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Pump and Fluid Systems

Chapter 3: Operations

weatherford.com

22

MP-16 2-Piece 5000 psi January 2013

3.3

Basic Troubleshooting

The following section provides a basic guide to dealing with potential problems which may

occur while using the MP-16 pump.  This section is intended only as a basic problem solving
tool,  to  help  users  ascertain  the  nature  of  the  problem  and  allow  for  basic  repairs  should
something  go  wrong.    If  problems  do  not  match  those  outlined,  or  persist  after  all
recommended solution options have been exhausted, do not attempt further work, but contact
a Weatherford professional to examine the system and make a recommendation.

3.3.1

Excessive Vibration

If there is excessive vibration

coming  from  the  pump,  the  most
common  cause  is  an  unbalanced  or
loose  connection  between  the  prime
mover  and  the  pump  itself.    If  using  a
direct  connection,  check  that  the
sprockets  and  sheaves  are  properly
balanced  and  aligned.    If  using  a  chain
or belt drive, check that the chains/belts
are  not  a  mixture  of  new  and  old
sections,  and  that  they  are  taut  on  the
sheaves and spacers.

If the drive connection seems

normal, check that the pump is level
and properly supported. Then check
that

the

motors

are

properly

synchronized  on  a  dual  shunt  wound
D.C. Motor Drive.  To do so, isolate one
motor by disconnecting one drive chain
or belt and operating the pump with one
motor.  If the vibration ceases, then the
motors  will  need  to  be  properly
synchronized before proceeding.

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Summary of Contents for MP-16

Page 1: ...Operations Maintenance Manual Model MP 16 Triplex Pump Two Piece Fluid End 5 000 PSI Manual Part Number 1923778 January 2013 ...

Page 2: ...n 13 2 1 7 Auxiliary or Ancillary Systems 13 2 1 8 Installation Checklist 14 2 2 Storage 15 2 2 1 General Storage Guidelines 15 2 2 2 Special Conditions Procedures 16 2 2 3 Upkeep 16 2 2 4 Returning to Service 17 Chapter 3 Operations 18 3 1 Starting Procedure 18 3 1 1 Initial Startup 18 3 1 2 Pre Start Checklist 19 3 1 3 Start Up Procedure 20 3 2 General Operations 21 3 3 Basic Troubleshooting 22 ...

Page 3: ...on Disassembly Parts Replacement 39 4 6 4 Piston Cup Replacement 40 4 6 5 Installing the Liner Retainer Wear Plate 41 4 6 6 Installing the Liner Piston 42 4 7 Valve Maintenance Procedures 45 4 7 1 Valve Assembly 45 4 7 2 Removing the Valves 46 4 7 3 Installing the Valves 47 4 8 Charts Diagrams 49 4 8 1 Torque Chart 49 4 8 2 Lubrication Chart 50 Chapter 5 Assembly Disassembly 51 5 1 L Style Fluid E...

Page 4: ...n Bearing 90 5 3 6 Installing the Crankshaft Assembly 91 5 3 7 Installing the Crossheads Crosshead Guides 93 Chapter 6 Glossary 96 Chapter 7 Parts Lists 102 7 1 Power End Assembly 102 7 1 1 Power Frame Assembly 103 7 1 2 Crankshaft Assembly 104 7 1 3 Main Bearing Assembly 105 7 1 4 Pinion Assembly 106 7 1 5 Crosshead Assembly 107 7 2 L Style Fluid End Assembly 108 7 2 1 L Style Suction Module Asse...

Page 5: ... Pump Type Triplex Maximum Rated Power 1 600 HP Pump Weight 59 700 lbs Maximum Discharge 5 000 psi Oil Capacity 100 gal Maximum Rated Speed 120 SPM Max Fluid Temp 140 F Minimum Rated Speed 20 SPM Mechanical Efficiency 90 Stroke Length 12 IN Liner Size in mm Rated Pressure psi Mpa Rated Capacity GPM BPD 120 RPM 115 RPM 110 RPM 105 RPM 100 RPM 95 RPM 90 RPM 1 600 HP 1 520 HP 1 454 HP 1 388 HP 1 322 ...

Page 6: ...Pump and Fluid Systems Chapter 1 Introduction weatherford com 2 MP 16 2 Piece 5000 psi January 2013 1 1 2 General Dimensions ...

Page 7: ...g their use of this or any other powerful and potentially hazardous equipment This manual has been prepared with the system s expected uses in mind For help with events situations and uses not typical to this system or for advanced troubleshooting issues please contact your local Weatherford representative 1 3 Manual Organization This manual has been laid out in accordance with the expected need o...

Page 8: ...olute minimum follow all of the safety guidelines outlined below Failure to follow the established safety guidelines can result in damage to equipment employee injury and or death At the same time it is important to remember that no set of procedures is perfect While these guidelines should help to significantly reduce the chance of an incident they are no match for an aware and reasoning human mi...

Page 9: ...ffective Lock Out Tag Out Before performing repairs or maintenance on any industrial equipment you should always follow standard Lock Out Tag Out procedures This includes not only shutting down the equipment but also isolating it from any potential power sources electric hydraulic mechanical etc In addition be sure to lock controls and tag the equipment as under maintenance to ensure that it is no...

Page 10: ...ystems Body parts and loose clothing can become caught on moving and rotating parts of the pump drive systems dragging personnel into the system and inflicting serious injury or death When working with drive systems keep all guards in place and in good condition and keep hands and clothing clear of the drive system cavity at any time when the drive is in motion Hydraulic Pneumatic Systems Hydrauli...

