Gardner Denver GD-2250T Operating And Service Manual Download

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ECN 1058968

GARDNER DENVER

301THD996 Revision D

April 2011

GD-2250T

WELL SERVICING PUMP

OPERATING AND

SERVICE MANUAL

Summary of Contents for GD-2250T

Page 1: ...ECN 1058968 GARDNER DENVER 301THD996 Revision D April 2011 GD 2250T WELL SERVICING PUMP OPERATING AND SERVICE MANUAL ...

Page 2: ...killed 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 refer to the yellow pages of your phone directory or contact Factory Tulsa Service Center Odessa Service Center Ft Worth Gardner Denver Well Servicing Pumps 4747 South 83rd East Avenue Tulsa Okla...

Page 3: ... operation 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 Warning is used to indicate the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning is ignored CAUTION Caution is used to indicate the pre...

Page 4: ...uctions for Ordering Repair 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 13 Section 4 Service Procedures 20 Section 5 Trouble Shooting 27 Section 6 Rebuilding Data Recommended Running Clearances 33 Warranty 35 ...

Page 5: ...17 Oil Stop Head Seal Gear Covers 23 Performance Rating GD 2250T 12 Periodic Routing Maintenance Schedule 17 Plunger Packing Lubrication 16 Plunger Packing Lubrication Recommendation Chart 19 Plungers and Packing Replacement 21 Power End 10 Power End Internal Lube Sytem 11 Power End Lubrication System 14 Power End Service 23 Preparation after Shipping and Storage 13 PREPARATION OPERATION AND MAINT...

Page 6: ... Power End Mounting Hole Pattern 13 Figure 3 2 Alternate Power End Mounting Hole Pattern 14 Figure 3 3 Power End Lubricant Recommendations 14 Figure 4 1 Fluid End Stay Rods Hex Nuts Tightening Sequence 21 Figure 4 2 Packing Assembly 21 Figure 4 3 Valve Cage Spring Retainer 22 Figure 4 4 Gunsight Spring Retainer 22 Figure 4 5 Conn Rod Crosshead Extension Rod Assembly 24 ...

Page 7: ...uired when 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 drugs The timely replacement of expendable parts and any other worn or damaged parts can prevent equipment damage and possible injury The original parts used in Gardner Denver pumps are designed...

Page 8: ...acked 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 hands and the hammer handle and maintain a firm grip on the handle to avoid losing control of the hammer while swinging and striking Carefully swing the hammer to avoid striking themselves anot...

Page 9: ...301THD996 Page 3 ...

Page 10: ... package unit support 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 into the individual motor engine pump or transmission torque converter or their separate support skids When lifting subassembled components for example a suction stabilizer attached t...

Page 11: ...cked and all the discharge 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 adequacy With time wear corrosion and fatigue can reduce the strength of all components Magnetic iron and steel components should be checked with magnetic particle or dye penetrant c...

Page 12: ...ually monitor the entire suction discharge and pump lubricating 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 When a gasketed joint is disassembled for any reason discard the used gasket and replace it with a new genuine Gardner Denver gasket befo...

Page 13: ...301THD996 Page 7 Pressure Equipment Directive 97 23 EC ...

Page 14: ...d 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 Heavy duty cradle covers must be securely fastened in the proper position on the pump at all times when the pump is operating If the pumped fluid releases harmful explosive or f...

Page 15: ...erious personal injury or death and can also change valve or control settings which could dangerously increase the delivery pressure to the pressure and flow directing device When operating a pressure and flow directing device use only equipment which automatically shuts off flow when an operator releases hand or foot pressure on the pressurized flow trigger control to prevent injury if the operat...

Page 16: ...the wand nozzle gun etc to pry loose material off items being cleaned Before starting operation in a cold environment check to make sure there is no ice in the fluid system and repeat this inspection each time before operation is restarted Before purchasing wands nozzles guns connections hoses etc manufacturers of these components should be contacted for detailed information on the design and safe...

Page 17: ...ear Manufactures 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 dangers inherent in the operation of a high pressure pump To avoid accidents and injuries all safety rules listed in this section and also all other applicable safety rules and regulations must be carefully observed The se...

Page 18: ...r application NOTICE The direction of rotation must be such that the top side of the crankshaft is moving towards the fluid end FIGURE 2 2 GD 2250T POWER END CROSS SECTION CROSSHEAD ASSEMBLY The crosshead assembly features a one piece high strength connecting rod This connecting rod is a much more durable design than the old multiple piece connecting rods commonly used by other companies This one ...

