WEATHERFORD WDD 1100 Pump

Table 1: Weatherford WDD1100 key technical specifications

Power End: a solid and durable foundation

Frame construction

The power end frame is welded with high-strength low-alloy steel rather than cast iron. After welding, the whole frame is subjected to a strict stress relief heat treatment process. This manufacturing method not only provides superior strength-to-weight ratio, but also avoids the defects such as internal shrinkage and cracks that may exist in the casting, the structural integrity and fatigue resistance of the frame under long-term high-frequency alternating stress are ensured.

Crankshaft and core components

Crankshaft and connecting rod: integrally forged from high strength alloy steel (42CRMO or modified 4340) . The forging process ensures the density and streamline distribution of the grain structure inside the material, eliminates the material defects from the source, and makes the strength much higher than that of the casting. After forging, these parts are also quenched and tempered to obtain the best comprehensive mechanical properties, and pass precision machining and dynamic balance test to ensure the ultimate stability at high speed operation.

Bearing: the use of world-renowned brands of heavy-duty roller bearings, a larger size means a higher rated dynamic and static load, can easily cope with the pump in full power operation of the tremendous impact, significantly extend the life of the bearing.

Lubrication system

WDD1100 uses a dual lubrication system combining forced lubrication and splash lubrication to ensure that all moving parts at the power end are adequately cooled and lubricated.

Forced lubrication: driven by the built-in gear oil pump, the filtered oil is continuously delivered to the main bearings, connecting rod big end bearings and pinion bearings and other key friction pairs through the internal oil circuit.

Splash lubrication: the crankshaft and gears stir and splash the oil pan during operation to provide sufficient lubrication for the crosshead, crosshead slide and gear meshing surfaces.

Hydraulic end: precision built for extreme environments

Modular design and materials of excellence

We are well aware that customer operating conditions vary widely, so we offer a variety of material options to achieve the best application fit. This is one of the core competencies of top OEM manufacturers and is designed to provide customers with"Tailored" solutions.

Standard-forged alloy steel: forged from high-quality alloy steel (35CrMo, AISI 4130/4135) and subjected to a rigorous heat treatment process, it has extremely high strength and toughness and is ideal for handling conventional drilling mud, excellent performance and cost-effective.

Corrosion resistant-forged duplex stainless steel: for highly corrosive fluid environments such as high salinity and high H2S (hydrogen sulfide) , we offer hydraulic ends made of forged duplex stainless steel. Compared with traditional materials such as nickel aluminum bronze, duplex stainless steel has a qualitative leap in strength, corrosion resistance and resistance to stress corrosion cracking, it ensures long pump life in the harshest chemical environments.

Valve integrity

Valve Assembly is the heart of the hydraulic end, and its performance directly determines the efficiency and reliability of the pump. The WDD1100 uses a fully open, API compliant valve assembly (typically API # 7 for this power level) .

Material and workmanship: the body and seat are forged from high grade alloy steel (AISI 8620,20CRNIMO) . For extreme durability, these parts are carburized and hardened to a high surface hardness
HRC ≥60, with excellent erosion and wear resistance; while the core maintains lower hardness and higher toughness to absorb impact load and prevent brittle fracture. All sealing surfaces are precisely ground to ensure the absolute reliability of the seal.

Valve rubber: made of high-performance polyurethane or special rubber material, with excellent elasticity and wear resistance, can provide lasting and reliable seal under high pressure, and the perfect fit with the seat.

Table 2: WDD1100 performance data (displacement vs. pressure)

Note: the following data are based on 8-inch strokes, 90% mechanical efficiency and 100% volumetric efficiency. The actual displacement will be slightly reduced due to compressibility and other factors.

This table provides a visual indication of the broad applicability of the WDD1100 pump. For example, a 7.5-inch large-size cylinder liner can be selected for surface drilling in large-size wellbores to obtain a large displacement of more than 1,148 GPM, ensuring effective cutting removal. For deep well operations or high-pressure testing, a 4.0-inch liner can be used to increase working pressure to 7,500 PSI 5. This flexibility enables WDD1100 to handle a wide range of operational requirements from drilling to completion, making it an ideal choice for drilling contractors to maximize asset value.

