TechnipFMC TRIPLEX M06 Operation And Maintenance Manual Download Page 48 | Manualshive

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Doc No: OMM50001243

Rev: C Page 48 of 68

This document and all the information contained herein are the confidential and exclusive property of TechnipFMC,

and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.

Figure 16: Back Cover Removal

Figure 17: Connecting Rod Cap and Shell Bearing Removal

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Summary of Contents for TRIPLEX M06

Page 1: ...ipFMC OPERATION AND MAINTENANCE MANUAL M06 M09 TRIPLEX PUMPS Rev ECN No Date Reviewed By Approved By Status C 5044404 07 NOV 2017 Rothe Michael McClain Mathew RELEASED Summary This is a manual for FMC M06 and M09 triplex plunger pumps These pumps have a stroke length from 1 50 inches to 2 25 inches and a maximum continuous duty power rating from 16 6 horsepower 12 4 kilowatts to 26 horsepower 19 4...

Page 2: ...s 14 5 0 How to Start a Pump 14 6 0 Lubrication of Power End 17 6 1 Recommended Lubricants 17 6 2 Oil Changes 17 7 0 Inspection and Preventative Maintenance Chart 18 8 0 Estimated Life of Wearing Components 20 9 0 Component Parts List 21 10 0 Service Procedures 26 10 1 Replacing Plunger Packing 26 10 2 Removing the Fluid Cylinder 30 10 3 Replacing Valves 32 10 3 1 Replacing AR Valves 34 10 3 1 1 I...

Page 3: ...may not be reproduced disclosed or made public in any manner prior to express written authorization by TechnipFMC 12 0 Critical Clearances 58 13 0 Trouble Shooting Pumps 59 14 0 Ordering Parts 62 15 0 Glossary of Commonly Used Terms 63 16 0 Reference Information 66 17 0 Maintenance Records 67 17 1 Check List for Starting a Pump 67 17 2 Maintenance Log 68 ...

Page 4: ... 23 Figure 5 Plunger and Packing Removal 29 Figure 6 Fluid Cylinder Removal 31 Figure 7 AR Valve Assembly 34 Figure 8 Using the Knockout Tool 35 Figure 9 Valve Disassembly 36 Figure 10 Eccentric Disc in Use 37 Figure 11 Removing the Seat 38 Figure 12 Hydraulic Power used to Remove Valve Seat 39 Figure 13 Threaded Tool in use 40 Figure 14 Typical Disc Valve Assembly 42 Figure 15 Illustration for th...

Page 5: ...ed or made public in any manner prior to express written authorization by TechnipFMC List of Tables Table 1 Pipe Pressure Chart 13 Table 2 Recommended Drip Lubrication Rates 16 Table 3 Lubricant Recommendations 18 Table 4 Maintenance Chart 19 Table 5 AR Valve Tool Guide 44 Table 6 Disc Valve Tool Guide 44 Table 7 Torque Values for Critical Pump Fasteners 57 Table 8 Clearance Chart 58 ...

Page 6: ...re disc or other type of properly sized over pressure safety device installed Always use a pressure gaUge when operating the pump The pressure must never exceed the maximum pressure rating of the pump or damage may occur This damage can cause leakage or structural damage resulting in injury to personnel Ensure that no valves are placed between the pump and pressure relief valve If the pump is star...

Page 7: ...of oil level and condition Heavy duty power ends are machined from a one piece gray iron casting for long trouble free life All pumps incorporate a reliable splash lube system with gravity feed return to sump Pressure lubrication of crossheads is an option Threaded covers are standard with cast fluid cylinders Bolted covers or cover clamps are available for some options Disc type or abrasion resis...

Page 8: ...isposed of properly 3 1 Short Term Storage If the pump is stored in an indoor temperature controlled environment for less than six 6 months no special steps are required to prepare it for storage As a general rule for pumps in corrosive fluid applications the fluid end should be drained flushed with water or other non corrosive cleanser and compressed air used to blow dry whenever idle 3 2 Short T...

Page 9: ...e the power end Never store the pump on the floor or ground Always place it on a shelf or pallet that is several inches above ground level Cover the entire pump with a canvas or plastic tarp Every two months inspect the unit Rotate the crankshaft by hand at least 4 turns during each inspection Drain and replace the rust inhibitor after every six 6 months of storage 3 4 Returning a Stored Pump to O...

