NOV 12-P-160 7500 MISSION L FE Mud Pump

 

Frame structure and stability

The pump's power end features a robust welded steel frame. This design delivers exceptional rigidity and structural integrity, effectively resisting the intense torque from 1600 HP power input and the continuous vibrations caused by reciprocating motion.

Transmission system - gear and crankshaft

Gear Set: The transmission system employs a herringbone gear design with a gear ratio of 3.439:1. Compared to straight gears, the herringbone configuration delivers smoother and more continuous power transfer while eliminating axial thrust, significantly reducing operational noise and vibration. Both the main gear and pinion are constructed from solid quenched high-quality alloy steel, ensuring exceptional wear resistance and impact resistance.

Crankshaft and pinion shaft: The crankshaft and pinion shaft form the core of power transmission, both constructed from monolithic forged alloy steel 11. The pinion shaft features a dual-drive design, enabling simultaneous operation from either or both sides of the pump, thereby providing drilling platforms with exceptional layout flexibility.

Bearings are configured and designed for long life

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Main bearing: 2 double row tapered roller bearings, used to bear the huge radial and axial loads of the crankshaft.

Small gear shaft bearing: 2 self-aligning roller bearings, which can compensate for the slight deflection of the shaft and ensure smooth gear meshing.

Crankshaft-linkage bearing: 3 cylindrical roller bearings, specially designed to withstand the pure radial load transmitted by the linkage.

Crosshead bearing: 3 double row needle bearings, compact structure to withstand the high frequency reciprocating load of the crosshead.

This precise bearing combination ensures reliable support of power transfer at every stage, minimizing wear.

lube oil system

The power unit features a standard composite lubrication system combining pressure lubrication and splash lubrication. The pressure system delivers clean lubricating oil precisely to critical bearing and gear meshing points through an integrated oil pump, while splash lubrication provides adequate oil film protection for other moving parts. To ensure optimal performance and maximum service life, it is recommended to use ISO VG 460 viscosity grade gear oil during the initial 2000-hour "break-in period" of equipment operation.

 

 

L-shaped modular design overview

Materials science and advanced manufacturing processes

Core material: The hydraulic end module is made of high-strength forged alloy steel. Industry standards typically use premium alloy steels such as 35CrMo or 40CrMnMo, which are carefully selected to provide the best combination of strength, toughness, and corrosion resistance.

Manufacturing and Processing: To maintain structural integrity under 7500 PSI cyclic loads, the module manufacturing process incorporates advanced techniques. Heat treatment optimizes material hardness and toughness, while rigorous non-destructive testing (NDT) methods-including ultrasonic and penetrant testing-ensures every module is free of internal defects before leaving the factory.

Autofrettage Technology: A hallmark of the 7500 PSI advanced module is its Autofrettage® process. This innovative technique applies ultra-high pressure to the module's inner bore, inducing plastic deformation. The resulting residual compressive stress in the inner wall effectively counteracts tensile stresses during operation, dramatically extending the module's fatigue life and enhancing its resistance to stress corrosion cracking. This breakthrough technology forms the foundation for ensuring long-term reliability under extreme pressure conditions.

API 7K Specification: The hydraulic end assembly and all its components are designed, manufactured, and tested in strict compliance with API Spec 7K. This authoritative industry standard for oil drilling and production equipment ensures product safety, quality, and global interchangeability.

High-performance wear parts

Cylinder liner: Two premium cylinder liner options are available to meet varying operational conditions and maintenance cycles.

High chromium bimetallic cylinder liner: composed of forged steel shell and centrifugal casting high chromium cast iron inner sleeve, with excellent wear resistance, service life of more than 800 hours under normal working conditions.

Zirconia Ceramic Liner: This component combines a forged steel casing with a zirconia ceramic liner. Featuring exceptional toughness, hardness, and wear resistance, the zirconia ceramic liner delivers a service life of 4,000 to 10,000 hours while significantly reducing piston wear. It is the ultimate solution for maximizing pump uptime and minimizing maintenance frequency.

Valve Assembly: The assembly complies with API MOD. 7 standards. The valve body and seat are fabricated from high-grade 20CrMnTi alloy steel through carburizing treatment, achieving a surface hardness exceeding $HRC60$ to withstand high-pressure fluid impact and abrasion. The sealing rubber is typically made of high-performance polyurethane material, ensuring reliable sealing and long-term durability under high-pressure conditions.

Piston and Piston Rod: The two-piece piston rod design enables piston replacement without removing the cylinder liner, simplifying maintenance and reducing downtime. It also offers various high-performance piston heads to accommodate different drilling fluid systems and operating conditions.

Easy to maintain design

In addition to being rugged and durable, the 7500 PSI hydraulic end is designed with a full consideration for on-site maintenance convenience, aiming to minimize downtime for each maintenance:

Fast Change™ Valve Cap: The standard threaded quick-change valve cap enables exceptionally fast and simple assembly and disassembly of the valve assembly.

Open maintenance space: The piston and cylinder sleeve area is completely open for inspection, cleaning and replacement of parts.

Flexible pipeline connections: Both suction and discharge manifold can be connected from either side of the pump, providing convenience for integrated installation on different drilling platforms.

