Emsco FD-1600HP with Blak-jak Mud Pump

The EMSCO FD-1600HP is a triplex single-acting piston mud pump with a rated power of up to 1600 HP (1193 kW), specifically designed for high-pressure, high-volume drilling operations, and widely applicable to onshore and offshore drilling rigs. Its robust structure and field-proven design ensure reliable operation in the most demanding drilling environments.

The FD-1600HP's power end features a robust Fabriform™ welded steel plate structure, which undergoes stress relief treatment after welding to ensure excellent rigidity and strength. The core components of the power end, such as the crankshaft and pinion shaft, are forged from high-strength alloy steel and undergo precision machining and heat treatment to withstand high loads and prolonged continuous operation.

Gear System:

Employs a herringbone gear drive for greater torque transmission, stable performance, and compliance with AGMA standards, ensuring high efficiency and long service life.

Bearing Configuration:

Key areas utilize heavy-duty bearings, such as spherical roller bearings for the main bearings, and roller bearings for the pinion shaft and crankpin bearings depending on the specific design, ensuring stable operation under high loads.

Lubrication System:

Features a combined forced and splash lubrication system, ensuring all moving parts are adequately lubricated and cooled. This includes components like the gear oil pump, filter, cooler, and pressure gauge, effectively extending the service life of power end components.

Fluid End: Designed for 7500 PSI High-Pressure Conditions

The FD-1600HP's fluid end is specially designed and reinforced to continuously withstand working pressures of up to 7500 PSI (51.7 MPa).

Module Design:

Utilizes an advanced Valve-Over-Valve design, which is compact, lighter, and occupies less rig space. An L-Shape fluid end option is also available, with separate suction and discharge modules for easier maintenance.

Materials and Manufacturing:

Fluid end modules are integrally forged from high-quality alloy steel (e.g., 35CrMo, 40CrMnMo, AISI 4130, AISI 4135, or AISI 8620) and undergo rigorous heat treatment processes (such as quenching and tempering, possibly including auto-enhancement) to achieve optimal internal microstructure and surface hardness, thereby minimizing erosion and stress cracking. All modules comply with API 7K standards.

Valve Assembly:

Equipped with API #7 valves (for standard FD-1600; high-pressure models may use API #7 or #8). Valve bodies and seats are typically integrally forged from high-quality alloy steel (20CrMnTi) and undergo carburizing and quenching treatment, achieving a surface hardness of over HRC60, ensuring high strength and wear resistance. Valve inserts are made of high-pressure, wear-resistant polyurethane, reliably operating at temperatures up to 300°F and pressures above 7500 PSI.

Valve Covers:

The standard FD-1600 uses screw-in valve covers. Quick-change valve cover systems like Sur-Lock® are available as options, significantly improving maintenance efficiency and safety.

Discharge and Suction Connections:

The discharge connection of the standard FD-1600 is typically a 5-inch API flange (5000 PSI rating). For 7500 PSI high-pressure conditions, 4-inch API 10000# or 5 1/8-inch API 10000 psi or higher API 6BX type flange connections are typically used to ensure connection sealing and strength. The suction connection is typically a 12-inch flange.

BLAK-JAK® Liner Retention System (LRS): Enhancing Maintenance Efficiency and Operational Safety

The EMSCO FD-1600HP mud pump can be optionally equipped with the innovative NOV BLAK-JAK® Liner Retention System (LRS), designed to simplify maintenance, reduce downtime, and significantly improve operational safety.

One-stop Solution

Compared to traditional liner retention methods, the BLAK-JAK® LRS can reduce liner change time by up to 75% and eliminates the need for heavy tools like sledgehammers, thereby reducing the risk of injuries. This system secures the liner with uniform circumferential clamping force, effectively preventing erosion issues caused by loose seals and reducing hydraulic load on the liner face.

Lok-CEL™ Components:

This mechanical component reliably secures the liner during pump operation. Its body and locking ring are made from high-yield strength alloy steel, making them robust enough to meet the challenges of today's high-stress drilling environments.