Page 10: ...equirements Take time to thoroughly plan all aspects of your installation 4 1 General Location It is important to position the pump on as flat and level a surface as possible to assist the splash oil lubrication system Park mobile equipment such as drilling machines on as level a surface as possible Whenever possible the pump should be mounted in a clean dry location with sufficient lighting and a...

Page 11: ...ible hose or a combination of both as circumstances require in your installation The suction pipe size should be at least equal to or one size larger than the pump inlet Long piping runs low suction heads or indirect pipe routing may require even greater over sizing of the suction line for proper operation of the pump A suction pulsation dampener is recommended to reduce the effects of acceleratio...

Page 12: ...ation by TechnipFMC Always ensure that calculated system Net Positive Suction Head available NPSHa exceeds pump Net Positive Suction Head required NPSHr by at least 5 feet 1 5 meters of water for proper operation of the pump NPSH requirements for each pump model are provided on the product data sheets available through FMC or your authorized FMC reseller FMC does not recommend using the pump in st...

Page 13: ... Bar CAUTION Always use pipe or hose that is designed for your particular pressure requirements Inadequate pressure ratings can allow hose or pipe to fail resulting in equipment damage and possible personal injury Normal hose pressure ratings are clearly marked on the outer surface of the hose Working pressure ratings of steel pipe can be obtained from the manufacturer or from the chart shown in T...

Page 14: ...mps using common suction and discharge piping headers It is recommended that the user contact FMC or experienced industry consultants for assistance with the design of the system and pump installation in these situations 5 0 How to Start a Pump CAUTION Always take special precautions when starting a pump for the first time or after any extended shutdown Never assume that someone else has properly ...

Page 15: ...icator ensure that it is filled to the recommended level Refer to Table 3 for the recommended packing lubricant Follow the vendor specifications for filling intervals and proper maintenance The recommended lubrication rates are specified in Table 2 Hand operate each lubricator pump to provide initial lubrication to packing It may be necessary to bleed the lubrication lines from the lubricator to t...

Page 16: ...ady to start NOTE Whenever possible use a bypass in the discharge line to allow the pump to start in an unloaded condition no discharge pressure Slowly close the bypass line to bring the pump into full load conditions Shut down immediately in if the flow becomes unsteady pressure fluctuates or if unusual sounds or vibrations are noted 11 Take temperature readings of the power end and stuffing boxe...

Page 17: ...not exceed 170 F 77 C for continuous duty or 180 F 82 C for intermittent duty less than 8 hours per day applications Crankcase temperatures that exceed these limits will cause the lubricant to prematurely break down The result will be poor lubrication and failure of power end components especially bearings The user should consider installation of a heating element such as those furnished by Watlow...

Page 18: ... to 100 F 18 C to 38 C 30 100 550 Texaco Meropa 100 Shell Omala 100 Shell Rotella T SAE 30 Exxon XD 3 30 wt Mobil Trans HD 30 5W 40 NA 90 0 40 15 0 100 99 1 40 13 9 100 Shell Rotella T Synthetic SAE 5W 40 Mobil SCH 627 High Ambient Temperature Service 100 F to 130 F 38 C to 54 C 50 250 1165 Texaco Meropa 68 Shell Omala 220 Shell Rotella T SAE 50 Exxon HD 3 50 wt Mobil Trans HD 50 5W 40 NA 90 0 40 ...

Page 19: ...ge Drain and refill with new oil after first 50 hours of operation Ensure that the magnetic drain plugs are cleaned to remove debris Period Inlet Strainer Inspect Clean if Required The amount of material in the strainer will determine the interval of cleaning Complete Pump Inspect General inspection of pump and system to check for proper operation of equipment Daily Packing sets Inspect Check the ...

Page 20: ...maintenance of the power end lubrication system will influence the life of the power end components The speed of operation and percent of maximum allowable load will influence the life of both power end and fluid end parts The temperature abrasiveness and lubricity of the liquid affect the life of fluid end expendables POWER END COMPONENT ESTIMATED LIFE Hours End and Main Bearings Roller or Ball 4...

