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300FWF996     Page 7

the  backward  thrust  of  a  hand  held  device.
In  addition,  a  safety  harness  or  safety  net
must  be  used  when  working  in  an  area
where the operator could be injured in a fall.
Stand to the side of any tubing or container
being  sprayed  to  avoid  back  spray  and
never  operate  a  hand  held  device  above
shoulder level.

Never  direct  the  pressurized  fluid  stream  at
yourself or any other person, control valves,
the  pump, pump  drive, suction  or  discharge
systems.  

The  pressurized  stream  can

cause  serious  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 operator is overpowered
or becomes disabled.

Check  to  insure  this  automatic  shut-off
equipment  is  operating  properly  before
every  use  and  never  circumvent  the
automatic  shut-off  for  any  reason  or  by  any
means when operating the equipment.

When  operating  any  type  of  high  pressure
liquid  jetting,  blasting  or  cleaning  devices,
the  operators  must  always  wear  protective
clothing  including,  but  not  limited  to,  a  hard
hat with full face visor, heavy duty rain coat
and  pants,  boots  with  nonskid  sole  and
safety  toe,  rubber  gloves  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  should
take  frequent  rest  breaks  and  cease
operations  when  they  become  tired  or
distracted.

Before  the  equipment  is  started,  the  work
area  must  be  inspected  and  properly
prepared  to  avoid  personal  injury,  death,
and/or  damage  to  equipment.   Make  sure

the  work  area  is  checked  for  hazardous
fumes,  has  adequate  ventilation  for  engine
exhaust and sufficient drainage for released
fluid.   Check  the  work  area  for  electrical
equipment,  connections,  outlets,  fixtures,  or
lines.  If any are present they must be made
watertight  and  the  electrical  power  to  these
devices  must  be  shut  off  to  avoid  electrical
shocks  from  fluid  contact.   The  work  area
should  be  clearly  marked  and  roped  off  to
keep unauthorized people and vehicles from
entering.   Remove all loose parts, tools and
equipment  from  the  work  area  before
beginning operation.

All  pressure  containing  devices  including
wands,  nozzles,  guns,  hoses,  connections,
etc.,  should  be  regularly  checked  for
condition.   These components should all be
tagged with their tested pressure capabilities
together 

with 

the 

date 

testing 

was

performed.  

Always  be  aware  of  the

pressure  level  in  the  system  and  never
connect  any  equipment  to  the  system
which  has  a  rated  or  tested  pressure
capability  below  the  system  operating
pressure.
   The  equipment  must  be  shut
down  and  the  system  pressure  released
before  changing  or  disconnecting  wands,
nozzles,  guns,  hoses,  connections  or  any
other pressurized system components.

All  pressure  containing  devices  including
wands,  nozzles,  guns,  connections,  etc.,
plus  all  automatic  shut-off,  pressure  and
control  equipment  should  be  treated  with
care.  Protect them from damage by people,
objects and vehicles.  Never lay them in dirt,
mud,  ice  or  other  loose  material  that  could
plug  the  fluid  opening  or  interfere  with  their
operation.   Never  use  the  wand,  nozzle,
gun,  etc.  to  pry  loose  material  off  items
being cleaned.

Before 

starting 

operation 

in 

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

HALLIBURTON EXHIBIT 1013, Page 13

Содержание GD-2500Q QUINTUPLEX

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

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

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

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

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

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

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

Страница 8: ...goggles Check to insure they have safe footing Fully engage the wedge to prevent it from disengaging violently from the cover as a blow is struck Wipe their hands and the hammer handle and maintain a...

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

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

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

Страница 12: ...umping units where flammable or explosive vapors could form should be equipped with an air inlet shut off If flammable or explosive vapors are present in the pumping site atmosphere an engine could co...

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

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

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

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

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

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

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

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

Страница 21: ...eventative will not clog the oil passages 5 Remove the breather and either plug or tape the opening 6 Coat the gear reducer input shaft and all exposed bare metal with a heavy rust preventive 7 Plug d...

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

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

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

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

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

Страница 27: ...pump FLUID END SERVICE This discussion starts with the description of steps necessary for removal and installation of the fluid cylinder assembly and proceeds to the removal and replacement of expenda...

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

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

Страница 30: ...d end tapered bores POWER END SERVICE DANGER Before attempting to service the power end of the pump the following safety precautions must be observed 1 Shift the pump transmission into the neutral gea...

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

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

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

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

Страница 35: ...line 3 Clean out line 4 Suction and or discharge 4 Remove the obstruction valves propped open Low Discharge Pressure 1 Worn or fluid cut valve 1 Replace valve assembly 2 Valve propped open 2 Remove t...

Страница 36: ...in supply tank Reduce pump speed 10 Air entering suction line 10 Repair suction line 11 Air entering charging pump 11 Tighten or replace shaft packing or seal 12 Air entering or charge gas 12 Repair a...

Страница 37: ...to 11 See Excessive Valve power end Noise problem 12 Cavitation noise transmitted 12 See Cavitation Fluid to or causing shock loading in Knock or Hammer problem power end Excessive Valve Noise 1 Pump...

Страница 38: ...Corrosion due to wrong 4 Determine and install correct stuffing box material stuffing box for pumped fluid 5 Stuffing box bore worn 5 Replace stuffing box Pumped Fluid In 1 Worn damaged or corroded 1...

Страница 39: ...rvice 5 Wrong size packing 5 Install correct size packing 6 Improper packing installation 6 Check installation procedure and install correctly 7 Excessive crosshead wear 7 Replace crosshead 8 Pump cav...

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

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

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

Страница 43: ...ours of operation or three 3 months after start up not to exceed 120 days after delivery to Purchaser whichever occurs first The exceptions are as follows 1 Power end is warranted for twelve 12 months...

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

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

Страница 46: ...r Gardner Denver Inc 4747 South 83rd East Avenue Tulsa OK 74145 PH 918 664 1151 800 637 8099 FAX 918 664 6225 www gardnerdenver com Specifications subject to change without notice Copyright 2001 Gardn...

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