DV-1 Operating Manual - Rev00

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OPERATING MANUAL

Issue/Rev. Date: 00/April 2007 ALL EARLIER REVISIONS OBSOLETE

This Operating Manual is valid for the following models:

PN 8693000276 PN 8693000281

PN 8693000277 PN 8693000282

PN 8693000278

PN 8693000279

PN 8693000280

Keep this manual for future reference!

DV-1 Vertical Drivehead

Operating Manual



D V-1 V e r t i c al Dr i v e h e a d

Publisher:

Weatherford Industria e Comércio Ltda.

Completion & Production Systems

Estrada Ivo Afonso Dias, 338 Distrito Industrial

São Leopoldo 93032-550, Rio Grande do Sul

Brazil

Tel.: +55-51-3579-8400

Fax.: +55-51-3579-8401

WEATHERFORD OPERATING MANUAL

TERMS AND CONDITIONS OF USE

A. The materials contained in this Weatherford Operating Manual are protected by copyright,

trademark and other forms of proprietary rights. Nothing contained herein shall be construed

as conferring any license or right to use or practice any copyright, trademark, patent or other

forms of proprietary rights. This Operating Manual may not be copied or converted to any

mechanical, electronic or machine-readable form, in whole or in part, without Weatherford’s

consent.

B. This Operating Manual is not intended to address every issue that may arise in the course of

operations of the device described therein or the planning of same. Each well and each job

are unique and have numerous variables. Experience and other specialized training can

complement the materials used in this Operating Manual.

C. Weatherford makes no representation as to the accuracy or completeness of the materials

in this Operating Manual. All materials are provided “AS IS” WITHOUT WARRANTY OF

ANY KIND WHATSOEVER, EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIM-

ITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PAR-

TICULAR PURPOSE OR NON-INFRINGEMENT. Weatherford expressly disclaims all re-

sponsibility for the consequences, direct, indirect, consequential or otherwise, of any errors

or omissions in the materials.

D. This information is confidential and proprietary property of Weatherford. Do not disclose to

unauthorized parties. Do not use except as permitted by Weatherford. Copyright 2007

Weatherford. All rights reserved.

p/n: 7693000005 DV-1 Vertical Drivehead Operating Manual

April 2007



SUMMARY OF CONTENTS

Contents Page

D V - 1 V e r t i c a l D r i v e h e a d

Preface

1 SAFETY

1.1 Risk involved when operating the Drivehead .................................. 1-1

1.2 Safety Instructions and Hints ..........................................................1-2

1.3 Designated Use..............................................................................1-2

1.4 Sources of Danger .........................................................................1-3

1.5 Operator’s Position.........................................................................1-4

1.6 Danger Zones.................................................................................1-5 1.6.1 Used Warning Signs and Labeling ......................................1-5 1.6.2 Safety Layout ......................................................................1-7

1.7 Qualification of Personnel...............................................................1-8

1.8 Protective Clothing .........................................................................1-8

1.9 Safety Measures for Installation .....................................................1-9

1.10 Emergency Behavior .................................................................... 1-10

1.11 Protective Devices........................................................................1-11

2 STORAGE, TRANSPORTATION AND INSTALLATION

2.1 Storage...........................................................................................2-1

2.2 Lifting Points for Transportation and Installation.............................2-1

2.3 Drivehead Instalation Procedure.....................................................2-3

3 GENERAL DESCRIPTION

3.1 Description of the Main DV-1 Vertical drivehead.............................3-3

3.1.1 Pc Pump System Schematic ...............................................3-3

3.2 Weatherford DV-1 Vertical drivehead .............................................3-4

3.2.1 DV-1 Vertical drivehead Schematic .................................... 3-6

3.3 Stuffing Boxes........................................................................ ........3-7

3.3.1 Conventional Stuffing Box with 2000 PSI Flange ................ 3-7

3.3.2 Conventional Stuffing Box with 2 7/8" EUE Pin ................... 3-8

3.3.3 Rotating Stuffing Box with 2000 PSI Flange........................ 3-9

3.4 Optional Components................................................................... 3-10

4 OPERATION

4.1 Starting up Procedure.....................................................................4-1

4.2 Shutting Down Procedure...............................................................4-3

4.3 Braking System Operation Procedure ............................................4-4

4.4 Operational Torque Limits ..............................................................4-5

4.5 Drive Head Removal Procedure .....................................................4-7

5 SERVICE AND MAINTENANCE

5.1 Preventive Maintenance Schedule..................................................5-1

5.2 Stuffing Box Maintenance...............................................................5-25.3 Stuffing Box Maintenance - Change Packing..................................5-3



SUMMARY OF CONTENTS

Contents Page


5.4 Bearing Box Maintenance .............................................................. 5-4

5.5 Belts and Change Procedure ......................................................... 5-5

5.6 Breaking System Gears - Oil Gange Procedure............................. 5-6

5.7 Hydraulic Oil Change Procedure.................................................... 5-7

5.8 Polished Rod Support Clamp ......................................................... 5-8

6 TROUBLESHOOTING

6.1 Stuffing Box ................................................................................... 6-2

6.2 Hydraulic Braking System .............................................................. 6-2

6.3 Moving Parts (Safety Advices) ....................................................... 6-3

7 APPENDIX

Appendix A - Definitions .......................................................................... 7-2 Appendix B - Project Considerations ....................................................... 7-5

Appendix C - Unit Conversions and Fluid Compatibility........................... 7-8

Appendix D - Useful Rules ...................................................................... 7-9

Appendix E - Formulas............................................................................ 7-9

Appendix F - Viscosity Chart ................................................................. 7-12

Appendix G - Bearing Lifetime............................................................... 7-12

Appendix H - DV-1 drivehead Spare Part List ....................................... 7-13

Appendix I - Belts Specifications ........................................................... 7-23

Appendix J - Painting Specifications...................................................... 7-24Appendix K - Certified Motors List ......................................................... 7-24

8 MODIFICATION HISTORY

Modification History ................................................................................. 8-1



PREFACE


PREFACE

With your new WEATHERFORD "DV-1 Angle Drivehead" you have purchased a piece of equip-

ment leading the field in performance and dependability.

This operating manual applies to the WEATHERFORD "DV-1 Angle Drivehead”. If there are any

further questions about areas, which are not explained in this manual or in cases of doubt it is im-

perative to consult our technical department for specialist assistance!

Each device, prior to leaving our facility, has been tested under simulated field conditions to ensure

its performance according to the specifications.

This operating manual is designed to provide the necessary information on operating liability, safety

measures, operation and maintenance for the WEATHERFORD "DV-1 Angle Drivehead".

In the interest of continued development WEATHERFORD reserve the right to incorporate modifi-

cations without updating the operating manual at the same time. These modifications to improve

the product do not, however, affect the essential features of the type described.

Not all options and variations described within this manual necessarily form part of your "DV-1 An-

gle Drivehead". The illustrations used in this manual are for explanation purposes only and did not

show always the actual state of your machine. For the exact scope of delivery see your purchasing

contract.

All persons involved in operation or maintenance of this device must read and understand this op-

erating manual thoroughly before starting operation. The contents of this manual have to be com-

plied with at all times. This operating manual is component of the unit, it is therefore imperative to

keep it in a safe place for later use and to submit it at resale!

In addition to serving as a ready reference for those already familiar with the WEATHERFORD "DV-

1 Angle Drivehead", this manual also provides step-by-step procedures for the less experienced

user.

Weatherford certifies that inspection and testing will be carried out in accordance with Weatherford

Quality Assurance manuals and procedures. Weatherford is an authorized manufacturer of progress-

ing cavity pumps and surface equipment and has in place a Quality Control Program in accordance

with ISO 9001:2000. Formal written procedures, competent personnel, and sufficient inspection

throughout all phases of the work establish the quality assurance program. Every effort is made to

ensure prompt detection of non-conformances, and to ensure timely and effective corrective action is

taken to prevent reoccurrence in the future.

No liability will be carried in the event of disregarding the safety notes, improper handling, contrary

use to the designated use of the unit and unauthorized conversions. For safety reasons, unauthor-

ized conversions and modifications to the unit are expressly forbidden.



CHAPTER 1. SAFETY

Operating Manual Rev. 00/ April 2007 Page 1 of 11


1 SAFETY

1.1 RISK INVOLVED WHEN OPERATING THE DRIVEHEAD

The Vertical Drivehead DV-1 is equipped with protective devices and has undergone a safety check

and certification before shipment. Incorrect operation or misuse threatens...

• … the life and limb of the operator and the surrounding personnel.

• … this device and other material assets of the operating authority.

• … the efficient performance of this device.

The operating authority of this unit must ensure, that all persons having to do with installation,

commissioning, operation, cleaning, maintenance, repair and servicing of the unit must …

• … be qualified according to the requirements and authorized by the operating authority.

• … follow this operating manual thoroughly. It is recommended to the operating authority, that all

persons having read the operating manual confirm the knowledge with their signature.

Safety is not a PROBLEM … it's the ANSWER!

Remember: If you are not part of the SOLUTION, you are

part of the PROBLEM!



CHAPTER 1. SAFETY

Page 2 of 11 Rev. 00/April 2007 Operating Manual


1.2 SAFETY INSTRUCTIONS AND HINTS

The following symbols are used in this manual:

WARNING

Describes a possibly dangerous situation.

Disregard can lead to death or severe injury.

CAUTION

Describes a possibly dangerous situation.

Disregard can lead to minor injury.

NOTICE

Describes a possibly harmful situation. Disregard can damage this device orother material assets in its working range.

This sign also marks useful operating hints.

1.3 DESIGNATED USE

The Weatherford Vertical Drivehead DV-1 is designed exclusively to drive Weatherford Tubular and

Insertable Progressive Cavity Pumps. The maximum torque, power ratings and other operational

limits are detailed in chapter 3, section 3.1.

The Drivehead DV-1 is designed for ambient operating temperatures from -30ºC to 50°C.

Using the Drivehead DV-1 for purposes other than expressly mentioned above or in the incorrect

configuration, is considered contrary to its designated use and is therefore prohibited. The manu-

facturer cannot be held liable for any damage resulting from such use. The risk of such misuse lies

entirely with the user.

Operating the machine within the limits of its designated use also involves observing the instruc-

tions set out in the operating manual and complying with the inspection and maintenance directives.



CHAPTER 1. SAFETY



1.4 SOURCES OF DANGER

The Vertical Drivehead DV-1 is a powerful electro-mechanical unit. Insufficient or improper mainte-

nance of the system can result in damages or malfunctions of the drivehead. Disregarding the

safety instructions can lead to severe injury.

The operating authority must ensure to operate the unit only in unobjectionable state. Consider the

above and follow these directives:

• All persons involved in operation or maintenance of this device must read and understand this

operating manual thoroughly before starting operation. The contents of this manual have to be

complied with at all times.

• The operator of the unit is responsible for all operations at the site.

• Leaks in the hydraulic system may cause injuries. If a leak occurs, suspend operation and re-

pair immediately.

• Before service, maintenance or repair work, the electrical power supply to the unit must be dis-

abled. Make sure that the motor cannot be started accidentally. Start repair or maintenance

work only with drivehead stationary and cold.

• Even if the unit is de-energized, the hydraulic system may remain under pressure. Ensure that

the system is completely recoiled and any torque stored in the rod assembly is released.

