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DANGER 

 

Failure  to  follow  safe  and  proper 
pump,  pump  package  or  component 
lifting or moving procedures can lead 
to  personal  injury,  death  and  /or 
equipment  damage  from  shifting, 
falling 

or 

other 

unexpected 

or 

uncontrolled equipment movements. 

 

 
Make sure the hoist, lift truck, ropes, slings, 
spreader  bar  or  other  lifting  equipment  you 
are  using  is  in  good  condition  and  has  a 
rated lifting capacity equal to or greater than 
the weight being lifted.  Lifting devices must 
be  checked  frequently  for  condition  and 
continued  conformance  to  rated  load 
capacity.    They  should  then  be  tagged  with 
the  rated  capacity  together  with  the  date  of 
inspection. 
 
Fully 

assembled 

pumps 

and 

pump 

packages  are  heavy  and  should  only  be 
moved  using  the  specified  lifting  lugs  or 
attachments.  
 
Many individual components have lifting 
eyes  or  lugs  which  must  not  be  used  to 
lift  assemblies,  as  they  are  designed  to 
bear the weight of the component only. 
 
Before  lifting  the  individual  component 
check  to  insure  the  lifting  attachment  is 
firmly  secured  to  the  component  with 
undamaged,  properly  torqued  fasteners, 
sound  welds,  or  other  secure  attachments.  
Examine  the  lifting  eyes,  lugs,  slots,  holes 
or  other  projections  to  insure  they  are  not 
cracked,  otherwise  damaged  or badly worn.  
The  repair  of  existing  or  addition  of  new 
welded lifting eyes, lugs or other projections 
should  only  be  performed  by  experienced, 
qualified welders. 
 
Package  units  should  be  lifted  with 
spreaders 

connected 

to 

the 

lifting 

attachments  normally built into the package 
unit support skid.  Packages too large to lift 
as fully assembled should be separated into 
smaller loads. 
For  these  smaller  loads  the  lifting  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  sub-assembled  components, 
for  example  a  suction  stabilizer  attached  to 
suction  piping  or  a  discharge  pulsation 
damper  attached  to  a  strainer  cross  and 
piping,  use  special  lifting  slings  designed to 
safely  support  the  combined  weight  of  the 
components. 
 
If  a  crane  or  hoist is being used to lift large 
components  or  assemblies,  one  or  more 
persons  should  assist  the  operator  from the 
ground  with  guide  lines  attached  to  the 
equipment being moved to properly position 
it and prevent uncontrolled movement. 
 
When you start to lift a pump, package unit, 
subassemblies  or  individual  components 
and  you  observe the equipment is tilting, or 
appears  unbalanced,  lower  the  equipment 
and  adjust  the  lifting  device  to  eliminate 
these  improper  lifting  conditions  before 
proceeding to move the equipment. 
 
It  is  poor  practice  and  dangerous  to  allow 
the equipment to pass over or close to your 
body or limbs.  Be prepared to move quickly 
out of danger if equipment starts to fall, slip 
or move unexpectedly toward you. 
 
PRESSURIZED PUMP SYSTEMS 

 
 

 

DANGER 

 

Fluids  under  high  pressure  can 
possess  sufficient  energy  to  cause 
personal 

injury, 

death 

and/or 

equipment  damage  either  through 
direct  contact  with  escaping  fluid 
streams  or  by  contact  with  loose 
objects the pressurized fluid propels. 

Содержание C2500Q QUINTUPLEX

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 32: ...Page 26...

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

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

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

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

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

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

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

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

Страница 41: ...Page 34...

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

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

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

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

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

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