Gardner Denver GD-2500Q QUINTUPLEX Operating And Service Manual Download

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ECN 1026734

GARDNER DENVER

300FWF996 Rev C

August, 2005

WELL SERVICING PUMP

MODEL

GD-2500Q QUINTUPLEX

OPERATING AND

SERVICE MANUAL

HALLIBURTON EXHIBIT 1013, Page 1

Summary of Contents for GD-2500Q QUINTUPLEX

Page 1: ...ECN 1026734 GARDNER DENVER 300FWF996 Rev C August 2005 WELL SERVICING PUMP MODEL GD 2500Q QUINTUPLEX OPERATING AND SERVICE MANUAL HALLIBURTON EXHIBIT 1013 Page 1...

Page 2: ...d 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 distributor...

Page 3: ...nimal 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 Warning is used...

Page 4: ...pair Parts i Foreword ii Index iv List of Illustrations v Section 1 Danger Notices 1 Section 2 Design Description and Specifications 9 Section 3 Preparation Operation and Maintenance 15 Section 4 Serv...

Page 5: ...ntenance Schedule 19 Oil Stop Head Seal Retainer and Gear Covers 24 Ordering Instructions Repair Parts I Performance Rating 14 Periodic Routine Maintenance Schedule 18 Plunger Packing Lubrication 17 P...

Page 6: ...2500Q Power End Rear Section View 11 Figure 2 4 GD 2500Q Gear Reduction Components 12 Figure 2 5 GD 2500Q Fluid End 13 Figure 3 1 Lubricant Recommendations 17 Figure 4 1 GD 2500Q Fluid End Tightening...

Page 7: ...Operators should not begin or continue operations when tired distracted or under the influence of alcohol or any type of prescription or nonprescription drugs The timely replacement of expendable par...

Page 8: ...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 hands and the hammer handle and maintain a...

Page 9: ...port skid Packages too large to lift as fully assembled should be separated into smaller loads For these smaller loads the lifting devices should be fastened to the lifting attachments normally built...

Page 10: ...ischarge line valves are open Check all fluid end discharge system components including pipes elbows connections threads fasteners hoses etc at least once every six months to confirm their structural...

Page 11: ...systems for leaks Thoroughly investigate the cause for leakage and do not operate the pump until the cause of the leak has been corrected Replace any parts which are found to be damaged or defective W...

Page 12: ...umping 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 co...

Page 13: ...jury death and or damage to equipment Make sure the work area is checked for hazardous fumes has adequate ventilation for engine exhaust and sufficient drainage for released fluid Check the work area...

Page 14: ...to the safe operation of high pressure liquid jetting blasting and cleaning equipment After you have selected and purchased these components follow the manufacturer s instructions completely in their...

Page 15: ...loped by American Gear Manufacturers Association The issue of personnel safety is the most important topic covered in this manual Therefore in the beginning of this manual the user is introduced to da...

Page 16: ...and assembly including dimensional and tolerance data running clearances for all bearings and recommended fastener torques PUMP DESIGN The GD 2500Q quintuplex pump uses only two major assemblies power...

Page 17: ...eads are on the same centerline The fluid end is held in place and in alignment with the power end by the twenty 20 stay rods See FIGURE 2 1 The power end is fully enclosed to contain the power end oi...

Page 18: ...aring It also connects to the crosshead oil supply giving a redundant oiling pathway This is repeated for the rest of the main bearing and crosshead components Oil is removed from the power end throug...

Page 19: ...provided in the fluid cylinder The conventional fluid end Valve Over Valve configuration offers field a proven arrange ment in terms of the valve and spring performance Improvements in the fluid end...

Page 20: ...1 91 191 17800 287 13500 478 8100 631 6100 4 2 17 217 15600 326 11800 544 7100 718 5400 4 5 2 75 275 12400 413 9300 688 5600 908 4200 5 3 40 340 10000 510 7600 850 4500 1121 3400 5 5 4 11 411 8300 61...