•Depressurize the system before any service and maintenance work in these areas.

• NEVER make any modifications, additions, or conversions without the manufacturer’s written

approval. This also applies to the installation and adjustment of safety devices. For safety rea-

sons, unauthorized conversions to the unit are expressly forbidden.

• Electric cables must be routed in a secure way. i.e. they must not be bent or clamped and

must be protected from mechanical damage.

• Damaged or missing warning information or labeling must be replaced immediately.

•

Use only original spare parts.



CHAPTER 1. SAFETY



1.5 OPERATOR’S POSITION

The position of the operator is not fixed. All operating indicators and handles must be easily acces-

sible (refer to Fig. 1.11 to identify these areas).

The drivehead is controlled via the electric control cabinet which is located between 5 and 20 me-

ters from the well (refer to Chapter 4 for further information).

CAUTION

Wear ear protection when working permanently in close prox-imity to the drivehead.

Fig. 1.1 Indicators and Handles’ Position

Legend:

Handle 1: Hydraulic backspin brake speed regulation (refer to chapter 4, section 4.3 for further in-

formation).

Indicator 2: Backspin brake gears’ oil level sight glass.

Indicator 3: Manometer – hydraulic braking system pressure.

Indicator 4: Hydraulic brake system’s oil level sight glass.

Indicator 5: Bearing Box oil level sight glass.

1

4

2

3

5



CHAPTER 1. SAFETY



1.6 DANGER ZONES

Every area of the unit or in its proximity where the risk of injury or health damage exists has to be

declared as danger zone.

• Danger zones must clearly be declared and protected by barriers and/or labeled with warning

signs to prevent unauthorized entering.

• Missing or unreadable warning labels at the unit or its surrounding area must be replaced im-

mediately.

• During operation, no other person than the operator must enter the danger zone.

• Only objects, which are essential to the operation of the unit, are allowed to be placed inside

the danger zone.

1.6.1 Used Warning Signs and Labeling

The following labeling is used on the DV-1 Vertical Drivehead:

CAUTION

Damaged or missing warning information or labeling must be replaced im-mediately.

Warning Sign No.: 1(Part No.: 1101000004)

Warning Sign No.: 2

(Part No.: 1101000005)

Caution Sign No.: 3(Part No.: 1101000007)



CHAPTER 1. SAFETY





Identification Tag No.: 6(Part No.: 3694000038)

Fig. 1.2 Labels and Warning Signs on the DV-1 Vertical Drivehead



CHAPTER 1. SAFETY



1.6.2 Safety Layout

Danger zone 1

• Excessive heat during and after breaking/recoiling. Wear suitable gloves when working on the

equipment.

• Rotating parts can cause injuries if approached when equipment is in operation. Stand clear when

equipment is in operation.

WARNING

Never operate the drive without all of the protective guards installed.

•

Equipment is remote operated and may start and/or stop without warning.

Fig. 1.3 Label and Warning Sign Positions and Safety Layout of the DV- 1 Vertical Drivehead.

Legend

= Number of danger zone

= Number of used warning sign or label according to Section 1.6.1

1

7

1 32 7

4

5

6



CHAPTER 1. SAFETY



1.7 QUALIFICATION OF PERSONNEL

Only trained and properly instructed personnel may operate the DV-1 drivehead. The individual re-

sponsibilities of the personnel who operate, set-up, maintain and repair this equipment must be

stated clearly. Remember, during operation, the operator is responsible for third parties.

Unclear responsibilities are a safety hazard.

The operating authority must ensure that ...

• … the operating manual is available to all involved personnel.

• … all involved personnel have read and understand the contents of this manual, in particular

the chapter on safety, before beginning work.

1.8 PROTECTIVE CLOTHING

The protective clothing required depend on the operator guidelines, however Weatherford recom-

mends the following:

Hardhat to protect the head against falling parts and overhead equipment.

Eye protection glasses must be worn to protect against flying particles.

Safety boots to protect against erroneous rest of the equipment.

Safety gloves to protect the hands against aggressive lubricants or hot surfaces or hy-draulic fluid.

Ear protection must be worn to protect against excessive noise.



CHAPTER 1. SAFETY



1.9 SAFETY MEASURES FOR INSTALLATION

• Installation or dismantling of this unit may only be carried out under supervision of a

WEATHERFORD employee or by WEATHERFORD trained staff, as otherwise there is a risk of in-

jury and permanent damage to the unit. The consequence would be expensive repairs, replacement

of components or expiration of warranty claims.

• The unit must only be used if it has been set up in accordance with regulations and in conformity

with the manual.

• DO NOT work on or tamper with the hydraulic braking system while equipment is in operation even

when the drive is disconnected from mains, rotational energy may still be stored in the string. En-

sure that the torque is fully released and the pressure in the hydraulic system is 0 bar before start-

ing work. Ensure that the motor is secured against unintentional start-up.

• All lifting equipment for the installation must have a minimum lifting capacity of 3.000 kg (6.615 lb).



CHAPTER 1. SAFETY



1.10 EMERGENCY BEHAVIOR

Emergency Shut Down During Normal Operation

The DV-1 Vertical Drivehead does not have an ‘Emergency Stop’ handle to stop the movement dur-ing normal operation. Refer to the documentation of the electric control panel to stop the electric

motor in case of an emergency.

Emergency Shut Down During Recoil/Backspin

The DV-1 Vertical Drivehead has a handle to control the hydraulic fluid flow that allows to stop the

backspin in a recoil scenario. To stop the drive completely close the valve (refer to Fig. 1.4 to iden-

tify valve handle location).

Use this ‘Emergency Shut Down’ handle immediately in case of a dangerous situation ...

• … for life and limb or

• … material damage of the unit or attached tooling.

WARNING

When the hydraulic brake valve is closed during recoil energy will be re-tained in the rod string. This energy MUST be released before any other jobis performed on the drive.

Fig. 1.4 Recoil control valve handle location

1



CHAPTER 1. SAFETY



1.11 PROTECTIVE DEVICES

• The DV-1 Vertical Drivehead is equipped with a safety shutdown temperature sensor that stops the

electric motor when the maximum rated stuffing box’s temperature is reached. The temperature

sensor is factory set to shutdown the motor before the temperature at the hottest spot in the stuffing

box reaches 200ºC.

• The DV-1 Vertical Drivehead is equipped with an automatic hydraulic recoil speed controller (hy-

draulic backspin brake). This device will automatically work whenever the normal rotational speed is

interrupted and the accumulated energy forces the system to spin backwards. The action of the

backspin brake will result in controlled recoil speed until the energy is completely released (refer to

chapter 4, section 4.3 for hydraulic backspin brake regulation and operation).

• One pressure relief valve installed inside the manifold block works as a safety valve for excessive

pressures at the hydraulic motor discharge. The relief valve is fixed to the maximum allowed pres-

sure of 247 bar / 3.515 PSI. In the event of over-pressure, the valve opens and connects the pres-

sure line directly to the tank.



CHAPTER 2. STORAGE, TRANSPORTATION

AND INSTALLATION

Operating Manual Rev. 00/April 2007 Page 1 of 5


2 STORAGE, TRANSPORTATION AND INSTALLATION

The Weatherford Driveheads have been designed to provide accurate operation under field condi-

tions. The following instructions must be observed during storage, transportation and installation

2.1 STORAGE

Weatherford Driveheads are shipped in preserved manner.

In case the driveheads are stored for a long period of time, the following recommendations must be

followed:

• Driveheads must be stored on vertical position using their own base or shipping crate.

• For parts with no paint protection, grease must be applied.

• Motors, reductors and other revolving parts must be manually revolved monthly.

• Lubricating oil must be replaced, in case driveheads were stored for more than a year.

2.2 LIFTING POINTS FOR TRANSPORTATION AND INSTALLATION

CAUTION

During lifting and transportation obey local regulations.

Ensure that all lifting equipment is in proper condition and certified for the relevant loads and tem-

peratures.

Driveheads must be lifted to the installation area with a crane or equivalent device by attaching to the

provided lifting eye rings or side holes (refer to Fig. 2.1 to locate the lifting points).

WARNING

Use only the designated lifting points. Do not lift the drivehead by thesheaves or by the electric motor.

WARNING

DO NOT step under the lifted equipment at any time.

WARNING

Stay clear from moving equipment.




AND INSTALLATION



D L - 1 A n g l e D r i v e h e a d

For transportation, lift the drivehead only at the designed lifting points (refer to Fig. 2.1 to locate the

lifting points). Attach steel wire ropes to all lifting eyes rings on top of the main frame or side holes

on the side of the main frame.

CAUTION

All lifting gear must have a minimum lifting capacity of 3.000 kg / 6.615 lb.

Ensure that all lifting equipment is in proper working condition.

Fig. 2.1 Lifting Points Location

1 2




AND INSTALLATION



2.3 DRIVEHEAD INSTALLATION PROCEDURE

After the installation of the pumping rods and after the polished rod is secured by the flow tee, follow the

procedure described next:

1. Grease the Cap Box (Stuffing Box).

2. File off any burrs and rough spots on the polished rod, to prevent damage to the stuffing box and/or

bushings in the drive shaft.

CAUTION

Never leave pipe wrench marks on the polished rod. This will prevent thepolished rod from being caught in the tight tolerances of the drivehead shaft

and stuffing box.

3. Apply lubricating oil on the polished rod to clean and lubricate it.

4. Install a polished rod alignment tool (bullet) on top of the polished rod, to keep from damaging the pol-

ished rod threads and/or the stuffing box packing.

5. Use a 3 point sling and lift the drivehead up and orient over the top of the polished rod with a

picker/crane truck or a winch line.

6. If it is difficult to pass the polished rod through, release the pressure on the stuffing box cap. After in-

stallation, retighten the stuffing box.

7. Remove the polished rod alignment tool and install the polished rod clamp then a pony rod.

8. Support the wellhead drive with the picker truck or winch line.

9. Lift the rod string using elevators only enough so the rod weight is removed from the clamp on the pol-

ished rod, at this time the lower polished rod clamp can be removed.

10.Lower the elevators and engage the polished rod drive clamp into the main shaft.

WARNING

Don’t leave more than 30cm of polished rod sticking up above the driveclamp. Longer stickup presents a safety hazard in the event of high speeds.

11.Secure the clamp on the polished rod following the procedure described next:

1) Place the two polished rod clamp pieces on the main shaft and insert the nuts and bolts into them

without tightening them. Observe that clamp slot must be at the bottom side and bolts heads must be

inserted as shown below for a correct clamp position.

CAUTION

Install the nuts and bolts into the clamp. Bolts 1, 2 and 3 should have thenuts showing and bolts 4, 5 and 6 should have the bolt heads showing.




AND INSTALLATION



D L - 1 A n g l e D r i v e h e a d

b) Ensure that the slot on the bottom of the clamp is correctly fitted with the main shaft and tighten the

nuts manually to maintain the two polished rod clamp pieces perfectly aligned. Is very important to

maintain this alignment in order to avoid angular forces in nuts and bolt heads.

c) Using an adequate tooling, tighten the nuts following the sequence indicated below, this tighten must

be progressive for each bolt until 340 Nm (250 lbs.ft) torque is reached.

1) Evenly tighten bolts 1, 2 and 3. (Do not tighten bolt 1 all the way, before moving to

bolt 2 and do not tighten bolt 2 all the way, before moving to bolt 3).

