BJ GORILLA 3000-T - Industrial Diesel Mfg · BJ GORILLA 3000-T 3000 HORSE POWER FRACTURING PUMP...

Industrial Diesel Incorporated

8705 Harmon Road

Fort Worth, Texas 76177

(800) 323-3659

www.industrialdiesel.net

TECHNICAL SPECIFICATION

BBJJ GGOORRIILLLLAA 33000000--TT

33000000 HHOORRSSEE PPOOWWEERR FFRRAACCTTUURRIINNGG PPUUMMPP TTEESSTT UUNNIITT

((GGOOOODD UUSSEEDD))

INTRODUCTION:

This specification covers the minimum requirements of the Trailer Mounted Fracturing Pump Test Unit; this unit is trailer mounted and suitable for use in oil field & industrial type

environments. This pumping unit is designed for many types of pumping services with different liquids including the following: hydraulic water blasting, acid solutions and other high pressure pumping with various fluid additives.

This unit is locally & remotely operated and controlled with the TTRRIICCOONN--IIIIII digital pump control system. The unit is capable of operating in temperature ranges of 0° to 120°F. DESCRIPTION: Major components to include: • Trailer, Radiator • Engine, Transmission • Triplex Pump • Low Pressure Plumbing System • High Pressure Plumbing System (Customer Supplied) • Control Panel / Enclosure For Unit Operation This unit is equipped with one (1) Detroit/MTU diesel engine rated 3000 BHP (+/-5% based on ambient conditions). The engine shall drive a triplex pump via a Twin Disc Inc. powershift transmission system. OVERALL PERFORMANCE:


8705 Harmon Road


(800) 323-3659


While delivering full horsepower in any speed range of the deck engine in any gear, and without exceeding the pump ratings, there shall be no components that will vibrate with excessive amplitudes in resonance with the forcing vibrations of the engine or pump. Also, there shall be no excessive rotational vibrations of the engine, transmission, or pump due to transmitted torque and the flexibility of the trailer and mounting systems. The unit shall be capable of operating during prolonged pumping operations. Details of this unit are as follows: EQUIPMENT SPECIFICATIONS: This unit shall be trailer mounted on a triple axle drop deck beam style oilfield type trailer. The approximate physical dimensions of this unit are as follows: (approximate) Overall Length - 44 ft. - 6’’ Width - 8 ft. - 6’’ Height - 13 ft. - 5’’ Weight – 84,250 Lbs. (Estimated trailer only- no treating iron) CHASSIS OILFIELD / HEAVY DUTY TRAILER

The trailer is designed specifically for the application with the following features:

Manufacturer ASPEN

Suspension 3, Axle air ride

Landing Gear Two speed w/ skirt braces

Fuel Storage 600 gallon capacity: (4) 150 gallon DOT approved fuel tanks

POWER SYSTEM DIESEL ENGINE Mounted on the trailer chassis will be a Detroit / MTU Model 16V4000 four-stroke oil well servicing diesel engine equipped with the following: • Engine rated a minimum of 3000 BHP at 1900 RPM (continuous duty rated) • Air-filter, dual stage, dry element, canister type with pre-cleaner and manual service indicators • Flywheel and flywheel housing (SAE O/18” Industrial) wet type, for use with Twin Disc Inc.

transmission • Lifting eyes • Manifold exhaust w/ stainless steel flex joint connection • Oil level dipstick • Oil pan, standard capacity • Pumps for fuel, lubricating oil, fuel transfer • Pumps, jacket water • Support, front trunnion • Thermostats and housing • Dual turbo charger • Vibration dampener • Exhaust system with industrial grade horizontal “Low Profile Type” silencer with rain cap and

adequate support brackets affixed to the engine block • Shutoff group electrical (standard- ECM controlled) • ECM diagnostics connection • Alternator (minimum 24 VDC, 90 amp) with dedicated battery bank • Tractor powered hydraulic Starter & Fan Drive system


8705 Harmon Road


(800) 323-3659


• Rear engine mounting for Twin Disc Inc torque converter complete with flywheel housing and drain common to torque converter housing drain.

