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MSI Hybrid Quintuplex Скачать руководство пользователя страница 84

Appendix B

TROUBLESHOOTING

Listed below are some common conditions that may require trouble shooting and their possible solutions.

Lubrication Oil Running Hot



High ambient temperatures.



Wrong grade of gear oil.



Lubrication pump volume not sufficient.



Lubrication pump cavitating.



Heat exchangers not functioning properly or undersized. (See

Section 5.3

)



Lubrication oil returning on top of pinion and bull gear, resulting in high oil shear between gear teeth.



Running the pump at max speed for a longer duration than the design of the lubrication cooling system
can withstand.



Air, water, or other contaminates in the lubrication oil.



Insufficient lubrication oil volume in reservoir. Reservoir lubrication oil volume in gallons should be
2.5 times the lubrication pump volume in gallons per minute.



Impending mechanical failure within power end or gear reducer.



Defective temperature transducer and or temperature gauge.



Faulty temperature transducer cable.

Lubrication Oil Pressure Running Low



High ambient temperatures; excessively high oil temperature causing low viscosity.



Lubrication oil relief valve set too low or leaking.



Ruptured oil line inside of power frame.



Lubrication oil pump is worn out or not functioning properly.



Lubrication oil pump is cavitating due to low head.



Lubrication oil pump inlet line blocked, or shutoff valve for isolating pump from reservoir is blocked or
partially closed.



Air entering the lubrication oil pump suction inlet due to a loose connection, which allows air to be
sucked into the inlet, or a fluid level in the reservoir that is too low or so low that it causes a vortex,
which allows air into the inlet.

Revision K 03/12/2019

MSI - A Division of Dixie Iron Works, Ltd. All rights reserved.

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Содержание Hybrid Quintuplex

Страница 1: ...Technical Manual MSI Hybrid Well Service Pump Triplex and Quintuplex Models MSI A Division of Dixie Iron Works Ltd 300 W Main St Alice TX 78332 www diwmsi com 800 242 0059 Revision K...

Страница 2: ...CATION AND INSTRUMENT CONNECTIONS 27 4 7 PLUNGER AUTO LUBE AND RELIEF SYSTEM 29 4 8 CHARGE PUMP INTAKE 30 4 9 PUMP DISCHARGE REQUIREMENTS 31 4 10 PUMP SAFETY PRECAUTIONS 31 4 11 PREPARING PUMP FOR USE...

Страница 3: ...LACING THE FLUID END 58 SECTION 10 GEAR REDUCER 61 10 1 DRAWINGS AND PART NUMBERS 61 10 2 CHECKING AND ADJUSTING BEARING PRE LOAD 63 10 3 REMOVAL OF GEAR REDUCER AND BEARING HOUSING 64 SECTION 11 POWE...

Страница 4: ...s the responsibility of the packager to select and install the relief valve Be sure that no valves are placed between the pump outlet and the pressure relief valve Starting the pump without previously...

Страница 5: ...or all fluid end plunger sizes the power end plunger is always larger in diameter The manner in which this is accomplished also improves the rigidity of the plunger stroke thus reducing packing wear a...

Страница 6: ...diameter fluid end plungers There are two Xtreme Service fluid end sizes one accommodates plunger sizes 2 75 3 00 and the other accommodates plunger sizes 3 25 4 50 See following pages for performanc...

Страница 7: ...8 438 6 667 200 GPM 93 110 129 150 196 248 600 PSI 9 999 8 402 7 159 6 173 4 726 3 734 300 GPM 139 165 194 225 294 372 PSI 6 666 5 601 4 773 4 115 3 151 2 489 450 GPM 208 248 291 337 441 558 PSI 4 444...

Страница 8: ...0 8 438 6 667 200 GPM 154 184 215 250 326 413 1 000 PSI 9 999 8 402 7 159 6 173 4 726 3 734 300 GPM 231 275 323 375 490 620 PSI 6 666 5 601 4 773 4 115 3 151 2 489 450 GPM 347 413 485 562 734 929 PSI...

