ZYF-1600 MUD PUMP UNITIZATION

INSTRUCTION MANUAL
807.09D2.00SM

September 2008

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 Contents
PREFACE................................................................................................3

1 GENERAL ...........................................................................................4

1.1 Type and Characteristic ................................................................4

1.2 Main technical parameters............................................................4

2 Structure and operating principle ..........................................................5

3 Installation and adjustment....................................................................6

3.1 Installation of transmission device ...............................................6

3.2 Inspection of sheave alignment ....................................................6

3.3 V belt pretightening force adjustment...........................................7

3.4 Fastening connecting bolt.............................................................7

3.5 Other part installation...................................................................7

4 Maintenance..........................................................................................7

4.1 Equipment normal action .............................................................7

4.2 Lubrication...................................................................................8

4.3 ZYF-1600 mud pump...................................................................8

4.4 Motor ...........................................................................................8

4.5 Narrow V belt...............................................................................8

5 Packing and transporting.......................................................................8

5.1 Packing ........................................................................................8

5.2 Transporting .................................................................................9

6 Parts list ..............................................................................................10

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 6.1 ZYF-1600 power-driven mud pump unitization .........................10

6.2 Spray Pump Assy .......................................................................12

6.3 Influx system..............................................................................14

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 PREFACE

ZYF-1600 power-driven mud pump unitization is ideal mud circulation

equipment for oil and gas exploration and development site. It is an
important component of ZJ50DZ drilling rig.
The design of ZYF-1600 power-driven mud pump unitization is in
accordance with oil and gas industry standard and relevant API
specification.
For the operating personnel familiar with the use of ZYF-1600
power-driven mud pump unitization, this manual introduce the general
content of ZYF-1600 power-driven mud pump unitization. As using the
mud pump, the content of structural parameter and maintenance and the
relevant data of the requisite corollary equipment (components), see the
corollary equipment manual, the drilling rig manual and other relevant
technical document in detail.

Before using mud pump unitization, administrator, technician and

operator have to read the manual and the relevant document to be
familiar with all the detail, in addition they also have to possess the
relevant safe operation knowledge and skill.
The complete management job and operation should be follow with
the relevant rules and regulations of the own system and the own
company.

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 1 GENERAL

ZYF-1600 power-driven mud pump unitization is ideal mud circulation

equipment for oil and gas exploration and development site. It is an
important component of ZJ50DZ drilling rig. ZYF-1600 power-driven
mud pump unitization is drived by two DC motor through narrow V belt.
It is using for transporting high-pressure drilling mud to well bottom,
using drill bit and spraying crashed rock, cooling bit and taking out rock
scraps.

1.1 Type and Characteristic

Base of ZYF-1600 power-driven mud pump unitization is ski-mounted

type, using two DC motor for power. Motor base and base of mud pump
are mounted on the base of mud pump unitization, it is easy to
disassembly, transport and hoisting. ZYF-1600 power-driven mud pump
unitization has features with simple construction, completely function,
reliable performance, convenient maintenance, and so on. The
transmission principle of ZYF-1600 power-driven mud pump unitization
is to through narrow V belt drive the mud pump by two DC motor.

1.2 Main technical parameters

1) ZYF-1600 Mud pump

● Mud pump model Horizontal triplex single action pump
● Rated power 1180 kW
● Rated Strokes 120 spm
● Stroke length 304.8 mm
● Gear Ratio 4.206：1
● Maximum pressure 34.3MPa
● Inlet diameter 12in
● Outlet diameter 5 1/8in
● Maximum liner diameter φ177.8