The engine throttle signal shall be connected electrically via the TTRRIICCOONN--IIIIII pump control system to the triplex pump over-pressure transducer and will, in over-pressure situations, cause the transmission system to default to computer neutral and set the engine throttle to idle. COOLING SYSTEM: A vertical “V” core remote mounted radiator system with horizontal air discharge is installed on the unit to include a single hydraulic pump powered dual low-speed motor driven, high torque motor driven fan assemblies, completed with a top mount surge tank, a water drain valve, a core guard, coolant level sensor and access panel for servicing. This radiator is designed to perform at ambient temperatures of 0° - 120° F. Separate cooling cores shall be provided as an integral part of the radiator design to include:

• Engine jacket water

• After-cooler • Fuel cooler • Transmission oil cooler

• Power end lube oil cooler rated for 90 Wt. or 85W140 gear lube for ambient temperatures of 30° -

120° F. TRANSMISSION SYSTEM: The engine shall coupled to a Twin Disc Model TA90-8501 power-shift transmission system and shall be connected to the triplex pump through All Power Transmission GWB 190.60 / 390.71 driveline assemblies. Transmission accessories shall include: TORQUE CONVERTER: • 8FLW2302-0 Torque converter • Net Input HP: 3000 HP • Max. Input Speed: 2100 RPM • SAE #0, wet flywheel mounting • Lockup clutch • Common engine flywheel & torque converter housing scavenge drains • Three (3) PTO drives operating at engine speed for mounting primary system and auxiliary pumps:

• Torque converter/Transmission tandem oil charge pumps • Torque converter scavenge pump • Triplex pump “Power End” lubrication pump • Radiator fan hydraulic motor drive system (Optional Retrofit Upgrade – Cost adder applies)

TRANSMISSION: • Full horse power, full-load powershift capability • TD-EC400 Digital CAN-bus Transmission shift Control System • Transmission cooler with all required hoses, thermostats etc. • Gear ratios are as follows:

1st 4.47: 1 2nd 3.57: 1 3rd 2.85: 1 4th 2.41: 1 5th 1.92: 1 6th 1.54: 1 7th 1.25: 1


8705 Harmon Road


(800) 323-3659


8th 1.00: 1 9th 0.80: 1 (Blocked) Brake (trans. output stall only) Warm-up (converter stall)

The electronic transmission shifting system shall be connected electrically to the triplex pump over-pressure indicator and will, in over-pressure situations, shift the transmission to neutral and reset the engine throttle to idle. ENGINE / TRANSMISSION MOUNTING: The engine is vibration isolated from the trailer by means of rubber vibration isolators and a front engine trunnion mount. This makes the engine / torque converter mount combination work as a one unit. This is accomplished with a three (3)-point flexible mounting system with a single mount at the front and two flexible mounts at the rear. This type of mounting system eliminates any alignment problems on equipment where normal flexing of the frame may occur. The torque converter can be can be separated from the engine / torque converter mount without disturbing the engine support. This allows removal of torque converter leaving engine mounting system intact and greatly simplifying service and maintenance. This mounting system will allow easy access to the torque converter and transmission strainers for maintenance purposes.


8705 Harmon Road


(800) 323-3659


DRIVE LINE: The drivelines utilized for connecting the torque converter to the transmission shall be an GWB 190.60 and the driveline utilized for connecting the transmission to the Triplex pump shall be an GWB 390.71. Installation of these drivelines shall not exceed the manufacturer’s recommends maximum angle under normal operation condition. The driveline shall include a removable metal guard. HYDRAULIC SYSTEMS: Three (3) auxiliary hydraulic systems shall be installed for powering the components incorporated on the unit other than typical transmission systems.

1. Fan Drive system: Incorporate in this system a closed loop hydraulic pump directly driven by the customer supplied tractor wet kit (Optional: upgrade-retrofit can be mounted and powered from the torque converter power take-off. Nominal parasitic loss [load] = 120 HP) This hydraulic pump will be in constant operation while the engine is running at any speed and will be forced air cooled by the radiator coolant system.

2. Deck engine hydraulic starting system: Incorporate a hydraulic pump directly driven from the truck chassis transmission hydraulic drive PTO (wet kit). This system shall be rated at 50-60 GPM @ 3500 PSI (approx.)

3. Power end lube system: Included will be a gear type pump rated for use with 90 wt. or 85/140 wt. gear oil) to the triplex power-end.