Page 19: ...rust bearings 2 Through the lubrication manifold oil is distributed to the main bearings and the outside of the crosshead There is a 4 drain hole on the bottom of the power frame User plumbing will direct drain oil flow back into the lube reservoir Packing components are lubed separately The drain from the packing is held in the drip pan FLUID END The conventional valve over valve configuration of...

Page 20: ...RFORMANCE RATING U S 100 RPM 150 RPM 200 RPM 330 RPM Plunger Size Inches GPR GPM PSI GPM PSI GPM PSI GPM PSI 7 5 4 59 459 5379 688 5044 918 3783 1514 2293 7 0 4 00 400 6174 599 5790 799 4343 1319 2632 6 75 3 72 372 6640 557 6227 743 4670 1226 2830 6 50 3 45 345 7161 517 6715 689 5036 1137 3052 6 00 2 94 294 8404 440 7881 587 5911 969 3582 5 75 2 70 270 9151 404 8581 539 6436 890 3900 5 50 2 47 247...

Page 21: ...tion openings 3 Drain oil from the power end and the gear reduction unit 4 Flush the power end with a rust preventative before flushing make sure that the 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 exposed bare metal with heavy rust preventive 7 Plug drain holes at the bottom of the pump fra...

Page 22: ...suction line independent of the pump suction manifold Fluid adds weight to the suction line 8 The use of suction stabilizers is always recommended 9 The discharge line should include swivels for flexibility or hose Support the discharge line and tie it down with vibration isolators 10 Allow 1 8 driveline end float CHARGING PUMP REQUIREMENT A centrifugal pump will be required to prime the fluid end...

Page 23: ...em should be filtered with a minimum 25 micron filter or finer per API specification 2 9 1 5 5 The suction pipe should be kept as short as possible and free of bends 6 Warning devices to monitor lube oil pressure and temperatures are highly recommended The triplex pump operates at very high rod loads and pressures and malfunction of the lube system may result in serious damage occurring in a very ...

Page 24: ...Page 16 FIGURE 3 3 Lubricant Recommendations ...

Page 25: ...rvoir with the recommended grade of oil See figure 3 2 above for power end Lubricant Recommendations 2 Fill the plunger reservoir with proper oil See Plunger Packing Lubrication Recommendations on Page 19 3 Remove all inspection covers on the top of the pump frame 4 Start the engine at the lowest possible RPM and operate pump at minimum pressure 100 psi Make sure that all roller bearings crosshead...

Page 26: ...e Startup and New Pump Run In Procedure page 19 Daily Routine Maintenance Tasks 1 Check the oil level in the lube oil reservoir 2 Periodically monitor lube oil operating pressure and temperature The maximum lube oil operating temperature depends on a particular grade of oil used in the pump lube system See FIGURE 3 3 3 Check the lube pump suction inlet vacuum A vacuum gage reading higher than 8 Hg...

Page 27: ...eplace the breather cap filter element 6 Check all pressure temperature and vacuum gages for proper operation and replace as necessary 7 Check all lube system warning and alarm devices for proper operation and replace if found defective 8 Check supply of on hand expendables such as packings valves and seats maintenance items such as seals O rings oil and breather filter elements and also maintenan...

Page 28: ...lips Petroleum 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 Texaco Oil Co Rockdrill Oil XL 40 F Rockdrill Oil XM 0 F Rockdrill Oil XH 10 F Union Oil of Ca Marok 150 STEAM CYLINDER OILS HIGH TEMPERATURE PUMPED FLUIDS Source Type Amoco Amoco Cylinder Oil ...

Page 29: ...d while working on 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 expendable parts such as valves valve seats plungers and packing Fluid End Removal 1 Disconnect suction manifold from unit piping and discharge lines at the discharge flanges on the fluid ...

Page 30: ...equence 6 Re install the plunger clamps piping connections and auxiliary equipment Plunger and Packing Replacement This service procedure can be performed with the fluid cylinder in place on the pump and consists of the following steps 1 Remove the suction cover retainer nut with the appropriate male hex wrench 2 Remove the suction cover with a threaded slide hammer type puller If necessary also r...

Page 31: ...ols required for this procedure are available For part numbers of the tools see Parts Manual WARNING Never try to remove or cut a valve seat with a torch Severe damage to the fluid end may occur 1 Remove the discharge cover retainer nut with the hex wrench provided with the pump 2 Remove the discharge cover with a slide hammer type puller 3 Remove the suction cover retainer nut with the proper hex...

Page 32: ...d retainer cap screws and remove the Head 5 Remove rotary union seals and oil hoses from gear covers 6 Remove input seal housing from left hand cover 7 Remove the cap screws in gear covers Covers can now be removed Crosshead Assembly FIGURE 4 5 1 Remove the fluid end following the procedure described in Fluid End Removal and Installation page 20 2 Remove the oil stop head seal retainer and off dri...