Страница 9: ...8 438 6 667 200 GPM 154 184 215 250 326 413 1 300 PSI 12 999 10 923 9 307 8 025 6 144 4 854 300 GPM 231 275 323 375 490 620 PSI 8 666 7 282 6 205 5 350 4 096 3 236 450 GPM 347 413 485 562 734 929 PSI...

Страница 10: ...the pump is shrink wrapped to create a vapor barrier Desiccant packets are placed within the shrink wrap to absorb internal moisture If the pump is to be shipped overseas it is also placed within a c...

Страница 11: ...service fluid will be trapped between the inlet and outlet valves and will spill out when removing the suction valve covers Preparation for spillage is important for safety and environmental reasons...

Страница 12: ...from the fluid end After removing the valve covers generously mist the inside with a suitable lubricating oil to displace moisture and create a protective film on the metallic components Wear proper p...

Страница 13: ...STALLATION 4 1 Pump Dimensions CG Lifting Points and Mounting Requirements See drawings and photographs on following pages Revision K 03 12 2019 MSI A Division of Dixie Iron Works Ltd All rights reser...

Страница 14: ...13 16 17 13 16 E D C A 1 2 3 4 5 6 7 8 G F B PUMP DIMENSIONS CRANKSHAFT C L C L CENTER CYLINDER 3 4 10 UNC 3 4 TYP 24 3 8 26 1 4 1 52 34 19 7 8 17 1 4 44 1 4 27 2 1 4 2 3 4 20 3 4 23 3 8 24 26 5 8 37...

Страница 15: ...OMMON CONFIGURATIONS FOR EITHER THE TRIPLEX OR QUINTUPLEX PUMP DIFFERENT GEAR POSITIONS AND PLUNGER SIZES WILL MOVE THE CG SLIGHTLY F E D C A 1 2 3 4 5 6 7 8 G B PUMP CENTER OF GRAVITY Revision K 03 1...

Страница 16: ...pages are average weights based on typical pump configurations Please contact MSI for configuration specific weights Safe lifting methods are shown below To lift complete pump use rated swivel liftin...

Страница 17: ...PT bull plug tapped to accept rated lifting eyes TIH 600 Gear Reducer Wt 900 LBS QIH 1000 1300 Gear Reducer Wt 1200 LBS Revision K 03 12 2019 MSI A Division of Dixie Iron Works Ltd All rights reserved...

Страница 18: ...Use MSI lifting sub LSA0001 TIH 600 Fluid End Wt 1600 LBS QIH 1000 1300 Fluid End Wt 2500 LBS Revision K 03 12 2019 MSI A Division of Dixie Iron Works Ltd All rights reserved Page 15...

Страница 19: ...also be given to major repairs that must be accomplished at the factory and the pump package should be designed to allow for removal of the pump MSI has provided a combination weather cover and safet...

Страница 20: ...TUPLEX PUMP WORKING SPACES DENOTED BY SHOULD BE PROVIDED IN ANY CONFIGURATION FOR ACCESS TO COMMONLY REPLACED ITEMS SUCH AS VALVES VALVE SEATS PACKING AND SEALS 8 G F E D C A 1 2 3 4 5 6 7 B MAINTENAN...

Страница 21: ...page for available tools MSI Hybrid Well Service Pump Enhancement The packing nut tool is conveniently located on the plunger access port weather cover It is securely mounted and provides at the ready...

Страница 22: ...ALL BORE LSA0016 LARGE BORE LSA0017 VALVE COVER TOOL UNIVERSAL FEC0024 PLUNGER SEAL TOOL UNIVERSAL PEC0232 D C A 1 2 3 4 5 6 7 8 G F E B PUMP SERVICE TOOLS PACKING NUT TOOL ALL SIZES FEC0368 CONTACT M...

Страница 23: ...the position of the prime mover and shaft should match one of the positions shown on the following pages The driveline shaft must include a slip joint with 1 minimum slip in the joint after installat...

Страница 24: ...5 STANDARD GEAR REDUCER 4 61 1 REDUCTION RATIO POSITION DIMENSIONS ROUNDED TO THE NEAREST 1 16 LEFT HAND 1 LEFT HAND 3 LEFT HAND 4 LEFT HAND 9 F E D C A 1 2 3 4 5 6 7 8 G B LEFT HAND 7 9 3 16 9 3 16...