2) Evenly tighten bolts 4, 5 and 6. (Do not tighten bolt 4 all the way, before moving to

bolt 5 and do not tighten bolt 5 all the way, before moving to bolt 6).

CAUTION

When doing the tightening, always follow the same sequence and maintainthe two polished rod clamp pieces alignment to ensure correct polished rodclamp fitting.

12.Lower the stuffing box assembly onto the flow tee and bolt or thread it into place. Tighten all wellhead

fittings to the maximum torque specifications.

13.Remove the pony rod and connect a sucker rod coupling.

14.Make sure all connections and screws are tightened as well as make sure of the drivehead belt ten-

sion.

CAUTION

Be sure connections are completely tight before starting up the unit. Failureto tighten connections correctly will damage drivehead equipment andcause loss of performance.

15.Check for friction between moving parts in order to avoid any moving parts malfunction.

Structural Bolts

Polished Rod Clamp

Clamp Slot




AND INSTALLATION



WARNING

Sheave-Belt guard must be always positioned and locked before start-up.Never put your hands on the moving parts of the drivehead in operation.

16.Before turning the mover on remove the plug that is on the top of the drivehead and put the oil relief in

its place.

CAUTION

This oil plug must be replaced by an oil relief before start-up to avoid inter-nal oil pressure. Not doing this could last on damaging drivehead oil retain-ers.

17.Refer to chapter 4 for drivehead starting up procedures.

CAUTION

DV1 drivehead is design for vertical well application with a maximum devia-tion (from the vertical) of 3 degrees.



CHAPTER 3. GENERAL DESCRIPTION



3 GENERAL DESCRIPTION

Progressive cavity pumping systems are extremely flexible in terms of their abilities to operate in a wide

range of applications. Even so, the success of this system in an application requires the pumping

equipment in particular to be adequately combined to the well’s conditions as well as the operational

environment. The pumping systems operate in integral form; therefore, it is important that individual

equipment is properly configured in order to build a system and the surface drive is one of the main

parts of the system and the one that operators must be more aware of the risks involved.

In general, there are 4 applications where progressive cavity systems can be used:

• Heavy Oil

• Coal bed Methane Dewatering

•

Average Oil• Light Oil

The following descriptions show each of these applications:

Heavy Oil

• API Gravity usually less than 18°API (specific gravity greater than 945 Kg/m³)

• High viscosity oil (“dead oil” viscosity varies from 500 to 15000 cP and can occasionally reach

30000-40000 cP)

• Shallow oil wells, usually from 300 to 900 m deep.

• Low to average production, from 1 to 70 m³/day.

• Usually a low gas/oil ratio (GOR).

• Sand production of up to 30% and occasionally greater.

Medium Oil

•

API gravity from 18 to 30°API (specific gravity from 875 e 945 Kg/m³)• Low viscosity, usually less than 500 cP.

• Depths from 600 to 1000 m.

• Fluid production varies from 50 to 500 m³/day.

• Pumps may be required to operate above 500 rpm.

• GOR greater than when compared to heavy oils.

• The quantity of water is frequently high (up to 95% or more)

• Sand production may vary from 0 to 1%.






Light Oil

• API gravity equal to or greater than 30°API (specific gravity less than 875 Kg/m³)

• Viscosity usually less than 20 cP.

• Oil wells usually deeper than 1000 m.

• Fluid production varies from 50 to 500 m³/day.

• Speed greater than 500 rpm.

• High quantity of water and low quantity of sand.

Coal bed Methane Dewatering

• Depths varying from 400 to 1200 m.

• Quantity of water produced from almost zero to more than 400 m³/dia.

• Pumping speed from 300 to 500 rpm are common.

• May produce a substantial quantity of gas.

• Water production frequently contains a high concentration of sand.

Contact Weatherford PCP Technical Support group for recommended equipment and operation procedures

specific for each of the applications above.






3.1 DESCRIPTION OF THE MAIN COMPONENTS OF A PCP SYSTEM

3.1.1 PC Pump System Schematic

Fig. 3.1 PC Pump Schematic






3.2 WEATHERFORD DV-1 VERTICAL DRIVEHEAD

The Weatherford Vertical Driveheads series DV-1 are designed for medium horsepower applications. The

motor is mounted on a support fastened to the drive frame. The belts and sheaves are assembled inside a

belt guard, providing maximum safety to operators and easy access when maintenance is needed. The

unit’s driving shaft is coupled to a polished rod through a polished rod clamp. Bushings inside the stuffing

box ensure perfect alignment of the polished rod and yet allow the rod to be pulled for well maintenance.

The drivehead is connected to the wellhead through the lower flange of the stuffing box or through a 2 7/8”

EUE Pin thread. Thrust bearings inside the drivehead body support the weight of the rods and fluid column.

These driveheads feature automatic hydraulic backspin control. For more information please refer to Fig 3.2

“DV-1 Vertical Drivehead Specifications”.

Features

• Integral hydraulic automatic backspin control safely dissipates system energy.

• Inactive brake system eliminates heat build up during normal operation.

• Available with NEMA or IEC motor doors.

Benefits

• Hollow shaft design allows easy field installation and flushby operations.

• Designed for safe operation.

• Low maintenance requirements.

Applications

• Up to 25 hp.

• Rpm rate up to 500.






DV-1 Vertical Drivehead Specifications

Fig. 3.2 DV-1 Vertical Drivehead Specifications

WARNING

Maximum ratings are individual specs. Maximum torque, HP and speed can-not occur simultaneously.

• The maximum torque is limited by the braking system.

• Ca90 load is for 90000 revolutions. Reducing load by one half increases life ten times. Reducing the

RPM by one half doubles the hours of life.

• Various connection types are available on request.

• Maximum sheave diameter depends on motor size. Smaller motors can accommodate larger drive

sheaves.

Drive Type Drive Ratio Drive Style

Input Shaft Main Shaft Type

Maximum Input Polish Rod Torque - (1) 750 ft x lbs 1017 N x m 30200 lbs 13696 kgf 116500 lbs 52834 kgf

Maximum Polished Rod Speed Maximum Motor Size - Single Motor 25 hp 18,5 kw Polished Rod Size 1.1/4 in 31,75 mm Maximum Suggested Temperature (Comp.-Temp.) Seal - 230 °F Seal - 100 °C Box oil type

Oil quantity

Height 47 in 1194 mm Drive/Frame Weight 930 lbs 422 kgf

1017 N x m

Brake oil type Oil quantity

API Wellhead Connection - (3)

Prime Mover

Driven Sheave Maximum Diameter 23,60 in 600 mm Driver Sheave Maximum Diameter - (4) 9,00 in 230 mm Driver Sheave Minimum Diameter - (5) 4,50 in 115 mm Drive Belt type Max. Number of Belts Minimum Center Distance 22,7 in 576 mm

Dimensions & Weights (excluding motor)

- ISO Rating

DRIVE NAME / MODEL DV1

Vertical Drive -

Well equipment compatibility

Automatic external hydraulicbrake/manifold with needle valve

200 IEC or 326T NEMA

Bearing Box Vertical

Hollow Shaft Ratings

600 rpm

Mobil SHC 629

8,7 L

17 L

Backspin resistance torque Maximum backspin Pump speed - up to

Backspin control

Maximum motor frame

Thrust Bearing - Ca90 Rating - (2)

V-Belts 4

Brake system

2.7/8" Pin or 3.1/8" 2000 Psi flange

Auxiliary equipment Electric

39 rpm Mobil SAE 10W/30

750f.ft






• Ensure that the top bearing in your motor can handle the additional overhung load that results from us-

ing smaller sheaves.

• “D” – Distance between the motor’s bases to its centerline.

3.2.1 DV-1 Vertical Drivehead Schematic

Clamp Guard

PR Clamp

Sheave Guard

Bearing Box

Electric Motor

Element Peripherals

Hydraulic Brake Stuffing Box

Fig. 3.3 DV-1 Vertical Drivehead Schematic






3.3 STUFFING BOX

All Progressing Cavity Drivehead require a Stuffing Box to create seal between the polished rod and the tub-

ing. Weatherford PC Pump manufactures a variety of stuffing boxes:

3.3.1 Conventional Stuffing Box w/ 2000 Psi Flange

Top Bushing

Caps

Spring

Grease Nipple Bottom Bushing

Flange 2000 Psi

Fig. 3.4 DV-1 Conventional Stuffing Box w/ 2.000Psi Flange






3.3.2 Conventional Stuffing Box w/ 2.7/8” EUE PIN

Cap

Top Bushing

Cap

Spring

Grease Nipple Bottom Bushing

2.7/8” EUE Pin

Fig. 3.5 DV-1 Conventional Stuffing Box w/ 2.7/8” EUE PIN






3.3.3 Rotating Stuffing Box w/ 2000 Psi Flange

Fig. 3.6 DV-1 Rotating Stuffing Box

Note: Rotating Stuffing Box Maintenance Procedures are available in a specific manual.

In case you need additional information, please contact your nearest Weatherford representative.






3.4 OPTIONAL COMPONENTS

Item Part Description

1 Support ArmSupport arm coupled to the drivehead’s structure in order to as-sure greater structural stability (Eliminating excessive vibrations)

2 SheavesSheaves used to reduce system rotation to the rotating speed de-sired.

3 BeltsBelts used to connect the motor sheave with the driveheadsheave.

4 Electric MotorElectric Motors connected to the drivehead trough the sheavesand belts, to give movement to the system.

5 Ejection ClampClamp connected to the polished rod in between the stuffing boxand the housing in order to avoid the ejection of the polished rodin case of a backspin.



CHAPTER 4. OPERATION



4 OPERATION

Operation of the DV-1 Vertical Drivehead consists on …

• …starting Up Procedure.

• …shutting Down Procedure.

• …braking System Operation Procedure.

4.1 STARTING UP PROCEDURE

WARNING

Wear all protective clothing recommended when working in close proximityto the drivehead.

1. Approach to the well head with caution, observing the other wells operating nearby. It is advisable to

set up a protecting barrier between the well and personnel before the start up.

CAUTION

If by any chance the operating conditions are unsafe, call your supervisor.

2. Make sure the clamp is properly installed, the belt guard in place and the stuffing box hand tight.

3. If you are performing this operation alone, make sure that someone else knows what you will be doing,

exact location and schedule. Minimize the quantity of people around the well. It is advisable to set up a

protecting barrier between the well and personnel before the start-up.

WARNING

The drivehead start up must be done only by trained and experienced per-sonnel who understand the normal and abnormal situations concerning“backspin” rotation and all the risks involved. The indications and recom-mendations included in this manual can NOT substitute a proper trainingprogram for operators.

4. Inform everybody present at the local about the risks involved. (i.e. “tailgate” or safety meeting).

WARNING

Do not allow more than 30 cm of polished rod above the drivehead. Therecan not be any pony rods connected to the top of the polished rod even ifthey are inside this range.

5. Set all casing, tubing, flow line and drivehead components correctly for operation.

CAUTION

Be sure connections are completely tight before starting up the unit. Failureto tighten connections correctly will damage drivehead equipment andcause loss of performance.

WARNING

Sheave-Belt guard must be always positioned and locked before start-up.Never put your hands on the moving parts of the drivehead in operation.