Liners

The cylinder liner is one of the most worn components in the hydraulic end, and we offer two levels of options to meet different operating conditions:

High chromium bimetallic cylinder liner: as standard, it consists of a high strength forged steel case and a high chromium cast iron liner. The inner sleeve is formed by centrifugal casting process with compact structure, high hardness and excellent wear resistance. Its service life can often exceed 800 hours and is a reliable option for handling most drilling muds.

Zirconia ceramic cylinder liners: this is the top option for extreme abrasive and corrosive environments. It consists of a forged steel housing and a solid-state sintered zirconia ceramic liner. Due to the ultra-high hardness and chemical inertness of the ceramic material, its service life can reach 4,000 to 10,000 hours, which is several times that of the bimetallic cylinder liner. In addition, its extremely low coefficient of friction extends the life of the piston.

Pistons

We offer a one-piece vulcanized bonded piston with a high-performance polyurethane or special rubber seal and a high-strength forged alloy steel core (42CRMO or 45 # steel) vulcanized at high temperature and pressure. This design ensures a strong bond between the seal body and the piston core, eliminating the risk of degumming and providing a durable, reliable seal and excellent performance in high-pressure and abrasive fluids.

Piston Rods/Pony Rods

The piston rod is the key component that transmits power to the power end. They are forged from high-strength alloy steel (SAE 4140/42CrMo) and quenched and tempered for optimum strength and toughness. The surface of the rod is precisely ground and plated with a thick and hard industrial grade hard chromium to provide a smooth surface and excellent wear and corrosion resistance.

Valve Assembly

API # 7 compliance ensures interoperability with industry components.

Valve body and seat: Made of high quality forged alloy steel (AISI 8620/20CrNiMo) , after carburizing and quenching treatment, the surface hardness reaches HRC ≥60, with strong erosion resistance. The precision-ground sealing surface ensures a perfect seal.

Valve rubber (insert) : made of wear-resistant, oil-resistant, extrusion-resistant high-performance polyurethane material to ensure that in a variety of mud conditions can provide a reliable seal and long service life.

Seals and Gaskets

We offer seals and gaskets made from a variety of materials including nitrile rubber (NBR) , hydrogenated nitrile rubber (HNBR) and polyurethane (PU) . HNBR materials are recommended for high temperature or highly corrosive applications to ensure optimum sealing performance and durability.

Other Accessories

To ensure the safe and efficient operation of the pump unit, we also provide a full range of accessories, including:

Pulsation Dampener: installed in the discharge line to absorb the Pulsation and protect the downstream equipment and pipeline.

Safety/Relief Valve: to prevent system overpressure, is the pump group essential Safety device.

Liner Wash System: continuously spray cooling fluid to the piston rod and the outer edge of the Liner, effectively reduce the temperature, Wash away the abrasive, and significantly extend the life of the Liner and piston.

Horizontal Directional Drilling

This is the primary and core area of application of WDD1100. The success of HDD operations relies heavily on a continuous, stable high-displacement mud cycle. The high flow rate characteristics of WDD1100(up to 1,148 GPM) ensure efficient cleaning of the wellbore, cooling of the bit and efficient removal of cuttings in long horizontal intervals.

Deep Well & High-Volume Drilling

On land and offshore large drilling platforms, especially when drilling large size holes (such as surface or intermediate casing sections) , the rapid and effective removal of large amounts of cuttings is the key to improving drilling speed (ROP) . As a 1600HP power unit, WDD1100 can provide sufficient hydraulic horsepower to meet the needs of large displacement for such operations. It is an ideal main pump or auxiliary pump for large drilling rigs.

Well Service & Stimulation

Although ultra-high pressure fracturing is the domain of specialist pumps, the WDD1100 performs well in many wellbore service operations. Its smooth, continuous pumping characteristics make it ideal for cementing and acidizing operations, ensuring that slurry or acid is injected at a uniform rate, thereby improving the quality of the operation. Its powerful continuous working ability and reliability make it a reliable power source for wellbore service applications that require long-term uninterrupted pumping.

Large-scale Fluid Transfer

In addition to oil and gas drilling, the capabilities of WDD1100 are also suitable for any industrial application requiring large-scale, medium-to high-pressure fluid delivery. This includes but is not limited to mine drainage, produced water reinjection, long-distance pipeline transportation and hydraulic descaling. Its rugged design and optional corrosion-resistant hydraulic end materials enable it to handle salty, sandy, and even somewhat corrosive industrial fluids.

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