engine. The noise will be made during the case’s operation and this
is normal.
2.2.2.4.2. Installation and Disassembly of Drive Chain Case
During drive chain case’s troubleshooting, the disassembly procedure as follows:

1) When the engine stop and sweltering dropping off, cooling, you can disassembly the
drive chain case.
2) First, disassembly cover(Number 5 in Fig 1), preserve bolts.
3) Disassembly input flange(Number 29), drive shaft’s bolts and nuts, preserve the bolts
and nuts so that you can use them if necessary.
4) Compress drive shaft(Number 4 in Fig 1) and shorten its length of 15mm to make sure
the transmission flat key can expose from installation plane. Offset the drive shaft with
a certain angle and use the support to prevent drive shaft hanging.
5) Open right-side cover board(Number 8), right-side cover board cushion(Number 9),
disconnect chain from right-side observation hole and fix the chain to the cab.
6) Disassembly enclosed fitting assembly(Number 44) and fixed bolts of cab(Number 45),
preserve bolts so that you can use anytime if necessary.
7) Adopt crane lifting hook to fix at cab’s lifting, tighten the lifting rope.
8) Disassembly the fixed bolts which are between cab(Number 45) and base, and lift the
drive chain case to the platform.
9) If the chain damaged, drag out the chain from cab and change it with spare chain. If
lubrication oil is dirty, drain the oil from drain outlet and adopt kerosene to clean shell
bottom, then inject new oil again.
10) After case’s troubleshooting, install the chain case to mud pump in accord with the
section 2.2.3.2.
25
2.3. Mud Pump System
Mud pump system consists of mud pump set, safety manifold, discharge manifold and so
on. Mud pump set is fixed on main pump skid, safety manifold is connected to right outlet
of mud pump set by tee joint, discharge manifold is connected to discharge five-path of
mud pump set by high pressure connecting pipeline. Mud pump system assembly as shown
in Fig 21, Fig 22, Fig 23.
Fig 21 Mud Pump System（NJBQ10.02.00）
26
List of mud pump assembly（NJBQ10.02.00）(Table 8):

Part drawing number
Mud Pump System
NJBQ10.02.00
NJBQ10.02.02.0 High Pressure Discharge
1 1
0 Manifold
27
RSF-1000 Mud F-1000 Mud

2 1
Pump Pump(Rongsheng)
3 YS21502M-70 Union Type Pressure Sensor 1
4 3-5M-21502F Pressure Sensor Connector 1

NJBQ10.02.01.0
5 Tee Joint 1
2.00
NJBQ10.02.01.0 Safety Pressure Relief
6 1
0 Manifold
2 1/16″×5M-4″1502M
7 FY4-35-1502M 1
Flange Union
Offered by
8 SLD41502-35 High Pressure Water Hose 1
customer
9 LZ118-8-2A Stud 16
10 LM118-8-2B Nut 32
11 R35 Sealing Gasket Ring R35 2
12 LZ114-8-2A Stud 8
13 LM114-8-2B Nut 16
14 R39 Sealing Gasket Ring R39 1
Fig 8 List of Mud Pump System Assembly(NJBQ10.02.00)
2.3.1. Mud Pump Set
Dimensions of mud pump set is as shown in Fig 24,Fig 25, Fig 27:
Fig 24 RSF-1000 Mud Pump Set

28
29
Fig 27 Axle Head of Mud Pump RSF-1000
2.3.1.1. Main Technical Performance Parameters of Mud Pump
Rated Input Power: 735 KW（1000 HP）

Rated Stroke: 140 SPM
Stroke: 254mm（10″）
Gear Ratio: 4.207:1
Max. Working Pressure: 34.5MPa
Valve Chamber: API 6 #
30
Max. Liner Diameter: 63/4″

Max. Liner Pump Pressure: 16.4MPa
Suction Tube Straight Port: 12″
Discharge Tube Straight Port: 51/8 ″ 5000 psi Flange
Overhang Diameter of Pinion Shaft: 196.85 mm
Enter Key: 2″X2″X8″
Dimensions: 4267x2350x1862 mm(Not include discharge five-path and shear pin safety
valve)
Weight(main engine): 18642 kg(Not include air dome, discharge five-path, belt pulley)
2.3.1.2. Displacement Pressure Gauge of Mud Pump Set
Displacement pressure table of RSF-1000 mud pump(Table 9):
Displacement and Pressure Relation Table of RSF-1000 Drilling Pump(British System)
Sleeve Diameter in 6 3/4 6 1/2 6 1/4 6 5 1/2 5 4 1/2
MPa 16.4 17.6 19.1 20.7 24.6 29.8 34.5