Страница 25: ...16 RIGHT HAND 14 12 5 RIGHT HAND 13 13 RIGHT HAND 12 12 5 RIGHT HAND 11 9 3 16 9 3 16 RIGHT HAND 10 12 5 RIGHT HAND 9 13 RIGHT HAND 8 12 5 RIGHT HAND 7 9 3 16 9 3 16 RIGHT HAND 6 12 5 RIGHT HAND 5 13...

Страница 26: ...4 61 1 REDUCTION RATIO LEFT HAND 5 LEFT HAND 9 LEFT HAND 4 LEFT HAND 13 LEFT HAND 14 POSITION DIMENSIONS ROUNDED TO THE NEAREST 1 16 6 5 16 15 1 4 16 1 2 16 1 2 16 1 2 6 5 16 15 1 4 Revision K 03 12 2...

Страница 27: ...IVE GEAR REDUCER 4 61 1 REDUCTION RATIO RIGHT HAND 14 RIGHT HAND 4 RIGHT HAND 5 RIGHT HAND 9 RIGHT HAND 13 POSITION DIMENSIONS ROUNDED TO THE NEAREST 1 16 C A 1 2 3 4 5 6 7 8 G F E D B Revision K 03 1...

Страница 28: ...olume relief capacity these types of pressure relief devices it is acceptable to install them on a fluid end gauge connection s While not intended as a full bore volume relief device connection point...

Страница 29: ...YPE CONNECTION DEPICTED TYPICAL INSTALLATION RELIEF DEVICE DISCHARGE PLUMBING EITHER OR BOTH ENDS EITHER OR BOTH ENDS HIGH PRESSURE OUTLET LOW PRESSURE INLET LOW PRESSURE OUTLET 5 6 7 8 G F E D C A 1...

Страница 30: ...t Connections Pump pressure RPM oil pressure and oil temperature instruments and safety controls are recommended See drawings on following pages Revision K 03 12 2019 MSI A Division of Dixie Iron Work...

Страница 31: ...WITH 1 2 MNPT PIPE PLUG TOP INLET PORT 1 2 FNPT PLUG UNUSED PORT 1 2 FNPT PLUG UNUSED SIDE ANY LOCATION 2 1502 FEMALE DISCHARGE PRESSURE PICK UP POINT THIS SIDE OR OPPOSITE SIDE USING WITH 1 2 MNPT PI...

Страница 32: ...the pump is in motion The Auto Lube System can be used in conjunction with the MSI Lube Relief System to provide outstanding lubrication performance The MSI Lube Relief System LRS is a bolt on system...

Страница 33: ...k and can even make offshore decks vibrate considerably The resulting annoyance is not the only effect Excessive vibrations can result in manifold and flow line fatigue failures which could result in...

Страница 34: ...or maintenance personnel from coming in contact with moving parts An approved pressure relief device shall be installed and maintained as near to the pump outlet as possible Oil temperature and pressu...

Страница 35: ...er the prime mover i e diesel engine is running and not on a PTO that rotates only when the transmission is in gear A properly designed system will allow for oil circulation through the MSI Hybrid Wel...

Страница 36: ...cal Lubrication Schematic A typical power end and gear reducer lubrication oil schematic is shown on the following page Revision K 03 12 2019 MSI A Division of Dixie Iron Works Ltd All rights reserved...

Страница 37: ...25 GPM MIN 7 FILTER 50 GPM 200 PSI MIN 25 33 MICRON ELEMENTS w 15 25 PSI RELIEF 8 HEAT EXCHANGER SEE MANUAL FOR SIZING 9 PRESSURE GAUGE LIQUID FILLED 0 200 PSI 10 POWER END LUBE INLET 1 2 NPTF 11 POW...

Страница 38: ...in order to maintain an internal well service pump pressure of 40 PSI The return line should be sized to accommodate the full capacity of the pump and should drain directly into the reservoir 5 5 Lub...

Страница 39: ...unsuspected sources such as low quality lubricants or filters Consult MSI Engineering if assistance is required in selecting a lubricant To keep the warranty in effect use an oil that contains an ext...