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 ● Outline Size (not including pulsation dampener, discharge
strainer and elbow) 4426×2413×2004mm
●Total Weigh t（not including the weight of spare parts） 24751 Kg
2) Model of motor
● Model YZ08、YZ08A
● Rated power 800kW
● Rated voltage 750V
● Rated current 1150A
● Max. current 1600A
● Rated Speed 970r/min
● Max. Speed 1500r/min
● Rated torque 8.034KN.m
● Excitation method Series excitation
● Operating duty Continuous
● Insulation grade H/H
● Type of cooling Forced air cooling
● Wind machine parameter 50Hz 380V 11kW
3) Belt transmission
● V belt model 10×8V-7620 Narrow V belt(American standard)
● Belt sheave diameter φ530/φ1020
4) Outside dimension and weight of mud pump unitization
● Outside dimension (L×W×H) 8534mm×3658mm×3006mm
● Weight 44670kg

2 Structure and operating principle

ZYF-1600 power-driven mud pump unitization mainly consist of 2 DC

motor, ZYF-1600 mud pump, narrow V belt, big and small sheave, base
of motor, skid, guard, charging system, power-driven spray pump
assembly, and so on. 2 DC motors drive mud pump by two group ten leng
narrow V belt. Base of motor can be adjusted by adjustment rod screw on

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 base of mud pump, so that tighten the belt. Rotary crane are fitted on
pump unitizations for changing easily-worn parts or inspecting mud
pump fluid end. Totally enclosed belt guards are mounted on both sides of
mud pump.

3 Installation and adjustment

Rig-up yard should be flat and rigid，recommend to use cement hardening

ground. After ZYF-1600 power-driven mud pump unitization arranged in
the rig-up yard, connect the pipe between the pump unitization and the
mud tank.

3.1 Installation of transmission device

The transmission device is the heart of mud pump unitization. The

accuracy of installation and adjustment will affect the performance and
service life of mud pump unitization. First connect motor base with pump
unitization base, then hang V belts and tighten them. Tighten all
connecting bolts (slightly tightening is enough, because if necessary some
parts will be moved and relevant bolts should be loosened or removed.)

3.2 Inspection of sheave alignment

When installing the transmission device on the base, it is necessary to

adjust the sheave, the adjustment method is: use two steel wires along one
side face of the two sheave, one is above the central line, the other is
under the central line, then move the small sheave (i.e. motor) until the
two steel wires contact the four points on the sheave, this shows the
coplanarity of the two sheave. Tighten belts (as follows), and then fasten
all bolts. As above mentioned, again measure big and small belt pulley's
coplanarity, if change is too much, should again adjust until it is qualified.
At last, fasten all connecting bolts.

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 3.3 V belt pretightening force adjustment

Adjusting rod screw don't move belt pulley's center distance for adjusting
belt tightening force until belt tightened side isn't saggy and belt on slack
side is tightened , then increase some center distance. For instance, when
center distance is 2540mm (100"), center distance 13mm (1/2″) should
be increased after center distance is adjusted. When center distance is
3810mm (150″), center distance 19mm (3/4″) should be increased after
being adjusted.

3.4 Fastening connecting bolt

All bolts should be thoroughly fastened after adjustment. Adjusting rod

screw only can be used for adjusting belt tightening force, but it can't bear
huge pull of belt pulley when belt pulley is working. So all fixed bolts
should thoroughly fastened and inspected regularly.

3.5 Other part installation

Safety guard, crane beam and other accessories should be fitted as

drawing 1 and connecting bolts should be fastened. Check ZYF-1600
mud pump whether filling the enough lubricating oil in the regulation.
The mud pump unitization should be started every time according to SPM
from low to high and it can run with a high speed after lubricating and
spraying system of F-1600 pump in good condition.

4 Maintenance

4.1 Equipment normal action

Equipment normal and fine maintenance is important link that lift

equipment service life. Periodic check motor action normal or not, check
bolt connector fasten or not, Periodic check drive belt safely or not,
assure parts to use normal and equipment to act regular.