Discharge Pressure
Psi 2410 2725 3100 3555 4125 4840 5000
Stroke Input Power

Displacement L/s
Jig/Minute KW HP
*140 *735 1000 41 38 35.2 32.4 27.2 22.5 18.2
130 683 929 38.07 35.28 32.68 30.1 25.26 20.89 16.9
120 630 857 35.14 32.57 27.86 27.77 23.3 19.28 15.6
110 578 786 32.21 29.85 27.66 25.46 21.37 17.68 14.3
100 525 714 29.28 27.14 25.14 23.14 19.43 16.07 13
1 5.25 7.14 0.293 0.271 0.251 0.231 0.194 0.161 0.130
1. The mechanical efficiency: η=90%, full coefficient: η=90%, volume efficiency: 100%;
2. Rated stroke and input power during continuous running.
Table 9 RSF-1000 Mud Pump Displacement and Pressure Table
2.3.1.3. Operation and Use Manual of Mud Pump Set
About mud pump spraying system, lubricating system of power end, spare parts manual, attachment
tools manual, mud pump operation and use manual, please refer to mud pump standard accessories.
31
2.3.2. Safety Manifold
Safety manifold is used for mud pump’s overload protection during operation process.
Adopt international advanced spring safety valve and it can realize overload pressure relief
protection function. Safety manifold is as shown in Fig 28.
Fig 28 Safety Pressure Relief Manifold(NJBQ10.02.01.00)
32
List of safety pressure relief manifold assembly(NJBQ10.02.01.00)(Table 10):
Part drawing number

Safety Manifold Pressure Relief Manifold
NJBQ10.02.01.00
1 NJBQ10.02.01.01 Flange 1 R35 sd Seal Groove
2 NJBQ10.02.01.02 Elbow 1
Welding Union M
3 NJBQ10.02.01.03 3
Head
Welding Union F
4 NJBQ10.02.01.04 3
Head
5 NJBQ10.02.01.05 T Type of Tee Joint 2
Safety Valve Imported
6 TAG32025-2IN 1
Flange
7 TAG32025-2B 3" Safety Valve Body 1
Safety Valve Outlet
8 TAG32025-2O 1
Flange
9 NJBQ10.02.01.06 Steel Tube 1
11 NJBQ10.02.01.08 Elbow 1
12 NJBQ10.02.01.09 Mud Brake Valve 1
Table 10 List of Safety Assembly
Safety manifold can realize emergency unloading function by safety valve. It can also
realize manual unloading function by mud brake valve. About safety valve’s use, please
refer to safety valve user manual. Mud brake valve mainly realize the function of switch
and generally the valve is in closing position. If pipeline pressure need to be unloaded, you
can swirl handle, start brake valve to realize unloading function. Please note this process
has a certain risk and please must raise your vigilance during operation.
33
2.3.3. Discharge Manifold
Discharge manifold mainly consists of parallel brake valve, T type of tee joint, flange union
set and so on. T type of tee joint divides the discharge manifold to two branches and add
brake valve to control discharge manifold’s start and stop separately so that it can realize
different discharging requirements. Meanwhile, it can realize pipeline’s completely closed
in order to prevent unforeseen circumstances. As shown in Fig 29.
Fig 29 Discharge Manifold Assembly Drawing(NJBQ10.02.02.00)
List of discharge manifold assembly(NJBQ10.02.02.00)(Table 11):
Part drawing number

Discharge Manifold
NJBQ10.02.02.00

4 1/16"x5M-4"FIG1502(F) Flange
1 NJBQ10.02.02.01 3
Union
2 NJBQ10.02.02.02 T Type of Tee Joint 1
3 NJBQ10.02.02.03 Parallel Brake Valve 2
4 NJBQ10.02.02.04 Welding Flange Straight Tube 1
5 NJBQ10.02.02.05 Sealing Gasket Ring R39 6
6 NJBQ10.02.02.06 Stud 48
7 NJBQ10.02.02.07 Nut 96
Table 11 List of Discharge Manifold(NJBQ10.02.02.00)
34
2.3.4. Assembly of Mud Pump System
Pressing plates are used to fix mud pump set and main pump skid base. Set positioning bolt
to position in the width and length direction and this can effectively prevent shock and
move during mud pump set’s operation. About mud pump set’s installation mode, please
refer to Fig 30, Fig 31, Fig 32, Fig 33.
Fig 30 Assembly Drawing of Mud Pump Set(NJBQ10.02.03.00)
35
36
List of mud pump set assembly(Table 12):
Schematic Diagram of Part drawing number