Страница 40: ...tended to collect plunger lubricant that bypasses the sealing element To clean the pan remove the screws and slide the pan out from below the pump Clean then reinstall it Revision K 03 12 2019 MSI A D...

Страница 41: ...Well Service Pump is equipped with an Xtreme style fluid end it will have large Maxbolts installed longitudinally through the fluid end The tension on these bolts is pre set at the factory and should...

Страница 42: ...ccur between the valve and the fluid end if the valves are not fully seated b Connect a 3 4 to 1 orifice test choke to the discharge circuit and adjust it to full open Shift the transmission to first...

Страница 43: ...d in the circulation tank 5 Leave the prime mover running so that oil to the MSI Hybrid Well Service Pump will continue to circulate and cool down any internal parts that were under heavy load prior t...

Страница 44: ...fluid end plunger lubrication system for leaks Check the supercharge piping for leaks Check the fluid end bolts see Section 6 1 5 7 3 Weekly Maintenance Check all items on daily list Check all valves...

Страница 45: ...e rings and header rings Clean the plunger pump s oil breather and the lubrication oil reservoir breather 7 6 Yearly or as Recommended Preventative Maintenance Replace worn fluid end plungers and pack...

Страница 46: ...5 Packing Nut 1 2 Packing Set 3 5 O Ring Stuffing Box Fluid End Side 3 5 Back Up Stuffing Box Fluid End Side 3 5 O Ring Stuffing Box Nut Side 3 5 Back Up Stuffing Box Nut Side 3 5 O Ring Packing Nut...

Страница 47: ...SECTION 9 FLUID END 9 1 Detail Section Drawings Service Tools See drawings on following pages Revision K 03 12 2019 MSI A Division of Dixie Iron Works Ltd All rights reserved Page 44...

Страница 48: ...085 9 PACKING NUT FEC0346 FEC0347 10 PACKING SET FEC0069 FEC0033 11 SEAL SUCTION DISCHARGE COVER FEC0095 12 STUFFING BOX ADAPTER FEC0066 FEC0010 13 SUCTION COVER GLAND FEC0338 14 SUCTION COVER NUT FEC...

Страница 49: ...UT FEC0351 FEC0348 FEC0349 FEC0350 13 PACKING SET FEC0258 FEC0054 FEC0055 FEC0040 14 SEAL SUCTION COVER FEC0013 15 SEAL DISCHARGE COVER FEC0015 16 STUFFING BOX ADAPTER FEC0260 FEC0058 FEC0059 FEC0036...

Страница 50: ...materials and personal protective equipment PPE will be needed 2 Open the weather cover and loosen the retaining screws on the plunger safety cover using a 9 16 wrench and slide it towards the rear o...

Страница 51: ...when installing the fluid end plunger MSI Hybrid Well Service Pump Enhancement It is not necessary to keep packing nuts matched with a particular cylinder Since there are no plumbing connections on t...

Страница 52: ...king nut face and snug with a 9 16 wrench Do not over tighten the screw 14 Reinstall the suction covers using the valve cover tool and a 10 lb hammer 15 Slide the safety cover back over the packing ac...

Страница 53: ...LIKE THIS WHEN IT IS FULLY DISENGAGED FROM THE ROTATION ARRESTING FEATURES OF THE FLUID END ADAPTER PACKING NUT READY FOR REMOVAL IN THIS CASE 1 32 APPROX GAP WHEN PACKING NUT IS FULLY ENGAGED EXTRACT...

Страница 54: ...PPE will be needed 2 Remove the spring and discharge valve from the top of the fluid cylinder 3 Rotate the pump by hand until the plunger is clear of the bore being serviced Do this for each remainin...

Страница 55: ...of well control 8 Reinstall the suction valve spring and the suction valve stop making certain the valve stop is turned until the retaining spring is securely seated in the groove in the cylinder Do...

Страница 56: ...4 5 6 7 8 G F E D B VALVE STOP REMOVAL LIFT SPRING TOWARDS CENTER OF BORE TO DISENGAGE LOCK AND ALLOW VALVE STOP REMOVAL Revision K 03 12 2019 MSI A Division of Dixie Iron Works Ltd All rights reserve...