6. For wells fitted with VFD (Variable Frequency Drive):

a) Turn ON/OFF switch to “OFF” position, then turn ON the main circuit breaker.

b) Verify that all the shutdown parameters are set.

c) Set VFD to zero frequency or minimum speed.

d) Set for normal operating mode with external shutdown enable.

e) Set the panel to show current (amperage) and torque, ensuring that all safety shutdown proc-

esses are properly set.

f) Put the ON/OFF switch on position “ON”.

7. During the initial operation (e.g. first few minutes), monitor for any unusual noises, vibrations, leaks and ex-

cessive temperatures or pressures. If anything abnormal is detected turn the equipment off and call your

supervisor for assistance.

WARNING

Turning on and off the equipment in excess can cause overheating of thebreaking system and drivehead oil.

8. Check and adjust the overpressure controller of the production line to the desired value.

9. Monitor all pressures and check for leaks.

CAUTION

Make sure connections are completely tight.The operator must be familiar with all applicable environmental regulationsin the event of leakage or spillage and prepared to take appropriate steps forcontrol and removal.

10.Check if the stuffing box is operating properly without excessive leakage.

CAUTION

ALWAYS switch off the drivehead BEFORE connecting or disconnecting anydrivehead components! NEVER attempt to do so with the drivehead moving.

To do so may cause injury to personnel and will damage the equipment.

11.Inform your supervisor that the start up is done and that you are leaving the area.






4.2 SHUTTING DOWN PROCEDURE

WARNING

Wear all protective clothing recommended when working in close proximityto the drivehead.

1. Become familiar with well operating conditions prior to shut-down including speeds, production, current

(amperage) and recent interventions.

2. Approach the well with caution to perform a visual inspection.

3. If you are performing this operation alone, make sure that someone else knows what you will be doing,

exact location and schedule. Minimize the quantity of people around the well. It is advisable to set up a

protecting barrier between the well and personnel before the shut down.4. Inform everybody present at the local about the risks involved. (i.e. “tailgate” or safety meeting).

WARNING

The drivehead shut down must be done only by trained and experiencedpersonnel who understand the normal and abnormal situations concerning“backspin” rotation and all the risks involved. The indications and recom-mendations included in this manual can NOT substitute a proper trainingprogram for operators.

5. Check for unusual noises.

CAUTION

If for any reason at any point of the procedure you suspect the operation isunsafe, keep yourself and all the personnel behind a barrier and call yoursupervisor immediately.

6. If the necessary steps have not been taken to control backspin, a protection barrier should be provided

near the control panel during the proceedings and make sure everyone is away from the well prox-

imities before initiating the shut down operation.

WARNING

Never operate a drivehead with a malfunctioning breaking system. A highspeed backspin may damage the equipment and put personnel at risk.

7. Check the following:

a) Well head pressures.

b) Motor current (if the current is above the usual the backspin speed will be higher)

c) The oil level of the braking system and drivehead.

8. If the well is fitted with VFD, use it to gradually slow the speed to the minimum possible before shutting

it down totally.

9. Turn off the drivehead through the main panel and observe the braking system performance.

10.Remain behind protection; observe any abnormal backspin (e.g. excessive speed).






WARNING

Do not approach to the wellhead until the backspin stops.

Turn off and lock the circuit breaker on the main panel before doing any in-tervention.

11.For breaking systems with adjustable holes, open the valve completely to make sure the rods column reach

balance.

CAUTION

Even after the drivehead shutdown and the stopping of the backspin, thereis still a possibility of recoil. This extra recoil is caused by the equalizationbetween the fluid inside the production tubing and the fluid inside the cas-ing.

4.3 BRAKING SYSTEM OPERATION PROCEDURE

Since the characteristics of the wells where the driveheads could be installed are unknown, braking systems

are always set for maximum operating conditions as a default manufacturing safety procedure.

1. The braking system is designed to operate at the maximum allowed nominal torque in a safety speed and

temperature range.

2. The brake system of the DV-1 Vertical Drivehead operates automatically if the valve “A” is left opened (fac-

tory default condition). If for any reason it is desirable to block the reverse movement the valve “A” should

be completely closed before starting the shut down procedure. The lock nut “B” is used to maintain the valve

“A” in the desired position.

3. There is a direct relation between the torque accumulated in the rod string and the pressure indicated in the

manometer. For the maximum nominal torque, the pressure will reach ~160 Bar.

NOTICE

In order to protect the hydraulic motor any pressure above 247 bar willcause a relief valve to open.






A

B

Fig. 4.1 Braking System Manifold.

4.4 OPERATIONAL TORQUE LIMITS

Weatherford has recently decided to be more involved in the applications of PCP driveheads for many motives.

History shows that most of the serious incidents with any PC Pump driveheads have occurred when the pump

is seized downhole and the PC Pumping system has been torqued up in an attempt to free the pump. In a di-

rect electric application, this input torque is typically limited only by the maximum horsepower the motor can de-

liver and the rod string’s ability to transmit torque down to the pump. Unknown for most operators is the fact

that all electric motors have the ability to deliver over 250% of the full load nameplate horsepower. This poten-

tial applied torque can far exceed the published structural and backspin control limits of the drivehead.

One way to limit the maximum torque input is to restrict the motor size and sheave ratio in order to limit the

maximum torque that can potentially be applied. Graphs have been prepared to illustrate safe operating limits,

and define where there is a potential problem with applying excessive torque to the system. By using the relevant DV-1 Vertical Drivehead graph and comparing the sheave ratio versus connected horse-

power for any given application the operation of the PC pump system will be as follows: • In Zone 1: The PC Pumping System is inherently safe. It is not possible to apply more torque than the

recommended maximum input torque with the equipment specified.

• In Zone 2: Operation should be carefully considered. If the motor was operated at its extreme torque limit

(potentially 250% of nameplate rated horsepower) such as to free a stuck pump during startup, it may be

possible to exceed the recommended load rating of the drivehead.

• In Zone 3: Operation is potentially dangerous unless an acceptable torque-limiting device is used (e.g.

VFD). Without such a device, it is likely that the load rating of the system can be exceeded.






0

50

100

150

200

250

300

350

400

450

500

550

600

5 7,5 10 12,5 15 17,5 20 22,5 25

P o l i s h e d R o d S p e e d ( r p m )

ZONE 01

ZONE 03

ZONE 02

for 750 lbf.ft

Electric Motor Horse Power ( HP )

Fig. 4.2 Operational Torque Limits.

If a sheave/horsepower combination falls within the Zone 2 or 3 of the curve, it does not mean that the

combination cannot be used. What is being illustrated here is that under certain circumstances (e.g.

seized pump), there is a potential risk for a recoil (back spin) event where the torque stored in the rod

string may be larger than the maximum drivehead rated torque.

Note that the level of potential risk will be affected by the sheave ratio, the maximum torque the motor can

deliver and the ability of the drivehead backspin control device to safely handle the torque and the energy

stored in the system. The backspin control system will experiment a peak torque at the beginning of this

operation; if this torque surpasses the rated capacity of the drivehead it may cause the mechanical failure

of one of its components during the first seconds. However, note that even if the peak torque is not exces-

sive, if the total energy stored in the system (which is affected by the completion geometry and the welloperating conditions) is too high and the backspin occurs too fast, it could lead to an overheating and

eventual failure of the backspin control system.

When operating any PC Pumping system in the Zone 2 or 3 it is recommended to use some type of accu-

rate torque limiting device. This torque control can be a vector flux drive controller with the torque limits set

below the drivehead rated capacity. It is important to remember that not all VFD's have vector technology;

for instance, a scalar drive will not provide accurate torque control. Torque limits on the vector drive must

not be increase to free a stuck (seized) pump. Doing so may damage the equipment and put personnel at

risk.






Once the proper drive has been selected and installed, they need to be maintained. It is imperative that the

manufacturer's maintenance procedures be followed, including routine oil changes and checks of the

backspin control device performance.

WARNING

Note that the input torque is typically limited by the maximum horsepower the

motor can deliver and the rod strings ability to transmit torque down the pump.

However, electric motors have the ability to deliver over 250% of the full load

nameplate horsepower and over 250% of the maximum published torque. In a

seized pump scenario and in the absence of torque limiting device, the system

will torque up in an attempt to free the pump. This applied torque can far ex-

ceed the published structural and backspin control limits of the drivehead.

4.5 DRIVEHEAD REMOVAL PROCEDURE

WARNING

Wear all protective clothing recommended when working in close proximity

to the drivehead.

1. Switch off the drivehead as described on the shutting down procedure on this Chapter.

WARNING

The drivehead removal must be done only by trained and experienced per-sonnel.

The indications and recommendations included in this manual can NOTsubstitute a proper training program for operators.

2. Disconnect all the hoses or wiring to the electric motor.

3. Attach a 600mm pony rod and rod coupling to the polished rod.

4. With the use of a flushby unit or rig attach the working line to the 600mm pony rod.

CAUTION

All lifting gear must have a minimum lifting capacity of 3.000 kg / 6.615 lb.

Ensure that all lifting equipment is in proper working condition.

5. Pull up the polished rod to pick up the rod weight.

6. Begin to loosen off the polished rod drive clamp bolts.

7. Once the clamp has been loosened off, begin to pull up the polished rod (approx. 600–900 mm).8. Isolate the production tubing through the BOP installed below the drivehead and close the flowline valve to

the production line.






9. Attach the winch line or picker to the lifting lugs on the drivehead. Ensure that the drivehead is balanced.

10.Begin to remove the bolts from the wellhead flange or unscrew the drivehead from the flow tee.

WARNING

Use only the designated lifting points. Do not lift the drivehead by thesheaves or by the electric motor.

DO NOT step under the lifted equipment at any time.

Stay clear from moving equipment.

11.Once the drive has been loosened off, begin to lift the drive with the winch line or picker. (approx. 600 – 900

mm).

12.Install a two bolt rod clamp and a 1” steel plate on the flow tee of the wellhead.

13.Remove the 600mm pony rod and rod coupling from the end of the polished rod.

14.Lift the drivehead off over the polished rod.



CHAPTER 5. SERVICE AND MAINTENANCE



5 SERVICE AND MAINTENANCE

WARNING

Only WEATHERFORD trained personnel may carry out troubleshooting, ser-vice and maintenance tasks.

Other personnel may be unaware of required methods and expertise, possi-bly leading to dangerous situations.

CAUT ION

Cleaning and maintenance intervals are crucial for the operational safety ofthe unit and must therefore be strictly adhered to.

Disregarding this caution will cause a potentially hazardous situation, whichcan result in personal injury and/or material damage.

CAUT ION

Use only original WEATHERFORD spare parts. Part numbers can be found inthe parts list in Chapter 7 of this manual.

Only persons having specific knowledge and experience in Drivehead sys-tems may carry out work on hydraulic equipment.

CAUT ION

Surfaces may be hot.

Let equipment cool down or wear suitable personal protective equipment.Clean or service only with drivehead stationary and cold!

5.1 PREVENTIVE MAINTENANCE SCHEDULE

DESCRIPTION FREQUENCY SECTION

Stuffing Box

Grease the packing Daily during the first two days of operation. After ini-tial period at least once a week but might be morefrequent depending on application details

5.2

Change packing Yearly or before if excessive leakage occurs 5.3

Bearing Box

Oil Change First change after one month, then repeat annually 5.4

Belts

Belts inspection Every three months, change if worn out 5.5

Braking System Gears

Oil Change Yearly 5.6

Hydraulic break system

Oil Change Yearly 5.7

Overhaul maintenance(bearings, ratchet system)

Should be performed only by Weatherford or trained personnel.Refer to specific training material for instructions.