Page 21: ...figuration is shown below for general reference purposes This will aid in identifying components for service procedures outlined in the following sections Actual pumps supplied by FMC may use different components or configurations To order service parts or see exact component configurations for your particular pump refer to the cross section parts drawing in the literature kit supplied with the pu...

Page 22: ...d may not be reproduced disclosed or made public in any manner prior to express written authorization by TechnipFMC Figure 3 Fluid End Components Forged Style The illustration above depicts a typical pump with a forged fluid cylinder AR type valves and V Ring packing NOTE Alternate construction details show round valve cover and two bolt style clamp bars ...

Page 23: ... Fluid End Components Std Cast Style The illustration above depicts a pump with a standard cast iron fluid cylinder Disc type valves and standard braided packing The standard cast iron fluid cylinder uses threaded plugs for valve covers The service procedures outlined in this manual are intended to describe the more popular type of pump Other configurations and minor design differences may exist w...

Page 24: ... 2 11 Bearing Cup 2 12 Bearing Cone 2 13 Oil Seal Bearing Housing 1 14 Back Cover 1 15 Gasket Back Cover 1 16 Cap Screw Bearing Housing 12 17 Cap Screw Back Cover 12 18 Washer Back Cover 12 19 Seal Holder Pony Rod 3 20 Seal Pony Rod 6 21 Deflector Shield 3 22 Magnetic Pipe Plug Oil Drain 1 23 Cap Screw Rear Foot 2 24 Set Screw Crosshead Wrist Pin 3 25 Key 1 26 Bushing Lube Vent 1 27 Lube Vent 1 28...

Page 25: ... Cylinder Attachment 2 56 Stud Valve Cover As Required 57 Washer Valve Cover As Required 58 Nut Valve Cover As Required 59 Cylinder Cover Clamp 3 60 Cylinder Cover 3 61 O ring Cylinder Cover 3 62 O ring Suction Flange For Flange config 1 63 O ring Discharge Blind Flange For Flange Config 1 64 O ring Suction Blind Flange For Flange Config 1 65 O ring Discharge Flange For Flange Config 1 66 Suction ...

Page 26: ...lean water be pumped through the fluid end before starting any service procedures that involve fluid end components This will remove a significant portion of contaminants left in the fluid cylinder by the normal pumpage and improve the ability to work with parts or see potential problems WARNING Many accidents occur every year through careless use or service of mechanical equipment You can avoid h...

Page 27: ...id scratching or damaging the plunger 43 5 Loosen plunger 43 and rotate the crankshaft so that the loose plunger is at the top end of the stroke toward front of fluid cylinder NOTE When manually rotating the crankshaft take care to avoid scratching or marring the shaft 6 Slide the three deflectors 21 back against the oil seal holders 7 Slide a soft plastic or metal bar with the appropriate diamete...

Page 28: ...ll seals or gaskets that are disturbed during a service procedure be replaced Ensure that all fasteners are tightened to the values specified in Table 7 Torque Values for Critical Pump Fasteners 14 When tightening fasteners on cylinder cover clamps use crisscross tightening in three stages of torque Begin at approximately 25 of the final torque value then 50 of the final torque and finish at full ...

Page 29: ... and all the information contained herein are the confidential and exclusive property of TechnipFMC and may not be reproduced disclosed or made public in any manner prior to express written authorization by TechnipFMC Figure 5 Plunger and Packing Removal ...

Page 30: ... starting any service procedures that involve fluid end components This will remove a significant portion of contaminants left in the fluid cylinder by the normal pumpage and improve the ability to work with parts or see potential problems WARNING Many accidents occur every year through careless use or service of mechanical equipment You can avoid hazards associated with high pressure equipment by...

Page 31: ... studs 52 53 to avoid injury 5 Disassemble the fluid cylinder assembly as required to inspect or perform service Refer to the appropriate section for proper disassembly and reassembly procedures 6 Inspect all parts for signs of wear or damage Replace parts if required 7 Reverse the previous steps to rebuild the fluid cylinder assembly after worn or damaged components have been replaced FMC suggest...

Page 32: ... fluid end must be removed as outlined in previous section for valve service The following procedure is written under the assumption that sufficient clearances exist WARNING Many accidents occur every year through careless use or service of mechanical equipment You can avoid hazards associated with high pressure equipment by always following the safety precautions listed in Section 1 0 CAUTION CHE...