Страница 57: ...d elongation Replace if any defects are found Only replace these with original equipment supplied by MSI Failure to use the proper grade of studs and nuts can result in injury death equipment damage a...

Страница 58: ...PER ASTM A194 ITEM NO DESCRIPTION PART NUMBER 600 1300 BHP 1000 BHP 1 DISCHARGE FLANGE SEAL FEC0014 FEC0148 2 DISCHARGE FLANGE STUD HC0091 HC0174 3 DISCHARGE FLANGE NUT HC0092 HC0085 4 UNION RESILIEN...

Страница 59: ...r erosion and corrosion Thoroughly clean and lightly polish the bottom face of the fluid cylinder with 220 240 grit Emory cloth 4 Remove the o rings from the suction manifold Clean out the o ring groo...

Страница 60: ...CONFIGURATIONS ARE AVAILABLE CONTACT MSI SALES FOR OPTIONS ITEM NO DESCRIPTION PART NUMBER 1 SUCTION MANIFOLD SEE NOTE 2 SUCTION MANIFOLD BOLT HC0108 3 SUCTION MANIFOLD O RING OC0079 8 G F E D C A 1 2...

Страница 61: ...examine the fluid end wetted surfaces for corrosion pitting Severe pitting greatly increases the likelihood of crack formation and failure can occur relatively unexpectedly 4 Whether replacing the old...

Страница 62: ...ers and packing nuts per Section 9 2 10 Replace the valves per Section 9 3 11 Reconnect the discharge lines pressure relief valve and the instrument connection for the pressure transducer 12 Follow th...

Страница 63: ...UID END BOLT 1 3 8 HC0136 3 2 1502 LIFTING SUB LSA0001 E D C A 1 2 3 4 5 6 7 8 G F B FLUID END REMOVAL 2 QUINTUPLEX PUMP USES 12 OF THE HC0136 BOLTS 1 3 AVAILABLE SEPARATELY Revision K 03 12 2019 MSI...

Страница 64: ...the entire pump should be returned to an MSI repair facility When field service of the gear reducer is needed it should be completed in a clean well equipped shop by a trained well service pump techn...

Страница 65: ...CER GRC0035 GRC0052 9 RETAINER WASHER GRC0042 GRC0048 10 SHIM SET GRC0032 GRC0055 D C A 1 2 3 4 5 6 7 8 G F E B GEAR REDUCER SHIM ADJUSTMENT 5 1 2 3 4 8 6 9 7 THE STANDARD TRIPLEX PUMP COMPANION FLANG...

Страница 66: ...the entire range of movement If there is more than 0 005 movement the pre load should be adjusted by following steps 4 7 4 Remove the eight 1 2 cap screws that hold the pinion bearing retainer to the...

Страница 67: ...ttach a lifting device to the gear reducer see Section 4 1 Use multiple lift points to balance and stabilize the gear reducer once it is free from the power end 4 Use a 1 7 16 wrench to remove the 7 8...

Страница 68: ...AR REDUCER GRA0001 GRA0003 4 HEX NUT HC0085 5 MAIN BEARING HOUSING PEC0063 6 BEARING HOUSING SEAL PEC0061 7 STUD BOLT HC0084 F E D C A 1 2 3 4 5 6 7 8 G B GEAR REDUCER BEARING HOUSING REMOVAL 3 1 4 1...

Страница 69: ...e The drive shaft and the windows containing the moving fluid end plungers and power end plungers must be covered with appropriate safety guards GEAR REDUCER AND DRIVE SHAFT GUARD PLUNGER PORT SAFETY...

Страница 70: ...ine running or with pressure in the fluid end There are three panels on the power end one on each side for accessing the crossheads crosshead guides power end plungers and wrist pins and one at the ba...

Страница 71: ...R HC0002 3 REAR ACCESS COVER PEC0077 PEC0095 4 REAR ACCESS GASKET PEC0080 PEC0096 5 SIDE ACCESS COVER PEC0078 6 SIDE ACCESS GASKET PEC0079 D C A 1 2 3 4 5 6 7 8 G F E B POWER END ACCESS PANELS 2 1 1 2...