Mud Pump Set Assembly NJBQ10.02.03.00
1 NJBQ10.11.00 Pedestal Assembly 1
2 NJBQ10.02.00 Mud Pump Assembly 1
3 NJBQ10.10.00 Drive Chain Assembly 1
4 NJBQ10.02.01 Pressing Plate Base 6
5 NJBQ10.02.02 Mud Pump Pressing Pump 6
6 GB/T97.1-2002 Flat Washer 30 6
7 GB/T 5783-2002 Bolt M30×60 6
8 NJBQ10.11.40.00 Push Rod of Mud Pump 4
Table 12 List of mud pump set assembly (NJBQ10.02.03.00)
2.4. Fuel System
Fuel system consists of fuel tank assembly, fuel pipeline and so on. It has fuel oil liquid
level alarm system so that it can alarm if the diesel liquid level reach to setting position in
order to remind operator to add diesel.
2.4.1. Fuel Tank Assembly
Fuel tank adopt t3 stainless steel to weld and it has good strength rigidity, with good
anti-corrosion function. Dimensions of oil tank is 1500x 606x702, oil tank can
accommodate 620L diesel(Fill Status). Engine incomplete combustion fuel pass through
radiator and then return to oil tank so that the oil tank temperature is not too high. Fuel oil
tank assembly is as shown in Fig 34.
37
Fig 34 Discharge Manifold Assembly Drawing(NJBQ10.04.00)
List of fuel oil tank assembly(NJBQ10.04.00)(Table 13):
Part drawing number

Fuel Oil Tank Assembly
NJBQ10.04.00
1 YWS-1000 Liquid Level Sensor 1 Module
2 NJBQ10.04.02.00 Oil Tank Support 1 Module
3 YWZ-450 Liquid Level Meter 1 Module
4 EF7-100 Air Filter 1 Module
5 NJBQ10.04.01.00 Oil Tank 1 304
6 NJBQ10.04.01.08 Oil Inlet and Outlet 2 304
Table 13 List of Fuel Oil Tank Assembly
2.4.2. Fuel Tube
Fuel tube is as shown in Fig 35:
38
Fig 35 Engine Fuel Oil-way(NJBQ10.04.00)
List of fuel tube schematic diagram(Table 14):
Schematic Diagram of Part drawing number

Fuel Tube NJBQ10.04.00
1 YSFLQ-01 Oil-water Separator 1 Module
2 RYGLQ-02 Fuel Oil Filter 1 Module
3 CYB-01 Diesel Oil Pump 1 Module
4 C32 Engine 1 Module
5 LQQ-01 Cooler 1 304

Table 14 List of Fuel Tube
2.5. Control System
Control system consists of electrically control system and pneumatic control system. Diesel
engine drive electric generator to generate electricity in electrically control system and the
electricity is stored in storage battery. The electricity mainly used to control electric
generator, injection skid motor, running parameters’ display of hydraulic transmission box,
39
mud pump and so on. Electric generator drive air compressor to generate compressing air in
pneumatic control system and the air is stored in gas bomb. The gas is used to the shift
gears of hydraulic transmission box.
2.5.1. Composition of Electrically Controlled System
Control system mainly include: engine control, transmission box control, injection pump
control, mud pump monitoring and control, anti-explosion control cabinet and operation
panel.
2.5.1.1. Engine Control
Engine control system includes engine, throttle switch, start key, alarm light, stop button,
jerk button, 24V power source, starting motor, parameter displayer and so on. The detailed
control principle and wiring is as shown in Fig 36, Fig 37.
Fig 36 Engine Control Principle and wiring 1
40
Fig 37 Engine Control Principle and wiring 2
41
2.5.1.2. Hydraulic Transmission Box Control System
Hydraulic transmission box control system mainly includes transmission box, gear shifting,
gear displayer, control valve and so on. The detailed control wiring is as shown in Fig 38,
Table 13.
Fig 38 Hydraulic Transmission Box Control Principle and Wiring

