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equipment  damage due to explosion, 
fire, extreme cold or chemical attack. 

 
Never  operate  a  pump  that  is  pumping 
hydrocarbons or other flammable, hot, cold, 
or  corrosive  fluids  when  any  part  of  the 
pump,  suction  system  or  discharge  system 
is  leaking.    Stop  the  pump  immediately  if 
any  leakage,  other  than  a  few  drops  per 
minute  of  packing  weepage,  is  observed.  
Keep  all  flame,  sparks,  or  hot  objects  away 
from  any  part  of  the  pump,  suction  system, 
or  discharge  system.    Shield  the  pump, 
suction  system  and  discharge  system  to 
prevent  any  flammable,  hot,  cold  or 
corrosive  fluid  leakage  from  dripping  or 
spraying on any components, flame, sparks, 
hot objects or people.  Inspect the plungers, 
packing, gaskets and seals for fluid leakage 
frequently  and  replace  all  worn  or  leaking 
parts. 
 
Selection  of  the  proper  gaskets,  seals  and 
stuffing  box  packing  is  even  more  critical 
when  flammable,  hot,  cold  or  corrosive 
fluids  are  being  pumped  than  when  other, 
inherently  less  dangerous  fluids  are  used.  
Contact 

Gardner 

Denver 

service 

representative  for  assistance  in  selecting 
the  proper  gaskets,  seals  and  packing 
before beginning operation. 
 
Since  some  packing  weepage  into  the 
cradle  area  is  inevitable,  a  drain  pan 
positioned  below  the  bottom  of  the  cradle 
area  must  be  connected  to  a  drain line that 
conducts  the  fluid  leakage  to  a  collection 
container  located  in  a  protected  area.    The 
entire  drain  system  and  container  must  be 
constructed  of  materials  resistant  to  attack 
from  the  pumped  fluid  or  from  explosion  or 
fire of the pumped fluid. 
 
Before  beginning  pumping  operations  or 
starting the pump power source (whether an 
engine  or  electric  motor)  check  the 
atmosphere  all  around  the  pumping  site  for 
the  presence  of  flammable  or  explosive 
vapors.    Do  not  begin  operation  and  stop 
ongoing operation if flammable or explosive 
vapors  are  detected.    Hot  surfaces,  sparks, 
electric  current  or  engine  exhaust  could 
ignite flammable or explosive vapors.  Each 
engine used as a power source on pumping 

units  where  flammable  or  explosive  vapors 
could  form  should  be  equipped  with  an  air 
inlet  shut-off.    If  flammable  or  explosive 
vapors  are  present  in  the  pumping  site 
atmosphere,  an  engine  could  continue  to 
run  on  these  vapors  even  after  the  engine 
fuel  line  is  shut-off  if  an  air  inlet  shut-off  is 
not used. 
 
In  addition,  on  pumping  units  used  where 
flammable  or  explosive  vapors  could  form, 
all  electric  motors  used  as  power  sources 
must be of explosion proof construction and 
all  electrical  components  and  wiring  must 
meet  the  current  National  Electrical  Code 
for explosive atmospheres. 
 
These  precautions  must  be  taken  to  avoid 
possible  personal  injury,  death  and/or 
equipment  damage  from  explosion,  fire  or 
burns. 
 
 
HIGH PRESSURE LIQUID JETTING, 
BLASTING AND CLEANING
  
 
 

 

DANGER 

 

Extreme caution must be exercised if 
any type of wand, gun, nozzle or any 
other  pressure  and  flow-directing 
device  is  attached  to  the  pump 
discharge  system  for  use  in  jetting, 
blasting,  cleaning,  etc.    This  type  of 
equipment  must  be  used  by  trained, 
experienced 

operators 

with 

the 

utmost  care.    High  pressure  fluid 
streams  can  either  by  direct  contact 
or by propelling loose objects, cause 
serious  personal  injury  or  death  to 
operators and/or other persons. 

 
 
Pressure  or  flow  directing  devices  often 
receive  pressurized  flow  through  flexible 
hoses,  which  can  burst  if  they  are  kinked, 
cut,  abraded  or  are  otherwise  worn, 
damaged  or  pressured  above  their  rated 
capacity.  Protect the hose and connections 
from  damage  by  people,  objects  and 

Summary of Contents for C2500Q QUINTUPLEX

Page 1: ...ECN 1058968 GARDNER DENVER 300CMC996 Revision C April 2011 WELL SERVICING PUMP MODEL C2500Q QUINTUPLEX OPERATING AND SERVICE MANUAL...