Stop the drivehead and release energy from the system before any maintenance, adjustment or repair

work and secure the starter against unintentional activation (refer to Shutdown Procedure, Chapter 4, Sec-

tion 4.2).

• Secure large components during exchange with a lifting device.

• Check that all loosened screwed connections are retightened after the maintenance or repair work is

done.

• Check all safety devices after service or maintenance.

• Tighten the stuffing box cap manually clockwise until the loosening between stuffing box’s ropes is

eliminated. Do not over tighten the cap. A small leakage is necessary to keep the stuffing box lubri-

cated.

CAUT ION

Do not over tighten the stuffing box cap. This may cause over-heating andtherefore a reduction of stuffing box’s parts and polished rod lifetimes.

• Check for leaks and make adjustments for necessary system sealing.

• Check the systems functionality (see Chapter 4).

5.2 STUFFING BOX MAINTENANCE - GREASE

Stuffing box maintenance procedures vary by well location. Depending on application severity, daily greasing

may be required but greasing weekly is recommended as minimum.

CAUT ION

Grease often the stuffing box for the first two days of operation of a newdrivehead.

1. Shut-down the drivehead following the shutting down procedures on Chapter 4, Section 4.2.

2. Close flow line valve to production tank.

3. Always wipe away any excess grease and dirt from around the grease zerk (refer to Fig. 5.1 for grease

zerk location) before greasing.

4. Apply 8 – 10 shots of grease (APG 2 EP – Bardahl).

5. Ensure the stuffing box cap is hand tight.

6. Do not over tighten the stuffing box, because it will generate overheat and shorten the life of the stuffing

box parts and polished rod.

7. Wipe away the excess grease from around the fitting.






Fig. 5.1 DV-1 Vertical Drivehead - Stuffing Box

5.3 STUFFING BOX MAINTENANCE – CHANGE PACKING

Stuffing box maintenance procedures vary by well location. Packing change will depend on application severity

and should be performed always when there is excessive leakage on the stuffing box that cannot be solved

with additional tightening torque on the stuffing box cap. The following procedure should be followed (refer to

Fig. 5.1 for cited parts location).



3. Release the stuffing box cap.

4. Remove the top packing rope.

5. Lift the bushing.

6. Remove the packing set (ropes). If necessary use a metal hook or a screw driver to help remove the

ropes.

7. Install the new packing set (six ropes). Lower the bushing. Install a new top packing rope.

8. Hand-tighten the stuffing box’s cap.

9. Do not over tighten the stuffing box, because it will generate overheat and shorten the life of the stuff-

ing box parts and polished rod.

Grease Zerk

Stuffing Box Cap

Top Packing

Bushing

Packing Set






5.4 BEARING BOX – OIL CHANGE



3. Set a safety clamp above the stuffing box to secure the polished rod during maintenance (see Fig. 5.3

for an example of safety clamp installed).

4. Prepare a system below the drain plug to collect the oil to be drained according to applicable environ-

mental regulation.

5. Drain braking oil by completely removing drain plug (refer to Fig. 5.2 for drain plug location).

6. Remove filling plug (refer to Fig. 5.2 for filling plug location) for oil replacement.

7. Screw back in the drain plug. Use Teflon tape to ensure plug’s thread proper sealing.

8. Complete the bearing box with 8,7 liters of Mobil SHC 629 oil.

9. Reinstall filling plug.

10. Turn on the drivehead by following the starting up procedures (see Chapter 4, Section 4.1) and adjust

the control valve by following the braking system operating procedure on Chapter 4, Section 4.3.

Fig. 5.2 DV-1 Vertical Drivehead - Gearbox

Filling Plug

Drain Plug






5.5 BELTS INSPECTION AND CHANGE PROCEDURE





4. Open the hinged belt guard.

5. Loosen the two motor plate tension screws.

6. Remove the old belt(s).

7. Install new drive belt(s) and tighten to the appropriate tension checking belt deflection to be equal to1.6% of sheaves’ centers distance (see Fig 5.4 for a schematic of how to measure this deflection).

Fig. 5.3 DV-1 Stuffing Box - Safety Clamp installed

Deflection (H) = 1.60% of A

Fig. 5.4 Belt deflection measurement schematic

Clamp






WARNING

To avoid excessive vibration and premature belts and sheaves wear align-ment between the sheaves must be checked.

8. Close and secure the hinged belt guard.

WARNING

Sheaves/belts guard must be always positioned and locked before start-up.Never put your hands on the moving parts of the drivehead in operation.

9. Disengage the safety clamp.

10. Open flowline valve to production tank.

11. Turn on the drivehead following starting up procedures on Chapter 4, Section 4.1.

5.6 BRAKING SYSTEM GEARS – OIL CHANGE PROCEDURE





4. Prepare a system below the oil drain to collect the oil to be drained according to applicable environ-

mental regulation.

5. Drain braking oil by completely removing drain plug “A” (refer to Fig. 5.5 for plugs location).

6. Remove filling plug “B” for oil replacement.

7. Screw back in the drain plug “A”. Use Teflon tape to ensure plug’s thread proper sealing.

8. Complete the dispenser with 0,8 liters of Mobil SHC 629 oil.

9. Reinstall filling plug “B”.








Fig. 5.5 Braking System Gears’ Oil Change – Drain and Filling Plugs Location

5.7 HYDRAULIC OIL CHANGE PROCEDURE

1. Shut-down the drivehead by following the shutting down procedures on Chapter 4, Section 4.2.

2. Set flow control valve to fully open position to ensure all torque in the polish rod is released.

3. Prepare a system below the oil dispenser to collect the oil to be drained according to applicable envi-

ronmental regulation.

4. Drain braking oil by completely removing drain plug (refer to Fig. 5.6 for drain plug location).

CAUT ION

Take care when draining off hot oil.

Wear protective gloves when opening the drain plug.

5. Remove air filter from top of dispenser for hydraulic oil replacement.

6. Screw back in the drain plug. Use Teflon tape to ensure plug’s thread proper sealing.

7. Complete the dispenser with 17 liters of SAE 10W30 oil.

CAUT ION

DO NOT mix different types of fluid!

Ensure that all consumables are disposed of safely and with minimum envi-ronmental impact.






8. Reinstall air filter.

9. Make sure that oil flows inside the hydraulic motor through the anti-clockwise system rotation.



Fig. 5.6 Hydraulic Braking System – Oil Drain Plug location

5.8 MAINTENANCE SAFETY - POLISHED ROD SUPPORT CLAMP

This polished rod support clamp is normally used for any maintenance purpose as a safety device.

Spiral Threads

Drain Plug

Air Filter






Fig. 5.7 Safety Polished Rod

Installation

1. Certify clamp jaws are in perfect conditions.2. Place polished rod clamp support between drivehead and wellhead flange.

3. If necessary replace stuffing box flange studs for longer ones.

4. Tighten lock bolts following this sequence:

1 3

4 2

CAUT ION

More than one polished rod clamp could be used for applications with largeaxial load. Weatherford Application Engineering must be consulted to de-termine number of clamps required.

Engaging

1. Switch off the drivehead by following the shutting down procedures on Chapter 4, Section 4.2.

2. Tighten screws using the spiral threads as a reference.

3. Torque up all screws with 339 N.m following sequence shown in step 4 of installation procedure.

4. Double-check bolts torque of 339 N.m.

CAUT ION

Screws must be tighten and loosen slowly to avoid any screws o´rings damage.

Disengaging

1. Certify rods load is being supported by upper drivehead clamp.

2. Slowly loosen screws staying alert for any eventual additional energy release.

3. Totally loosen all four screws.

4. Turn on the drivehead by following the starting up procedures on Chapter 4, Section 4.1.

WARNING

• Maximum axial load per clamp must not exceed 4 Tons (metric).• Polished rod clamp must never be used as a rod torque safety device.

• Polished rod clamp must be used only for rods axial load supporting.



CHAPTER 6. TROUBLESHOOTING



6 TROUBLESHOOTING

The DV-1 Vertical Drivehead is designed for oil production operations.

If a malfunction occurs, compare with the symptoms listed in this troubleshooting chapter.

To replace a worn or broken part, refer to Section 7, Section 7.8 for the equipment drawings and part

lists.

After any major repair, the DV-1 Vertical Drivehead must be serviced as described in Chapter 5, 'Ser-

vice and Maintenance'.

WARNING

Only WEATHERFORD trained personnel may carry out troubleshooting, ser-

vice and maintenance tasks.

Other personnel may be unaware of required methods and expertise, possi-ble leading to dangerous situations.

NOTICE

If you are unable to solve a technical problem concerning this product, con-tact WEATHERFORD technical support at:

+ 55-51-3579-8400

Fax: + 55-51-3579-8401

e-mail: [email protected]

WARNING

DO NOT attempt to perform any repair, disassembly, or maintenance whilethe drivehead is running.

Uncontrolled operation of the equipment while repair or maintenance workis in progress may cause serious injury to personnel and damage equip-ment!

CAUTION

Use only original WEATHERFORD spare parts. Part numbers can be found inthe parts list in Chapter 7, Section 7.8.

Only persons having special knowledge and experience in Drivehead sys-tems may carry out work on hydraulic equipment.






6.1 STUFFING BOX

Symptom / Possible Cause Possible Cause Corrective Action

Stuffing box with excessive leak-age

Stuffing box cap is too loose Tighten the Stuffing box cap to minimize leakage.

Stuffing box cap showing exces-sive wear

Possibly due to excessivetightening

Replace the Stuffing Box Caps.

Bushings excessive wear Possible misalignment (dueto excessive unsupportedweight)

An indication of misalignment is that the cap willnot thread on and off easily. Adjust the position ofthe drive with support arms to minimize load (mo-mentum) of the motor assembly on the driveheadbase.

Polished rod seized inside stuff-ing box

Possibly due to wrench marks File off any wrench marks.

6.2 HYDRAULIC BRAKING SYSTEM


Inconsistent Pressure reading Pressure indicators are faulty Check pressure gauges

Excessive noise and/or noise

during backspin

The oil dispenser could be

running out of hydraulic oil

Check hydraulic oil level and fill up if necessary,

refer to Chapter 5.’Oil Change Procedure. Checkfor oil leakages. Check hoses and connectors forproper engagement

Excessive backspin speed Damage in the Pressure Re-lief Valve or lack of choke inthe manifold

Replacement of whole manifold; send old manifoldfor inspection and/or refurbishment

Fig. 6.1 DV-1 Manifold (Braking System)

Flow Control

Valve

Manifold

Relief Valve






6.3 MOVING PARTS (SAFETY ADVICES)

All Weatherford PC Pump driveheads have moving external parts like drivehead sheaves, electric

mover sheaves, transmission belts, main shaft, polished rod, and polished rod clamp.

The driveheads are built with a belt guard and a clamp guard, and there is also the possibility of a

greaser guard to ending the possibility of any contact with the polished rod when equipment is operat-

ing.

WARNING

• Never put your hands on the moving parts of the drivehead in operation.