Page 33: ... cover o rings be replaced if nicked or if the o ring has any other damage If the pump uses threaded covers then a thread sealant should be applied before installation 5 Install the valve cover with the o ring in place over the studs 56 Installation Tip Apply grease around each o ring on the valve cover to prevent the o ring from falling out of the cover when turned over for cover installation Rep...

Page 34: ...he primary difficulty in removing an AR Valve is associated with the removal of the tapered seat from the matching locking taper in the fluid cylinder If the pump is used for discharge pressures in excess of 3 000 psi or for corrosive fluids this can be a difficult task requiring specialized tooling For applications involving pressures of 5000 psi or more FMC recommends the use of AR valves with t...

Page 35: ...luid cylinder and is stopped by the bottom of the valve seat The tool is struck sharply with a hammer and the valve is loosened The suction valve can be removed first through the cylinder cover if the fluid cylinder is equipped with them and the discharge valve through the valve cover If the fluid cylinder does not have cylinder covers the fluid end must be removed first to allow access See Sectio...

Page 36: ...d on all sizes of the AR valves in all of the pump models The discharge valve is removed first The valve must be disassembled with the cage spring and valve body removed from the fluid cylinder prior to the seat being pulled A special hex drive tool will assist in removing the cage from the seat Figure 9 Valve Disassembly Cage Removal Tool Hex to be used with a socket to apply torque Lugs to fit o...

Page 37: ...is keeps the threaded disc engaged with the edge of the seat Figure 10 Eccentric Disc in Use The tension rod is located through the top of the fluid cylinder and through a strong back that rests on the top of the fluid cylinder A nut is threaded over the tension rod and tightens down on the strong back The nut is tightened to place tension in the rod putting upward pressure on the seat of the flui...

Page 38: ... feet apart when applying striking action Keep head back so the tool does not strike your jaw when the seat pops Ask for a work partner to steady you to avoid slipping The bumper sliding upward against the stop nut creates a pinch point that can cause hand injury if gripped improperly Always hold the bumper by the handles only and use leather work gloves to lessen the shock to your hands Figure 11...

Page 39: ... power to generate the load that the bumper strong back and nut would generate This is shown if Figure 12 It is useful to put dry ice on the seat if it will not loosen Allow five minutes for cooling of seat before attempting removal Dry ice is often available at grocery stores WARNING Dry ice will cause freeze burns to skin if contacted Use thick leather gloves when handling Figure 12 Hydraulic Po...

Page 40: ...ng and valve body removed leaving only the seat in the fluid cylinder prior to use of the puller A threaded adapter is screwed into the seat after the cage spring and valve body have been removed An adapter nut mates the threaded section to the tension rod strong back and other parts used on the Eccentric Type to apply tension and then impact loading to remove the seat from the fluid cylinder The ...

Page 41: ... the surfaces Do not oil the seats or the seating surfaces in the fluid cylinder Confirm that they are dry before installation 3 Position the valve assembly directly over the mating taper in the fluid cylinder 4 Let the valve drop into the taper Check to see that the seat is sitting in the taper properly and not cocked to one side If the valve drops straight it will seize on the taper When correct...

Page 42: ...of stainless steel seat disc and stop are a cost effective design with excellent performance and ample life These valve assemblies come pre assembled from the factory and should not need to be disassembled Figure 14 Typical Disc Valve Assembly When a worn or malfunctioning valve is detected it must be replaced With disc valves the most difficult task associated with replacing a valve is the remova...

Page 43: ...re are two 2 Knock Out tools available for removing valves from M06 series pumps The P534695 Small Ball Knock Out tool is the preferred tool for disc valve removal The P504436 Knock Out tool can also be used in the M06 pump models Figure 15 Illustration for the Ball Knock Out Tool The suction valve is removed first All Knock Out tools are used in a similar manner to the P504436 tool shown in secti...

Page 44: ...e seating surfaces in the fluid cylinder Confirm that they are dry before installation 3 Position the valve assembly directly over the mating taper in the fluid cylinder 4 Let the valve seat drop into the taper Check to see that the seat is sitting in the taper properly and not cocked to one side If the seat drops straight it will seize on the taper When correctly seated it cannot be pulled up by ...