List of hydraulic transmission box control principle(Table 15):
Gear displayer Wiring Introduction
Plug Pin 1 2 3 4 5 6
Gears Power
1st 2nd 3rd 4th 5th 6th
Source
Wicking Color Purple Red Orange Yellow Green Blue
Plug Pin 7 8 9 10 11 12
42
Gears Power Neutral

Back Gear Lock +24V Earth
Source Position
Wicking Color Germanium White Black Red Black
1~10 Plug Pin 10 Cores Cable(10 Meters)
11、12 Plug Pin 2 Meters Independent Wire

Table 15 Gear displayer Wiring Introduction
2.5.1.3. Injection Pump Control System
Injection pump control mainly includes injection pump, anti-explosion motor, contractor,
thermal relay, phase sequence protector and so on. The detailed wiring and control principle
is as shown in Fig 39, Fig 40.
Fig 39 Charge Pump Main Control Loop
43
Fig 40 Charge Pump Start Control Loop
2.5.1.4 Mud Pump Display System
Mud pump display system mainly includes NJB-2 mud pump complicated monitoring
system, 24V power source, pressure sensor, velocity sensor and so on. The detailed control
principle and wiring is as shown in Fig 41.
44
Fig 41 Mud Pump Display System
2.5.1.5 .Anti-explosion Control Cabinet
Control cabinet is a positive pressure type anti-explosion control cabinet. It meets EX2
anti-explosion requirements and all kinds of strict operating conditions’ requirements, well
site’s construction requirements, protection grade requirements. The detailed outside
drawing is as shown in Fig 42.
45
Fig 42 Anti-explosion Control Cabinet
Control panel mainly integrate above control switch, parameter displayer so as to realize
centralized control and detection. The detailed panel drawing is as shown in Fig 43.
Fig 43 Anti-explosion Control Cabinet Operation Panel
46
2.5.2. Pneumatic Control System
Pneumatic control system mainly includes blast pump, gas bomb, pneumatic FRL, pressure
gauge, safety valve, silencer and so on. The schematic diagram is as shown in Fig 44.
Fig 44 Pneumatic Control Assembly Drawing(NJBQ10.06.04.00)

List of pneumatic control system(Table 16):
Pneumatic Control Part drawing number

System Principle NJBQ10.06.04.00
1 DQB-01 Blast Pump 1 Module
2 NJBQ10.07.00 Gas Bomb 1 Module
3 AQF-02 Safety Valve 1 Module
4 YLB-04 Pressure Gauge 1 Module
5 SLJ-05 Pneumatic FRL 1 304

Table 16 List of Pneumatic Control System
47
3. Injection Skid System

Injection skid system mainly includes pipeline assembly, base, pipeline support and so on.
It can meets self-absorption and injection of mud pump set. This skid with two sets of
injection sand pump and they can work at the same time and spare to each other.
3.1. Structural Type

Structure of injection skid system assembly is as shown in Fig45:
Fig 45 Injection System Assembly Drawing(NJBQ10.03.00)

List of injection skid system assembly is as shown in Table 17:
Part drawing number
Injection System
NJBQ10.03.00
NO. Code Name Qty.
1 NJBQ10.03.01.00 Pipeline Assembly 1
2 NJBQ10.03.02.00 Base Assembly 1
3 NJBQ10.03.03.00 Sand Pump Base 2
4 NJBQ10.03.04.00 Pipe Support 12
Table 17 List of Injection System(NJBQ10.03.00)
48
3.2. Pipeline Assembly

Pipeline assembly is as shown in Fig 46:
Fig 46 Injection System Assembly Drawing(NJBQ10.03.01.00)
List of pipeline assembly is as shown in Table 18:

Part drawing number
Pipeline Assembly
NJBQ10.03.01.00
NO. Code Name Qty.
1 DN300-1.0DF Turbine Worm Butterfly Valve 2
3 GB/T26121-2010 XTQ1RF1.0-150 Flexible Rubber Joint 2
4 NJBQ10.03.01.02 Injection Pump Set(Levoduction) 1
5 GB/T26121-2010 XTQ1RF1.0-200 Flexible Rubber Joint 2
6 NJBQ10.03.01.03 Pipeline Assembly 1
7 NJBQ10.03.01.05 Pressure Gauge 2
8 NJBQ10.03.01.06 Basketfilter 2
9 GSRG-DN300 Wire Braider Rubber Hose 2
11 GB/T 9115.1—2000 DN150 Welding Flange 6
12 GB/T5782-2000 Bolt M20x85 136
13 GB/T93-1987 Gasket 12 8
49
14 GB/T6170-2000 Nut M20 208
15 GB/T93-1987 Gasket 20 208
16 GB/T5782-2000 Bolt M20x165 24
17 GB/T5782-2000 Bolt M20x140 48
18 GB/T5782-2000 Bolt M12x55 8
19 GB/T6170-2000 Nut M12 8
20 GB/T93-1987 Gasket 12 8
Table 18 List of Pipeline Assembly(NJBQ10.03.01.00)
3.3. Charge pump Skid Performance Parameters
Whole machine parameters:

Flow: 2×200m3/h
Lift: 36 m
Power: 2×55Kw
Overall dimensions: 2900×3132×1750
Weight: 5700 Kg
Sand pump parameters:
Type: SB6×8J-12 1/2
Inlet Diameter: 8〞（DN200）
Outlet Diameter: 6〞（DN150）
Flow: 200m3/h
Lift: 36m
Speed: 1480 r/min
Sand Pump Motor Parameters:
Power: 55kW
Voltage: 415V
Frequency: 50Hz
Explosion-proof: ExdⅡBT4
Protection Grade: IP55
Insulation Grade: F
50
3.4. Charge Pump Skid Operation Instruction

The principle of Charge Pump skid is as shown in Fig 47:
Fig 47 Charge Pump Skid Schematic Diagram

Components list of Charge pump skid schematic diagram is as shown in Table 19:
Schematic Diagram List of Charge pump System
NO. Name Qty. Description
1 Butterfly Valve 3 8″ Butterfly, Number 1, 2, 3
Centrifugal Displacement: 200m3/h, Lift: 36m,

2 2
Pump Number 9, 10
3 Butterfly 2 12″ Butterfly, Number 4, 5
4 Butterfly 3 6″ Butterfly, Number 6, 7, 8
Pressure Gauge
5 2 Range: 0-1Mpa, Number 11, 12
of Low Pressure
6 Filter 2 Flow: 200m3/h, Number 13, 14
Table 19 Schematic Diagram List of Charge pump System
51
3.4.1. Notes
1) Please don’t install the backflow pipeline opposite connected to the suction pipeline.
2) Please check if the power voltage, power frequency in accord with motor rated voltage,
rated power frequency before use.
3.4.2. Preparation Before Startup
1) Check valve switch situation before start, make sure butterfly 2, 7 is in close status;
2) Check if the pipeline of injection system leak or not, sand fixed bolts and other
connection has looseness or not.
3) Start sand pump before mud pump starting and stop sand pump after mud pump
stopping.
4) Pipeline Ⅰ and pipeline Ⅱ connect to mud pump skid Ⅰ and mud pump skid Ⅱ.
5) Mud pump skid Ⅰ stop, sand pump 10 start work. The mud is inhaled by mud tank
through pipeline Ⅰ suction port, butterfly 3, 8 is in open state and butterfly 2, 7, 5 is
in closing state, the pressure of pipeline is read by low pressure gauge. If sand pump 10
break down, butterfly 3, 8 shut down, butterfly 5 open, mud enter into mud pump
through suction port, pipeline, filter 14. All this can ensure continuous operation
requirement.
6) Mud pump skid Ⅱ start work, sand pump start work. mud flow to Ⅱ suction inlet
through mud pump, butterfly 1, 6 is in open state, butterfly 2, 7,4 is in closing state, the
pressure of pipeline is read by low pressure gauge. If sand pump 9 break down,
butterfly 1, 6 close, butterfly 4 open, mud enter into mud pump through suction port,
filter 13. All this can ensure continuous operation requirement.
7) Pipeline Ⅰ, pipeline Ⅱ can work at the same time or work separately.
8) About detailed description of sand pump, please refer to sand pump operating
instruction.
52
3.5. Charge Pump Skid Connection
1) Reserve Fig 200FxM union connector between suction inlet and mud tank, pipeline
erection is carried out by user.
2) Injection system and mud pump is connected through steel braided hose. One end
flange connection of steel braided hose is flange connection, the other end is Fig
200FxM union connection.
3.6. Charge Pump Skid Maintenance
Before equipment maintenance, please make sure the power source is cutoff and give alarm
information.
1) Periodical check the inner filter screen, check if there is clutter blocking or not. Open
head cover first during inspection, get filter element out second, use light oil to clean
or use steam for back wash. If filter screen deformation or damage appeared, change it
immediately.
2) Protect suction inlet and discharge port during transportation so as to prevent clutter
entering.
3) About sand pump maintenance, please refer to sand pump maintenance manual.
53
4. Installation and Debugging