Page 11: ...stem failures and injury so be sure to use only approved solvents read all safety precautions before using and follow all appropriate procedures Never mix fluids lubricants or solvents Fluid Lubricant and Solvent Disposal Follow all normal health and environmental guidelines when disposing of fluids lubricants or solvents In the event of a spill follow the appropriate steps and procedures to ensur...

Page 12: ...tion mandates the use of Teflon Tape always start the wrap two 2 or more threads from the opening to prevent Teflon contamination of the hydraulic system Do Not Modify Never modify the pump to perform beyond the rated specifications or use substitute parts or components without first consulting and receiving written consent from Weatherford Failure to do so may put too much stress on certain compo...

Page 13: ...e the transport skid and mount the pump directly to a larger skid usually one with power and inlet piping to reduce the overall size and weight of the equipment package 2 1 2 Location and Orientation CAUTION Always make sure pumps are mounted on a level surface and are locked down evenly Failure to do so can cause twisting which places unnecessary strain on the frame and the pump and can result in...

Page 14: ...use worn or damaged belts or chains Do not exceed the recommended tension rating as it can result in damage to the shafts Once tensioned perform a final alignment check and ensure all mounted bolts are secure To do so first verify that the sides of the sheaves are equidistant from the centerline of the groove Then simply stretch two lengths of string or wire along one side of the sheaves one above...

Page 15: ...n when the mud pump is operating at lower speeds For this reason it is recommended that a booster pump be used powered by an electric AC motor The mud pump control panel should be configured so that the mud pump cannot be started until the charging pump is running and has developed at least 20 PSI For full operating instructions and guidelines for using a particular charging pump see the documenta...

Page 16: ...ow and thereby ensure the efficient operation of the pump Drain valves should be installed at the lowest point in the piping while vents should be located at the highest point available Do not under any circumstances use any valve that has the potential to choke the flow of fluid through the line Suction Pressure Relief Valve It is recommended that a suction pressure relief valve be used in the su...

Page 17: ... buildup and pipe erosion and no immediate turns next to the pump discharge should be used 45 long radius elbows should be used to minimize flow frictional pressure concerns Furthermore discharge piping should be supported but allowed to move along the axis of the pipe to ensure that any thermal expansion will not unnecessarily load the fluid end connections Discharge Pulsation Dampener A discharg...

Page 18: ...o the supply tank but not the pump suction WARNING The Relief Valve must not be connected to the strainer cross as the systems can interfere with one another resulting in potentially life threatening situations WARNING Do not put any type of shut off valve between the pressure relief valve and the discharge manifold in order to protect the system against damage resulting from accidental or incorre...

Page 19: ...d reservoir and worked into all of the bearings Recheck oil level after first 15 minutes of operation and add more as needed Extension Rod and Diaphragm Stuffing Box Seals Ensure the extension rod and diaphragm stuffing box seals are properly installed as per 5 3 7 Installing the Crossheads Crosshead Guides 2 1 7 Auxiliary or Ancillary Systems Any Auxiliary or Ancillary systems such as liner wash ...

Page 20: ...ves are installed at the proper locations and clear for use Ensure a pressure gauge is installed at the suction point preferably with a thermometer and a low pressure alarm Check that the suction piping is properly sized and that there are no components that may choke or disrupt flow tight elbows partial valves metering devices etc Discharge Checklist Ensure the discharge piping is properly sized ...

Page 21: ... more the fluid end should be cleaned and flushed with water which has had its pH raised to 10 or more in order to kill any sulfide reducing bacteria in the pump Over time these bacteria can create sufficient Hydrogen Sulfide to attack the hardened steel parts in the fluid end and harm or even kill personnel when the pump is reopened Once the fluid end has been cleaned 1 quart of internal rust inh...

Page 22: ...s with freezing or near freezing temperatures it is vital to ensure that a pump is dry prior to storage and to thoroughly inspect the pump prior to use Severe Environment Precautions In severe environments take the following additional steps The oil in the power end should be drained and the fill cap removed and then refilled with 8 quarts of internal rust inhibitor vapor emitting oil Replace the ...

Page 23: ...re clean and in good condition Check the oil reservoir for the possible accumulation of condensation and drain and flush by removing the pipe plugs on either side Fill the power end with lubricant to the proper level with a clean EP gear oil of the proper viscosity see 4 3 Lubrication on page 29 Make sure the oil is poured into the crosshead reservoir and worked into all of the bearings Fluid End ...

Page 24: ...rocedures Check that all components are correctly positioned and secured and are not damaged or corroded Drain and flush as necessary to remove any condensation that may have formed during shipment or storage CAUTION New pumps should always receive a full inspection to make sure it has not suffered damage and that all parts are properly set in place Failure to do so can result in serious equipment...

Page 25: ...Checklist Remove any debris and note any excessive rust on the system Ensure liners are installed and there fasteners are torqued to the proper value Ensure piping is attached and proper stud bolt torque has been applied Check that all valves have been installed and that the valve covers are tight Power End Checklist Check that the rods and pistons have been installed Check that the crosshead exte...

Page 26: ...ture is too low use an external heat source to reduce viscosity If oil temperature is too high provide a cooling loop to lower temperature CAUTION Do not operate the pump if the oil temperature is out of range 5 Rotate the pump by hand to verify that there are no restrictions on its movement 6 Open the bypass valve 7 Open the valve at the suction tank 8 Open the discharge and suction line valves 9...