These hydraulic systems shall incorporate all equipment such as hydraulic oil tank (as required), suction filters, return line filters w/ bypass protection, relief valves w/ monitoring liquid filled gauges, pressure operated directional control valves to insure a complete and functional system. All plumbing utilized in the hydraulic system shall not exceed the radiator and component manufacturer’s recommended pressure and temperature ratings during normal operation. (Refer to well service pump manufacturers recommended hydraulic circuit diagrams) HIGH PRESSURE PUMP: A Gardner Denver Model GD3000, 3000 BHP rated triplex pump is utilized. The pump is typically equipped with 5.0” diameter plungers (Fluid end NOT INCLUDED). The triplex pump includes the following features: • 7.8:1 gear reduction • 11” stroke • Rod load: 350,000 lbs. • Straight Keyed input shaft Fluid End: (Customer Supplied) • High strength VOV forged alloy steel fluid end • High performance RSL self-adjusting packing formulated for –50 to +300 degrees F. • Wing guided type valves and seats w/ urethane inserts • One piece hardened Colmony plungers • Cylinder size: 5.0” (or customer specified) • Center 2” Fig. 1502 gauge connection (1) • Dual 3” Fig. 1502 discharge flanges • Steel 6” “Log Type” suction manifold • Approximate combined weight: 18,550 lbs.


8705 Harmon Road


(800) 323-3659



8705 Harmon Road


(800) 323-3659


SUCTION / DISCHARGE MANIFOLD: (Customer Supplied) The 6” “Log style” style suction manifold included with the pump shall extend to the edge of the unit and shall be inclined to the rear of the unit. This shall terminate via a 6” tee with two (2) 4’’ Fig. 200 female unions connections with two (2) 4’’ manual butterfly valves. HIGH PRESSURE DISCHARGE MANIFOLD: (Customer Supplied) The discharge Manifold included with the pump shall include dual 3’’ Fig. 1502 discharge end connections. A 2’’ Fig. 1502 center gauge pump sub-connection with Fig. 1502 connection shall be installed on the triplex pump center gauge opening and shall be utilized for the unit pressure transducer. FLUID END PLUNGER LUBRICATION: A 24 VDC electrically driven Beka-Max EP-1 grease type plunger lube system is installed to provide fluid-end plunger lubrication to the plunger packing area. The self-contained system shall include the reservoir, over pressure relief, indicating lights and accessories necessary to provide metered lubrication to each of the plungers on an adjustable, timed interval. Lubrication will only be distributed to the fluid end when the transmission system is in an operating gear. A removable drip pan will be installed below the plungers and fluid end to recover waste lubricating fluids. The grease system will have adequate capacity for continuous operation up to 8 hour prior to needing a new charge of grease. Recharging is performed via externally accessible refill coupling for ease of service. POWER END LUBRICATION: A hydraulic pump driven off the torque converter auxiliary PTO connection shall lubricate the power end of the triplex pump. The power end lubrication system shall include all components such as relief valve, thermostatic valve, inline Parker IL8 series pressure filter with manual indicator, instrumentation, plumbing and lube oil cooler and reservoir per Gardner Denver lube oil circuit recommendations.

TRIPLEX


8705 Harmon Road


(800) 323-3659


CONTROL & INSTRUMENTATION SYSTEM REMOTE CONTROL AND UNIT MOUNTED SYSTEM INTERCONNECT ENCLOSURE:

The TTRRIICCOONN--IIIIII Digital Pump Control System includes a locally mounted stainless steel NEMA 4x interconnect enclosure isolated from the chassis by cable type shock mounts and have a hinged locking door and MIL spec wash / shade hood. The engine gauge/monitoring system mounted for exterior viewing is a 6”x 9” CAN-Bus interface, SAE J1939 color display for viewing all available engine operating data in real-time. The local operator’s control panel utilizes a 6” x 9” color display module to provide intuitive viewing of all major component operating run data as well as additional sensor feedback information. System data include:

• Radiator fan drive pump system main pressure

• Radiator fan drive pump charge pump pressure

• Radiator fan drive pump oil temperature

• Engine RPM

• Engine hours

• Engine coolant temperature

• Engine oil pressure

• Transmission range w/ torque converter lockup status

• Transmission oil temperature

• Transmission oil main pressure

• Pump lube oil temperature

• Pump lube oil pressure

• Pump rate (BBL/Min)

