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JET Manual 02Triplex Pumps

Version 1.1

JET Manual 02 Triplex PumpsInTouch Content ID# 4127825 Version: 1.1 Release Date: July 31, 2006 Owner: Well Services Training & Development, IPC

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Copyright © 2006 Schlumberger, Unpublished Work. All rights reserved.This work contains the confidential and proprietary trade secrets of Schlumberger and may not be copied or stored in an information retrieval system, transferred, used, distributed, translated, or retransmitted in any form or by any means, electronic or mechanical, in whole or in part, without the express written permission of the copyright owner.

Trademarks & service marks“Schlumberger,” the Schlumberger logotype, and other words or symbols used to identify the products and services described herein are either trademarks, trade names, or service marks of Schlumberger and its licensors, or are the property of their respective owners. These marks may not be copied, imitated or used, in whole or in part, without the express prior written permission of Schlumberger. In addition, covers, page headers, custom graphics, icons, and other design elements may be service marks, trademarks, and/or trade dress of Schlumberger, and may not be copied, imitated, or used, in whole or in part, without the express prior written permission of Schlumberger. A complete list of Schlumberger marks may be viewed at the Schlumberger Oilfield Services Marks page: http://www.hub.slb.com/index.cfm?id=id32083

An asterisk (*) is used throughout this document to designate a mark of Schlumberger.

Other company, product, and service names are the properties of their respective owners.

iiiJET 02 - Triplex Pumps |

Table of Contents

1.0 Introduction 51.1 Learning objectives 51.2 Safety warning 5

2.0 Introduction to Triplex Pumps 73.0 Triplex Pump Main Components 9

3.1 Triplex pump components 93.1.1 Chain case 93.1.2 Power end 93.1.3 Fluid end 10

3.2 Pump types 113.2.1 Cementing/completion services 113.2.2 Mixed cement/frac services 123.2.3 Fracturing services 153.2.4 Coiled tubing services 16

4.0 Pump Rate Calculation 195.0 Specifications and Ratings for PG Series Triplex Pump 21

5.1 Chain case 215.2 Power end 215.3 Fluid end 22

5.3.1 Specifications 236.0 Routine Maintenance 25

6.1 Pump cavitation 256.2 Power end 26

6.2.1 Temperature 266.2.2 Noises 266.2.3 Pony rod seals 266.2.4 Sludge and cement 276.2.5 Chemical and salt water corrosion 276.2.6 Power end lubrication system 276.2.7 Hydraulic pump types 29

6.3 Fluid end 306.3.1 Fluid end lubrication system 306.3.2 Plungers and packing assembly 34

iv | Table of Contents

6.3.3 Fluid end cover retainers 356.3.4 O-ring and backup ring 356.3.5 MacClatchie valves seats 376.3.6 Valve seats (MacClatchie valve seats) 396.3.7 Packing 41

6.4 Chain case lubrication system 597.0 Servicing 61

7.1 STEM 1 inspection and operation of the triplex pump 617.2 Triplex pump STEM 2 inspection 63

7.2.1 Chain case 637.2.2 Power end 647.2.3 Fluid end 667.2.4 Packing oilers (Alemite) 677.2.5 Triplex pump annual inspection 67

8.0 Troubleshooting 699.0 Appendix 1 – Priming Procedures 71

9.1 Priming triplex pumps using gravity feed 719.2 Priming triplex pumps using a pressurizer pump 71

10.0 Appendix 2 – Hydraulic Horsepower Test (HHP) 7311.0 References 7512.0 Check Your Understanding 77

5JET 02 - Triplex Pumps |

1.0 Introduction

The purpose of any pump is to convert mechanical energy provided by motors, engines, turbines, and other prime movers into fluid energy as efficiently as possible. The pump should be light, compact, simple, and easy to operate and maintain while providing the efficiency and the power required.

Schlumberger Well Services uses low-pressure and high-pressure pumps (also called positive displacement pumps). High-pressure pumps use plungers to displace fluid.

This training introduces you to one of the most common high-pressure pumps in the oil field industry, the triplex pump.

1.1 Learning objectivesUpon completion of this training, you should be able to:

explain the function of a triplex pump•

identify the various components of the •triplex pump

describe how the triplex pump operates•

identify different pump models•

identify the sizes and ratings on the triplex •pump

maintain the triplex pump•

troubleshoot common pump problems•

maintain the triplex pump•

service the triplex pump.•

1.2 Safety warningProper supervision is required during hands-on training. Request assistance from your supervisor if you are unfamiliar or uncomfortable with the operation.

Ensure that all safety devices are in place and operational before using a triplex pump. This includes overpressure shut downs and rupture disc valves.

When working on the pump, follow the procedures in Well Services Safety Standard 4 - Facilities and Workshops.

When conducting function testing on the pump, follow the procedures in Well Services Safety Standard 5: Location Safety.

Terms used in this training

Reciprocating pump

A mechanical device consisting of single-acting, positive-displacement elements, such as pistons or plungers and used to impart a pulsating flow to a liquid. The reciprocating pumps used by Well Services are single-acting triplex (three plungers) and quintuplex (five plungers) units.

Single-acting

A pump in which the liquid in each plunger is discharged only during the forward stroke for one-half of the crank revolution.

6 | Introduction

Positive-displacement pump

A pump utilizing a plunger or cylinder to displace fluids, usually under pressure. Closing a valve on the discharge side results in overpressure.


2.0 Introduction to Triplex Pumps

A triplex pump is any type of pump assembly consisting of three plungers.

The reciprocating plunger pump is the most efficient pump for pumping abrasive fluids at high pressure (1,000 psi and above) and requires the least amount of maintenance.

Figure 2-1. Triplex Pump

Figure 2-1. Cross Section of Triplex Pump

8 | Introduction to Triplex Pumps

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3.0 Triplex Pump Main Components

3.1 Triplex pump componentsMost types of pump assemblies have three main components:

3.1.1 Chain caseThe chain case, also called a speed reducer: Reduces the input shaft revolutions per minute (rpm). Well Services uses chain cases on PG series pumps and gear reducers on most other pumps.

Figure 3-1. Chain Case

The chain case has two important functions:

It provides flexibility when mounting the •pump assembly in different locations with respect to the prime mover output shaft center-line. You can mount the chain case on either side of the power end.

It converts a low-torque, high-rpm engine •output to a high-torque, low-rpm output more suited to the power end requirements. The prime mover drives the chain over the upper and lower sprockets that are

mounted on the pump pinion shaft. When the prime mover rotates the lower shaft, the chain transmits the power to the upper shaft and rotates as well. This shaft then transfers the rotation to the power end pinion shaft. The different diameters of the two sprockets in the chain case reduce the prime mover output speed increasing the torque input to the pump.

Figure 3-2. A Typical Twin PG Pump Layout

To prevent the chain case from moving when power is applied, secure the chain to the chassis or skid using a pair of torque rods.

3.1.2 Power endConverts rotational power into reciprocating power. The power end functions the same way as a crankshaft in a motorcar engine. The pinion shaft drives the crankshaft using bull gears. The eccentrics of the crankshaft change the rotation of the mainshaft into a reciprocating action. The reciprocating force is then transferred to the connecting rods and crossheads, moving the plungers in the fluid end.

10 | Triplex Pump Main Components

Figure 3-3. A Typical Twin PG Pump Layout

Figure 3-4. Gears Top

Figure 3-5. Gears Side

3.1.3 Fluid endThe fluid end receives the power from the power end. This part of the triplex pump receives fluid at a low pressure, applies horsepower to the fluid, and discharges fluid at a high pressure.

The mechanical pumping action is similar to a conventional piston-type internal combustion engine or a reciprocating piston-type air compressor.

Figure 3-6. Pump (Detail)

As the plunger is drawn toward the power end during the suction stroke, it reduces the pressure inside the chamber between the suction and discharge valves. This causes the suction valve to lift and allow the fluid to flow into the suction manifold through the suction port, around the suction valves, and into the chamber.

When the plunger moves in the opposite direction toward the fluid end, also called discharge stroke, the fluid inside the chamber is forced out. The suction valve closes immediately and the fluid lifts the discharge valve from its seat and flows into the discharge chamber.


Figure 3-7. Flow Through Fluid End

3.2 Pump typesTriplex pumps are used in cementing services, mixed cement/frac services, fracturing services, and coiled tubing services.

3.2.1 Cementing/completion services

3.2.1.1 Pump types5-in-stroke PG series pump

The PG series pump was the main pump for all cementing services equipment until recently. This pump was available in a magnesium frame (truck mounted) and steel frame (offshore). Power end gear reduction is internal using a bull gear and pinion shaft. The pump is usually coupled to a chain case to provide additional reduction and driveline offset.

Figure 3-8. 5-in Stroke PG Series

Table 3-2. General Specifications for the PG Series Pump

6-in-stroke SPM TWS600S pump

This pump uses stuffing box construction in the fluid end. The plunger size can be varied over a limited range. This can be done by only changing the stuffing box.

This pump is used as a replacement for the PG series pump on new completion/cementing equipment designs. It features a crankshaft style power end with a bolt-on gear reducer.