Page 27: ...epending on suction piping the available head and the weight pressure viscosity and aeration of the fluid being pumped as well as the type of mud Experienced operators should be able to determine the limiting speed by slowly bringing the pump up to speed and listening closely to its operation As the limiting speed is approached the pump will begin to knock and pound indicating cavitations in the f...

Page 28: ...commendation 3 3 1 Excessive Vibration If there is excessive vibration coming from the pump the most common cause is an unbalanced or loose connection between the prime mover and the pump itself If using a direct connection check that the sprockets and sheaves are properly balanced and aligned If using a chain or belt drive check that the chains belts are not a mixture of new and old sections and ...

Page 29: ...t there are no restrictions in the suction line and that both the suction and discharge strainers are sufficiently clear to allow fluid to pass through If plugged clean and reinstall If this does not solve the problem then shut down the pump and check the valves Ensure the valve seats are secured in the bore and that neither they nor the valves are misaligned washed out or damaged Also check that ...

Page 30: ...wrist pin and the crosshead Insert a 0 002 feeler gauge and see if it will fit through all 360 Next check the clearance of the crossheads which should have between 0 014 and 0 030 between them and the guides Also check the crankpin insert bearings which should be tight in the frame and can cause knocking when loose Finally check the crosshead guides for upsets as these can also cause knocking If n...

Page 31: ...ant into the liner Remove any plugs or restrictions on the coolant flow Drilling fluid that contains a high concentration of sand or other solids will rapidly degrade pump components usually evidenced by streaks in the liner bores In such cases the mud tanks should be cleaned and the de sanders should be checked and replaced as needed If the drilling fluid has a pH above 8 5 then it is considered ...

Page 32: ...iner piloting diameters are lightly coated with drill collar compound before installation Then check for trash on the wear plate as it must be clean and dry for the liner to seal properly Check the piloting diameters for paint or burrs and remove if discovered Also check the liner retention flange looking for an egg shaped deformation in its structure If found remove and replace ...

Page 33: ... magnetic retriever tool One 1 dampener charging kit including three 3 charge hoses One 1 crankshaft pinion rotating tool One 1 wear ring plate puller One 1 maintenance bar for valve closure One 1 standard set of push pull adjustment tools 4 2 General Maintenance Guidelines Regular maintenance of the MP 16 triplex pump will help to ensure not only a long operational life but will also enhance the ...

Page 34: ...be thoroughly inspected and the cause of the problem rectified Replace any components that are worn beyond the recommended clearance 4 2 2 Fastener Torque Specifications When tightening multiple bolts on flanges it is considered the best practice to tighten opposite bolts first to ensure a tight flat seal The diagram below provides a recommended order in which to tighten the bolts to best ensure a...

Page 35: ...a speed of 40 RPM must be maintained in order to ensure proper lubrication of all components However pumps may be operated below this speed if an auxiliary power end lubrication system is used Under no circumstances should the pump be run at speeds below 40 RPM without the use of auxiliary power end lubrication system 4 3 3 Power End Lubrication Guidelines During operation significant loads will b...

Page 36: ...r is used the operator must exercise greater than normal care and maintenance in order to prevent heat and corrosion damage in those parts in or adjacent to the liner piston chambers Coating clamps and all exposed surfaces with a thread compound will minimize the effects of corrosion Used lubricant accumulates in compartmentalized sumps beneath the connecting rods where it is re circulated by the ...

Page 37: ...he gauges is greater than 15 psi when the pump is at operating temperature clean the strainer and strainer magnets During operation examine the belt drive if utilized If slipping or squealing is noticed disengage and turn off belt drive and adjust tension as necessary Be sure to check the sheave alignment before returning to service Observe the condition of the pistons and liners and look for unev...

Page 38: ...ition and in working order 4 4 3 Monthly Maintenance Checklist Check over all tools used to work on the pump ensuring that they are in good working order and readily available If a strainer cross is used ensure it contains a strainer sleeve Clean the sleeve and check for damage or corrosion Check all of the studs and nuts on the fluid cylinder for tightness including the valve cover bolt on the ri...

Page 39: ...4 5 Annual Maintenance Checklist Check the crosshead guides for grooves which indicate improper lubrication or foreign matter in the lube oil If found check the lubrication system and the condition of the crosshead extension rod seals and replace if severely worn or scarred Check the clearance of the crossheads and the main gears and record the data for future reference Inspect the condition of th...

Page 40: ...g maintenance on fluid end components CAUTION Even while at rest the fluid end of the system is under significant pressure which if accidentally or inappropriately released can cause significant equipment damage and injury to nearby personnel All pressure must be vented from the system before any maintenance on the fluid end is performed see 4 5 1 Venting Pressure in the Fluid End above 4 5 2 Pre ...

Page 41: ...ny maintenance procedures 4 6 1 Removing the Piston Liner as a Unit The pistons and liners should be removed as a unit The following procedure provides standard guidelines for this process 1 After rotating the pump so that the pony rod is almost fully retracted remove the clamps affixing the piston rod sub rod to the crosshead extension and rotate the pump until the crosshead extension is at the e...

Page 42: ... nut from the liner assembly 4 Extract the liner by inserting a pry bar between the liner collar and the end of the pilot bushing and carefully sliding it free of the liner retainer CAUTION These parts are heavy and should be handled using a sling or other appropriate handling device in order to avoid potential injury or equipment damage ...

Page 43: ... January 2013 4 6 2 Removing the Liner Wear Plate 1 The liners must be removed in order to access the wear plate Use the procedure 4 6 1 Removing the liner and wear plate 2 Remove the wear plate from inside the liner retainer flange 3 Unbolt liner retainer flange and remove from discharge module ...