Страница 72: ...will need to be screwed onto the end of the power end plunger This tool will help guide the seal onto the plunger and prevent damage to the wiping edge See drawing on following page 6 Gently guide th...

Страница 73: ...f the quintuplex pump 15 Install new seals in the power end plunger seal housing according to the drawing 16 Reassemble in the reverse order of these instructions NOTE Torque screws to the values show...

Страница 74: ...GER SEAL HOUSING GASKET PEC0237 6 POWER END PLUNGER SEAL HOUSING SCREW HC0945 7 POWER END PLUNGER SCREW HC0467 8 POWER END PLUNGER LOCK WASHER HC0023 USE INSTALLATION TOOL TO GUIDE SEAL ONTO POWER END...

Страница 75: ...rod cap 6 Support the cap of the connecting rod and gently tap it from both ends using a brass punch to disengage the dowel pins Be extremely careful not to mar the journal surface of the crankshaft...

Страница 76: ...ssive heat Discoloration would tend to suggest that the bearing is not receiving sufficient lubrication check lubrication plumbing for obstructions NOTE Due to the construction of the crosshead bushin...

Страница 77: ...8 G F E D B CONNECTING ROD INSTALLATION CRANK ROTATION A DIRECTION OF FORCE DETAIL A TANG PREVENTS BEARING ROTATION UNDER LOAD Revision K 03 12 2019 MSI A Division of Dixie Iron Works Ltd All rights...

Страница 78: ...EAD BEARING RETAINER HC0504 9 CROSSHEAD BEARING RETAINER BOLT HC0503 10 CROSSHEAD PIN PEC0218 11 CROSSHEAD PIN BOLT HC0049 12 CROSSHEAD PIN WASHER HC0025 13 POWER END PLUNGER PEC0220 14 POWER END PLUN...

Страница 79: ...the rear screws that hold the crosshead guides into place using a 15 16 socket Slide the crosshead guides aft to release them Remove the guides through the side access panel openings Inspect the cross...

Страница 80: ...GUIDE PEC0056 2 CROSSHEAD GUIDE BOLT HC0083 F E D C A 1 2 3 4 5 6 7 8 G B CROSSHEAD SLIDE REMOVAL COMPONENTS DEPICTED IN GENERAL DIRECTION OF REMOVAL 2 1 Revision K 03 12 2019 MSI A Division of Dixie...

Страница 81: ...Stroke Length inches T Torque foot pounds force a To calculate the HHP output when the rate and pressure are known HHP PSI x FR 1714 b To calculate the BHP input recommended when the rate pressure an...

Страница 82: ...ze are known A x ID Pipe x ID Pipe 7854 0 FV A x FR 3208 0 i To calculate the internal size of piping recommended to maintain a specified flow velocity when the GPM and desired flow velocity are known...

Страница 83: ...llons U S 231 Cubic Inches Cubic Inches 0 004329 Gallons U S Cu Ft Sec 448 831 GPM GPM 0 002228 Cu Ft Sec Head Feet water 0 4331 PSI PSI 2 309 Head Feet water Kilowatts 1 341 Horsepower Horsepower 0 7...

Страница 84: ...olume in gallons per minute Impending mechanical failure within power end or gear reducer Defective temperature transducer and or temperature gauge Faulty temperature transducer cable Lubrication Oil...

Страница 85: ...essure as the pressure relief valve and the valve is cycling open and closed Solids in the pumping medium are trapped between the valve and valve seat Valve insert is damaged or missing Valve guide le...

Страница 86: ...packing Blown valve cover seals Lubrication Vent Smoke Insufficient flow of lubricating oil causing overheating of bushings or bearing surfaces Continuing to run the pump will cause expensive repairs...

Страница 87: ...8 UN 1660 1245 1 5 8 8 UN 2300 1 3 4 8 UN 2400 Specific Installation Torques Connecting Rod Cap Nuts Install 5 8 11 castellated nuts using Loctite Threadlocker Blue and torque to 150 ft lbs of torque...

Страница 88: ...MSI A Division of Dixie Iron Works Ltd 300 W Main St Alice TX 78332 www diwmsi com 800 242 0059 361 664 6597...

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