Table 3-1. PG Series Pump Head Capacities


This pump is a much more compact design and is rated at 600 hp input, compared with 250 hp for the PG series pump. This is also advantageous for the new higher horsepower cementers being developed and is more suitable for continuous pumping operations associated with coiled tubing services.

Figure 3-9. 6-in-stroke SPM TWS600S Pump

Table 3-3. 6-in-stroke SPM TWS600S Pump Compatibility Table

3.2.1.2 ComponentsValves and seats

There are no special valves and seats for cementing/completions services. Several vendors can supply these components.

Some locations use valves with stretch-on rubber inserts for better results during pressure testing since they tend to hold pressure better.

Rupture disc suction valves of the correct rating are required for all completions/cementing pumping applications.

Packing

Using a universal header ring packing is recommended for completions services.

Table 3-4. Fluid Pump and Compatibility Table

Suction stabilizers

Suction stabilizers are not used in completions services.

3.2.2 Mixed cement/frac servicesGD1250 pump

The GD1250 pump is a lightweight design offering high horsepower per pump weight. It was originally used on the PumperPOD*, which is a frac pump and blender combination. It is also used on high-horsepower offshore skids as a replacement for the MD1000 pump.

Three series of fluid ends are available. Two of these fluid ends can be fitted with multiple


plungers and have interchangeable stuffing boxes.

Figure 3-10. GD1250 Pump

Table 3-5. GD1250 Pump Compatibility Table

MD1000 pump

The MD1000 pump type triplex pump gets its name from its developer, Michel Drevet, and its maximum hydraulic horsepower (hhp) output, which is 1,000 hhp. Unlike the other two types of triplex pumps, the MD1000 type uses a single swashplate rather than separate wheels to operate the three plungers.

The MD1000 pump consists of three 120 degrees thrust rods connected to an oscillating plate. Each thrust rod is, in turn, attached to a crosshead, which operates a plunger. As power turns the gears of the power end, one thrust rod is at the maximum forward position, while a second is in forward motion, and a third is in backward motion.

Advantages of the MD1000 pump

These models have many advantages over traditional triplex pumps, but are commonly used only in offshore applications. These advantages include

global efficiency: While a traditional, •crankshaft-type pump typically has a maximum efficiency of 80%, the MD1000 type of pump has an efficiency of 93%. This means that there is more hydraulic horsepower delivered to the fluid being pumped, that intermittent horsepower is closer to continuous horsepower, and that less horsepower is dissipated in heat. This

last point is especially important, because it means that the cooler operation requires a smaller oil cooler, which saves in both weight and size.

Figure 3-11. MD1000 Pump


weight/horse power ratio: The weight of •the MD1000 type of pump with its input horsepower has a ratio of 6.68. The same ratio for a crankshaft pump varies from 8.33 to 19.82. This means that the MD1000 pump provides more hydraulic horsepower for the same pump weight. In fact, pump weight can be reduced by up to one third that of the crankshaft pump and still deliver the same horsepower. This means that more hydraulic horsepower and less dead weight can be transported. For offshore operations where transportation costs are significant, this is a great advantage.

plunger size: If the plungers on an MD1000 •pump and a crankshaft pump are the same, the MD1000 pump will have a higher working pressure and flow rate.

horsepower/volume ratio: The input •horsepower of the MD1000 pump with its overall volume has a ratio of 13.52.

The same ratio for the crankshaft pump is between 3.5 and 10. This means that if the two pumps have the same volume, the MD1000 pump will deliver more hydraulic horsepower. Or if the horsepower is the same, the MD1000 pump will require less overall volume. So, for any given application, the MD1000 pump will be a smaller, more compact unit than the crankshaft alternative and will be easier to transport.

balance: The swashplate design allows •the mainshaft assembly to be perfectly balanced. This reduces vibrations in the system and leads to longer bearing life and reduced noise. Related to this, the main center line of the MD1000 pump is aligned with the center line of the prime mover (motor or engine). This allows for a better equipment layout design and reduction in space required.

Table 3-7. General Specifications for the MD1000

Table 3-6. MD1000 Pump Compatibility Table


Table 3-8. Fluid End Options

3.2.3 Fracturing services

3.2.3.1 Pump types8-in-stroke HD2250 pump

HD2250 is the standard pump for fracturing services. Currently, it is placed behind a 2250 brake horsepower prime overs. Older units may have an earlier version called the 1800 AWS pump. This pump uses internal gear reduction. Each plunger size uses a different fluid end.

Figure 3-12. 8-in-stroke HD2250 Pump

Table 3-10. General Specifications for the SD2000 Crossbore Pump

SD2000 Crossbore pump

The 11-in-stroke pump was originally developed to replace the in-line fluid ends. This pump has a weight disadvantage for trailer units since it weighs approximately 4,000 lbm more than the HD2250 pump.

Table 3-9. 8-in-stroke HD2250 Pump Configuration Table


Table 3-11. SD2000 Crossbore Pump Configuration Table

3.2.3.2 ComponentsValves and seats

Bonded insert valves are used in fracturing services otherwise, the proppant-laden fluids will get under the snap on inserts and lead to valve failure.

Rupture disc suction valves of the correct rating are required for all pumping applications. Valves and seats are available from several vendors.

Packing

Header ring packing is standard for all services. For more detailed information, refer to Section 6.3.7 - Packing.

Table 3-12. Fluid Pumped and Compatibility Table

3.2.3.3 Special CO2 considerations Commonly, CO2 is used with fracturing jobs. Special equipment, such as a CO2-rated suction manifold capable of handling high suction pressure, is required.

Figure 3-13. CO2 Blanking

When pumping CO2, the suction stabilizer must be disconnected by blanking off the suction header.

For CO2, you can use up to 5,000 psi standard header ring packing and plunger lube. Pressure above 5,000 psi requires the use of special header rings.

At higher pressures, CO2 gas is entrained in the header ring during pumping and released after the job. This causes the packing to fail when a conventional job is performed after a CO2 job.

3.2.4 Coiled tubing servicesWith coiled tubing services, different pump parameters are required. Due to the high friction pressure through the coiled tubing, fluid can only be pumped at a limited maximum pump rates. Use the dedicated coiled tubing triplex pumps for this type of application.


3.2.4.1 Pump types6-in-stroke OPI600 pump

Figure 3-14. 6-in-stroke OPI600 Pump

Table 3-13. 6-in-stroke OPI600 Pump Configuration Table

PG/Butterworth pump

To convert a standard PG pump for high-pressure coiled tubing services, use a stainless-steel Duralife fluid end.

While the PG pump is not designed for continuous pumping coiled tubing operations, the Duralife fluid end performs better than a standard triplex in this application. The 2.5-in plunger size is well suited for low rate pumping, and this pump offers replaceable fluid cylinders. The stainless steel construction makes this pump well suited for pumping sea water or brines.

Figure 3-15. Duralife Fluid End


Table 3-14. Duralife Fluid End Options

Table 3-15 PG Pump General Specifications


4.0 Pump Rate Calculation

Pump rate bpm=( bbl/rev) main shaft × rpm main shaft

rpm main shaft=Engine (rpm)

(Power end ratio × Transmission ratio)

Example

Stimulation pumper float SPF-343

Allison 9800 series transmission - 4th gear (1.77:1 ratio)

Engine rpm = 1,900

HD2250 power end 6.353:1 ratio

IOPI fluid end (5 ½ plungers)

rpm main shaft= Engine (rpm) (Power end ratio × Transmission ratio)

1900 6.363 × 1.77

= = 169 rpm[ ]

Pump rate bpm= ( bbl/rev) main shaft × rpm main shaft = 0.05698 × 169 = 9.6 bbl/min[ ]

20 | Pump Rate Calculation



5.0 Specifications and Ratings for PG Series Triplex Pump

5.1 Chain caseMost twin pump cement units, such as CPS and CPT, use a standard 23.15-in center-to-center chain case for the downhole pump using a 90-in pitch long chain.

Mixing pumps use an extended chain case (6-in extension section to increases the chain case length to 29.15 in center-to-center. They also use a 95-pitch long chain. To extend the chain case, add a spacer and increase the chain length. Both chains are known as quad 80 chain, which means 80 pitch (length from pin to pin) and 4 links wide.

Figure 5-1. Chain Case

Figure 5-2. Chain Case Cross Section

Torque arms are designed to stabilize and control the reaction of the torque being applied through the chain case. To adjust the torque arms, complete the following steps:

Rotate the torque arms using the 1. left-hand threads to change their length.

Set one of the torque arms to the 2. desired position.

Ensure that the driveshaft is clear from 3. any obstruction.

Adjust the other torque arm in any 4. direction to tighten and lock the chain case into position.

Tighten all locking nuts in position.5.

6.

22 | Specifications and Ratings for PG Series Triplex Pump

5.2 Power endOn PG pumps, you can configure the power end to be driven from the left- or right-hand side. These two configurations do not require different parts but are distinguished by the way the pinion shaft is installed in the power end frame. When changing the position of the pinion shaft, retime the timing gears.