Hydra-CEL™ Components:

This is a removable hydraulic assist device used to apply tension to the Lok-CEL™ and pressure to the liner during installation and removal. Its main structure is made of aerospace-grade aluminum alloy, which is lightweight and anodized for enhanced corrosion resistance. The Hydra-CEL™ is equipped with a relief valve to prevent overpressure and features a large hydraulic piston to ensure reliable metal-to-metal contact between the liner and fluid cylinder.

FD-1600HP Compatibility:

The BLAK-JAK® LRS is fully compatible with the FD-1600HP's 7500 PSI fluid end. Reference part numbers for EMSCO FC-1600 (OEM module type, highly related to FD-1600HP) include: Hydra-CEL™ Component (80-502-103), Lok-CEL™ Top Component (80-501-110), and Lok-CEL™ (Short Component) (80-501-110S).

To ensure continuous reliable operation of the FD-1600HP at 7500 PSI, we offer a range of high-performance wear parts and key accessories:

Liners:

Recommended Type: For demanding 7500 PSI conditions, Zirconia ceramic liners are highly recommended. These liners offer extremely long service life (typically 4000 to 10,000 hours), excellent wear and corrosion resistance, and effectively reduce piston wear.

Alternative Type: High-chrome bimetallic liners are also a reliable option. They feature an "HP" lip design (liner outer shell with a shoulder to prevent inner sleeve slippage), offering excellent wear, erosion, and corrosion resistance. They have a normal service life exceeding 800 hours, and the bore hardness can reach HRC 62-69.

Pistons:

Design and Material: For 7500 PSI high-pressure conditions, integrally bonded polyurethane pistons or high-performance rubber pistons are recommended. The piston core is typically manufactured from high-strength forged alloy steel such as 42CrMo, ensuring structural integrity under high pressure. The piston rubber uses specially formulated polyurethane or nitrile rubber materials, offering excellent tear strength, wear resistance, extrusion resistance, and adaptability to various drilling fluids (oil-based, water-based, synthetic-based) and operating temperatures up to 220°F to 300°F.

Piston Rods:

Material and Manufacturing: Piston rods are forged from high-strength alloy steel (e.g., 42CrMo or SAE 4140), undergo heat treatment, and surface chrome plating, providing high strength, excellent wear resistance, and superior corrosion resistance. This ensures the piston rod resists wear and deformation during high-frequency reciprocating motion, thereby guaranteeing sealing reliability and a long service life.

BLAK-JAK® HydrA-LIGN™ Piston Rod System: This system provides self-alignment, reducing uneven wear on liners and pistons, and further enhancing maintenance safety and efficiency through its quick-connect design.

Pulsation Dampener:

Type and Specifications: K-20 or KB-75 type pulsation dampeners are recommended, typically with a design capacity of 20 gallons and a rated working pressure of 7500 PSI.

Connection Method: Typically uses API 6BX type flange connections (4-inch API BX155 10000psi) to ensure sealing reliability under high pressure.

Safety Relief Valve:

Specifications and Standards: Must be equipped with a safety valve rated for at least 7500 PSI and comply with relevant API and other industry standards to ensure reliable pressure relief in case of overpressure, protecting the pump body and piping.

Liner Spray System:

Components and Function: Includes a spray pump (typically centrifugal), a cooling water tank, and spray lines/nozzles, used for continuous cooling and lubrication of the liner and piston to effectively extend their service life.

When equipped with the 7500 PSI fluid end, the performance parameters of the EMSCO FD-1600HP mud pump vary depending on the selected liner size, to meet the specific pressure and displacement requirements of different drilling operations.

Table 1: EMSCO FD-1600HP Key Technical Specifications

Table 2: EMSCO FD-1600HP (7500 PSI Fluid End) Performance Reference Data

(The following data is based on the performance characteristics of a typical 1600HP, 12-inch stroke, 7500 PSI fluid end pump. Specific values may vary slightly depending on the manufacturer and specific configuration. Calculations are based on 90% mechanical efficiency and 100% volumetric efficiency.)

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