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 4.2 Lubrication

The motive mechanical part proceeds sufficient lubrication that is

important, lubrication affect the limiting life directly. After starting up, it
should be check each oil site normally or not, if oil becomes not sufficient
or contaminated refills or change it immediately.
Mud pump’s lubrication sees ZYF-1600 Mud Pump Operation &
Maintenance Manual in detail.

4.3 ZYF-1600 mud pump

Detail usage and maintenance for mud pump refer to “ZYF-1600 Mud
Pump Operation & Maintenance Manual”.

4.4 Motor

Detail usage and maintenance for motor refer to “YZ08 motor Operation &
Maintenance Manual”.

4.5 Narrow V belt

Detail usage and maintenance for 8V-7620 narrow V belt refer to “V belt
Operation Manual”.

5 Packing and transporting

When transporting ZYF-1600 power-driven mud pump unitization tear

two YZ08 DZ motors and other accessory down from mud pump
unitization, transport by itself. Before the customer use the mud pump
unitization, assemble it on the basis of drawing.

5.1 Packing

5.1.1 Motor
It should be tear two motor down when the mud pump unitization is

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 dispatched form the factory, single motor and small sheave assembly
transport together as no packing.
5.1.2 Mud pump
Mud pump following with the base of mud pump unitization adopt the
whole transportation as no packing, the exposed part of mud pump butter,
use the plastic cloth dressing, fastened by the mat cloth and the iron wire.
The other exposed joints use the plastic cloth dressing, fastened by the
mat cloth, prevent rusting.

5.2 Transporting

5.2.1 Single motor and small sheave assembly transport together as no

packing.
5.2.2 Mud pump following with the base of mud pump unitization adopt
the whole transportation as no packing.
5.2.3 The discharge strainer and tool list of mud pump adopt the iron box
transportation.
5.2.4 Belt guard adopts the transportation as no packing.
5.2.5 Belt and spare parts adopt the iron box transportation.

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 6 Parts list

6.1 ZYF-1600 power-driven mud pump unitization

See the figure 1 for the pump unitization arrangement.

Fig.1
Table 1 parts list
No. Drawing No.or Code Denomination Qty Remarks
1 807.09D2.001 Big sheave assembly 2
2 807.09D2.002 Bearing Spacer 2
3 GB/T39-1987 Washer 30 8
4 AC1-1-07 Bolt 11/8″－7UNC×11″ 8
5 AC1-1-07 Bolt 3／4″－10UNC×4″ 2
6 807.09D2.003 Cover plate 2

10

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 No. Drawing No.or Code Denomination Qty Remarks
7 AC1-1-05 Bolt 5／8″－11UNC×2 6
8 807.09D2.005 Key 2
9 807.09D2.02.00 Pump pedestal 1
10 807.09D2.03.00 Belt guard 2
11 807.09D2.04.00 Base of motor 2
12 807.09D1.06.00 Oil-level gauge 2
13 Spray pump Assy 1
14 807.09D2.004 Small sheave 1
15 807.09D1.07.00 Oil-release pipe assembly 2
16 YZ08 DC motor (R) 1 outsourcing
17 YZ08A DC motor (L) 1 outsourcing
18 807.09.00 ZYF-1600 mud pump 1
19 8V-7620 Narrow V belt 20 USAstandard
20 807.09D2.05.00 Influx system 1
21 L=300 Theft proof chain 2 outsourcing

11

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 6.2 Spray Pump Assy

See the figure 2 for the spray pump assy

Fig.2
Table 2 part list
No. Drawing No.or Code Denomination Qty Remarks
1 GD100.110.00 Base 1
2 JB5338-1991 AC motor 1
3 GD100.120.00 Coupling 1
4 GD100.100.01 Guard 1
5 GD100.400.00 Centrifugal spray pump 1
Pressure gauge Y60
6 1
0~1MPa
7 GD100.100.02 Rubber cradle 6×12δ3 1
8 GD100.100.03 Gauge seat 1
9 GB/T3287-2000 Tee Rc1" 1