The well site should be flat and have enough strength , it is recommended hardened cement
floor. The F-1000 mud pump skid be installed according to Fig 1 to Fig 3, and connected
with the hinge. Install the mud pump set on the main pump skid according to Fig 30 to Fig
33. The plate bolt of mud pump set should be tightened when the connection of chain box
flange and shaft flange completed, and mud pump is located by adjusting the mud pump
jack. The suction manifold of the pump should be connected with the infusion pump and
the discharge manifold connected to the ground manifold with high pressure hose or rigid
pipe. The drive shaft hole be injected grease, checking the oil level of the chain box, and it
is must be ensure there are enough lubricant in pump housing.
The frequency of stroke should be from low to high when start the unit in each time, to
ensure that the spray system and lubrication system are normal operation before marking
the pump to high speed.
4.1. Installation Adjustment of Transmission Gear
Gearing is a core part of F1000 mud pump, and the installation accuracy directly affects the
performance and life of the pump. Mud pump group should be placed in the correct
position on the main pump skid, and then connect the chain box flange and shaft flange,
keeping the axis of the two flanges in a straight line, and fastening bolt before the mud
pump is located.
4.2. Connection of High and Low Pressure Manifold
It is used the flexible hose to connect the infusion pump and mud pump unit, it is better that
to make the outlet of infusion pump and suction of mud pump in a straight line. The height
difference between the two pump can’t be too large, otherwise the life of flexible hose
will be reduced because of excessive bending.
Surface manifold is secured to the ground when the mud pump outlet connect to high
pressure surface manifold, then tighten the bolts with required torque to make sure the
54
high-pressure manifold not shock and leak. Security manifold connected to the mud tank
via a high pressure manifold to prevent mud splashing.
4.3. Start of Pump Skid
4.3.1. Preparation before Startup
1) Check all components to ensure proper installation;

2) Check all fasteners to ensure no loose;
3) Check all valve to ensure the correct position, such as "ON" or "OFF";
4) Check all lubricant components whether to meet the requirements of lubrication in
operation and maintenance manuals;
5) Check whether the antifreeze filling the engine water tank in accordance with the
requirements;
6) Check the engine to ensure that adequate and appropriate amount of lubricating oil;
7) Check the added diesel tank is appropriate, the oil level limit is not exceeded;
8) Ensure that the switch of start motor on the diesel engine is in "OPEN" position.
9) Make sure that the hydraulic transmission shift lever is in the "FREE" position.
10) Before starting the hydraulic transmission, ensure that the oil level in the "FULL"
position
4.3.2. Start of Pump Skid
Check the items mentioned above has been detected, and to ensure correct, please follow
these steps to start the engine.
1) It is no more than 30S press the start button to start the engine, and start again time
interval of less than two minutes. After starting, the diesel engine should be running at
low speed, then gradually speed up to normal operating speed.
2) It is to prohibit the shift before the hydraulic transmission oil temperature rose to 71 ℃
-93 ℃, and to ensure the oil level is located between the upper and lower limits for
driving the pump.
55
3) Check the rotating parts, ensure proper operation.