Page 44: ...Pump and Fluid Systems Chapter 5 Assembly Disassembly weatherford com 38 MP 16 2 Piece 5000 psi January 2013 4 Remove liner retainer seal and wear plate seal ...

Page 45: ...nt parts for the pistons on the MP 16 pump 1 Remove the piston rod nut and slide the piston hub off of the piston rod NOTE Always replace seals which have been loosened or manipulated during maintenance procedures 2 Re install the piston ensuring that the undamaged O ring seal remains properly aligned with the groove in the piston hub Lock into position using the piston rod nut and torque to 1 000...

Page 46: ...umps come with a molded piston Some operators choose to utilize older style pistons which have replaceable cups or rubbers Use the following procedure to replace the cups on this type of piston 1 To remove simply remove the snap ring from the front of the hub and slide the piston cup free 2 To reinstall simply slide the new cup onto the hub and secure in place with a snap ring ...

Page 47: ... for installing the Liner Seal and Wear Plate 1 Clean the fluid end counter bore and install the wear plate seal and the liner retainer pilot ring 2 Slide the wear plate into the appropriate gland area until it seats properly against the fluid end A small amount of grease may be helpful in accomplishing this 3 Replace the liner retainer flange on the discharge module and bolt back into position ...

Page 48: ... the liners are generally sturdier than the pistons and have a significantly longer operational life In most cases a liner should last through about 2 3 pistons 1 Check that all parts are clean and free of nicks and burrs as per 4 5 2 Pre Installation Procedure 2 If necessary Install the Wear Plate as per 4 6 5 3 Coat the inner diameter of the liner and the outer diameter of the piston with grease...

Page 49: ... grease to the inner diameter of the liner retainer and insert the liner into position 5 Insert the adjusting nut into position on the liner NOTE For fluid ends with a liner retention flange and nut insert the liner into the flange and hammer on the retainer nut 6 Rotating the pump by the pinion turning tool support the piston rod as the pin is guided into the pilot bore ...

Page 50: ... the piston rod clamps match and install around the piston rod and crosshead extension end flanges respectively ensuring that the water connection holes remain at the top center 8 Assemble the clamp halves Ensure that a gap of or less exists between the clamp halves but that they are not touching If they touch replace the clamps Torque the bolts to 314 ft lbs ...

Page 51: ...riately released can cause significant equipment damage and injury to nearby personnel All pressure must be vented from the system before any maintenance on the fluid end is performed see 4 5 1 Venting Pressure in the Fluid End 4 7 1 Valve Assembly The standard valve assembly is as shown It consists of the valve itself the valve seat and a spring The valve stem inserts into a bushing which itself ...

Page 52: ...and remove along with valve plug and seals 2 Lift the valve spring and valve out using a hook or a magnetic retriever tool The valve can be lifted out by hand 3 If removing the seat a hydraulic valve seat puller appropriate to that particular style of valve seat should be used to remove the seat from the bore exercising care not to directly strike the valve seat ...

Page 53: ...eat and cover are clean dry and free of nicks burrs or cracks as per 4 5 2 Pre Installation Procedure 2 Use a valve seat driver or wood block to insert the valve seat into position and press to obtain an initial seal Exercise care not to strike the valve seat directly with a metal hammer or steel bar 3 Install the valve into the seat and center the spring on the valve ...

Page 54: ...valve seal as the action of pumping causes stress and deformations that prevent it from properly sealing the bore once removed 5 Reinstall the valve covers and valve cover seals Tighten screw glands using a stout steel bar and sledge hammer 6 After the pump is reassembled run for approximately 15 minutes then shut down the pump and release the pressure Tighten the valve corner again with a sledgeh...

Page 55: ...x Nuts Clamp Load Lbs Tightening Torque Dry Lubed K 0 223 K 0 223 Ft Lbs Ft Lbs 1 2 13 0 138 10 350 96 72 9 16 12 0 177 13 275 139 104 5 8 11 0 22 16 500 192 143 3 4 10 0 327 24 525 342 256 7 8 9 0 452 33 900 551 413 1 8 0 594 44 550 828 620 1 1 8 8 0 776 58 200 1 217 911 1 1 4 8 0 984 73 800 1 714 1 284 1 3 8 8 1 215 91 125 2 328 1 744 1 1 2 8 1 471 110 325 3 076 2 303 1 5 8 8 1 769 132 675 4 006...

Page 56: ...quent oil changes should occur every six months or 2 000 running hours whichever comes first Oil Change Procedure 1 Shut down and lock out the pump as per standard procedure The drain plug should be removed and the pump gear lube oil drained immediately after shutdown is complete 2 Remove the pump gear inspection opening cover plate 3 Visually inspect the gearing status and report any damage defec...

Page 57: ...ficant equipment damage and injury to nearby personnel if vented inappropriately All pressure must be properly vented from the system before any maintenance on the MP 16 is performed see 4 5 1 Venting Pressure in the Fluid End 5 1 1 Removing the Discharge Manifold 1 Remove the sections of the discharge piping connected to the discharge manifold 2 Remove the nuts connecting each of the discharge mo...

Page 58: ...i January 2013 3 Carefully remove the discharge manifold from the pump NOTE Some of the manifolds may differ in appearance but are removed in the same manner 4 Replace all of the gaskets and seals connecting the discharge manifold to the discharge modules When doing so always use new components ...

Page 59: ...ny piping connected to the suction manifold 2 Remove the cap screws connecting each of the suction modules to the suction manifold WARNING The suction manifold is a weighty piece of metal which can cause serious injury if dropped Be sure the manifold is sufficiently supported before removing the cap screws 3 Carefully remove the suction manifold from the pump ...