Note:The district mechanic retimes the timing gears.

Figure 5-3. Front Gears

Figure 5-4. Pump Top

Figure 5-5. Left-Hand Drive

Note:There are a few instances in which the PG series power end turns the opposite direction. This is not common, but you will find it on units that have two PG pumps facing each other and are driven by conventional diesel engines.

5.3 Fluid end

Figure 5-6. Pump Detail


There are five different fluid ends available for the PG series power end. The most common ones are the G, L, and H ends. Those are machined from forged AISI 4340 steel or better.

The R and S fluid ends are used for special applications requiring extremely high pressures, such as stimulation jobs. They are usually autofrettaged to lengthen their life.

Autofretaging is similar to the process used in making artillery gun barrels to improve metal resistance to fatigue. The material is heat treated and stress relieved simultaneously at high pressure.

5.3.1 SpecificationsTable 5-1. Specifications

*Calculate the maximum flow rate of a triplex pump based on 97% volumetric efficiency.

Figure 5-7. Fluid End Side View

Figure 5-8. Fluid End Front View

Note:It is recommended to use both discharge ports for flow rates over 8.2 bbl/min to prevent the erosion of the discharge port, bushing, and manifold. Maximum fluid end pressure limitations are based on the power end maximum rod load rather than fluid end pressure limitations.

24 | Specifications and Ratings for PG Series Triplex Pump

The assembly of the PG05 triplex pump weighs 5,250 lbm (2.4 tones). It is used on offshore skid units, such as the CPS 362, where weight is not a critical factor. It is also used in corrosive environments such as offshore areas, where the PG03, which has a magnesium frame, is resistant to severe corrosion. The CPT 372, CPT 462, and CPS 310 heli-units use PG03 because weight is an important design factor.

Table 5-2. Fluid End Ratings


6.0 Routine Maintenance

Like any equipment, maintaining the triplex pump ensures many years of trouble-free service. This section provides guidelines for the proper steps for care, maintenance, and repair of triplex pumps.

6.1 Pump cavitationCavitation is the main damaging factor to a triplex pump during operation, especially when the pump pounds and the treating lines shake and jerk violently. Another cavitation reason is the premature rupture of burst disks (suction valves) at much lower pressures than their rated burst pressures. In either case, the result is an operation failure.

Cavitation usually results from

using a worn or damaged pressurizing •pump that is not maintaining adequate pressure on the pump suction manifold

an air leak in the suction manifold•

pumping too fast for the pressurizing •centrifugal pump to keep a sufficient fluid supply to the triplex pump.

Cavitation occurs when the chamber is not full of liquid and the plunger changes direction from suction to discharge. The plunger does not push fluid out the discharge, but compresses vapor causing a momentary change in the pump loading and the plunger’s velocity. This sudden change in velocity causes a tremendous shock to the power and fluid ends, leading to mechanical failure or fatigue.

Cavitation causes barrel counters and job recorders to read incorrectly. These counters measure the volume of fluid being pumped

by counting the number of revolutions on the pinion shaft or engine output shaft. These counters continue to count as long as the pump is turning, even when nothing is being pumped.

Cavitation is more likely to occur when pumping oil, even after proper priming, than when pumping water since water has a much lower vapor pressure than oil.

To prevent cavitation, perform the following steps:

Ensure that the triplex pump is properly •primed by bleeding all air from the system.

Note:Annually inspect fluid ends for cracks using the magnetic particle testing process. Contact Gardner Denver for light service. Check with your maintenance supervisor for more information.

Ensure that the pulsation dampener is in •good operating condition and purged of air while priming a pump on a fracturing unit.

When pumping high viscosity mud that •is stored in displacement tanks for a long period of time, circulate the mud back to the tanks before pumping it to prevent the mud from becoming a gel or to restrict suction.

Do not suck slurry at a slow speed. If •the slurry is foamy and the job must be completed at a high rate, use an antifoam product to minimize foaming.

26 |Routine Maintenance

If pumping out of two or more tanks or •when changing displacement tanks, open the second tank valve before closing the first one to prevent air from entering the system.

Ensure that all suction hoses used do •not have air leaks at the connections or around the nipples. It is possible to conduct a pressure test on suction hoses and connections by carefully pressurizing them with a centrifugal pump like the RA45.

If there are indications of cavitation, reduce •the pump rate immediately and correct the problem before increasing the pump rate again.

If cavitation occurs when using a pump that •does not have a pressurized suction, check the O-ring seal on the suction manifold of the fluid end to see if the hoses and connections are tight.

6.2 Power endTo ensure that the power end is operating correctly, inspect and check the following temprature and noises.

6.2.1 TemperatureDuring any job, frequently check the power end lubrication pressure gauge and the frame temperature. The power end is considered overheated when you are unable to touch the frame for more than a few seconds. Overheating occurs during extended pumping at or near maximum horsepower levels. Shut down the pump if the power end is overheating.

Warning:The power end can catch fire if heated excessively. If the power end has a magnesium frame, it is impossible to extinguish the fire.

Best practice:If a fresh water hose is available, run a stream of cool water over the frame to cool it down during extended pumping.

6.2.2 NoisesListen for unusual noises such as clicking or knocking. Noises are caused by

loose eccentrics or damaged keys/keyways •

damaged bull or pinion gears •

worn or damaged main bearings, •crosshead, or connecting rod bushings

damaged main crankshaft •

cracked eccentric.•

Problems with the fluid end can also be mistaken for power end noises. Inspect the fluid end carefully to eliminate this as a source of noise or knocking.

6.2.3 Pony rod sealsThe purpose of the pony rod seals is to keep oil in and dirt out of the power end. If the exposed end of the pony rod shows signs of pitting or dullness, this is an indication that the pony rod seals could wear out quickly.


Figure 6-1. Pony Rod Seals

Slinger rings are installed on the pony rod to help prevent dust or dirt from entering the crosshead area and causing damage to the pony rod seals. To work effectively, slinger rings must fit firmly on the pony rod at all times. Also, slinger rings prevent pressurized fluid from being blown into the power end and past the pony rod seal in the event of a plunger packing failure.

6.2.4 Sludge and cementDuring a STEM 2 inspection, remove the rear power end cover or inspection plate and feel the bottom of the frame for cement or other sludge. Sludge can quickly wear out the bearings and brass bushings inside the power end.

Figure 6-2. Rear Power End Cover

Important:Ensure that lock-out tag-out procedures are followed before reaching inside the power end.

6.2.5 Chemical and salt water corrosionInspect the surface of the power end frame for chemical and salt water corrosion. Scrape or wire brush any corrosion, and then re-prime and paint the power end.

Important:If you have a magnesium frame power end offshore, take extreme care to prevent corrosion (electrolytic) from the salt environment. It can quickly damage the power end.

6.2.6 Power end lubrication systemCheck each unit’s maintenance manual for the proper lubricant.


Table 6-1. Power End Lubrication System Table

Note:When checking the oil level, always remove the dipstick and allow air to escape from the tube. Replace the dipstick and check for the correct oil level.

A mechanically or hydraulically driven pump pumps the lubricating oil out of the power end. The oil then flows through a filter to the line’s cross fitting, then to the mainshaft and crossheads.

Figure 6-3. Oil Level

Oil level

When using a PG pump in high horsepower or continuous pumping operations, an external oil cooler may be required to keep the pump below the maximum allowable operating temperature.

Power ends in frac services have oil coolers installed during manufacturing.

A pressure relief valve maintains the system pressure from exceeding a set pressure.

There are two different styles of power end oil filters and arrangements: internal bypass and external bypass.

Warning:Since pressure in a hydraulic system is a result of resistance and the flow rate varies with engine rpms, the pump is sized so that it maintains adequate oil pressure at low engine speeds. However, oil pressure becomes low when components wear. This can create catastrophic power end failures, especially when the following conditions exist at the same time:

The power end is working at very low •rates and high discharge pressures.

The rpm is low to create enough oil •pressure to maintain a good film of oil on the eccentric bearings.

The rod load is high.•

Always watch and maintain the power end oil pressure. Proper sizing of the fluid end prevents these types of failure.


Remove and inspect the oil filter condition. Clean and replace as necessary.

To check the oil’s color or clarity, compare a sample from the power end with a new one.

A bypass around the oil filter ensures a continued flow of oil in the event the filter becomes clogged. A relief valve controls the bypass process. On older styles, the valve is mounted directly onto the filter and has a hose. The valve directs any bypass flow to the downstream side of the filter.

On new styles, the bypass is in the filter housing and has a predetermined differential setting. The new-style filters have an indicator that clearly indicates when and if the filter is bypassing: green for good and red for bypassing. This indicator works only when the oil is flowing through the filter. During the job, check and record the condition on a STEM I report.

A relief valve that is mounted directly to the bottom of the power end frame controls oil pressure. A pressure gauge mounted on the control panel or directly on the power end lube oil circuit allows the operator to monitor oil pressure on each pump.

Important:Keep oil clean at all times. A milky color usually indicates water contamination.