• Always maintain the polished rod clean for later RPM reference, cap tightening, etc. If clean-ing of the polished rod is necessary, do so with the drivehead stopped.

• The Sheave/Belt guard and the clamp must always be positioned and locked before start-up.

• Always stop the drivehead for any operation that involves contact with moving parts.

• Watch out for clothes, gloves, cloths, ropes and other materials that may get caught and putpersonnel at serious risk.

• Before stopping the drivehead always make sure that the brake is set-up to lock the drive-head avoiding an accelerated backspin.

• Before turning on the drivehead always check for friction between moving parts in order toavoid any moving parts malfunction


Cannot get a consistent read-ing of RPM at the Polished Rod

Missing or dirty reflect-ing element on the Pol-ished Rod

Turn the equipment off and then replace reflecting tape.Never try to clean the polished rod while the drive-head is rotating.

Fractured or broken Sheave Excessive vibration, ex-cessive backspin speed

Inspect brake, perform a controlled backspin operationand monitor speed (see chapter 4 for safety remarks).Replace Shaves. Never forget to close and lock thesheave guard and most importantly, never operate adrivehead with a malfunctioning breaking system.

Excessive belt wear and/or fail-ure

Belt breaking happensfor many reasons, such

as: over tightening, mis-alignment, and sheavechannels problems.

Make sure the belts are always correctly set-up, watch outfor wear and tear, replace them in the end of their opera-

tional lifetime, and most important, always close and lockthe sheave/belt guard.

Bent Polished Rod Mechanical damageduring installation; ex-cessive length; exces-sive backspin speed

Check Polish rod length; Replace the Polished Rod andrelocate the Polished Rod Clamp. This problem occurswhen too much rod length is left above the polished rodclamp. In case of a high speed backspin rod bendingor even rod breaking may occur with a extreme riskfor field personnel.



CHAPTER 7. APPENDIX



7 APPENDIX

Contents Page

7.1 Appendix A. Definitions ....................................................................................................................2

7.2 Appendix B. Project Considerations.................................................................................................5

7.3 Appendix C. Unit Conversions and Fluid Compatibility .................................................................... 8

7.4 Appendix D. Useful Rules ................................................................................................................9

7.5 Appendix E. Formulas ......................................................................................................................9

7.6 Appendix F. Viscosity Chart ........................................................................................................... 12

7.7 Appendix G. Bearing Lifetime......................................................................................................... 12

7.8 Appendix H. DV-1 Drivehead Spare Part List ................................................................................ 13

7.9 Appendix I. Belts Specifications ..................................................................................................... 22

7.10 Appendix J. Painting Specifications ............................................................................................... 23

7.11 Appendix K. ATEX Certified Motors List......................................................................................... 23

NOTICE

If you are unable to solve a technical problem concerning this product, con-tact WEATHERFORD technical support as follows:

+ 55-51-3579-8400

Fax: + 55-51-3579-8401

e-mail: [email protected]



CHAPTER 7. APPENDIX

Page 2 of 23 Rev. 00April 2007 Operating Manual


7.1 APPENDIX A. DEFINITIONS

Applied Torque

Applied torque is that applied to the top of the rod string by the surface drive.

Auxiliary Equipment

Auxiliary equipment is any component which can be changed by the end user. Examples are sheaves, belts,

motors guards, motor controllers, torque limiting devices, and speed limiting devices.

Backspin

Backspin is the process by which the surface drive turns in the direction opposite to normal operation. Back-

spin is driven by the energy stored in the rod string (strain energy) and in the residual differential fluid pres-

sure across the pump after the system is shut down.

Dissipation Rate

Dissipation rate refers to the power transferred to the surroundings by the braking system in the form of heat.

Dynamic Fluid Level

Dynamic fluid level is the distance from the wellhead to the top of the liquid column in the annular space be-

tween the tubing and casing during normal operation.

Electric Motor Brake

Electric motor brakes control the power from the electric prime mover during backspin to create a braking ef-

fect on the system.

Energy Capacity

The energy capacity of a surface drive is a measure of the total work the brake can do over the expected du-

ration of a shutdown event. For example, a braking system which manages stored energy by absorption and

not dissipation has a finite energy capacity defined by thermodynamic characteristics and maximum allowable

operating temperature. A brake which can dissipate energy as fast as it is generated by the shutdown process

has an infinite energy capacity.

Flow Losses

Flow losses refer to internal friction of moving fluids resulting in pressure loss.

Fluid Dump Case

The fluid dump case describes most normal shutdowns where power to the surface drive is removed thereby

allowing backspin. The differential fluid pressure across the pump causes the rotor and rod string to rotate in

the direction opposite to normal pumping, allowing fluid to flow from the production tubing back through thepump. Backspin continues until torque resulting from differential pressure across the pump equals friction

torque in the system.



CHAPTER 7. APPENDIX



Fluid Energy

Work potentially done by gravity acting on the fluid in the production system.Fluid Head

Fluid head is pressure resulting from gravity acting on a column of fluid. Fluid head is used to describe the

pressure differential between two fluid columns contributing to the total differential pressure across the pump

which in turn produces torque.

Friction Brake

A friction braking system reacts torque by applying a normal force to a sliding surface creating drag.

Hydraulic Brake

A hydraulic braking system reacts torque by pumping liquid through an orifice resulting in a pressure drop.

Mass Moment of Inertia

Mass moment of inertia is a measure of rotating equipment response to acceleration (due to applied torque).

Progressing Cavity Pump (PCP)

A progressing cavity pump is comprised of a stator and rotor. The geometry of the assembly is such that it

constitutes two or more series of spiral, separate cavities. When the rotor rotates inside the stator, the cavi-

ties move spirally from one end of the stator the other, creating a positive displacement pumping action.

PCP Surface Drive

The surface drive is a machine which transfers rotational power from the prime mover to the rod string, trans-

fers axial load from the rod string to a surface foundation, and manages stored energy during shutdown

events.

Residual Fluid Head

Residual fluid head is the condition caused by friction in the PC-Pump, equaling torque generated by fluid

pressure over the effective area of the pump, resulting in non-obvious presence of energy in the system whichmay be released unexpectedly.

Rod String

The rod string is a rod or series of rods capable of transferring torsion from the surface drive to the pump.

The rod string typically reacts axial load from the pump to the surface drive.

Safe Operating Torque

Safe Operating torque is that applied torque which will never result in an unsafe operating condition. This

value will be very low; specific applications will permit assignment of a less conservative operating torque.



CHAPTER 7. APPENDIX



Strain Energy

Strain energy is the energy stored in the elastic torsional deformation of the rod string. Strain energy is typi-cally of smaller magnitude than the fluid energy, but may be released much more quickly thereby placing dif-

ferent requirements on the braking system.

Stuck (Seized) Pump Case

The stuck or seized pump case describes one extreme of the possible conditions at shutdown. PCP rotors

sometimes become "stuck" in the stator and become effectively locked together. The top of the rod string

continues to turn while the bottom stops, causing the rod string to further wind up as a torsional spring caus-

ing increased torque. When drive torque is removed, backspin may occurs with a extremely high acceleration

for a very short period, potentially leading to a very high backspin speed.

Thrust Bearing

Device typically contained in the surface drive which reacts axial load from the rod string while allowing it to

rotate.

Torque Limiting Device

A torque limiting device prevents the system from applying torsion greater than a prescribed value to the rod

string. Slow reaction time and dependence on ambient temperature makes "heaters" in the electric power

supply system unacceptable as torque limiting devices. Acceptable devices will apply torque no greater than

110% of the torque limiter set point during a stuck pump event.

Tubing Head Pressure/Casing Head Pressure

Tubing head pressure/casing head pressures are measured at the wellhead and contribute to the total differ-

ential pressure across the PC-Pump.



CHAPTER 7. APPENDIX



7.2 APPPENDIX B. PROJECT CONSIDERATIONS

Weatherford currently manufactures different kinds of wellhead drives to match diverse application en-

countered by progressing cavity pumping systems. Each one has been designed for a special purpose, to

choose the best drivehead for a specific application the following should be considered:

• Depth of well

• Fluid level

• Pump size

• Size of sucker rods, polished rod and tubing connection

• Operating torque

• Desired speed range

• Prime mover (electric motor or internal combustion engine)

When purchasing a PC pumping unit, the design considerations play an important role in the safe opera-

tions of the unit. The application designer must establish the maximum surface loading and ensure the

equipment being purchased will operate within its rated limits. The loading or work done by a PC pumping

system is primarily determined by the following:

• Pump intake pressure

• Pump discharge pressure

• Rod string/tubing friction

• Internal pump friction

Several other factors influence these parameters and they usually change throughout the life of an oil well.

Other factors may include:

• Fluid contaminants

• Pressure, volume, temperature properties of the production medium, reservoir characteristics, tub-

ing roughness

• Side wall stress as a result of tubing/rod contact

• Tubing and casing pressure fluctuations• Interference pump fit between rotor/stator

Computer aided software tools are available to help determine these factors. Calculations must be made

before purchasing a unit. When predicting load limits, a safety factor of at least 10 percent should be con-

sidered to account for error associated with the reliability of assumptions or the accuracy of mathematical

correlations.

Operating loads may change through the operating cycle life. After the initial start up, actual operatingloads should be confirmed to verify design expectations. If the system loading exceeds the design,

changes to operating parameters or equipment are necessary.



CHAPTER 7. APPENDIX



Control devices that will protect the unsupervised system and provide the operator with an indication of

equipment condition are equally important. The PC drive systems could include instrumentation to monitor

and control the following: braking mechanism temperature, backspin speed, operating torque, and hydrau-

lic fluid levels.

All new installations require a design input data sheet be filled out, ensuring that a qualified person within

the producing company has reviewed the design of the unit being installed.

Fig. 7.1 Well Data Sheet.

To receive this Data Information Sheet please contact your local Weatherford Distributor.

For an electronic copy please contact us at www.weatherford.com

Current: Projected:

Rod Grade:

Water S.G.:

Water Salinity:

Rod Type: Conventional Rod Continuous Rod Rod coupl: Normal Slim hole

Perforations:

Treating Chemicals:

SURFACE EQUIPMENT

ppm

Viscosity Correlation:

Company name:

Horizontal: Slant:

Contact:

Current Production: Vertical:

Producing Fluid Level From Surface:

Top: Bottom:

Pump Landing Depth:

IPR DATA Static Reservoir Pressure:

Casing Pressure: Flowline Pressure:

Tubing Size: Casing Size:

e-mail:

Total Depth:

Country: Date:

Please attach if available:

Hydraulic Pump and Mover:

Sheave Relation: Reduction Relation:

Bottom Hole Temperature:

Grades

CO 2 :

API Grade:

Well name: Location:

Fax: Phone:

Units circle one

Projected Production: Water Cut: Abrasive Cut: GOR: Total Viscosity:

Pertinent Information:

Surface Drive:

Frequency:

Flow Tee to drivehead Connection:

Test Point #2

Flow Tee Style and Size

Rod Size:

WELL DATA PRODUCTION AND FLUID DATA

(kpa-psi):

Electric Mover :

Fluid Rate(s) (bfpd-m3pd): Producing Pressure(s)

Bubble Point Pressure:

Productivity Index:

Perforation Evaluation: Fluid Analysis:

Line Voltage:

Direct Hydraulic Test Point #1 Gas Mover: Brand

hp Size

H 2 S:

Temperature Gradient:

rpm

Aromatic (Benzene, Toluene, Xylene):

TMD m

TMD m TMD m TMD m

TMD m TMD m kpa kpa mm mm mm

kpa kpa

m3/kpa

m3/d m3/d % % m3/m3

cp °C

ppm ppm

°C °C/100m

mol%

°C °C °C

cp cp cp



CHAPTER 7. APPENDIX



A file should be maintained for each PC pump system in the field. The file should include the following

information:

1) Equipment Specifications

Equipment specifications should include the maximum allowable: forward speed, backspin speed,

drivehead fluid temperature, hydraulic fluid levels, pressures, braking mechanism temperature, horse-

power/torque, thrust loading, and motor fan speed. It should also include the power factor and motor ef-

ficiency, nameplate volt/amps and motor speed.