4) Check the meter, ensure that the display is correct.
5) Follow the operation manual, strict inspection and calibration of all moving parts.
56
5. Troubles Shooting
5.1. Trouble and Troubleshooting of F-1000 Mud Pump

Skid
NO. Trouble Reason Troubleshooting
1. The connecting rod bolts 1. Tighten the bolts
Percussion loose 2. Replace the connecting rod
1
sound 2. The rod sleeve damage sleeve
3. Valve or spring damage 3. Replace valve or spring
Pressure 1. valve or spring damage 1. Replace the valve or valve
2 gauge swing 2. Inadequate pump suction spring
serious 2. Increase perfusion pressure
Packing 1. The lubrication system 1. Check the lubrication system
3 shortened life blockage
expectancy 2. Plunger abrasion 2. Replace the plunger
1. The lubrication system 1. Check the lubrication system
Packing blockage
4
smoke 2. The lack of oil 2. Check the lubricant tank
3. Compression nut too tight 3. Adjust the compression nut
Oil becomes Change the oil and clean the
5 Water atomization or leak
cloudy filter
5.2. Trouble and Troubleshooting of Hydraulic

Transmission Box
NO. Trouble Reason Troubleshooting
1. The level is too low 1. refuel to a predetermined oil level
2. The filter is blocked 2. Clean oil filter
3. oil line leak 3. Check and repair leaks oil line
1 Low pressure 4. The pump is worn or damaged 4. Replace worn or damaged parts
5. The oil bubble serious 5. Drain to the quantitative
6. The spring of hydraulic control 6. Increase adjustment shims or
valve is too soft or damage replace the spring
1. The oil level is too low or too high 1. Add oil or oil drain.
2. Cooling water level too low or leak 2. Add coolant or repair leaking
High oil
2 3.Oil line (filter and cooler) blockage components
temperature
4.The long working hours and low 3. Clean or replace pipeline
efficiency of torque converter 4.Shifting to ensure efficient
57
5. The guide wheels are stuck operation

6. Fuel pump worn leading to oil 5. To repair guide wheel clutch
reduction 6. Repair pump
1. The oil level is too low 1. Refuel to a predetermined oil level
2. The filter is blocked 2. Clean filter
Outlet pressure
3. Oil line leak 3. Check and repair leaks Oil
of torque
3 4. Pump wear, damage 4. Replace worn or damaged parts
converter is
5. The oil foam serious 5. Drain to the quantitative
low
6. Balancing valve Stuck at "on" 6. Repair or replace the valve spring
position, the spring be stucked
1. The shifting pressure is too low, 1.Adjust the main pressure and
There si no
the clutch or brake does not work clutch or the brake pressure
4 power output in
2. The piston ring damage 2. Replace the seals
some stalls
3. The clutch slip 3. Repair or replace clutch plate
58
6. Package and Transportation

It is recommended that the mud pump group and the main pump skid to take apart when
transporting the F-1000 mud pump, it is convenient for main pump lifting and without
being limited by the width of the road. We can transport the high pressure manifolds and
secure manifold with fixing them to perfusion pump skid if the perfusion pump transported
and packed independence.
6.1. Package
All exposed machined parts should be coated with butter and wrapped with plastic sheeting,
then banding with linen and wire. Other exposed interfaces coated with butter and blocked
with blocking plate or plastic sheeting, to prevent corrosion and dregs.
All components installed in the pump skid should be secured on the skid by wire or other
fastening tools, in case of the components shift on the pump skid. When fastened with wire,
it is necessary to adopt protective measures avoiding surface damage of components.
6.2. Transportation
The main pump skid ,mud pump and perfusion skid are transported independence when the
F-1000 mud pump skid shipped and other spare parts are transported by metal box. Main
pump skid, mud pump and perfusion skid are packaged by wood before transportation.
6.2.1. Transportation of Main Pump Skid
The main pump skid be transported independence after disassemble. It is easy to get the
dimension and gravity position of main pump skid from Fig 48 and Fig 49.
59
Fig48 Dimension and Gravity Position of Main Pump Skid
Fig49 Dimension and Gravity Position of Main Pump Skid

Main pump skid weight:14,000 kg , it is recommend to use two cranes hoisting
60
6.2.2. Transportation of Mud Pump Set
It is easy to get the dimension and gravity position of mud pump set (include chain box)
from Fig 50 and Fig 51.
Fig50 Dimension and Gravity Position of Mud Pump Set (Include Chain Box)
Fig51 Dimension and Gravity Position of Mud Pump Set (Include )
Main pump weight:21,500 kg

61
6.2.3. Transportation of Perfusion Skid
It is easy to get the dimension and gravity position of main pump skid from Fig 52 and Fig
53.
Fig52 Dimension of Perfusion Skid
Fig53 Dimension of Perfusion Skid