Page 60: ...the Suction and Discharge manifolds as 5 1 2 and 5 1 1 respectively 2 Remove the liners and wear plates as per 4 6 1 and 4 6 2 respectively WARNING Each discharge module is a weighty piece of equipment and can cause serious injury if dropped Be sure the module is properly supported before removing the cap screws 3 Unbolt the suction modules from the fluid end If only one discharge module is to be ...

Page 61: ...sembly Disassembly weatherford com 55 MP 16 2 Piece 5000 psi January 2013 4 Remove the suction module from the discharge module 5 Remove the suction module seal from the discharge module 6 Unbolt the discharge modules from the fluid end ...

Page 62: ...Pump and Fluid Systems Chapter 5 Assembly Disassembly weatherford com 56 MP 16 2 Piece 5000 psi January 2013 7 Remove the discharge module from the pump frame ...

Page 63: ... metal designed to withstand intense pressures and can cause serious injury if dropped Be sure that each module is sufficiently supported before hoisting and beginning installation procedures 1 Slide the discharge modules into position on the pump frame Care should be taken to ensure that the threads on the studs are not damaged 2 Install the nuts on the studs and partially tighten the discharge m...

Page 64: ...suction module seals into the glands on the discharge modules Some grease will aid in the installation of the seal 4 Slide the suction manifolds into position on the discharge module attachment studs Be careful not to damage the threads 5 Attach the nuts and torque the suction modules into position on the discharge modules ...

Page 65: ...s Chapter 5 Assembly Disassembly weatherford com 59 MP 16 2 Piece 5000 psi January 2013 6 Install the seals wear plates liner retainers and liners as per 4 6 5 and 4 6 6 7 Reinstall the suction and discharge modules as per ...

Page 66: ...cross on the MP 16 1 Place the new discharge cross into position and bolt to secure to the discharge manifold and cross support 2 Reattach the Pressure Relief Valve Pulsation Dampener and other components to the discharge cross 5 1 6 Installing the Liner Wash System Drop the liner spray manifold over the piston assemblies and slide at the bottom of the chamber The hose may be connected at either s...

Page 67: ...dures especially any and all safety regulations involved 5 2 1 Removing the Wiper Box Diaphragm Plate The crosshead diaphragm plates are all line bored with the pump frame and must not be interchanged Take note of which cylinder and pump each plate was removed from so it can be reinstalled properly Do not attempt to remove the diaphragm plate unless the outer diameter of the stub rod flange is gre...

Page 68: ... Piece 5000 psi January 2013 3 Rotate the pump so the crosshead extension rod is fully retracted towards the power end and remove the baffle 4 Remove the bolts affixing the wiper box to the diaphragm plate 5 Slide the wiper box off the crosshead extension and out of the pump frame ...

Page 69: ...r 5 Assembly Disassembly weatherford com 63 MP 16 2 Piece 5000 psi January 2013 6 Unbolt the diaphragm plate and gasket and slide free of the frame The resulting opening should be large enough to permit the removal of the crosshead ...

Page 70: ...Each wrist pin corresponds to a specific crosshead and must not be interchanged It is best to mark each crosshead and wrist pin set to avoid confusion 1 Remove the Wiper Box and Diaphragm Plate as per 5 2 1 2 Rotate the pump so the crosshead extension rod is fully extended towards the fluid end Unbolt the extension rod from the crosshead ...

Page 71: ...herford com 65 MP 16 2 Piece 5000 psi January 2013 3 Carefully slide the extension rod free of the crosshead and remove 4 Remove the nameplates from the side of the pump to gain access to the crossheads 5 Unbolt the wrist pin retainer plate from the crosshead ...

Page 72: ...lize the tapped holes in the retainer plate to jack the wrist pin from the crosshead and mark to indicate which crosshead they were removed from 7 Remove the crossheads through the hole created by removing the diaphragm plates Place wooden boards on the crosshead guides to prevent scoring by the connecting rod ends ...

Page 73: ...ides to the frame NOTE The upper guides are only affixed to the frame by the bolts and so must either be secured or removed during the unbolting procedure 3 Remove the crosshead guides Shims if present should be left in place if the guide is to be reinstalled If not a new shim package and realignment will be necessary NOTE It is extremely important to make note of the size and placement of shims d...

Page 74: ... 2 2 Make sure to support the connecting rods with come a longs and line the inner surfaces of the crosshead guides with wood or heavy cardboard to protect them from damage when removing the crankshaft assembly 2 Unbolt and remove the main bearing cover NOTE This will allow access to the main bearings for lubrication and basic maintenance However in order to perform full maintenance on the bearing...

Page 75: ...haft main bearing housings 5 Slowly lift the crankshaft assembly free of the pump frame WARNING The crankshaft assembly is an extremely weighty system and can cause damage serious injury and death if dropped or if allowed to impact other objects or personnel Handle with extreme care and follow all applicable safety procedures when lifting this system ...

Page 76: ...g carrier or to remove the main bearing from a crankshaft that has already been removed from the power frame 1 Remove the main crankshaft assembly as per 5 2 4 and support the crankshaft assembly so that the load is not resting on the main bearings 2 Loosen the main bearing To do so loosen the bolts on the outer retainer 2 or 3 turns and then inject grease into the grooves in the race until the be...

Page 77: ...y Disassembly weatherford com 71 MP 16 2 Piece 5000 psi January 2013 3 Remove the bolts and inner retainer from the main bearing 4 Slide the main bearing and shims free of the crankshaft 5 Remove the main bearing oil seals from the crankshaft ...