2) Sheave and Belt Information

Sheave dimensions, belt types and sizes, maximum rated sheave rpm.

3) Sizing Data

Normal operating horsepower at the motor, start-up horsepower requirements and torque, normal op-

erating torques and operating speed, production volumes, bottom hole flowing pressure, static reservoir

pressure, maximum tubing head pressure, and thrust loading.

4) Commissioning/Start-up Measurements

Start-up values at design speed such as: starting volts/amps, running volt/amps, calculated starting and

running horsepower and torque, forward and backspin rpm hydraulic fluid level, braking mechanism

temperature, production volumes, annular fluid level data, and polished rod stick up amount.

5) Limit Set Points -Control Devices (if applicable)

Shut down settings for the following: hydraulic drivehead fluid levels, maximum braking temperature,

backspin speed, forward speed, running torque, start-up torque and low torque shutdown.

6) Equipment/Operating Changes

A list of any changes to operating parameters or equipment. After changes are made, the operator

must ensure the system is still operating within the design parameters.

a) The operator must ensure that the equipment is operating within its rated limits after every PCworkover.

b) The production operator should review the design to ensure the equipment will operate within the

calculated parameters.

c) The operator must be familiar with the recommended shutdowns limits for the equipment. The op-

erator can refer to the operator's manual for these maximum limit values.

d) The actual loads should be checked at least every 6 months to ensure the operating loads fall

within the design parameters.e) For right angle drive assemblies, the drive assembly should be installed perpendicular to the con-

trol panel to ensure that in the event of a sheave failure, debris would be deflected away from per-



CHAPTER 7. APPENDIX



sonnel standing at the control panel. Caution must also be used in the placement of other equipment

on the lease, to ensure that a sheave failure would not adversely effect other equipment or personnel.

7.3 APPPENDIX C. UNIT CONVERSION AND FLUID COMPATIBILITY

S.I.

S.I. to Imperial

Multiply by

Imperial to S.I.

Multiply by Imperial

( °C ) 1.800 + 32 0.5556 – 17.8 °F

( m³ ) 6.29 0.159 bbls

( m³ ) 0.03531 28.32 mcf

standard cubic meter gas per

standard cubic meter oil 5.618 0.178

standard cubic foot gas per

standard barrel oil (scf/STB)

( Kg ) 2.205 0.454 lbs

( Kg. m² ) 23.70 0.0422 lbs/ft³

Kg/ m³ 0.0624 16.02 lbs/ft³

Kj 0.9479 1.055 Btu

KN 0.2248 4.448 Kip

Kpa 0.145 6.895 psi

KW 1.341 0.7457 hp

L 0.220 4.54 g

MPa 0.145 6.895 Ksi

m 3.281 0.3048 ft

mm 0.0394 25.4 in

N 0.2248 4.448 lbf

N-m 0.7376 1.356 ft-lb

Fig. 7.2 Unit Conversion Chart

Mobil BP Castrol Shell

SHC 626 - - DELINA HT 68

SHC 629 ENERSYN HTX 150 ALPHA SYN-T220 DELINA HT 150

SHC 630 ENERSYN HTX 220 ALPHA SYN-T320 DELINA HT 220

Fig. 7.3 Fluid Compatibility Chart



CHAPTER 7. APPENDIX



7.4 APPPENDIX D. USEFUL RULES

Electric Motor Power Consumption

2.4 Amps per HP for 230 V (assuming three phase, 60Hz)

1.2 Amps per HP for 460V (assuming three phase, 60Hz)

Fluid Level Depression

0.7 m (2.3 ft) per PSI of annulus pressure

Fresh Water Density

1000 Kg/m3 = 62.43 Lbs/ft3 = 9.80 Kpa/m = 0.434 psi/ft

7.5 APPPENDIX E. FORMULAS

Fluid Rate

100

ovolumétricVN Q

η =

Where:

Q = Fluid Rate ( m3/day )

V = Pump Displacement ( m3/d/100rpm )

N = Pump Rotational Speed ( rpm )

ovolumétricη = Pump Volumetric Efficiency ( % )

Pump Torque

fricçãonet T

VPT +=

6,124

Where:

T = Pump Torque ( ft.lbs )

V = Pump Displacement ( m3/d/100rpm )

net P = Net Lift ( m of head )



CHAPTER 7. APPENDIX



FricçãoT = Pump Friction ( ft.lbs )

Power (Electrical)

2,431

... pV LP

line η =

Where:

P = Power ( Hp )

line L = Line Current ( amps )

V = Line –to-Line Voltage ( V )

η = Motor Efficiency ( % )

p = Motor Power Factor

Net Lift

81,9

)()( csgliquid csggaschptbglossestbgliquid thpnet

PPPPPPP

++−++=

Where:

net P =Net Lift ( m head ) chpP = Casing Head Pressure ( kPa )

thpP = Tubing Head Pressure ( kPa ) csggasP = Casing Gas Column Pressure ( kPa )

tbgliquid P = Tubing Liquid Column Pressure ( kPa ) csgliquid P = Casing Liquid Column Pressure ( kPa )

tbglossesP = Tubing Flow Losses ( kPa )

Fluid Density

10005,131

5,141×

+=

API ρ

Where:

ρ = Fluid Density ( Kg/m3 )

API = API Gravity



CHAPTER 7. APPENDIX



Belt Length

C

d Dd DC L

4

2(

2

)(2

−+

+=

π

Where:

L = Belt Length ( in )

C = Center Distance ( in )

D = Driven (Large) Sheave Pitch Diameter ( in )

d = Driver (Small) Sheave Pitch Diameter ( in )

Sheave Rim Velocity

12

DN V

π =

Where:

V =Sheave rim velocity ( ft/min )

π = Sheave Diameter ( in )

N = Sheave RPM ( Rpm )

Polished Rod Speed (RPM)

oteduçãoCabeç

abeçote DIAMPoliaC

otor DIAMPoliaM tor RPMPoliaMo

RPM Re

][ ×

=

Viscosity

1000

γρ µ =

Where:

µ =Dynamic Viscosity ( centipoise )

γ = Kinematics Viscosity ( centistokes )

ρ =Fluid Density ( Kilograms per cubic meter )



CHAPTER 7. APPENDIX



Crude Oil Viscosity as a Function of Temperature

1

10

100

1000

10000

-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Temperature (Celsius)

K i n e m a t i c V i s c o s i t y [ c S t ]

12o

14o

16o

18o

20

22o

24o

26o

28o

30o

32o

34

36

38o

40o

API Gravity

7.6 APPPENDIX F. VISCOSITY CHART

Fig. 7.4 Oil Viscosity Chart.

7.7 APPPENDIX G. BEARING LIFETIME

0

100

200

300

400

500

600

10 20 30 40 50 60 70 80 90 100 110

Vida Nominal (horas x1000)

R o t a ç ã o ( R P M

)

4 TON 5 TON 6 TON 7 TON 8 TON 9 TON

Fig. 7.5 DV-1 Bearing Lifetime Graph.