Page 2: ...lled in pump maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services For the location of your local authorized Gardner Denver distribut...

Page 3: ...tion and minimal downtime DANGER Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored WARNING Warn...

Page 4: ...ons For Ordering Repair Parts i Foreword ii Index iv List of Illustrations v Section 1 Danger Notices 1 Section 2 Design and Description 9 Section 3 Preparation Operation and Maintenance 14 Section 4...

Page 5: ...er Packing 16 Monthly Routine Maintenance Schedule 18 Oil Stop Head Seal Retainer and Gear Covers 23 Ordering Instructions Repair Parts i Periodic Routine Maintenance Schedule 17 Plunger Packing Lubri...

Page 6: ...ure 2 1 C 2500Q Quintuplex Pump 9 Figure 2 2 C 2500Q Gear Reduction Unit 11 Figure 2 3 C 2500Q Fluid End 13 Figure 3 1 Lubricant Recommendations 16 Figure 4 1 Fluid End Removal and Assembly 21 Figure...

Page 7: ...en operating high pressure pumping equipment Operators should not begin or continue operations when tired distracted or under the influence of alcohol or any type of prescription or nonprescription dr...

Page 8: ...damaged or badly worn Wear safety shoes and goggles Check to insure they have safe footing Fully engage the wedge to prevent it from disengaging violently from the cover as a blow is struck Wipe their...

Page 9: ...to the lifting attachments normally built into the package unit support skid Packages too large to lift as fully assembled should be separated into smaller loads For these smaller loads the lifting d...

Page 10: ...ef pressure Any pipe line used to direct pressurized relief flow to another location such as a collecting tank is not blocked The discharge system is not blocked and all the discharge line valves are...

Page 11: ...engine start switches or starter controls are clearly tagged with warnings not to start the pump while repair work is in process Whenever the pump is operating continually monitor the entire suction d...

Page 12: ...he atmosphere all around the pumping site for the presence of flammable or explosive vapors Do not begin operation and stop ongoing operation if flammable or explosive vapors are detected Hot surfaces...

Page 13: ...s with rough grip surface and ear noise protection Full operator attention and alertness are required when operating this equipment to avoid personal injury death and or equipment damage The operators...

Page 14: ...se wands nozzles guns connections and hose etc be considered for purchase that you judge to offer the highest quality of design construction and safety since these components are among the most critic...

Page 15: ...and also all other applicable safety rules and regulations must be carefully observed The sections on Pump Design Description and Specifications describe the pump design list the pump specifications a...

Page 16: ...icity The connecting rods bolt to the conn rod bearing housings The conn rod bearing housings are accessible through the rear of the pump and the connecting rod crosshead assemblies through the nose o...

Page 17: ...rosshead slides This is repeated for the rest of the main bearing and crosshead components Oil is removed from the power end through a 4 drain connection in the bottom of the frame Oil passages in the...

Page 18: ...the packing nut or gland Plunger packing lube holes are provided in the fluid cylinder The EWS Fluid End is a forged alloy steel block is designed for severe applications The EWS utilizes heat treated...

Page 19: ...31 6100 4 2 17 217 17900 326 11800 544 7100 718 5350 4 5 2 75 275 14150 413 9350 688 5600 908 4250 5 3 40 340 11450 510 7550 850 4550 1121 3450 5 5 4 11 411 9500 617 6250 1028 3750 1357 2850 5 75 4 49...

Page 20: ...rust preventative will not clog the oil passages 5 Remove the breather and either plug or tape the opening 6 Coat the gear reducer input shaft and all bear metal with a heavy rust preventive 7 Plug d...

Page 21: ...ed pump size to minimize losses in the suction piping Lube Pump Suction Piping Sizing and Requirements In the past failure to meet these requirements has lead to pump damage because of restricted oil...

Page 22: ...will be required to charge the fluid end suction manifold The charge pump should be sized according to the volume to be pumped by the quintuplex pump so that there is no less than 50 psi charge when t...

Page 23: ...observe the suction vacuum gage reading oil pressure and temperature and check for leaks 12 Run the pump at 80 90 strokes per min at the following loads 40 of full rated load 30 min 60 of full rated l...

Page 24: ...triplex pump fluid end worn valves and seats should be changed as soon as possible to prevent washing them out with the pumped fluid 5 Check the plunger packing lubrication pump for proper operation I...

