NOI HEX 240 5.5 TAPERED SEAT FE

Table 1.1: HEX 240 Performance Specifications

parameter	specifications
model	NOI HEX 240 5.5 TAPERED SEAT FE
Total installed capacity	2,400 HP (2 x 1,200 HP AC motors)
Maximum continuous input power	950 kW (approx. 1,275 HP)
Maximum exhaust pressure	517 bar / 7,500 psi
maximum pump discharge	3,900 l/min / 1,030 GPM
maximum speed	212 RPM
Number of pistons	6
Cylinder Liner Configuration	Fixed 4.5-inch
stroke length	11.8 inches (300 mm)

Note: The total installed power (2400 HP) represents the drive motor's total capacity, providing the pump with sufficient power reserve and operational flexibility. The maximum continuous input power (950 kW) is the rated value of the pump's mechanical components under continuous operation. This configuration ensures reliable operation under various conditions while maintaining peak load handling capability.

Table 1.2: Physical and Operational Specifications

parameter	specifications
External dimensions (length x width x height)	4.1 m x 3.0 m x 2.8 m
driving system	2 x 1,200 HP AC motors
lube oil system	Rolling bearings: Forced oil circulation; Linear guide rails: Splash lubrication
Hydraulic end configuration	Conical valve seat, six-cylinder axial piston

Built for durability: materials, manufacturing and core components

Power side: the cornerstone of reliability

The power unit is the core of the HEX 240, and its robust design ensures the pump's long-term operation.

Frame and Guide Rails: The drive end is constructed with a high-strength welded steel frame, providing essential rigidity to withstand extreme working conditions. Clevis (U-clamps) and track rollers are guided by robust INA roller-type custom guide rails, featuring splash lubrication to absorb high impact forces and acceleration.

Cam and Bearing Assembly: The power unit's core component is a specially cast steel asymmetric cam manufactured with a multi-axis control system. Its operational surface undergoes specialized heat treatment to withstand high-frequency stress and surface wear. The substantial forces are managed by a precision FAG bearing system.

The axial force is supported by a large (1240x1540x140 mm) tapered roller thrust bearing.

Radial guidance is provided by a cylindrical roller bearing.

The reaction force bearing is a angular contact ball thrust bearing with spring preloading to prevent sliding.

The whole bearing set is lubricated by a forced oil circulation system.

Small gear shaft: Radial forces are supported by two FAG cylindrical roller bearings, while axial forces are handled by a FAG four-point contact ball bearing.

Hydraulic end: an engineering example of high pressure integrity

" TAPERED SEAT FE" ：

Tapered Seat (Conical Valve Seat): This design is essential for achieving reliable metal-to-metal sealing under extreme pressures up to 7,500 psi. The conical structure ensures uniform load distribution across the valve seat surface on the hydraulic side, reducing stress concentration and significantly lowering the risk of 'washout' -a primary cause of hydraulic end failure.

Manufacturing and Materials: The hydraulic end module is fabricated from high-quality, high-strength forged alloy steel, either AISI 4135 (35CrMo) or AISI 8620. The forging process refines the metal's grain structure, significantly enhancing its durability and fatigue resistance.

Advanced heat treatment and quality control: Each module undergoes rigorous heat treatment processes (such as quenching and tempering) to achieve optimal hardness (HB285-330) and wear resistance. Subsequently, all finished products must pass strict non-destructive testing (NDT), including ultrasonic and penetrant testing, to ensure material integrity and eliminate any potential defects, fully complying with API 7K standards.

Table 2.1: Key wear parts materials and specifications

component	structure	Grip material options	function
cylinder sleeve	High strength forged steel shell, embedded hot press fitting sleeve.	Zirconia ceramic: Maximum service life (5,000+ hours), hardness>HRC90. High chromium iron alloy: Excellent wear resistance (about 800-1000 hours), hardness HRC 60-69.
plunger	Bonded, double hardness design for optimal performance.	High-performance polyurethane composite is chemically bonded to the piston core of high-strength forged steel (40Cr/42CrMo).	Rated pressure up to 7,500 psi, temperature resistance up to 220°F (104°C), high temperature formulation can be higher.
Valve and valve seat	One-piece, fully open, forged valve body design to achieve maximum strength and flow.	High-quality forged alloy steels (e.g., 20CrMnTi, 40CrNiMo).	After deep carburizing and quenching treatment, the surface hardness is>HRC60, with excellent wear resistance, in line with API standard.

Application areas and operational excellence

The HEX 240 is designed to meet the most demanding drilling challenges, and its superior performance makes it excellent for the following high-end applications:

Deepwater and ultra-deepwater drilling: In these operations, extremely high pressure is required to manage ultra-long fluid circulation strings, and the high pressure capability and reliability of HEX 240 are critical.
Large displacement and complex horizontal wells: These require sustained high flow rates and pressure to ensure effective cuttings removal, which HEX 240's stable output delivers.
High-precision MWD/LWD operations: Non-pulsing fluid flow is essential for precise wellbore trajectory control and formation evaluation. The HEX 240 serves as the ideal power source for advanced directional tools that rely on clear mud pulse signals.
Space and weight constrained rigs: Whether it's a modern compact onshore rig or a space-precious offshore platform upgrade project, the high power density of the HEX 240 maximizes hydraulic horsepower per square foot.

In terms of maintenance, the HEX 240 also offers notable advantages. Its cartridge-style valve system enables faster and safer replacement of valves and seats compared to traditional designs, thereby directly reducing maintenance downtime and improving operational efficiency.