12

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 No. Drawing No.or Code Denomination Qty Remarks
10 GD100.100.04 Core 25/R1" 1
11 GD100.100.05 Nut 25 2
12 HG4-761-74 Hoseφ25-0.7×3m 1
13 GD100.100.06 Core 25 1
14 GD100.100.07 Nut M39×2 1
15 GD100.100.08 Connector 28/R1" 1
16 GB/T3287-2000 Connector R1" 2
17 GB/T5782-2000 Bolt M10×65 8
18 GB/T97.1-2002 Washer 10 10
19 GB/T93-1987 Washer 10 10
20 GB/T6170-2000 Nut M10 10
21 GD100.100.09 Block M10 2
22 GB/T5781-2000 Bolt M10×20 2
23 HG4-761-74 Hoseφ38/0.7×1.5m 1
24 Hose clip No.2 2
25 GD100.100.10 Hose connector 2
26 GB/T3287-2000 Bend Rc1 1/2" 1
27 GB/T3287-2000 Connector R1 1/2" 1
28 GD100.100.11 Shim δ0.35 4
29 GD100.100.12 Shim δ1.5 4
30 GD100.100.13 Discharge flange 1
31 GD100.100.14 Shim δ1.5 2
32 GD100.100.15 Inlet flange 1
33 GB/T5782-2000 Bolt M12×55 8
34 GB/T6170-2000 Nut M12 8
35 GB/T93-1987 Washer 12 8
Support
36 GD100.100.16 4
L50×50×5L=60
37 GD100.100.17 Block M16 4
38 GB/T93-1987 Washer 16 4
39 GB/T5781-2000 Bolt M16×35 4

13

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 6.3 Influx system

See the figure 3 for the influx system

Fig.3
Table 3 part list
No. Drawing No.or Code Denomination Qty Remarks
1 807.09.05.10.002 Flangeδ34 1
2 Washer δ3 1
3 AC1-1-05 Bolt 1-8UNCx4" 12
4 AC2-1-00 Nut 1-8UNC" 12
Seamless pipe
5 1
φ325×15 L=110

14

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 No. Drawing No.or Code Denomination Qty Remarks
6 GB/T12459-1990 Bend 90E(S)300-Sch60 1
Seamless pipe
7 1
φ325×15 L=860
8 GB/T9116.1-2000 FlangeDN150-PN10RF 4
9 AC1-1-05 Bolt3/4-10UNCx5 1/4" 8
10 AC2-1-00 Nut 3/4-10UNC" 52
11 D371X Butterfly valve DN150 1
12 GB/T9116.1-2000 FlangeDN300-PN10RF 2
13 D371X Butterfly valve DN300 1
14 AC1-1-05 Bolt3/4-10UNCx6 1/4" 12
Seamless pipe
15 1
φ325×15 L=550
16 807.09D2.05.01.00 Filter 1
17 Pneumatic union12" 1
18 D371X Butterfly valve DN200 1
19 GB/T9116.1-2000 FlangeDN200-PN10RF 3
20 AC1-1-05 Bolt3/4-10UNCx5 1/4" 8
21 AC1-1-05 Bolt3/4-10UNCx3 1/4" 24
Upright pulsation
22 807.09D2.05.02.00 1
dampener assembly
23 Gasket δ3 2
Seamless pipe
24 1
φ168×10 L=160
Seamless pipe
25 1
φ168×10 L=440
Seamless pipe
26 1
φ168×10 L=385
27 GB/T12459-1990 Bend 90E(L)150-Sch80 1
28 GB/T12459-1990 Bend 90E(L)200-Sch60 1
Seamless pipe
29 1
φ219×10 L=270
30 Centrifugal sand pump 1
unit
31 Gasket δ3 1
32 807.09D2.05.001 Base plate δ20 2
33 AC1-1-05 Bolt3/4-10UNCx1 1/4" 4
34 GB/T93-1987 Washer 20 4

15

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