Page 25: ...etroleum EP 500 Summer or EP 300 Winter 10 F Shell Oil Co Torcula Oil 32 50 F Torcula Oil 100 20 F Torcula Oil 150 15 F Torcula Oil 320 10 F Sun Oil Co Rockdrill 500 Light 5 F Rockdrill 1000 Heavy 5 F...

Page 26: ...p FLUID END SERVICE This discussion starts with the description of steps necessary for removal and installation of the fluid cylinder assembly and proceeds to the removal and replacement of expendable...

Page 27: ...stay rods 6 Reinstall the plunger clamps piping connections and auxiliary equipment FIGURE 4 1 C 2500 Fluid End Plunger and Packing Replacement This service procedure can be performed with the fluid c...

Page 28: ...or cut a valve seat with a torch Severe damage to the fluid end may occur Before starting make sure that special tools required for this procedure are available For part numbers of the tools see the P...

Page 29: ...d pops POWER END SERVICE DANGER Before attempting to service the power end of the pump the following safety precautions must be observed 1 Shift the pump transmission into the neutral gear 2 Shut off...

Page 30: ...ment pins PILOT the halves together Do not damage pins 3 CAUTION Both halves are heavy 4 Remove half bearing with prying action 5 Rod half of bearing may be tapped on one edge with a rubber hammer or...

Page 31: ...d Removal and Installation page 20 3 Remove the oil stop head seal retainer and gear covers as described in Oil Stop Head Seal Retainer and Gear Covers page 23 4 Remove the crosshead assemblies as des...

Page 32: ...Page 26...

Page 33: ...ap rings and braze together in 3 or 4 places for strength WARNING Do not drive against rollers or bearing cage Drive only against the bearing race as severe damage to the bearings could occur WARNING...

Page 34: ...ogged suction line 3 Clean out line 4 Suction and or discharge 4 Remove the obstruction valves propped open Low Discharge Pressure 1 Worn or fluid cut valve 1 Replace valve assembly 2 Valve propped op...

Page 35: ...tling time in supply tank Reduce pump speed 10 Air entering suction line 10 Repair suction line 11 Air entering charging pump 11 Tighten or replace shaft packing or seal 12 Air entering or charge gas...

Page 36: ...transmitted to 11 See Excessive Valve power end Noise problem 12 Cavitation noise transmitted 12 See Cavitation Fluid to or causing shock loading in Knock or Hammer problem power end Excessive Valve N...

Page 37: ...sealing surface 4 Corrosion due to wrong 4 Determine and install correct stuffing box material stuffing box for pumped fluid 5 Stuffing box bore worn 5 Replace stuffing box Pumped Fluid In 1 Worn dam...

Page 38: ...Customer Service 5 Wrong size packing 5 Install correct size packing 6 Improper packing installation 6 Check installation procedure and install correctly 7 Excessive crosshead wear 7 Replace crosshead...

Page 39: ...mmer problem Stud Failures 1 Catastrophic failures 1 See Catastrophic Failures problem 2 Improper nut torquing 2 Check torque specifications and torque to correct values 3 Stud bending due to uneven 3...

Page 40: ...e Assembled in Bearing Housing 7 266 7 268 Crosshead Guide Bore 9 874 9 872 Crosshead OD 9 858 9 856 Wristpin Dia 2 500 2 499 Wristpin Bushing Bore 2 508 2 509 RECOMMENDED RUNNING CLEARANCES ACTUAL Ne...

Page 41: ...Page 34...

Page 42: ...Plunger Clamp Bolts 1 2 13 58 5 8 11 110 Pinion Bearing Housing 3 4 10 160 Intermediate Rod to Crosshead 3 4 10 160 Conn Rod to Bearing Housing Lock Nuts 3 4 10 180 Fluid End Suction Manifold 7 8 9 26...

Page 43: ...anty Period for all products is 1 250 hours of operation or three 3 months after start up not to exceed 120 days after delivery to Purchaser whichever occurs first The exceptions are as follows 1 Powe...

Page 44: ...regoing warranty is the sole and exclusive warranty of the Company The Company hereby extends other manufactures warranty or guaranties if any given to Company by such manufacturer but only to the ext...

Page 45: ...o this warranty shall not be construed as an admission by the Company that any product was not as warranted WARRANTY REQUESTS Products to be returned for warranty analysis shall be approved for return...

Page 46: ...representative or Gardner Denver Inc 4747 South 83rd East Avenue Tulsa OK 74145 PH 918 664 1151 800 637 8099 FAX 918 664 6225 www gardnerdenver com Specifications subject to change without notice Cop...

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