Table 1: Performance data of NATIONAL 12-P-160 at 120 SPM pump speed

Cylinder liner size (inches)	Maximum exhaust pressure (PSI)	displacement (GPM)	displacement (LPM)	Stroke displacement (gal)
4.0	5000	235	889.6	1.96
4.5	5000	298	1128.0	2.48
5.0	5000	367	1389.2	3.06
5.25	5000	404	1529.3	3.37
5.5	5000	444	1680.7	3.70
5.75	5000	486	1839.6	4.05
6.0	4670	529	2002.5	4.41
6.25	4305	574	2172.8	4.78
6.5	3980	620	2346.9	5.17
6.75	3690	670	2536.3	5.58
7.0	3430	720	2725.5	6.00
7.25	3200	772	2922.3	6.43
7.5	2990	826	3126.7	6.88

Note: GPM = gallons per minute; LPM = liters per minute.

Key technical specifications

The table below summarizes the key technical parameters of the NATIONAL 12-P-160 mud pump, which can be used as a quick reference guide.

Table 2: Key technical specifications

class	parameter	specifications
Rated Power	Rated input power	1600 HP (1193 kW)
	Pump type	Three cylinder, single acting reciprocating piston pump
operational factor	Rated Pump Speed	120 SPM (races/min)
	stroke length	12 inches (304.8 mm)
Power end	Gear type	double helical spurgear
	gear ratio	$3.439:1$
Hydraulic end	Maximum cylinder liner bore	7.25 inches (184.2 mm)
	Hydraulic end nominal pressure	7500 PSI (requires corresponding high-pressure module)
	Valve chamber API number	MOD. 7
Physical size	overall length	Approximately 209 inches (5309 mm)
	Total width (including pinion shaft)	Approximately 113.75 inches (2889 mm)
	total height	Approximately 75 inches (1905 mm)
	Total weight (excluding pulley)	Approximately 54,700 pounds (24,810 kg)
linkage	Inlet hose flange	10" ASA-150 lb R.J. flange
	Exhaust pipe flange (High pressure version)	6" API-10,000 psi R.J. flange

 

 

 

• Exhaust Pulsation Buffer: This is a critical component in high-pressure mud systems. The reciprocating motion of the mud pump inherently causes pressure fluctuations during discharge. The buffer absorbs these pressure peaks through its internal air bladder, ensuring smoother fluid flow in the discharge line. This not only significantly reduces vibrations in high-pressure pipelines, protecting downstream risers, water hoses, and downhole measurement tools, but also provides more stable wellbore pressure – a crucial factor for precision pressure-controlled drilling operations.
• Suction Stabilizer (Suction Bag): Installed at the pump's suction end, this stabilizer ensures complete and turbulence-free drilling fluid intake during each stroke. It effectively eliminates pressure fluctuations and cavitation in the suction line, prevents incomplete cylinder liner filling, thereby enhancing the pump's volumetric efficiency and reducing impact damage to the suction valve and cylinder liner.

 

 

• Hydraulic Cylinder Sleeve Locking Device: As a major upgrade to traditional manual sleeve locking nuts, the patented 6576-22A Hydraulic Cylinder Sleeve Locking Device (HLR) by Southwest Company employs a set of high-strength disc springs to secure the sleeve. During sleeve replacement, applying pressure through a compact hydraulic pump effortlessly compresses the springs, enabling safe and rapid removal of the old sleeve. This innovative design not only dramatically reduces sleeve replacement time but also significantly enhances operational safety.
• Cylinder Liner Piston Spray/Wash System: This independent cooling and lubrication system continuously sprays coolant onto the contact surfaces between pistons and cylinder liners, effectively dissipating friction heat generated by reciprocating motion while flushing away abrasive particles. The system significantly extends the service life of these two critical wear-prone components, demonstrating remarkable effectiveness under high pump speed and abrasive drilling fluid conditions.

 

 

• The discharge filter manifold is a multi-functional integrated component installed at the pump's discharge end. It features a built-in filter to capture large particles or foreign objects that could damage downstream equipment, while providing standardized flange interfaces for connecting the discharge pulsation buffer and main high-pressure pipeline. The high-pressure model of this discharge filter manifold can withstand up to 7500 PSI, ensuring the integrity of the entire discharge system.
• Drive System: The pump is designed with exceptional drive adaptability. It can be directly connected to a dedicated AC variable frequency motor for precise speed control, or driven through a belt or chain drive system by the central power system of the drilling platform, meeting the power layout requirements of different drilling platforms.

Target operating environment

Deep Well & High-Pressure Drilling: This pump is widely recognized as the ideal choice for deep well drilling operations. In such operations, the extreme well depth and complex downhole conditions require the mud pump to simultaneously deliver high pressure to overcome significant circulation pressure losses while maintaining sufficient displacement for effective wellbore cleaning. Whether for large displacement wells (ERD), shale gas horizontal wells, or high-pressure gas wells, the 12-P-160 delivers reliable hydraulic support.

Intensive offshore drilling operations: The reliability of equipment is paramount on marine drilling platforms, as any unplanned downtime could result in substantial financial losses. The 12-P-160 has become the standard configuration for offshore platforms (including jack-up platforms, semi-submersible platforms, and drillships) through its rugged design and stable performance. This equipment withstands marine corrosion and continuous operational challenges, ensuring smooth progress in deepwater drilling projects.

Other industrial applications

Although primarily designed for the oil and gas industry, the 12-P-160 demonstrates exceptional high-pressure and corrosion-resistant fluid handling capabilities, making it equally suitable for other demanding industrial applications. For instance, in geothermal drilling, it effectively circulates high-temperature, highly mineralized geothermal water; in mining operations, it enables long-distance, high-head transportation of mineral slurries.

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