To adjust a pressure-relief valve, remove the large cap. To increase pressure, turn the adjustment screw clockwise. To reduce pressure, turn the screw counterclockwise.

Important:There are oil seals inside the main shaft-bearing cap of the power end. When these seals wear, oil pressure drops. You can check oil pressure using the gauge attached to the cap.

Note:Always consult your supervisor before tampering with any adjustments.

Figure 6-4. Pressure Relief Valve

6.2.7 Hydraulic pump typesThere are two different styles of power end lube pumps: gear-type hydraulic pump and vane-type hydraulic pump. When the gear-type is mounted to the auxiliary drive shaft, which rotates twice the engine rpm, an angle drive adapter is used to reduce the rpms. The vane type hydraulic pump is directly mounted to the gear train on the engine through a splined input shaft. In both cases, the engine oil pressure increases if the shaft seal leaks.


Caution:Since a Tyrone pump uses a straight input shaft, take special care when installing the tapered drive adapter. The spacing of the drive gear is critical to ensure that the gear is set correctly in the center of the driving gear of the angle drive. Failure to set it correctly lowers the power end oil pressure in critical situations.

Important:The Webster brand pump is obsolete and must be replaced with a Tyrone pump. Order a complete replacement kit.

Figure 6-5. Power End Lube Pump

Figure 6-6. Power End Lube Pump

6.3 Fluid endTo ensure that the fluid end is operating correctly, inspect and check the componebts described below.

6.3.1 Fluid end lubrication systemThe fluid end lubrication system uses an air-driven pump to transfer packing oil to the plungers. The check valves that are installed directly onto the fluid end prevent cement from migrating into oil lines. A divider block is used in this system to distribute oil to the plungers. The recommended oil to use is 15W40 clean engine oil.

Important:For optimum packing life, it is essential to properly lubricate the plungers and packing. An improperly lubricated packing leaks in a few seconds of pumping, damaging the polished surface of the plungers. It will also generate heat and shorten the packing life.


Note:The Alemite pump used for the fluid end lubrication system is a grease pump that allows pumping high-viscosity oils.

Caution:Never reuse packing oil because dirt and debris will contaminate the system, damage the pump, and plug the divider blocks.

The divider block uses two codes: number 12 to indicate that the block will discharge out of one side, and number 24 to indicate that the block will discharge out of both sides.

These coded blocks cannot be used interchangeably. Each block must complete its cycle. Plugging it in any hole stops the cycle and shuts down the lubrication system. If it becomes necessary to abort lubrication to a centrifugal pump, for example, reroute the hose to the reservoir.

Figure 6-7. Dividers

The air-operated Alemite pump delivers lubricating oil to a McCord divider block, which in turn delivers oil equally to each plunger. The divider block outlet is connected through a check valve to each fluid end-packing bore. From there, oil flows into the fluid end and enters the lantern gland for even distribution to the packing.

Note:The Alemite pump also provides lubrication to the centrifugal pump through a parallel discharge line or divider block on older units.

The current Alemite pump used on the PG series cementing pumps is Model 9668 with a medium pressure pump (5:1 ratio). The pump section works in conjunction with the pneumatic logic air motor, model 338066- A1. To adjust the Alemite pump rate, set the air pressure regulator between 110 psi and 120 psi. Regulate the metering valve on the discharge side of the pump to control the desired amount of lubrication oil.

Figure 6-8. Alemite Pump Flow Diagram


Important:On model 338066-A1 pneumatic logic air motors, do not use an air lubrication system. These motors are packed with Teflon lubricant and do not require any additional lubrication except during service or repair. However, they require clean dry air.

Note:A blockage in any of the oil delivery lines indicates failure of the entire plunger lubrication system. The McCord divider block does not operate if any of its outlet ports are blocked.

Current-generation pump units have a lube oil filter installed downstream of the Alemite pump.

Unlike the old Alemite pumps, you cannot rely on the air motor sound to determine the lubrication rate. Install a pressure gauge in the discharge side of the pump to determine air pressure. Typical pressure is between 30 psi and 40 psi.

6.3.1.1 Air-over-oil lubrication systemThe air-over-oil lubrication system is a highly reliable, low-maintenance lubrication system. It replaces conventional Alemite systems in both cementing and fracturing services. In 1999, this system became the standard plunger lubrication system for new cementing and fracturing units. It can also be retrofitted on existing pumping equipment in the field.

This new lubrication system uses an air-pressured oil reservoir that forces oil

through the delivery lines to each packing bore. Adjusting the metering valves regulates oil flow. The metering valve is located between the oil reservoir and the packing bore check valve.

This system is simple and easy to maintain due to the limited number of components.

The lubrication system provides the following advantages when properly installed:

reduces oil consumption.•

lessens the amount of wasted plunger •lubricant.

does not affect packing life. •

is compatible with all packing types. •

simplifies operations in environmentally •sensitive areas, including offshore.

uses air pressure to force lubricant to the •plunger packing and centrifugal pumps.

has no moving parts to jam or fail.•

reduces maintenance costs. •

provides annual operating savings that are •estimated at USD 2,500 per unit.

To convert existing units to the air-over-oil lubrication system, remove the entire existing plunger lubrication system except for the waste oil catch tank. Parts for the new system include:

an ASME-coded, pressurized, oil tank and •mounting bracket

distribution manifold and hoses•

new check valves at the fluid end•

wiper rings behind the lantern ring to •contain lubrication oil.


Note:Follow Schlumberger guidelines as described in Maintenance Bulletin No. 625E and Well Services Safety Standards, including Safety Standard 26 – Air Tanks and Receivers and Safety Standard 27 - Inspection and Testing of Pressure Relief Valves and Gauges.

Major Components

Tank

The tank must have the following characteristics:

ASME-coded•

certified to 200 psi/13.79 bar•

maximum capacity of 16.4 galUS/62 L•

fill point at top sight plug of 13.2 galUS/50 L•

The tank has the following safety features:

two-piece fill cap•

brass, three-way, pressure/bleed ball valve•

150 psi pressure-relief valve•

0 psi-100 psi liquid-filled, pressure gauge•

three liquid-level, sight plugs – 1,750 •psi/119 bar maximum working pressure.

Warning:To ensure safe and reliable operation, you must use the specified replacement tank. Do not make substitutions or use locally manufactured tanks.

Fluid end modifications

Fluid end parts that must be modified are

three Haskel SS, 15,000 psi •

check valves•

three wiper seals, to be installed in the •packing nuts on fracturing units.

Distribution manifold and hoses

The distribution manifold simplifies hose routing. All the hose connections are push-lock to enable you to make field installations without special tools or hose crimping.

Chain case

The chain case requires minor maintenance if checked regularly. Check for the following:

contaminated oil•

torque rods with loose ends, which are •worn, improperly adjusted, or corroded.

Note:Grease the torque rods when performing a STEM 2.inspection.

Unusual sounds such as slapping noises indicate the following:

The chain is hitting the inside of the case.•

The companion flange splines are worn.•

The chain case bearings are faulty. •

Important:Any unusual noises that cannot be precisely traced require immediate attention.


6.3.2 Plungers and packing assemblyThe fluid end is rugged and requires little attention. Detailed repacking procedure will be described in Section 6.3.7.1.

Figure 6-9. Tighten Packing

Complete the following before each job:

STEP 01 Tighten the plungers and check the packing.

STEP 02 If the packing is a double stack or header ring, verify that the packing gland nuts did not back off.

STEP 03 On conventional Alemite systems, adjust the oil flow from the Alemite pump to the packings. Check for leaks along the air and lubrication lines.

STEP 04 In air-over-oil systems, ensure that the three-way pressure valve is on and the lube level in the tank is correct.

STEP 05 Inspect the Martin Decker gauge protectors to ensure that they are pumped up and working properly.

STEP 06 Carefully check the rubber diaphragms to ensure that they have not been

perforated. Perforated diaphragms could cause cement to flow into the lines leading to the overpressure shut downs and console gauges.

Caution:Do not over-tighten the packings. Never re-tighten the header ring packing.

Figure 6-10. Rubber Diaphragm

Rubber diaphragm

Figure 6-11. Overpressure Shutdown

STEP 07 Check the OPSD at this point to protect the equipment and most importantly the operators on:


On CPS-361 units with air throttles, the •OPSD cuts off air supply for the throttle and transmission to set the engine to idle position and to return the transmission shift cylinder to the neutral position.

There are two ranges available for OPSD: •0 psi to 10,000 psi and 0 psi to 15,000 psi.

Calibrate the OPSD when performing a •pressure test on the triplex pump using an accurate pressure gauge or other instrument as follows:

STEP 08 Adjust the OPSD to 1,000 psi.

STEP 09 Bring the pressure up to the OPSD trips, which should be 1,000 psi +/- 500 psi.

STEP 10 Check OPSD accuracy.

STEP 11 Adjust the calibration plate to coincide with the OPSD trip pressure.

STEP 12 Perform steps 1 through 4 at different pressure rates to ensure the OPSD accuracy on the unit.

Note:Do not exceed the maximum allowable working pressure of the fluid end.

