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300FWF996    Page 21

SECTION 4
SERVICE PROCEDURES

This  section  describes  various  assembly
and  disassembly  procedures  necessary  for
pump  servicing  or  parts  replacement.   The
General  Requirements  and  Safety  Rules
section  is  a  reminder  for  the  maintenance
personnel of the critical importance of safety
rules  and  precautions  while  working  on  the
pump.  

Notes  on  dangers  and  notices

specifically related to service procedures are
repeated and placed in this section also.

The  pump  consists  of  two  major  modules:
(1)  the  fluid  end  and  (2)  the  combination
power end and gear reduction  components.
(See SECTION 2) The description of service
procedures  follows  the  modular  concept.
Due  to  many  expendable  parts,  fluid  end
servicing is rather common in the field and is
therefore  presented  in  the  very  beginning
followed  by  the  power  end  /  gear  reduction
components servicing procedures.

General Requirements and Safety Rules

DANGER

Before any attempt to work on pumps
is 

made, 

all 

safety 

rules 

and

precautions described in this manual
must be read and clearly understood.

DANGER

Only  qualified  and  specially  trained
personnel should be allowed to work
on this pump.

DANGER

Proper capacity hoist and lifting
devices should be used 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, and packing.

Fluid End Removal and Installation

1.

Disconnect  suction  manifold  from  unit
piping  and  discharge  lines  at  the
discharge  flanges  on  the  fluid  end,
plunger  lubrication  lines,  and  also  any
accessories  such  as  stroke  counters,
pressure gages, etc. from the fluid end

2.

Open any cover or covers on the top of
the cradle and disconnect the plungers
from  the  extension  rods  by  removing
plunger clamps.

3.

Move  the  plungers  inside  the  fluid
cylinder  as  far  as  possible,  taking  care
not to damage the plunger or pony rod.

4.

Connect  hoist  to  the  fluid  end  and
tighten  the  slings  until  they  are  snug
only. Make sure that hoisting slings are
not  too  tight,  because  that  may  put  a
strain on the stay rods and damage the
threads when the cylinder is removed.

5.

Remove all twenty (20) heavy hex nuts
from  the  fluid  end  mounting  flange
using  a  hydraulic  tensioning  tool  or
hammer  wrench.  (A  hydraulic  or
manual 

torque 

wrench 

is

recommended 

for 

proper 

re-

installation. )

6.

Pull the fluid end assembly horizontally,
straight  away  from  the  power  end  until
it is completely free from the tie rods.

7.

Move  the  fluid  end  to  the  service  area
for changing valves or other service.

HALLIBURTON EXHIBIT 1013, Page 27

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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