Page 78: ... stored separately to avoid confusion 1 Remove the main bearings as per 5 2 5 and support the crankshaft assembly so that the load is not resting on the connecting rods 2 Unbolt and remove the outer bearing retainer from the crankshaft 3 Carefully slide the connecting rod off of the crankshaft Note that the outer race of the crankpin bearing will remain attached to the connecting rod exposing the ...

Page 79: ...psi January 2013 4 Unbolt and remove the inner bearing retainer from the crankshaft WARNING Make sure that all bearing parts are kept with the same bearing Do not mix parts between the bearings 5 Slide the crankpin bearing inner race off of the crankshaft 6 Remove the crankpin bearing shoulder ...

Page 80: ...the bearing to push or pull the outer race of the wrist pin bearing from the connecting rod NOTE Do not drive the bearing from the rod with a hammer as this may damage the bearing 2 If the inner race of the wrist pin bearing needs to be replaced it may be slipped off of the wrist pin by heating it with a torch The bearing race should not have to be raised to over 200 F to press the wrist pin out o...

Page 81: ...dure to remove the crosshead guides 1 Remove the Crossheads as per 5 2 2 2 Remove the four 4 bolts which affix the crosshead guides to the frame NOTE The upper guides are only affixed to the frame by the bolts and so must either be secured or removed during the unbolting procedure 3 Remove the crosshead guides Shims if present should be left in place if the guide is to be reinstalled If not a new ...

Page 82: ...ear If it does become necessary to remove the Main Gear use the following procedure 1 Remove the connecting rods from the crankshaft as per 5 2 6 2 Unbolt the main gear from the crankshaft 3 Slide the main gear from the crankshaft The gear may have a slight shrink fit to the crankshaft so exercise care not to warp or damage the gear during removal NOTE It is helpful to place match marks on the cra...

Page 83: ...The following procedure outlines the removal of the pinion shaft bearings 1 If necessary unscrew and remove the key from the pinion shaft keyway 2 Disconnect the oil lube lines and drain and then unbolt the pinion oil seal plate Be sure to support the pinion shaft to prevent it from moving 3 Slide the oil seal plate and spacer free of the pinion shaft ...

Page 84: ...e 5000 psi January 2013 4 Remove the pinion oil seal and race from the pinion shaft 5 Unscrew and remove the bolts and washers securing the pinion bearing carrier to the power frame 6 Use the jackscrew holes in the pinion bearing carrier and remove it and the spacer from the power frame ...

Page 85: ...ill be shrunk fit onto the pinion shaft and it is important to protect the finish of the inner race if the bearing is to be reused 8 Remove the Pinion Bearing Carriers as per 5 2 10 9 Slide the shaft out of the pump frame Since the bearings are carrier mounted the shaft can be removed out of either side of the frame However be sure to note its original orientation as it should be replaced facing t...

Page 86: ...should use lock nuts and security washers should be used on all bolts in tapped holes inside the pump 5 3 1 Installing the Pinion Shaft Bearings It is possible to install the pinion assembly with or without crankshaft and gear in place Use the following guidelines to install the pinion shaft 1 Install the pinion bearing inner races on the pinion shaft by heating to 300 F in an oil bath electric ov...

Page 87: ... into the pump before installing the bearing carrier assemblies Make sure the pinion shaft is properly supported before proceeding 4 Slide the bearing carrier assemblies and gaskets over the pinion shaft and into the pump frame exercising caution as they meet the inner race 5 Install the pinion oil seal and race onto the pinion shaft ...

Page 88: ...Disassembly weatherford com 82 MP 16 2 Piece 5000 psi January 2013 6 Reinstall the oil seal place and spacer on the pinion shaft 7 Once all maintenance is complete reconnect the oil lube lines and pressurize the system Reattach key as required ...

Page 89: ...ft assembly is an extremely weighty system designed to withstand intense pressures and can cause significant damage serious injury and death if dropped or if allowed to impact other objects or personnel Ensure it is properly supported and secure before taking any other steps 2 Slide the gear over the pilot on the crank This may require heating the gear If that is the case then be sure to uniformly...

Page 90: ... 5000 psi January 2013 3 Install and tighten the bolts on the gear as per the Torque Chart on page 49 Always use new bolts when mounting the main gear 4 Reinstall the connecting rod between the right end of the crankshaft and the gear as per 5 3 3 Installing the Connecting Rods Bearings ...

Page 91: ...ing rod first and then the outer bearings All bearings must be placed against a stop such as a shoulder or a set of bolt retainers and should be placed so that the roller assembly may be removed by removing the retainer rings Use the following procedure 1 Heat the connecting rods bearings in an electric oven or oil bath to 200 F Each bearing consists of 3 parts outer race inner race and rollers wh...

Page 92: ...2 Piece 5000 psi January 2013 3 Slide the heated bearing onto the crankshaft with the loose ring leading 4 Install the inner retainer to lock the bearing into place 5 Slide the connecting rods back into position on the crankshaft exercising care not to bump or damage the main gear ...

Page 93: ...sembly weatherford com 87 MP 16 2 Piece 5000 psi January 2013 6 Secure the connecting rod into position by installing the outer bearing retainer 7 Reinstall the main bearings as per 5 3 4 8 Reinstall the crankshaft into the power frame as per 5 3 6 ...

