OPI 1000HDL Mud Pump

Structural design: The advantages of L-shaped modular design

OPI 1000HDL features an advanced L-shaped, two-piece, interchangeable modular hydraulic end design. This design offers significant operational advantages over traditional integrated (or valve-on-valve) hydraulic ends.

Reduced maintenance costs: The L-shaped design separates the suction and discharge modules. Due to their distinct fluid dynamics characteristics, these modules experience different wear rates. This modular design allows for selective replacement of the worn suction module without replacing the entire expensive hydraulic end assembly, significantly reducing spare parts costs.

Enhance maintenance efficiency: Valve and seat replacement are the most common maintenance tasks for mud pumps. The L-shaped design enables safer, faster, and more convenient access to valve components, effectively shortening maintenance windows and increasing equipment uptime.

Excellent stress distribution: Compared to some one-piece designs, the L-shaped module has more metal structures to support internal pressure, and its stress distribution is more optimized, reducing the risk of cracks in high stress areas, thus extending the overall fatigue life of the hydraulic end.

High pressure integrity materials and manufacturing processes

Material Selection: To meet high-pressure requirements, the hydraulic end module is fabricated from high-strength forged alloy steel, typically using grades such as AISI 4135 (or 4130),35CrMo, or 40CrMnMo. These materials deliver the essential strength and toughness for high-pressure applications.

Forging Process: By using forging instead of casting, the material's internal grain structure becomes dense and continuous, eliminating potential internal voids and defects found in castings. This forging process endows the hydraulic end with unparalleled strength, ductility, and fatigue resistance, capable of withstanding millions of cycles of slurry pump operation.

Heat treatment: After forging, the module will undergo a strict computer-controlled heat treatment program to achieve the best balance between hardness and toughness, ensuring its performance stability under extreme conditions.

Autofrettage process

Key components and rated values

Pressure rating: The standard hydraulic end has a rated working pressure of 5,000 PSI. For deeper and more complex well conditions, we also offer a high-pressure version rated up to 7,500 PSI, usually as an upgrade kit.

Valve System: The pump employs a valve assembly compliant with API #7 specifications, the industry standard for pumps in this horsepower class, ensuring global availability and interchangeability of wear parts.

Valve cover: The design of threaded ring and pressure cover is adopted to facilitate quick and safe disassembly and assembly for checking and replacing the valve parts.

frame construction

Material and process: The power end frame adopts steel plate welding structure, and the whole welding stress relief heat treatment is carried out after welding.

Gear drive system

Gear type: The pump's transmission system employs a pair of helical gears (man-shaped gears).

Materials and manufacturing: The large and small gear shafts are made of forged alloy steel and are heat treated.

crankshaft ASSY

Material: The crankshaft, the core component of the power end, is fabricated from monolithic high-strength forged alloy steel. For high-end applications, modified AISI 4340 (nickel-rich) or 42CrMo is typically employed.

Bearings and Lubrication

Bearing configuration: The power end adopts high quality and heavy load roller bearings in key positions such as crankshaft main journal, pinion shaft and crosshead pin to bear huge operating load.

Lubrication system: a dual lubrication system combining splash lubrication and forced lubrication.

cross head assembly

Material: The crosshead body is usually made of high strength ductile cast iron or cast steel, and the matching replaceable guide plate (slip plate) is made of high quality manganese bronze material.

Design advantage: The steel/iron crosshead slides on the manganese bronze guide plate, forming a low friction, high wear resistance motion pair. This material combination can minimize heat generation and wear, thus extending the service life of these key centering parts.

The following performance data are based on the pump's 10-inch stroke length and calculated using industry standard 100% volumetric efficiency (VE) and 90% mechanical efficiency (ME).

OPI 1000HDL Performance Data Sheet

Note: The above data are calculated based on 100% volumetric efficiency and 90% mechanical efficiency. The maximum pressure is limited by the pump's rated power.

High-quality wear parts: the cornerstone of reliability and optimization of total cost of ownership

OPI 1000HDL Wearable Parts and Material Specifications

With its powerful power and pressure capacity, the OPI 1000HDL is the ideal choice for the following demanding applications:

Deep well drilling: When drilling oil and gas wells thousands of meters deep, high-density, high-viscosity mud must be pumped to stabilize the wellbore and carry cuttings. The OPI 1000HDL's high power and high-pressure capacity ensures effective mud circulation in long vertical and horizontal well sections.

High-flow operation: In surface sections of drilling operations, high flow rates are required to effectively clean the wellbore. The pump can be configured with a large liner to provide the required high flow rate.

High pressure pumping operations: In addition to serving as the main circulation pump, it can also be used for auxiliary operations requiring high pressure, such as cementing, fracturing support, and well control operations.

Onshore and offshore rig support: Its robust design and reliable performance make it a standard configuration for large onshore rigs and highly reliable offshore drilling platforms (including jack-up platforms, semi-submersible platforms and drilling ships).

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