Perfusion skid weight:5,700 kg
62
7. Attachment
Attachment 1: C32 Industrial Engines Operation and Maintenance Manual
Attachment 2: C32 Industrial Engine Parts Manual
Attachment 3: Operating Manual of Winstar Gearbox BY920B
Attachment 4: Maintenance Manual of Winstar Gearbox BY920B
Attachment 5: Parts Manual of Winstar Gearbox BY920B
Attachment 6: Operation and Maintenance Manual & Parts Catalog of RS-F1000 Mud
Pumps
Attachment 7: User Manual of Centrifugal Pump V2.1
Attachment 8: Outline Drawing of F-1000 Mud Pump Skid
Attachment 9: Diesel Tank Dimensions
Attachment 10: Electrical Schematics
Attachment 11: Parts List
Attachment 12: Consumable Parts List
63

F-1000 Operation Manual Kerui Package

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What are the main components of the F-1000 mud pump skid?

What are the main components of the F-1000 mud pump skid?

What are the main technical parameters of the F-1000 mud pump skid?

What are the main technical parameters of the F-1000 mud pump skid?

F-1000 Mud Pump Skid

Shandong Kerui Petroleum Equipment Co.,Ltd

1.1. Structural Composition ......................................................................... 1

1.2. Main Technical Parameters................................................................... 3

2. F-1000 Main Pump Skid................................................................................ 4

2.1. Power System ....................................................................................... 6

2.1.1. Summary .................................................................................... 10

2.1.2. Main Parameters ........................................................................ 10

2.2. Transmission System .......................................................................... 14

2.2.1. Cross-axle Type of Universal Drive Shaft................................. 15

2.2.2. Drive Chain Case ....................................................................... 17

2.3. Mud Pump System.............................................................................. 26

2.3.1. Mud Pump Set ........................................................................... 28

2.3.2. Safety Manifold ......................................................................... 32

2.3.3. Discharge Manifold ................................................................... 34

2.3.4. Assembly of Mud Pump System ............................................... 35

2.4. Fuel System ........................................................................................ 37

2.4.1. Fuel Tank Assembly .................................................................. 37

2.4.2. Fuel Tube ................................................................................... 38

2.5. Control System ................................................................................... 39

2.5.1. Composition of Electrically Controlled System ........................ 40

2.5.2. Pneumatic Control System ........................................................ 47

3. Injection Skid System .................................................................................. 48

3.1. Structural Type .................................................................................... 48

3.2. Pipeline Assembly .............................................................................. 49

3.3. Charge pump Skid Performance Parameters ...................................... 50

3.4. Charge Pump Skid Operation Instruction........................................... 51

3.4.1. Notes .......................................................................................... 52

3.4.2. Preparation Before Startup ........................................................ 52

3.5. Charge Pump Skid Connection........................................................... 53

3.6. Charge Pump Skid Maintenance ........................................................ 53

4. Installation and Debugging .......................................................................... 54

4.1. Installation Adjustment of Transmission Gear ................................... 54

4.2. Connection of High and Low Pressure Manifold ............................... 54

4.3. Start of Pump Skid .............................................................................. 55

4.3.1. Preparation before Startup ......................................................... 55

4.3.2. Start of Pump Skid ..................................................................... 55

5. Troubles Shooting ........................................................................................ 57

5.1. Trouble and Troubleshooting of F-1000 Mud Pump Skid ................. 57

5.2. Trouble and Troubleshooting of Hydraulic Transmission Box .......... 57

6. Package and Transportation ......................................................................... 59

6.1. Package ............................................................................................... 59

6.2. Transportation ..................................................................................... 59

6.2.1. Transportation of Main Pump Skid ........................................... 59

6.2.2. Transportation of Mud Pump Set .............................................. 61

6.2.3. Transportation of Perfusion Skid ............................................... 62

1.1. Structural Composition

Fig1 F-1000 Mud Pump Skid（NJBQ10.00）

Fig2 F-1000 Mud Pump Skid（NJBQ10.00）

Fig3 F-1000 Mud Pump Skid（NJBQ10.00）

List of F-1000 mud pump skid assembly(Table 1) :

Part drawing number

NO. Code Name Qty. Remarks

Main Pump Skid

2 NJBQ10. 03.00 Injection Skid Assembly 1