Page 94: ... Installing the Main Bearing Install the main bearings onto the crankshaft 1 Reinstall the connecting rods as per 5 3 3 and check that the ends of the crankshaft and bearings are grease free 2 Reinstall the main bearing seals 3 Install the main bearings into the bearing carriers Secure using the outer retainer ring ...

Page 95: ...mbly Disassembly weatherford com 89 MP 16 2 Piece 5000 psi January 2013 4 Slide the main bearing and carrier onto the taper 5 Install the inner retainer of the main bearing and bolt all retainers in accordance with the Torque Chart page 49 ...

Page 96: ...form heat WARNING During this process parts can become extremely hot Allow a few minutes after heating for the gear to stabilize and handle with care Do not overheat or apply flame directly to the connecting rods 2 Slide the outer race of the wrist pin bearing onto the connecting rod ensuring that the ends of the bearing are flush with the sides 3 Heat the inner race of the wrist pin bearing and t...

Page 97: ...to the power frame taking care that it is well supported throughout this process and avoiding sudden or jerky movements Be sure to cover the crosshead guides with wood or cardboard to prevent damage WARNING The crankshaft assembly is an extremely weighty system and can cause damage serious injury and death if dropped or if allowed to impact other objects or personnel Handle with extreme care and f...

Page 98: ... Systems Chapter 5 Assembly Disassembly weatherford com 92 MP 16 2 Piece 5000 psi January 2013 3 Replace the rear cover of the power frame and secure into place 4 Reattach the main bearing covers onto the power frame ...

Page 99: ...are reinstalled in the exact location that they were removed from Failure to do so will result in excessive piston and liner wear 1 Insert and position the crosshead guides within the frame see above note then bolt to secure 2 Install the outer race of the wrist pin bearing as per 5 3 5 Installing the Wrist Pin Bearing and then pack the wrist pin bearing rollers with grease to ensure that the roll...

Page 100: ...pin into the wrist pin bearing and gently push into position NOTE Do not force or drive the wrist pin The pin should be a close tight fit but it must not bind the bearing 5 Bolt the wrist pin to secure into place and the reinstall the name plates on the side of the pump 6 Slide the extension rod into position on the crosshead and bolt to secure ...

Page 101: ... Piece 5000 psi January 2013 7 Replace the diaphragm plates and bolt into position in the power frame 8 Check the wiper box for damaged or defective components then reinsert into position on the diaphragm and bolt to secure 9 Reinstall the baffle into position on the extension rod ...

Page 102: ...on the crossheads Sometimes known as the Wrist Pin Bushing Breather A vent which allows for pressure equalization between the inside and the outside of the pump Bull Gear See Main Gear Bypass Line A length of piping leading off the main line used to vent excess pressure from the pump Bypass Valve See Valve Bypass Cage Guard A safety system consisting of a wire mesh cage which surrounds and prevent...

Page 103: ...e manifold and to prevent return flow Drain Valve See Valve Drain Drilling Fluid The fluid used when drilling wells Also known as Mud Drilling Mud See Drilling Fluid Drive System A system which provides power transmission and speed reduction from the prime mover to the pump power end Usually includes a manual pump rotating device Drive Chain A drive system consisting of a multiple strand roller ch...

Page 104: ...screws into place over the liner bushing to hold the liner in place Also known as the Liner Retainer Nut Liner Retainer See Liner Bushing Liner Retainer Nut See Liner Lock Ring Liner Spray System See Liner Wash System Liner Wash Pump See Pump Liner Wash Liner Wash System A lubrication system consisting of a number of valves which spray lubricants onto the pistons and extension rods Also known as t...

Page 105: ...flow to the suction of the main pump Pump External Lubricating An electrically powered pump located outside of the power frame which provides lubrication pressure to the pump crankcase Pump Internal Lubricating A crankshaft powered pump located inside of the crankcase which provides it with lubrication pressure Pump Liner Wash An electric centrifugal pump circulating liner wash and cooling fluid f...

Page 106: ... a bracket to keep the fastener from loosening Torque A measure of twisting force usually indicated in terms of foot pounds Triplex Pump See Pump Triplex Valve A structure which regulates the flow of fluid through a system by opening and closing under set conditions Valve Assembly A configuration of parts including but not limited to the valve itself a seat spring and spring retainer all in normal...

Page 107: ... through which the extension rod reciprocates and in which liquid leakage is controlled by means of wipers Wrist Pin The component which connects the connecting rod to the crosshead Wrist Pin Bearing See Bearing Wrist Pin Zerk Fitting A lubrication fitting in mechanical systems used to allow grease to be added with a grease gun ...

Page 108: ...mp made and so may include parts and systems that are not included on the particular unit this manual came with For a specific list of exactly which parts and components are on a particular unit consult the specifications sheet that came with the pump 7 1 Power End Assembly Item Description Part Number Qty Assembly Power End 1138827 1 1 Assembly Crankshaft 0908406 1 2 Assembly Pinion 0908407 1 3 A...

Page 109: ...15931 Assembly Power Frame 1 1 1134668 Cover Power End Rear 1 2 1133853 Bolt Main Bearing Housing 4 3 1128575 Cap Breather 3 4 1814075 Machining Power Frame 3 5 0908884 Cover Main Bearing 2 6 1133830 Gasket Main Bearing Cover 2 7 1124677 Bolt 11 UNC x 1 24 8 0879134 Washer Flat 24 9 1134280 Cover Crosshead 2 10 1771957 Gasket Crosshead Cover 2 11 1134670 Screw 28 ...