Page 33: ...shead Guide and Stay Rods 1 The crosshead guides or slide should be replaced if excessively worn or damaged See Clearances page 33 2 If the crosshead guides must be replaced it is recommended that it be done either by Gardner Denver or a qualified machine shop 3 The stay rods are threaded into the power frame They can be easily replaced by unscrewing and re torquing new rods See Torque on pg 34 4 ...

Page 34: ...ould come up and over the top of the pump out to the centerline for easy balanced lifting of the crankshaft This tool must be capable of lifting the crankshaft in a horizontal position 7 The crankshaft is now free to move 8 Install the special crankshaft lifting tool and balance the crank with an overhead lift 9 Thread the crankshaft through the bearing races until all of the bearings are free 10 ...

Page 35: ...e only against the bearing race as severe damage to the bearings could occur WARNING When reassembling the crankshaft assembly make sure to follow these steps 1 Pack the outer races in dry ice before assembling in the frame 2 Heat the inner bearing races before installing on crankshaft 250 F max oven or oil bath 3 Braze the retaining rings on the crankshaft Avoid direct contact with the inner race...

Page 36: ...e 3 Clogged 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 open 2 Remove the obstruction 3 Pump cavitating 3 See Cavitation Fluid Knock or Hammer problem 4 Fluid leakage 4 Replace plungers packing and or fluid end seals 5 Erroneous gauge reading 5 Recalib...

Page 37: ...ttling 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 12 Repair and recharge escaping from suction stabilizer stabilizer 13 Multiple pumps operating in 13 Use a suction stabilizer phase on each pump Separate lines may also be needed Suction or Discharge...

Page 38: ...noise 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 Noise 1 Pump cavitation 1 See Cavitation Fluid Knock or Hammer problem 2 Seal on inserted valve 2 Replaced seal or valve damaged or missing 3 Broken weak valve spring s 3 Replace spring s Oil Lea...

Page 39: ...ve and 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 damaged or corroded 1 Replace extension rod Crankcase extension rod 2 Worn oil stop head seal 2 Replace seal 3 Stuffing box leakage 3 See Stuffing Box Leakage problem Short Valve Life 1 Abrasives i...

Page 40: ...tions 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 8 Pump cavitating 8 See Cavitation Fluid Knock or Hammer problem Catastrophic Failures 1 Pump overloaded 1 Reduce pump speed and or Broken Shafts pressure Bent Rods etc 2 Start up against close...

Page 41: ... or Hammer 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 Check nut seat surface for nut seating flatness Rework or replace as required 4 Corrosive attack by pumped 4 Treat fluid or use corrosion fluid resistant studs 5 Studs damaged before 5 Check co...

Page 42: ...ing Rod Bearing Bore Assembled in Bearing Housing 7 254 7 259 Crosshead Guide Bore 9 877 9 880 Crosshead OD 9 860 9 855 Wristpin Dia 2 500 2 499 Wristpin Bushing Bore 2 503 2 505 RECOMMENDED RUNNING CLEARANCES ACTUAL New in Maximum Allowable Wear Limit in Connecting Rod Bearing to Crankshaft 007 011 018 Crosshead Knuckle to Thrust Bearing 0005 0020 006 Main Bearing Installed Clearance 002 008 019 ...

Page 43: ... 58 Pinion Bearing Housing 3 4 10 160 Conn Rod to Bearing Housing Stud 3 4 10 Hand Tighten Conn Rod to Bearing Housing Nut 3 4 10 280 Suction Manifold to Fluid End 7 8 9 340 Discharge Flange to Fluid Cylinder Nuts 1 8 511 Rod Cap to Rod Fasteners 1 8 475 Bull Gear Retaining Screws Gr 8 1 1 4 7 1350 Fluid End to Stay Rods Nuts 1 3 4 8 2000 Stay Rods into Frame 1 3 4 8 1000 2 8 1300 Extension Rod to...

Page 44: ...e Warranty 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 Power end is warranted for twelve 12 months from date of start up or eighteen 18 months from date of delivery to the Purchaser whichever occurs first 2 Forged steel fluid cylinders are warranted for...

Page 45: ...the foregoing 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 extent the Company is able to enforce such warranty or guaranties The Company has not authorized any party to make any representation or warranty other than as expressly set forthherein SELLER HERE...

Page 46: ...uant to 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 in writing by the Company prior to shipment All requests for product return shall be submitted by email Facsimile or letter to Warranty Department c o Gardner Denver Petroleum Pumps 4747 South ...

Page 47: ...l 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 Copyright 2001 Gardner Denver Inc Litho in U S A ...

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