Units with standard transmission: cutting •off air disconnects the clutch to disable the transmission and set the engine to the idle position.

Electronic engines: electrical power to the •engine electronic control modules throttle connection is cut off to set the engine to the idle position.

6.3.3 Fluid end cover retainersUse a pipe wrench to remove or reinstall retainers, and then top them with a heavy hammer to ensure proper seating.

Figure 6-12. Tighten Cap

Tightening the cover retainer with a pipe wrench is only to prevent the nuts from being backed out due to vibration. The actual seal efficiency will not improve by overtightening the nuts.

6.3.4 O-ring and backup ringAfter removing the suction or discharge covers, remove the O-rings and backup rings to inspect and clean the groove from cement or other debris. After the O-rings and backup rings are reinstalled in the groove, sparingly grease the cover and retainer threads. Excessive greasing causes a grease lock, which prevents properly tightening the cover or extrudes the O-rings and backup rings from the groove. Extruded O-rings are easily cut or nicked. If this happens, remove the cover and replace the damaged seals.


Note:Grease lock occurs when grease acts like an incompressible hydraulic fluid in a jack. Grease caught between threads and an O-ring prevents tightening the threads. When pressure is applied on the cover retainer, the O-ring may give way. Generally, this happens with the suction and discharge covers as the O-ring seal is entering the sealing bore of the fluid end. When pushing excess grease ahead of the threads on the retainer, grease gets trapped as the O-ring begins to seal. Excess grease does not squeeze past the O-ring and prevents tightening the cover.

Figure 6-13. Suction Cover

Figure 6-14. Discharge Cover

Figure 6-15. O-Ring

Figure 6-16. Preventing Thread Tightening


Common practice:When installing the port-end bushing, insert the bushing with the short shoulder towards the fluid end first for effective sealing when the fluid end seal area is in good sealing condition. When the seal effectiveness is reduced with use, reverse the direction of the bushing, placing the longer shoulder in first. This offsets repositioning the O-ring to an effective sealing area. This procedure can improve the sealing efficiency.

6.3.5 MacClatchie valves seatsValves are manufactured as discharge valves and suction valves.

6.3.5.1 Discharge ValvesDischarge (MacClatchie) valves have thin legs and a low strike.

Figure 6-17. Discharge Valve

Figure 6-18. Discharge Valve Cross Section

6.3.5.2 Suction valvesSuction (burst disk) valves also have thin legs and a low strike.

Figure 6-19. Suction Valves

Figure 6-20. Suction Valves Cross Section


Suction (burst disk) valves were designed to do two things:

Protect the treating equipment and power •end from damage due to accidental and violent overpressuring the fluid end

Prevent injury or death of personnel due •to a rupture of treating equipment resulting from overpressurizing the triplex pump.

Warning:Never use discharge valves in the suction side of the fluid end or burst disk valves in the discharge side of the fluid end.

These valves were designed to last at least 500,000 pressure cycles. The life of these valves is equal to approximately 8,300 barrels pumped per plunger in a TGO (3-3/4-in) fluid end and approximately 14,700 barrels pumped per plunger in a THO (5-in) pump. With the cross section of the jobs performed at Schlumberger, the valves or packing would be worn out long before this volume is reached.

Note:A pressure cycle is defined as one plunger stroke at the maximum pressure rating of the fluid end.

Table 6-2. Burst Disk Pressure Rating

There have been instances of premature failure of burst disk valves, and in almost all cases, the causes have been attributed to one of the following:

Circulation at excessively high rates during •the priming of pumps while using gravity feed: This causes pressure peaks that are not visible on pressure gauge and exceeds the pressure ratings of burst disk valves. To prime a pump, use a rate no more than 50% of the rated volume output of the pump being primed.

High pressure testing of lines: When the •pump is not properly primed, it causes the plunger to accelerate and jerk, creating a water-hammer effect. If possible, pump at a low rpm using a larger pump to build some pressure in the system, then change to the smaller pump as required.

Cavitation during pumping: Maintain a •minimum of 20 to 30 psi suction at all times on the suction side of the triplex pump. If cavitation becomes imminent, immediately slow down the pump. The larger the fluid end, the more vulnerable it becomes to suction problems, especially at high rates.

Figure 6-21. Valve Seats


Figure 6-22. Valve and Seat

Note:The old style high-strike valve body is obsolete and is no longer manufactured. High strike is the amount of metal contact between the valve body and seat when the valve is closed.

Three types of valve inserts are available depending on the service requirements:

Rubber inserts1. (black) are used for basic cementing and acid jobs. However, they have poor resistance to abrasives such as sand and hydrocarbons.

Urethane inserts2. (yellow) are used for sand fracture stimulation. They have poor resistance to acids. They last approximately one year in hot, humid conditions.

Urethane bonded inserts3. (yellow) are supplied as one integral piece of urethane insert bonded to a steel valve body. This type is used in high-pressure fracturing jobs using proppants. The insert prevents abrasives from working

their way between the valve body and the insert. If the insert becomes damaged, remove it using a low-heat cutting torch. Once removed, install either standard rubber or urethane inserts. You can use the valve for cementing or general pumping only.

Note:If using a cement pumping unit in sand control service, the bonded insert valve must be used.

Urethane inserts deteriorate with time while being stored. Their shelf life is approximately one year when not stored properly ideal storage area is a cool, dark place with low humidity. The insert turns yellow along the edges when it starts to deteriorate. Later, the whole insert begins to change to yellow and starts to crumble like old bread.

To install an insert, soak it in hot water for a few minutes and then force the insert over the indentation.

Note:When stocking inserts, take into account factors such as average consumption.

6.3.6 Valve seats (MacClatchie valve seats)

Two valve seat types were previously available: tapered and straight-hole. The straight-hole type is obsolete and no longer available. Only the tapered type is currently used.

When pumping at a high pressure or when a plunger makes a complete pressure cycle, the closing valves hammer the seat. Constant


hammering presses the valve seats tightly into the fluid end.

Use a valve seat gauge to determine the degree of wear on the seat. Replace the seat when the indicator becomes flush with the top of the gauge or when you see signs of pitting, corrosion, and wash-outs.

Figure 6-23. Check the Valve Seat For Pitting, Erosion, Washouts, and Cracks When the Fluid End Is Opened.

Figure 6-24. Straight-hole and Tapered Valve Seat

Figure 6-25. Seat Wear

Perform the following steps to reset the valve seats.

STEP 01 Clean the bore and remove any rust, scales, and cement. Inadequate removal of these scales causes the O-ring to hang up and get cut or bruised on the valve seat bore.

STEP 02 Set the seat in the bore, ensuring that the O-ring is seated correctly in its groove.

Figure 6-26. Install Seat

Important:Do not use any lubricant on the seat or in the valve seat bore.


Figure 6-27. Drive the Seat into the Bore.

STEP 03 Place the seat squarely in the bore.

Figure 6-28. Place Old Valve

STEP 04 Place an old valve, without an insert, on the seat.

STEP 05 Strike the center of the valve with a steel bar to drive the seat into the bore.

STEP 06 Remove the old valve.

Figure 6-29. Remove Old Valve

STEP 07 Complete repacking of the pump and pressure test the fluid end to the rated pressure.

6.3.7 PackingField testing has demonstrated the superior life of the header ring packing system over conventional, single-stack (hard and soft ring assembly), and elastoplast packing in cementing services, and over the double-stack packing in fracturing services. This new system also provides superior results in drilling (mud) systems.

Single-stack (rubber/fiber or hard/soft assembly) and double-stack (Elastoplast) packing assemblies are now replaced with the header ring packing for cementing, fracturing, and coiled tubing services. Refer to Maintenance Bulletin 1103, InTouch Content ID# 2023279, for details on ordering and installing new header ring packing assemblies.

6.3.7.1 Fluid end repacking procedureUse the following tools to repack the fluid end:

piece of hardwood (not the handle of the •hammer)


short piece of broomstick or old hammer •handle

plunger puller tool•

4-lbm (2-kg) hammer•

C wrench for the gland nuts•

an 18- 24-in pipe wrench•

on older fluid ends, a hex nut and steel bar•

rags or other clean-up material.•

Figure 6-30. Tools

Note:Use the packing tool kit (P/N 570376000) if it is available on location.

STEP 01 Tap the ears of the fluid end cover with a hammer until the cover starts to loosen up.

Spares

O-rings•

backup rings •

valve inserts•

springs•

Warning:Wear safety equipment. Turn off the air or electric supply to the pump. Ensure that the pump cannot be started. Display warning signs prominently on the controls, following the lock-out tag-out procedure in Well Services Safety Standard 15.

Figure 6-21. Warning Label

Note:Whenever working above ground level, use a purpose-built platform. A proper platform provides enough space for laying out pump parts in a logical order if troubleshooting is required.


Figure 6-32. Knock Cap

STEP 02 Use a pipe wrench to unscrew the cover from the fluid end body. The suction valve retainer is removed with the cover.

Figure 6-33. Wrench Cap

STEP 03 Extract the suction valve retainer and place the cover and retainer in a logical order on the platform or pallet.