Page 110: ...bly Item Part Number Description Qty 0908406 Assembly Crankshaft 1 1 1133837 Retainer Inner Race 2 2 1124696 Bolt Retainer 40 3 1134816 Retainer Outer Race 3 4 1133857 Bearing Crankpin 3 5 0908427 Strap Eccentric 3 6 0908384 Crankshaft 1 7 0908408 Gear Main 1 8 1124662 Cap screw 1 8 UNC X 4 12 9 1133856 Nut Lock 1 8 UNC 12 ...

Page 111: ... 3 Main Bearing Assembly Item Part Number Description Qty 1 1133852 Retainer Main Bearing Inner 2 2 1124696 Cap screw DH 11 UNC x 1 32 3 1134820 Retainer Main Bearing Outer 2 4 1133859 Bearing Main 2 5 1134819 Carrier Main Bearing Left 1 1133825 Carrier Main Bearing Right 1 6 1133846 Spacer Main Bearing 2 ...

Page 112: ...24735 Washer Lock M14 12 3 1134036 Carrier Oil Seal 2 4 1134037 Gasket Oil Seal Carrier 2 5 1134027 Ring Oil Seal Wear 2 6 1124733 Seal Oil 8 x 10 x 2 7 0908359 Bearing Pinion Shaft 2 8 1124732 Cap screw HH 9 UNC x 2 16 9 0885578 Washers Lock M22 16 10 1134040 Carrier Pinion Bearing 2 NS 1134039 Gasket Oil Seal Carrier 2 11 1134026 Shaft Pinion 1 12 1124713 Key 2 x 2 x 8 2 NS 1134043 Turning Tool ...

Page 113: ...ead 1 5 1134267 Bolt Extension Rod 8 6 0908402 Rod Crosshead Extension 1 7 1134266 Baffle Fluid Disc 1 8 1134264 Gasket Wiper Box 1 9 1134263 Box Wiper 1 10 1124899 Cap screw HH 16 UNC x 1 4 11 0908042 Washer Lock 1 12 1317769 Seal Single Lip 1 13 1123535 Spring Wiper Box 1 14 1317786 Seal Double Lip 1 15 1124898 O Ring 140 x 7 1 16 1134271 Retainer Ring Wiper Box Seal 1 NS 1134260 Guide Upper Cro...

Page 114: ... Fluid End 1 1 1134306 Manifold Suction 1 2 0767109 Gasket Suction Manifold 3 3 1257196 Bolt Suction Manifold Mounting 24 4 1134290 Manifold Discharge 1 5 1231042 Seal Discharge Manifold 3 6 1738845 Stud Nut Discharge Manifold Mounting 12 7 1903638 Stud Nut Fluid End Mounting 30 8 1317809 Seal Module 3 9 1317069 Flange Liner Retainer 3 10 1383132 Screws Cap Liner Plate Retainer 24 ...

Page 115: ...Description Qty 1 1317027 Module Suction Studded 1 2 1317854 Stud Tapered with Nut 12 3 1317966 Gland Valve Cover Screw 1 4 1317905 Flange Valve Cover 1 5 1317766 Seal Valve Cover NBR 1 Item Part Number Description Qty 1 1317949 Plug Valve Cover with Valve Gate 1 2 1317926 Guide Valve Bushing 1 3 1738844 Stud Valve Guide with Lock Nut 2 4 1317889 Bushing Valve Guide 1 5 1012724 Nut Lock 2 ...

Page 116: ...e 1 2 1738845 Stud Discharge Manifold Mounting with Nut 6 3 1903638 Stud Power End Mounting with Nut 10 4 1317854 Stud Flange Mounting with Nut 12 5 1418005 Stud Suction Module Mounting with Nut 6 6 1317966 Gland Valve Cover Screw 1 7 1317905 Flange Valve Cover 1 8 1317766 Seal Valve Cover 1 9 1418004 Locating Pins 2 10 1383132 Bolt liner mounting plate 8 11 1317069 Flange Liner Mounting MP 16 1 ...

Page 117: ...ket Liner 3 NS 1878015 Plate Liner Wash Baffle 1 5 1317809 Seal Wear Plate 3 6 1317089 Ring Liner Retainer Pilot 3 Liners Liner Gaskets Liner Size Chrome Iron Zirconia Ceramic Rubber Urethane 4 000 1317099 1317116 1317805 1317807 4 500 1317159 1317175 1317805 1317807 5 000 1317213 1317225 1317805 1317807 5 500 1317264 1317276 1317805 1317807 6 000 1317313 1317324 1317805 1317807 6 500 1317359 1317...

Page 118: ...1 NS 1878015 Liner Baffle 1 Item Description Bonded DD Urethane Bonded DD HT Urethane Bonded Nitrile Replaceable Nitrile Complete 8A Replaceable Nitrile Rubber 8B Qty 8 Piston 4 00 inch 1317542 1317541 1317543 1317544 1317520 3 Piston 4 50 inch 1317550 1317549 1317551 1317552 1317522 3 Piston 5 00 inch 1317558 1317557 1317559 1317560 1317524 3 Piston 5 50 inch 1317566 1317565 1317567 1317568 13175...

Page 119: ...1318061 1318056 1318055 1318058 1318057 3 1a Replaceable Insert 1317998 1317994 1317995 1317996 1317997 3 2 Valve Spring CS 1318029 1318029 1318027 1318027 3 Valve Spring SS 1318037 1318037 1318031 1318031 1318035 1318035 3 3 Valve Seat 1318014 1318014 1318012 1318012 1318013 1318013 6 NS Puller Head 1317878 1317878 1317876 1317876 1317877 1317877 3 NS Valve Seat Puller Kit 1241141 1241141 1241141...

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