Page 45: ...ns listed in Section 1 0 NOTE Ensure that all pressure inside the pump fluid cylinder has been bled off before starting any service work CAUTION CHECK TO ENSURE THAT THE POWER IS LOCKED OUT AND TAGGED OUT 1 Remove the cradle cover 28 from the power frame 1 by removing the wing nuts 29 2 Slide the deflector shield 21 off the end of the plunger rod 3 Remove the seal holders 19 by threading the speci...

Page 46: ...er to Figure 16 and Figure 17 with the following instructions 1 The cradle cover 28 should be removed and the plungers 43 disconnected from the plunger rods 7 to perform the steps in this section 2 Remove drain plug 22 to allow all oil to drain from power frame into a container for proper disposal Use proper precautions if power frame is hot above 130 F 54 C to avoid burns from hot oil or hot surf...

Page 47: ... Reinstall or replace shell bearings 4 in the connecting rod and connecting rod caps Ensure that rod caps are properly assembled with their mating connecting rod Torque the fasteners holding the end caps to the mating rod per the values given in Table 7 Torque Values for Critical Pump Fasteners Use back and forth pattern from one fastener to the other tightening with a torque wrench After the cap ...

Page 48: ... contained herein are the confidential and exclusive property of TechnipFMC and may not be reproduced disclosed or made public in any manner prior to express written authorization by TechnipFMC Figure 16 Back Cover Removal Figure 17 Connecting Rod Cap and Shell Bearing Removal ...

Page 49: ...T Installation Tip Mark each bearing housing and the power frame to allow installation back in the original position 1 The cradle cover 28 and back cover 14 should be removed to perform the steps in this section Also the plungers should be disconnected from the plunger rods Refer to the procedures in Section 10 4 1 and 10 4 2 for details 2 The plunger rod seal housings 19 must be removed to allow ...

Page 50: ...e been removed If that is not adequate tapped jack screw holes which are the same size as the cap screws holding the housing in place are provided in each bearing housing to help remove stuck housings 5 Count and record the number of shims on each side to facilitate reassembly The bearing cups 11 and crankshaft oil seal 13 will remain in the bearing housing 6 To remove the crankshaft 2 carefully m...

Page 51: ...using an automotive type bearing puller or cutting torch Bearing cups 11 can be removed from the bearing housing using a puller if a sufficient lip is available for the puller arms to grab An alternate procedure involves running a weld bead around the inside surface of the cup When it cools this will reduce the interference between the cup and bearing housing enough to free the cup If either the c...

Page 52: ...od requires service Keep components matched together 10 Inspect all components for signs of wear or damage and replace if required Carefully check the crankshaft bearing surfaces for pits scratches or other signs of wear The connecting rod bearings should be inspected for deep scratches or the top metal surface worn away NOTE Connecting rods and caps are matched sets and must always be reassembled...

Page 53: ...from the shoulder unless it is held in position until it cools enough to grab the shaft Use a 001 thick feeler gauge to ensure the cone is fully seated against the shoulder after parts have cooled 14 Thoroughly clean all parts with solvent and apply a thin coat of oil before reassembly 15 Use a press to seat the new cups 11 into the bearing housings Never use new bearing cones with old bearing cup...

Page 54: ...l or replace the rod bearings 4 in the connecting rod and connecting rod caps per instructions in section 10 4 2 Ensure that rod caps are properly assembled with their mating connecting rod 21 A dial indicator must be used to properly adjust the endplay of the crankshaft Improper adjustment may result in excessive temperature vibration noise and reduced bearing life FMC recommends between 002 tigh...

Page 55: ... crankshaft to one side of the power frame using a light tap from a rubber mallet or a pry bar Rotate the crankshaft several turns and repeat the light taps from a rubber mallet or the use of a pry bar to ensure the crankshaft is to one side 24 Mount indicator base on the power frame with the indicator tip on a machined shoulder surface of the crankshaft do not measure from a cast surface and the ...

Page 56: ...ment Rotate the crankshaft several turns and repeat the effort to move the crankshaft in the direction described in this step Repeat the dial indicator measurement Remove or add shims as necessary to achieve proper endplay 002 tight to 005 loose Distribute shims equally on both bearing housings Verify the endplay with the dial indicator 27 Install the seal housing 19 in the power frame per instruc...