Figure 6-34. Remove Discharge Cover

STEP 04 Remove the suction valve. Inspect its condition and then place it with the other parts from the same chamber.

Figure 6-35. Remove Suction Cover

STEP 05 Remove the discharge cover. If a Martin Decker sensor is attached, remove it first. Place all the parts together with those from the same chamber.


Figure 6-36. Remove Suction Valve

STEP 06 Using a wrench and hammer, break the plungers from the pony rods.

Note:Do not put a wrench on the pony rod. Use the tapered end on the plunger for screwing or unscrewing the plunger as required.

Figure 6-37. Loosen Piston

STEP 07 Unscrew the plungers completely from the pony rods using the pipe wrench. Do not damage the threads on the pony rods.

Figure 6-38. Remove Piston

STEP 08 If a plunger is covering the suction valve, rotate the drive shaft to the chain case using a pry bar in the u-joint to retract the plung.

Figure 6-39. The Correct Way


Figure 6-40. The Wrong Way

Warning:Using a pipe wrench can cause drive shaft tube damage. Any pipe wrench marks on the drive shaft create a crack and can cause a catastrophic failure or twist-off during a job.

STEP 09 Use the C spanner to unscrew the packing gland nut and release the packing compaction.

Figure 6-41. Loosen Packing Nut

STEP 10 Install the plunger remover by carefully screwing it with a turning motion. Slowly remove the plunger from the chamber.

Figure 6-42. T-bar

Figure 6-43. Remove Piston with Bar

Caution:While removing the plunger, ensure that it does not fall out and cause an injury. Do not drop or nick the plunger on the chromed surface.

STEP 11 Completely unscrew the packing gland nut and place it with the other parts.


Note:If the pony rods are not fully withdrawn as close to the power end as possible, it may be difficult to withdraw the packing gland nuts.

Figure 6-44. Loosen Packing Nut

STEP 12 Using a piece of hardwood, gently and evenly tap the brass on the opposing sides. The brass is close to the packing bore. Any slight misalignment makes the brass difficult to remove.

Figure 6-45. Punch Out Packing

STEP 13 Carefully remove the male packing adapter. Cement might be stuck around it making it difficult to remove.

Important:Do not use excessive force.

STEP 14 Repeat the previous steps for all chambers.

STEP 15 Inspect the parts as follows:

Wipe the O-rings and backup rings to 1. inspect them for stretching, bruises, or cuts.

Important:Do not use diesel or solvent on rubber parts. O-rings may swell on contact with diesel or solvents.

Clean and inspect the O-ring grooves 2. for foreign particles. Inspect the coarse ACME threads for damage or cracks. Use a file to fix small thread bruises.

Figure 6-46. Clean and Inspect O-Ring Grooves


Inspect the valve bodies for washouts, 3. pits, and corrosion. Check the valve inserts for abrasion damage or cracks. Replace as necessary. Check the burst disk to ensure that it is intact. Replace the springs if they are distorted or corroded.

Figure 6-47. Inspect the Valve Bodies

Inspect and change the plungers if they 4. are dull or show score marks. Using dull or scored plungers severely reduces the packing life.

Caution:Do not reuse the packing.

Figure 6-48. Scratched Plunger

Inspect the fluid end body by ensuring 5. that the valve seats are not washed out or pitted. Check the ACME threads and

packing bores. Thoroughly clean out cement, sand, rust, or dirt using a wire brush, emery cloth, or steam cleaner.

Figure 6-49. Internals

Clean and inspect the brass for any 6. sign of discoloration, distortion, nicks, or bruises. Install the brass over the plunger to check for its eccentricity (ovaling). Place the brass on a flat piece of glass to check for distortion. Rub the brass with a fine emery cloth to remove minor scratches and nicks.

Figure 6-50. Piston and Brass

Check the oiling system (Alemite or air- 7. pressure type) to ensure that a positive flow of oil is coming through the oiling hole at the top of the packing bores. Start the unit and turn on the lube system.


Figure 6-51. Air Pump

Warning:Turn off the power or air supply after checking the oil system, and hang warning signs.

Note:Perform repacking according to Maintenance Bulletin 1103. Always verify the packing assembly order before repacking.

Important:If the packing is not the header ring packing, remove the older packing and install a conversion kit. Obtain and install the correct conversion kit according to Maintenance Bulletin 1103.

6.3.7.2 Valve seat removal and installationThere are several valve seat puller types.


TYPE 01: Valve seat puller assembly P/N 428024000:

This type is designed for use on conventional triplex pump fluid ends, especially stimulation pumper fluid ends that do not have suction caps and require the lug to swivel. By rotating the assembly to the vertical position, it passes through the valve seat from above and subsequently rotates freely into the engaged position below the valve seat.

Figure 6-52. Valve Seat Puller


TYPE 02: Valve seat puller assembly P/N 902857000:

This type is designed for an MD1000 fluid end and can be used in conventional fluid ends that have suction caps. This puller allows the insertion of a split washer onto the tie rod after it passes through the valve seat from above.

Figure 6-53. Valve Seat Puller


TYPE 03: Clamshell-type puller assembly P/N 902857000:

You can machine this type approximately 0.040 in at each pulling shoulder for a total of 0.080-in for an 0.080 in reduction in circumference. This is necessary when pulling suction seats in the small bore SPM fluid ends, to fit the puller through the seat.

Figure 6-54. Clamshell-Type Puller

Note:The steps below provide a guideline for pulling a valve seat, but are not necessarily the only method used in the field.

Important:Pulling a valve seat requires two people. If you have valve seats in questionable condition, pull them before failure occurs.

To pull a valve, use these tools:

valve seat puller•

hammer•

24-in pipe wrench •

chisel or old screwdriver•

bucket and cleaning solvent•

rags•

grease•

other spares, such as O-rings or backup •rings

Figure 6-55. Tools

STEP 01 Open the fluid end as described in the fluid end repacking procedure section. After removing the suction and discharge covers, check and replace, if necessary, the valve seat by feeling the seating area. Use the proper seat wear gauge for the fluid end as defined in the Treating Equipment Manual.

Figure 6-56. Valve Seat


STEP 02 Using puller assembly P/N 428024000, install the collar onto the threaded rod. Adjust the placement of the collar by estimating the length of threaded rod required to reach the valve seat.

Figure 6-57. Puller with Threaded Rod

STEP 03 Insert the collar and threaded rod through the pressure plate.

Figure 6-58. Puller

STEP 04 Thread the nut under the pressure plate from the bottom of the threaded rod to secure the collar and pressure plate.

Figure 6-59. Threading Puller

STEP 05 Attach and hand-tighten the head to the threaded rod without the lug and pin components.

Figure 6-60. Ensure Position

STEP 06 Lift and insert the complete assembly into the top of the fluid end. Ensure that it is centered so that the head passes readily through the valve seat. The head should now be visible below the valve seat that will be pulled.


Note:Follow the correct safety procedures when lifting heavy objects.

Figure 6-61. Puller at the End

STEP 07 Install the lug and pin components onto the head.

Figure 6-62. Lug and Pin

Figure 6-63. Pull

Figure 6-64. Pull

Important:Do not attempt to make replacement lugs or pins at a local machine shop. These parts are made of high strength steel. Using the wrong material will result in lug or pin failure when pulling seats.

STEP 08 Making sure that the lug is horizontal, rotate the connecting rod until the lug makes contact with the lower side of the valve seat.


STEP 09 Continue to rotate the connection rod, slowly continuing to pull the valve until completely extracted.

6.3.7.3 Header ring packing installationTo install the header ring packing, do the following:

STEP 01 Use a disc or puller to remove the old packing and brass. The steel junk ring has a stepped bore.

Figure 6-65. Remove Old Packing and Brass

STEP 02 Clean and lubricate the packing nut threads.

Figure 6-66. Clean Cement and Proppant

STEP 03 Clean any cement and proppant from the bore and inspect it for damage.

STEP 04 Install the junk ring.

Figure 6-67. Install Junk Ring

STEP 05 Install the header ring.

Figure 6-68. Install Header Ring

STEP 06 Install the pressure ring.


Figure 6-69. Install Pressure Ring

STEP 07 Install the female adapter - brass and PEEK.

Figure 6-70. Repack

STEP 08 Install the lantern ring.

Figure 6-71. Install Lantern Ring

STEP 09 Install the packing nut.

Figure 6-72. Install Female Adapter

Tighten the packing nut to seat the a. packing.

Loosen the packing nut a ½ turn.b.

Hand-tighten until it touches the c. packing.

Tighten a ¼ turn and paint the d. alignment marks on the packing nut and fluid end.

Loosen the packing one turn.e.


STEP 10 Lubricate the packing and plunger.

STEP 11 Drive the plunger through the packing with a slide hammer or using a large piece of wood. Tap the end of the plunger to ensure that the plunger and the pony rod are connected.

Figure 6-73. Drive Plunger with Packing

STEP 12 Coat the pony rod pin with never-seize thread compound and then tighten the plunger onto it. Snap tight with a sharp blow using a hammer and a pipe wrench.