CHAPTER 7. APPENDIX



7.8 APPPENDIX H. DV-1 DRIVEHEAD SPARE PART LIST

969301400.7 – DV-1 PERIPHERAL COMPONENTS



CHAPTER 7. APPENDIX



969301400.7 DV-1 PERIPHERAL COMPONENTS

POS. CODE DESCRIPTION QUANT

1 3693085007 CHAVETA TIPO B 18 X 11 X 76 1,0

2 3693074000 ESTRUTURA DO CABECOTE 1,03 3693030003 PROTETOR DAS CORREIAS 1,0

4 3693075009 POLIA DA BOMBA 4 X 5V 1,0

6 3669019008 CLAMP 1 1/4" 2,0

7 1801011089 PAR.CAB.SEX.BSW 3/4" X 4" 6,0

8 3693024001 BASE DO MOTOR 2,0

9 3693073001 ESTRUTURA DO ESTICADOR 1,0

10 3693046005 PINO DO PROTETOR 4,0

11 1817007063 ZINCADO AMARELO3/4" - A325 6,0

12 1809007060 ZINCADO AMARELO6X65 DIN 933 4,0

13 1809044056 ZINCADO AMARELO2X90 DIN 933 4,0

14 3693079005 RESERVATORIO 18LT 1,015 1809027057 PAR.CAB.SEX. M12X30 DIN 933 9,0

154 1821013094 BUJAO CAB.QUADRADA 1/2" NPT 1,0

16 1817002040 PORCA SEX. M12 DIN 934 SA 4,0

160 3287000001 PROTETOR CLAMP 1,0

18 1821007001 CURVA FMEA/FMEA 3/4"BSB-G 1,0

20 1821006002 NIPLE DUPLO 3/4"BSP-GALVANI 1,0

21 1821008000 TAMPÃO GALVANIZADO ROSCA 1" 1,0

22 3693049002 BUJO RESPIRO ROSCA 3/4"BSP 1,0

25 1823004000 INDICADOR DE NIVEL SNA076BS 1,0

26 1809004009 PAR. CAB. SEX. M12X18 DIN 9 2,0

27 1818002039 ARRUELA PLANA M12 DIN 125 - 8,0

28 3693061005 PINO ESTICADOR DAS CORREIAS 1,0

29 1817014046 PORCA SEX. M16 DIN 93 6,0

30 1818004046 ARRUELA DE PRESSAO M16 DIN 8,0

31 3693040001 PARAFUSO ESTICADOR DAS CORR 1,0

32 1817001005 PORCA SEX. M22 DIN 934 - C 2,0

33 3281081005 PLAQUETA DE IDENTIFICACAO 1,0

34 1819004071 REBITE DE REPUXO T-310 (DUR 4,0

35 1821003176 BUJAO SEXT.INT.3/8"NPT SAE 1,0

36 3693012005 CHAPA C/ M16 P/ FIXAR MOTOR 4,0

36 3693057001 CHAPA C/ M12 P/ FIXAR MOTOR 4,0

37 1809045055 PAR.CAB.SEX. M12X50 DIN 933 2,0

38 1809005008 PAR. CAB. SEXT. M12X70 - DI 3,039 1821003005 AMA 7/8"UNF JIC X 1/2"NPT 1,0

41 3693055003 APOIO DO PROTETOR - DV1 1,0

42 1809006007 PAR. CAB. SEXT. M16X70 DIN 2,0

43 1819006051 PINO DE SEGURANCA 3,2 X 32 5,0

45 1821026008 MANGUEIRA 3/4" X 270MM 1,0

46 3693077007 MANGUEIRA 1/2" BLOCO-RESERV 1,0

47 1819017030 ABRAÇ FLEXÍVEL ROSCA S/FIM 2,0

50 1821015001 ESPIGO 3/4"NPT X 3/4" 1,0

51 1818003047 AR. DE PRES.M12 DIN 127 - C 16,0

52 1821023001 ADAPTADOR MACHO 7/8" UNF MACHO 1,0

53 1821024000 CONEXÃO GIRATÓRIA 90 GRAUS 1,0162 1840000001 SCREW HEX M8 X 1,25mm 2,0

163 1890003954 WASHER 8,4mm 2,0

164 9694000030 SENSOR CONECTION BOX 1,0



CHAPTER 7. APPENDIX



969301200.9 – DV-1 BEARING BOX 9 TONS

969301200.9 DV-1 BEARING BOX 9 TONS


101 3694030001 TAMPA MANCAL ROLAMENTOS DV/DL-1 1,0

102 3693054004 CAIXA DE ROLAMENTOS - DV1 (035) 1,0

103 3693082000 EIXO MOTRIZ DV-1 1,0

104 3694035006 JUNTA ESPACADORA DA COROA 1,0

105 1825011024 ROLAMENTO 29415 E 1,0

113 3669005004BUCHA DO EIXO P/ ﾘ1.1/4" SAE 660

1,0140 1825007011 ROLAMENTO RADIAL 6212 - SKF 2,0

141 1824053026 RETEN. MOD.R5 ﾘ60Xﾘ80X8 - FREUDENBERG 2,0

142 1824036019 O'RING 2-218 PARKER/NITRILICA 1,0



CHAPTER 7. APPENDIX



143 1812003004 PARAF. SEXT. INT. M16X30 DIN 4,0

158 1824004026 RETENTOR DIN 3760 00223 BR SABO 1,0



103 3693082000 EIXO MOTRIZ DV-1 1,0


105 1825011024 ROLAMENTO 29415 E 1,0

113 3669005004 BUCHA DO EIXO P/ ﾘ1.1/4" SAE 660 1,0

140 1825007011 ROLAMENTO RADIAL 6212 - SKF 2,0





969301300.8– DV-1 BEARING BOX 4 TONS



CHAPTER 7. APPENDIX



969301300.8 DV-1 BEARING BOX 4 TONS




103 3693082000 EIXO MOTRIZ DV-1 1,0

104 1825014021 ROLAMENTO OBLIQUO 31315 1,0


106 3285005134 ANEL DE ENCOSTO BL1-4-7 1,0

113 3669005004 BUCHA DO EIXO P/ ﾘ1.1/4" SAE 660 1,0

140 1825007011 ROLAMENTO RADIAL 6212 - SKF 2,0







CHAPTER 7. APPENDIX



969400800.3 – DV-1 HYDRAULIC BRAKE KIT



CHAPTER 7. APPENDIX



969400800.3 DV-1 HYDRAULIC BRAKE KIT


1 3694042007 GEAR COVER DV/DL-1 1,02 1809029064 SCREW HEX. M16X45 DIN 933 4,0

3 1818004046 PRESSURE WASHER M16 DIN 127 SAE 4,0

4 3693039004 BALL CASE 1,0

5 3693050008 DUST COVER 1,0

6 1825005004 BALL BEARING 6212 ZZ- SKF 1,0

7 1827002030 HYDRAULIC MOTOR. 1,0

8 3693041000 WHEEL COVER 1,0

10 1818003047 PRESSURE WASHER ZINCED M12 DIN 127 2,0

11 1825007002 BALL BEARING 6210 ZZ - FAG/SK 1,0

12 1809000007 SCREW ¼” 1,0

13 3693042009 HYDRAULIC MOTOR WASHER 1,0

14 1824123013 O-RING 3-910 PARKER/NITRIL 2,015 3693076008 COUPLING. 3/4"UNF X 7/8"UN 1,0

16 3693078006 MANIFOLD 170-175 BAR 1,0

17 1821005254 MANOMETER 2.1/2" 300BAR C/GLICERINA 1,0

18 1845026114 RETAINING RING SHAFT 60MM 1,0

20 3693068008 HYDRAULIC MOTOR SEALING JOINT 1,0

21 1820008057 SPHERE 1/2" 20,0

25 1820010053 SPHERE 3/4" 5,0

26 3694044005 BRAKE WHEEL DV/DL-1 1,0

27 1812002005 SCREW HEXT. INT. M12X35-1 2,0

28 3694041008 BRAKE GEAR DV/DL-1 1,0

29 3694000002 BRAKE PINION DV/DL-1 1,0

30 1819017030 FLEXIBLE CLAMP 2,031 1821015001 COUPLING 3/4"NPT X 3/4" 1,0

32 1812008107 SCREW HSEX.INT M12x25 DIN 91 3,0

33 1809008032 SCREW HEX.M8X10 DIN 933 - CLASSE 8,0

34 1818003038 FLAT WASHER M8 DIN 125 - CLASSE 8 8,0

35 1818001003 PRESSURE WASHER. BSW 1/4" - ZINC. A 1,0

36 3694047002 KEY TYPE A 18 X 11 X 50MM 1,0

37 1821014002 DRAIN PLUG HEX 3/4"NPT 1,0

40 1821026008 HOSE 3/4" 270MM 1,0

41 1821003176 DRAIN PLUG HEX.3/8"NPT SAE 1045 1,0

42 1821023001 COUPLING ADAPTER 7/8"UNF-3/4" 1,0

43 1821024000 TURNING COUPLING 90°3/4" 1,0

44 1821028006 COUPLING ADAPTER 7/16"UNF X 1/4"NPT 1,045 1821011096 DRAIN PLUG. SQUARE. 3/4"NPT 1,0

46 3694045004 BRAKE RATCHET DV/DL-1 1,0

47 1824053026 SEAL MOD.R5 60X80X8 – FREUDENBERG VITON 1,0

48 3694052004 HYDRAULIC MOTOR PINION WASHER 1,0

49 3694000046 SIGHT GLASS KIT 1,0



CHAPTER 7. APPENDIX



9693002127 – STANDARD STUFFING BOX 3.1/8” - 2000 PSI FLANGE

969300212.7 DV-1 STUFFING BOX 1.1/4" FLANGE 2000 PSI


1 3693007002 DRIVEHEAD BODY FRAME 1,0

2 3669013004 DRIVEHEAD FRAME CAP 1 1/4" 1,03 3669014003 UPPER BUSHING 1 ¼” 1,04 3693086006 LOWER BUSHING 1 ¼” 1,05 3669016001 ROD SPRING 1 ¼” 1,06 3693008001 STUFFING BOX 1¼ ” FLANG 1,0

7 3693047004 FLAGE STAND 2000PSI 1,08 1809009068 SCREW HEX.M16X70 DIN 93 2,09 1818001030 FLAT WASHER M16 DIN 125 2,0

11 1821003390 COUPLING 1/2"NPT X 3/4" 1,012 1823004028 GREASE ZERK 1/4"NPT 1,0

13 1819017030 CLAMP 1,014 3669049002 GASKET BMW:53-1660 P/ 1 1/4" 1,015 1821002006 HOSE. REF.GATES 12LOLA 3 1,016 1812001140 SCREW HEX.INT. 5/1 3,018 1809018058 SCREW HEX. M12X35 DI 6,0

19 1818003047 PRESSURE WASHER. M12 DIN 127 - 6,023 1817006046 NUT HEX. M16 DIN 934 2,0

20 1821016000 DRAIN PLUG R.3/8NPT CONIC 3/4" 1,0

21 1329000354 PIPE PLUG RTB SENSOR 1,022 3694000040 ADAPTER TO RTB SENSOR 1,0



CHAPTER 7. APPENDIX



9693001128 – STANDARD STUFFING BOX 2 7/8” EUE PIN

969300112.8 DV-1 STUFFING BOX 1.1/4" R. 2.7/8" EUE PIN


1 3693007002 DRIVEHEAD BODY FRAME 1,0

2 3669013004 DRIVEHEAD FRAME CAP 1 1/4" 1,0

3 3669014003 UPPER BUSHING 1 ¼” 1,04 3693086006 LOWER BUSHING 1 ¼” 1,05 3669016001 ROD SPRING 1 ¼” 1,06 3693009000 STUFFING BOX R. 2.78” EUE PIN 1,0

7 3693063003 FLAGE STAND 2000PSI 1,011 1821003390 COUPLING 1/2"NPT X 3/4" 1,012 1823004028 GREASE ZERK 1/4"NPT 1,013 1819017030 CLAMP 1,014 3669049002 GASKET BMW:53-1660 P/ 1 1/4" 1,0

15 1821002006 HOSE. REF.GATES 12LOLA 3 1,016 1812001140 SCREW HEX.INT. 5/1 3,018 1809018058 SCREW HEX. M12X35 DI 6,019 1818003047 PRESSURE WASHER. M12 DIN 127 - 6,024 1821016000 DRAIN PLUG R.3/8NPT CONIC 3/4" 1,025 1329000354 PIPE PLUG RTB SENSOR 1,026 3694000040 ADAPTER TO RTB SENSOR 1,0



CHAPTER 7. APPENDIX



APPPENDIX I. BELTS SPECIFICATIONS

COGGED SIZES

NONCOGGED SIZES



CHAPTER 7. APPENDIX



APPPENDIX J. PAINTING SPECIFICATIONS

PAINT APPLICATION SYSTEM IT-PINT-001

Color / CodeProcess

SurfacePreparation

ApplicationQuantity

Minimum Paint

Thickness (µµµµm)Application

Grey Revran N5(A 7270340)

50 Drivehead Peripheral Components

Red Epoxy Primer

Base / Primer

SIS-055900

B Sa 21/2

1

25 Drivehead Steel

Blue Safire Epoxy Metal Paint Fin-ished

Grey RevranN5 / Red Epoxy

Primer1 35 Drivehead Metal Paint Finished

Process

Black Epoxy PD MUNS-SEL N 1,0

Metal Paint Fin-ished

Red EpoxyPrimer 1 50 Drivehead Metal Paint Finished

Process / Clamps

Orange Epoxy PD

MUNSSEL 2,5YR 6/14

Metal Paint Fin-

ished

Red Epoxy

Primer1 50

Drivehead Metal Paint FinishedProcess / Clamps

Belts Cover

Dust Epoxy Paint Elec-trostatic (Red / Blue)

Metal Paint Fin-ished

ChemicalProcess 1 75

Belt Cover / Drivehead MetalPaint Finished Process

APPENDIX K. ATEX CERTIFIED MOTORS LIST

PART NUMBER POWER DESCRIPTION

182700007.2 5.5 CV 6 poles 380Volts 50Hz IPW-55 Motor Frame 132M Exp. Proof.

182732001.7 7.5 CV 6 poles 380Volts 50Hz IPW-55 Motor Frame 132M Exp. Proof.

182721601.4 10CV 6 poles 380Volts 50Hz IPW-55 Motor Frame 160M Exp. Proof.



CHAPTER 8. MODIFICATION HISTORY

D V - 1 A n

g l e D r i v e h e a d

D V - 1 A n

g l e D r i v e h e a d

MODIFICATION HISTORY

DateSections/Pages Comment

Reported FixedBy

All Initial Release for ATEX Certification April 2007

DV-1 Operating Manual - Rev00

Documents

Transcript of DV-1 Operating Manual - Rev00