Page 21: ...eventative 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 exposed bare metal with a heavy rust preventive 7 Plug d...

Page 22: ...failure to meet these requirements has lead to pump damage because of restricted oil flow in the lube pump inlet Therefore the following guidelines developed as a result of long experience should be a...

Page 23: ...several hours of the pump run in are performed at the factory during the acceptance tests as a part of quality assurance procedure However the new pump break in period process may continue for the fir...

Page 24: ...ading and entire system for proper operation 14 If the quintuplex pump is equipped with a transmission run the pump for 30 min in each gear in the higher gear ranges pulling full horsepower in each ge...

Page 25: ...after extended continuous operation Monthly 100 hour Routine Maintenance Tasks 1 Clean the strainer and replace the oil filter element 2 Check the entire lube system for leaks and eliminate them 3 Che...

Page 26: ...rill 32 35 F Exxon Arox EP 46 20 F Arox 150 35 F Mobil Oil Co Almo 525 20 F Almo 527 20 F Almo 529 10 F Almo 532 0 F Pacer Oil Rockdrill 150 10 F Rockdrill 600 0 F Phillips Petroleum EP 500 Summer or...

Page 27: ...pump 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 expenda...

Page 28: ...ections and auxiliary equipment FIGURE 4 1 GD 2500Q Fluid End Tightening Sequence Plunger and Packing Replacement This service procedure can be performed with the fluid cylinder in place on the pump a...

Page 29: ...new fluid end size by following steps 1 through 6 on page 22 Valve and Seat Replacement This procedure may be performed with the fluid end on the pump WARNING Never try to remove or cut a valve seat...

Page 30: ...d end tapered bores 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 gea...

Page 31: ...unscrew the four slotted nuts holding the rod cap in place 10 Remove the rod cap CAUTION The rod cap is held in place by two dowel pins DO NOT DAMAGE PINS 11 After removal of the rod cap the rod will...

Page 32: ...pinion bearing housings Using jackscrew holes remove one housing 6 With one pinion bearing housing removed pull the corresponding pinion bearing from the pinion as the bearing will not pass through th...

Page 33: ...k 15 If the crankshaft main bearings are to be replaced all bearing retainers must be removed from the crankshaft The crankshaft should be held in a vertical position and the bearings rapidly heated a...

Page 34: ...he retaining rings in the frame after installing the outer main bearing races Also braze the retaining rings securing the inner and outer bearing races of the outer two main bearings on either end of...

Page 35: ...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 open 2 Remove t...

Page 36: ...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 12 Repair a...

Page 37: ...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 Noise 1 Pump...

Page 38: ...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 damaged or corroded 1...

Page 39: ...rvice 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 8 Pump cav...

Page 40: ...em Stud Failures 1 Catastrophic failures 1 See Catastrophic Failures problem 2 Improper nut torque 2 Check torque specifications and torque to correct values 3 Stud bending due to uneven 3 Check nut s...

Page 41: ...Centers 10 00 Connecting Rod Bearing Bore Assembled in Journal Bearing Housing 7 507 7 510 Crosshead Guide Bore 9 000 9 004 Crosshead 8 981 8 979 Wrist Pin 5 000 5 001 Wrist Pin Bushing Bore 5 009 5...

Page 42: ...asteners 3 4 10 280 Intermediate Rod to Crosshead 3 4 10 160 Fluid End to Suction Manifold 7 8 9 260 Discharge Flange to Fluid Cylinder Nuts 1 8 475 Bull Gear Retaining Scews Gr 8 1 1 4 7 1050 Stay Ro...

Page 43: ...ours 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 Power end is warranted for twelve 12 months...

Page 44: ...if any given to Company by such manufacturer but only to the extent the Company is able to enforce such warranty or guaranties The Company has not authorized any party to make any representation or w...

Page 45: ...WARRANTY REQUESTS Products to be returned for warranty analysis shall be approved for return in writing by the Company prior to shipment All requests for product return shall be submitted by email Fac...

Page 46: ...r 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 Copyright 2001 Gardn...

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