Figure 6-74. Coat with Never-sieze Thread Compound

STEP 13 Start the pump and check the installation. Note that the packing does not require further adjustment.

Important:Change the plungers when they become dull or show score marks. Using dull or scored plungers severely reduces the packing life.

Figure 6-76. Plunger with Score Marks

Figure 6-75. Clean Plunger

6.3.7.4 Repacking the pumpTo repack the header ring, do the following:

STEP 01 Since one of the fluid end chambers is repacked, install the valve springs and cover retainer assemblies. Clean, inspect, and replace these parts if necessary.

STEP 02 Install the O-rings and backup rings. Using excess grease creates a grease lock during the installation of retainers and covers.


Caution:Do not soak O-rings in solvents.

Figure 6-77. Suction Cover

STEP 03 Coat the retainer with a thin layer of grease and install the suction valve. Screw in the suction valve cover/retainer assembly until it touch the springs. Use a piece of wood to compress and engage the spring under the cover, while simultaneously screwing the retainer in.

Caution:Do not tie the springs with rope or wire.

Figure 6-78. Push Valve

STEP 04 After the suction spring is under the cover, tighten the assembly by hand or with a pipe wrench. Tighten the retainer with a few hammer strikes.

Caution:Ensure that the suction cover is properly installed with the flat side holding the valve spring compressed. Covers are sometimes installed 90-180° out of the proper position. It is crucial that the flat portion of the wedge that compresses the suction spring be exactly perpendicular to the valve. To check the position, ensure that the two screw holes in the suction cap are perpendicular to the wedge surface.


Figure 6-79. Align Cover

STEP 05 Ensure that the O-ring and backup ring are in good condition and clean the groove. Lightly grease the groove. Excessive grease prevents the rings from properly seating.

STEP 06 Carefully install the discharge cover and retainer. Ensure that the discharge valve spring is properly centered so that it engages the spring retainer stub on the bottom of the discharge cover.

Caution:You must never put a burst disk valve in the pump discharge.

Figure 6-80. Insert Discharge Cap

STEP 07 Hand-tighten the discharge cover and then hammer it to properly seat the cover.

STEP 08 Perform a STEM I inspection, and then check that you have installed all the parts. Start the unit and observe for correct operation of the Alemite lubricator.

STEP 09 Engage the pump in low gear and tighten all the packing nuts with the C spanner.

Caution:Any moving piece of equipment could become a hand trap.

Figure 6-81. Tighten Packing

STEP 10 After tightening the packing assembly, circulate water for 15-20 minutes at different rates to verify that the packing and lubrication systems are performing properly.


Caution:Do not use an extension handle on a packing gland nut wrench. It will damage or overtighten the packing nut and assembly. Remove any nut that becomes hard to tighten. Check the packing nut and fluid end threads for damage or hardened cement.

Figure 6-82. Do Not Use Extension Handle

6.4 Chain case lubrication systemTable 6-3. Lubricant Specifications

Each chain case is equipped with either a sight glass or a dipstick to indicate the oil level in the case. The oil level indicator should be centerlined with the bottom of the input shaft.

Figure 6-83. Power End Oil Level

Note:When checking the oil level, always remove the dipstick and allow the oil level to settle. Reinsert and remove the dipstick to check the correct oil level.

Ensure that you have only the required amount of oil to prevent the chain case from overheating. When a chain case is overheated, the bearing grease seals become damaged. If overheating continues, oil breaks down chemically, losing its viscosity, lubricating, and cooling properties, which will severely damage the bearing and chain case.


7.0 Servicing

7.1 STEM 1 inspection and operation of the triplex pump

Before starting the triplex pump, properly STEM the unit using the following:

STEP 01 Tightly screw the plungers to the pony rods (crossheads) with a pipe wrench. Do not overtighten.

Figure 7-1. Tighten Plunger

STEP 02 Ensure that the oil levels in the chain cases, power ends, and packing lubricant reservoir are correct and that the specified lubricants are used. For the Alemite pump to operate and deliver lubricant to the plunger’s packing, open the air supply valve.

Figure 7-2. Power End Oil Level

STEP 03 With pressure on the power end lube circuit, verify that the Alemite pump is functioning. Adjust the oil flow as described in Maintenance Bulletin 982.

Note:Refer to Maintenance Bulletin 1085 (InTouch ID: 2023265) for the air-over-oil lubrication system.

STEP 04 Ensure that the power end oil pressure is correct while the pump is running. At 1,000-rpm pinion speed (2/3 of the maximum pumping rate), oil pressure should be approximately 50 psi for cold oil and 40 psi for warm oil (above 100 degF).

STEP 05 Put the pump back in neutral gear and ensure that the packing gland nuts are snug. If the header ring packing is installed, regular tightening in not required. Verify that the gland nuts have not backed off.

62 |Servicing

STEP 06 For single stack (cementing), tighten the packing gland nuts before each job.

STEP 07 For elastoplast (cementing), tighten the packing gland nuts before each job.

STEP 08 For double stack (fracturing), perform periodic adjustment per Maintenance Bulletin 1103 (InTouch ID: 2023279).

STEP 09 For header ring packing with a Teflon back-up ring, verify that the nuts did not back off. Once adjusted, the header ring packing does not require additional adjustment.

Note:Do not overtighten the header ring packing.

Refer to Maintenance Bulletin 1103 for part replacement information.

STEP 10 Ensure that the pump is ready for priming and operations.

STEP 11 After completion of any pumping operation, pump clean water through the discharge piping until you see clean water flowing from the pump. Then stop pumping.

Caution:Never loosen the fluid end packing gland nut during this operation.

STEP 12 Remove the suction manifold caps, and flush the manifold out with water. If the weather is cold and there is a chance of freezing, drain all water from the pump by

fanning the pump and prying up the suction valves.

Figure 7-3. Tighten Cap

STEP 13 Check under the pony rods (behind the fluid end) to ensure that the drip pan drain is not blocked. Flush out the drip pan with water.

Figure 7-4. Top View

STEP 14 Check and replace the pony rod seals on the power end if there is an oil leak. Ensure that the slinger rings are not loose. These rings prevent any high-pressure fluid that leaked past the packing from damaging the pony rod seal and entering the power end.


Figure 7-5. Never Seize

Summary

Before starting a job, perform a STEM 1 prejob inspection:

Check plunger tightness.1.

Check the condition and lubricant level 2. of the chain case.

Check the condition and lubricant level 3. of the power end.

Check the condition and lubricant level 4. of the packing oil (Alemite) reservoir.

Check the operation of the packing oiler 5. (Alemite).

Check the power end lube oil pressure: 6. 50 psi for cold oil, 40 psi for hot oil.

Check that the gland nuts are tight.7.

Proceed to prime the pumps.8.

Clean the pump and manifold by 9. pumping clean water through it.

Flush out the suction manifold.10.

Drain the pump if there is cold weather.11.

Check the crosshead seals.12.

Check that the slinger rings are not 13. loose.

7.2 Triplex pump STEM 2 inspectionIt is the responsibility of the equipment operator to perform a STEM 2 inspection every 6 months or 300 hours, whichever comes first with assistance from the mechanic.

7.2.1 Chain caseTo check the chain case, do the following:

Check the condition of the torque-rod 1. end bushings and lock nuts. Replace worn bushings.

Grease the torque-rod ends and adjust 2. the length as necessary.

Inspect the retaining pin.3.

Figure 7-6. Torque Rods

64 |Servicing

Note:End bushings are no longer available as separate items. You must change the torque-rod assembly when replacing the bushings. Check the Equipment Parts Manual (InTouch Content ID# 3015447).

Grease the chain case bearings. Check 4. the condition of the oil filter cap/breather. If necessary, wash the filler cap/breather in solvent and blow dry.

On older units, remove the oil and 5. reinstall the barrel counter drive cable.

Carefully grease the barrel counter 6. right-angle drive if a grease zerk is installed. Most barrel counters use a proximity switch to determine pump rate. No lubrication is required.

Figure 7-7. Grease Zerk

Example:TRO uses a 0.249 ratio,TGO - .385, TLO - 0.466 and THO - 0.555 gear ratio. When using incorrect ratio, the mechanical barrel counter will not be accurate. This ratio coincides with the bbl/per revolution for each fluid end (InTouch Content ID# 3015637)

Switch the end caps to reverse the 7. right-angle drive and to change the rotation of the cable.

7.2.2 Power end

Figure 7-8. Power End

Inspect the power end mounting for 8. loose, worn, or broken bolts.

Inspect the frame for cracks or broken 9. sections.


Figure 7-9. Ensure Slinger Rings Fit Snugly on the Pony Rods

Important:The power end frame and mountings are exposed to extreme loading and vibration during pumping operations. Fix damaged mountings or loose bolts immediately to avoid expensive repairs. Bolts should be torqued 600 ft.lbf (+ 10%).

Note:Never weld a magnesium power end.

Check for oil leaks, and take oil samples 10. to inspect for metal particles or water contamination, and determine the cause. Ensure that the slinger rings fit snugly on the pony rods. Replace broken or missing slinger rings.