• Pump rate totalizer (BBLs)

• Pump discharge pressure

• Over pressure trip setting


8705 Harmon Road


(800) 323-3659


• System Error message text (SPN/FMI) Additional screens are available for component specific run data and sensor calibration

• Main Operator’s screen (as listed above)

• Transmission screen

• Pump screen

• Alternate screen Other operator controls include-

• Engine “OFF / RUN / START” switch

• Engine throttle control (rotary duel speed sense control)

• Engine “EMERGENCY KILL” switch

• Transmission range “UP / DOWN” selector switch

• Engine/Transmission “NEUTRAL IDLE” switch

• System “FAULT” indicating lamp (RED)

• Control system “OFF / ON” switch

• Work lights “OFF / ON” switch

• Pump plunger lube system “MANUAL / AUTO” switch Internally mounted hardware: Engine / transmission monitoring system- (internally mounted for service support)

• One (1) PowerView display module featuring the following display screens (* as available by ECM programming): (Back lighted monochrome display) • Engine tachometer • Engine coolant temperature • Engine oil pressure • Transmission oil pressure • Transmission oil temperature • Engine hour meter (digital)

* Note: Additional data may be available for viewing based on ECM configuration

• One (1) Twin Disc Transmission Display & Diagnostics module: (Back lighted monochrome display) Displayed data include *

• Transmission range • Diagnostic menus • Error indication

* Note: Additional data may be available for viewing based on ECM configuration

• CAN-bus control module • Terminal bocks, relays and fuse blocks • Clearly labeled terminal blocks and wiring terminations

Additional features included on local interconnect enclosure

• Battery disconnect switch


8705 Harmon Road


(800) 323-3659


REMOTE SUITCASE

The remote TTRRIICCOONN--IIIIII digital operator pump control system is installed in a weather-tight rugged suitcase enclosure for remote control of the unit up to 200’ away. The remote operator’s control suitcase utilizes a 6” x 9” color display module to provide intuitive viewing of all major component operating run data as well as additional sensor feedback information. System data include:

• Radiator fan drive pump system main pressure

• Radiator fan drive pump charge pump pressure

• Radiator fan drive pump oil temperature

• Engine RPM

• Engine hours

• Engine coolant temperature

• Engine oil pressure

• Transmission range w/ torque converter lockup status

• Transmission oil temperature

• Transmission oil main pressure

• Pump lube oil temperature

• Pump lube oil pressure

• Pump rate (BBL/Min)

• Pump rate totalizer (BBLs)

• Pump discharge pressure

• Over pressure trip setting

• System Error message text (SPN/FMI) Additional screens are available for component specific run data and sensor calibration

• Main Operator’s screen (as listed above)

• Transmission screen

• Pump screen

• Alternate screen Other operator controls include-

• Engine “OFF / RUN / START” switch

• Engine throttle control (rotary duel speed sense control)

• Engine “EMERGENCY KILL” switch

• Transmission range “UP / DOWN” selector switch

• Engine/Transmission “NEUTRAL IDLE” switch

• System “FAULT” indicating (flashing Red field) All wiring penetrations are routed into the enclosure via environmentally sealed grommets with strain relief protection and permanently numbered to match electrical wiring schematics. Included is One (1) 200’ remote control data cable w/ MIL-spec twist-lock cable connector. All instruments, switches, controls, etc. are clearly labeled in English. ADDITIONAL ITEMS: The well service pump shall include (1) 2” 1502 gauge connection to utilize the supplied O - 15,000 PSI, FIG. 1502 Viatran pressure transducer. This pressure transducer is connected to the

TTRRIICCOONN--IIIIII display system on the local and remote control for over pressure monitoring.


8705 Harmon Road


(800) 323-3659


Available Options: (Price adder applies)

• This control system is available with a quick connect data connection (customer specified) for feeding running data to the data recorder for real time monitoring.

• Unit mounted remote cable reel

• TTRRIICCOONN--IIIIII ““CCOOMMMMAANNDDEERR”” 12 Unit central pump control with touch screen interface

BJ GORILLA 3000-T - Industrial Diesel Mfg · BJ GORILLA 3000-T 3000 HORSE POWER FRACTURING PUMP...

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