Page 57: ...nch during the installation of all critical fasteners listed in Table 5 below Values are in foot pounds Ft lb and newton meters N m Typical sizes are shown in Table 5 below Table 7 Torque Values for Critical Pump Fasteners Fastener Torque Values ITEM NO COMPONENT DESCRIPTION M06 SIZE FT LB N m 3 Connecting Rod Bolts 0 375 30 41 16 Bearing Housing Bolts 0 375 25 34 17 Back Cover Bolts 0 375 25 34 2...

Page 58: ...s additional clearance is a maximum of 002 inches of total diametral wear that can be added to the clearance values in Table 6 For radial clearance use of the total diametral value All dimensions are shown in Inches Table 8 Clearance Chart DESCRIPTION M06 Crankshaft Throw Diameter Stroke 1 50 Crankshaft Pin or Journal OD 2 311 2 312 Connecting Rod Crank Clearance Max Total 0 003 Crosshead Diameter...

Page 59: ...ace packing or damaged parts Insufficient flow from pump ONLY Pump speed is too low Relief valve improperly adjusted or worn Worn pump valves Excessive leakage from pump packing Plunger worn Valve taper seating area washed out in fluid cylinder Check belt tightness or power to motor Check relief valve and adjust setting Inspect pump valves and repair or replace Adjust or replace packing or damaged...

Page 60: ...ng inadequately supported Excessive short radius elbows or tees See above Install discharge pulsation dampener Install supports at proper locations Correct installation to minimize turns and short radius fittings Pump requires excessive power Discharge pressure too high Plungers too large Speed too high Packing too tight Misaligned coupling Belts too tight Power end bearings too tight Low motor vo...

Page 61: ...lation Install strainer or filter Correct problem and replace damaged valves Correct problem and replace damaged valves Increase submergence or baffle to stop vortex Pipe back to reservoir tank Replace damaged components Cracked fluid cylinder or broken fluid end bolts Discharge pressure too high Hydraulic shock cavitation or entrained air Discharge valve stuck closed Fluid freezing in fluid cylin...

Page 62: ...n authorized parts retailer in your area Always insist on genuine FMC replacement parts Use the assembly drawing and bill of material included with this manual to determine the components and corresponding part numbers required to service the pump Confirm that the part number on the drawing or bill of material matches the part number of the pump requiring parts When ordering parts always reference...

Page 63: ...he suction stroke and often sounds like a mechanical knock Cavitation results in the formation of gas bubbles or cavities in the fluid that cause vibration and damage to components when they collapse DAMPENER A device that reduces pressure pulsations in the suction or discharge piping This may be referred to as a suction stabilizer accumulator or surge suppressor DISPLACEMENT The volume swept by a...

Page 64: ...e NPSHA for a reciprocating pump is expressed in units of feet of water or meters of water NPSHr An abbreviation that stands for Net Positive Suction Head Required This is the minimum total inlet pressure required by the pump for proper operation This value is a function of pump design and speed and is determined by the pump manufacturer through a specific NPSH test NPSHa should exceed NPSHr by at...

Page 65: ...OWER FRAME The major portion of a power pump that encloses and supports all other components of the power or drive end It is called a pump case in old literature STROKE LENGTH The length of one complete unidirectional one direction motion of the piston or plunger Stroke length is usually expressed in inches PUMP VALVE A check valve that allows flow of liquid in one direction FMC pumps have a serie...

Page 66: ...and Serial Numbers will be needed when ordering service parts This information is stamped on the metal nameplate located on the pump power frame This page may be used to make notations about special parts procedures phone numbers and other important information related to your pump Pump Model ________________________________________ Pump Part Number ________________________________________ Serial ...

Page 67: ...pressure relief valve and all accessory equipment have been installed and properly adjusted Verify that all joints are pressure tight 5 Open the suction line valve to allow fluid to enter pump Prime the fluid cylinder if necessary on the initial start up or after the system piping has been drained The valve covers may have to be cracked open to assist with priming CAUTION Do not loosen the valve c...

Page 68: ...nformation contained herein are the confidential and exclusive property of TechnipFMC and may not be reproduced disclosed or made public in any manner prior to express written authorization by TechnipFMC 17 2 Maintenance Log DATE SERVICED BY SERVICE PERFORMED REMARKS ...

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