Inspect the power end lubrication oil 11. suction hoses. If a suction hose is collapsing, it indicates that the oil is severely contaminated and the lube pump does not have enough oil. To

clean the lubrication system, do the following:

Drain the oil.a.

Analyze a sample in a lab. b.

Remove the power end back cover.c.

Clean and flush inside the power d. end with a solvent.

Flush and clean the hoses.e.

Clean the lubrication system, oil f. pump, and filter.

Install the fluid end’s back cover g. and fill with new oil to the specified level.

Note:Oil volume for the power end is 17 galUS in addition to the oil required for hoses, pump, and filter.

The maximum pressure differential across the filter is 75 psi. If pressure becomes higher, a relief valve in the system opens and the oil bypasses the filter and continues to supply the power end.

Note:Prime new or reassembled lubricating pumps before operating the unit by opening the lines and filling the pump with oil. Reconnect the hoses and then crank the engine for 30 seconds with the engine Stop button pressed down.

66 |Servicing

Listen for any unusual noises and 12. perform a hydraulic horsepower test to reveal any potential mechanical problems. Record the test results for future reference, and place a copy with the STEM 2 report. Refer to Appendix 2 in this training for the hydraulic horsepower test procedure.

7.2.3 Fluid endCheck the fluid end by doing the following:

Inspect the packings, packing glands, 1. and plungers for any wear, leaks, or looseness.

Caution:It is unnecessary to remove the packings for inspection unless there are indications that the packing assembly is leaking or failing. Packings are usually damaged during removal from the fluid end bore. Do not over tighten the packing gland nut. Refer to Maintenance Bulletin 1085 for more information.

Open the fluid end and inspect the 2. valves, valve seats, inserts, and springs for cracks, wear, or damage. Compare them to new components if in doubt. Replace as necessary.

Figure 7-10. Valve Seat

Figure 7-11. Damaged Inserts

Replace any damaged backup rings and 3. O-rings on the discharge and suction covers. Remove all hardened cement from the O-ring groove.

Inspect the ACME threads of the fluid 4. end and cover retainers for cracks. Ground off the first or last thread if cracked no more than 1/2 of a thread. If more than 1/2 of a thread is cracked, replace the fluid end. Notify your maintenance department before repairing threads.

If the packing is failing prematurely, 5. tighten or replace the plungers and packing gland nuts as necessary. Check


for proper lubrication from the Alemite pump.

Note:Signs of wear on the bottom of a failing packing indicate excessive crosshead wear on the power end.

Check the tightness of the tie rod nuts 6. (900 ft/lbf). Tighten as required.

Note:Loose tied rod nuts can cause the fluid end to crack due to uneven stress.

Figure 7-12. Packing Oiler System

7.2.4 Packing oilers (Alemite) Check that the lube tank is clean. Drain, flush, and refill as necessary.

Note:Water can easily enter the tank where the Alemite pump is mounted and become mixed with the lubrication oil giving a false indication that the packing is leaking.

7.2.5 Triplex pump annual inspectionThe mechanic performs the annual inspection of triplex pumps. However, it is essential for the operator to understand the requirements as well as the importance of the mechanic’s responsibilities. (The procedure for the annual inspection is covered in the fluid end section of the Treating Equipment Manual.)

68 |Servicing



8.0 Troubleshooting

Troubleshooting - Power End

Symptom Cause Correction

Crosshead seal leaking Seal has come loose from the holder.

Clean seal holder and install new seal per overhaul manual.

Crosshead seal leaking Corroded and rough crosshead shank wearing on seal.

Install crosshead sleave #459569000 per overhaul manual

Knocking around in power end

Loose eccentric because of keyway enlarged by overload.

Replace mainshaft, eccentrics, and connecting rod inserts per overhaul manual

Cement in power end Leakage or jetting of cement past fluid end packing into the enclosure box and crosshead seal into the power end.

Remove cement. Wash with water. Fill with diesel fuel (Circulate 15 minutes and drain). Repeat with fresh diesel fluid. Replace fluid end packing, crosshead seals, lubrication filter element, connecting rod inserts. Fill with clean oil.

Table 8-1. Troubleshooting Power End

70 |Troubleshooting

Troubleshooting - Fluid End

Symptom Cause Correction

Pump is rough running 1. Worn valve and insert 2. Worn valve seat 3. Broken valve spring 4. Pumping fluid cavitation 5. Object under valve

1. Replace valve. 2. Check the seat gauge or replace seat. 3. Replace springs. 4. Pump rate too fast or suction line plugged. 5. Remove object.

Packing life is short

Packing is smoking Packing life is short

1. Clogged lubricator line 2. Dull or worn finish on plunger 3. Improper installation 4. Worn packing bore

1. No oil 2. Clogged lubricator line 3. Packing nut too tight

1. Service and clean divider block and check valve. 2. Replace plungers. 3. See packing manual. 4. Replace fluid end if worn grooves more that 1/64-in deep.

1. Check lubricator reservoir. 2. Clean divider block and check valve. 3. Loosen nut slightly.

Packing is leaking 1. Worn out or too loose 2. Worn plunger

1. Tighten or replace packing. 2. Replace plunger.

Priming is difficult 1. Choked valve 2. Broken valve spring

1. Inspect and straighten valve. 2. Replace spring.

Leakage at discharge outlet 1. Worn seal or bushing 2. Washed out discharge bore

1. Replace seal (O-ring). 2. Replace fluid end.

Table 8-2. Troubleshooting Fluid End


9.0 Appendix 1 – Priming Procedures

Refer to WS Quality Management System - QHSE Standatds for recommended procedures (InTouch Content ID# 4055049).

9.1 Priming triplex pumps using gravity feed

To prime the triplex pumps using gravity feed, do the following:

STEP 01 Place the first pump in high gear at idle speed. Make sure there are fluid returns in the displacement tank.

STEP 02 Increase the triplex pump rate to 3 bbl/min (0.5 m3/min). Continue pumping until you have a steady continuous return of the fluids.

STEP 03 Return the pump to neutral gear and run the engine at idle speed.

STEP 04 Repeat step 1 through step 3 for the second pump.

STEP 05 Close the gravity feed lines.

STEP 06 Open the pressure feed lines to the pumps.

9.2 Priming triplex pumps using a pressurizer pump

STEP 01 Start the priming procedure using the engine pressuring and make-up centrifugal pumps.

STEP 02 Place the pump in high gear at idle speed.

STEP 03 Make sure there are fluid returns in the displacement tank.

STEP 04 Increase the pump rate to 3 bbl/min (0.5 m3/min), and run the engine fast enough to operate the hydraulic system. Continue pumping until there is a smooth return of fluids.

STEP 05 Return the pump to neutral gear, and maintain engine speed at the same rpm.

STEP 06 Repeat step 2 through step 5 for the second pump.

STEP 07 Prime each pump through the mixing equipment.

72 |Appendix 1 – Prime-Up Procedures



10.0 Appendix 2 – Hydraulic Horsepower Test (HHP)

Follow all applicable Well Services safety standards for rig-up, priming, and pumping.

Hydraulic horsepower tests are generally conducted at the district to verify unit performance.

To perform a hydraulic horsepower test, do the following:

STEP 01 Obtain the performance curve for your unit to get the actual hydraulic performance for the unit.

STEP 02 Rig up using Well Services Safety Standard 5 – Pressure Pumping Location Safety. You will need a water supply, charge pump (if the unit does not have a pick-up pump), and a discharge choke.

Important:This procedure assumes that you have a remote-actuated choke. If not, you must shut down while making adjustments to the choke. Rig up the choke to allow isolation and bypass.

STEP 03 Conduct a STEM 1 inspection of the unit.

STEP 04 Pressure test the discharge piping, and verify that the unit overpressure shut downs are functioning using Well Services Safety Standard 5.

STEP 05 Referring to the unit performance curve, select a gear in the mid-range that results in a pumping pressure of 5,000 psi or lower and rates of 8 bbl/min or lower (assuming full engine rpm) for units rated under 1,000 hhp. For large frac units, select a gear that results in a maximum pumping pressure of 10,000 psi or lower, and rates of 8 bbl/min or lower.

STEP 06 Open the choke, select the appropriate gear, and establish the desired rate at full engine rpm. If using a remote choke, slowly close the choke until the engine drops the correct amount. If the engine’s full-load drop is not known, drop the engine 25-50 rpm.

STEP 07 If you are using a manual choke, shut down the unit and adjust the choke in small increments until the correct drop is obtained.

STEP 08 Note the rate and pressure, and calculate the hydraulic horsepower.

74 |Appendix 2 – Hydarulic Horsepower Test (HHP)



11.0 References

All Schlumberger employees must be familiar with the relevant safety regulations and precautions because of many hazards involved in the oilfield industry. Be sure that you know the relevant contents of the material data safety sheet (MSDS) regarding required personal protective equipment (PPE) and handling procedures when handling chemicals.

Treating Equipment Manual, Version B, InTouch Content ID# 3013931

Safety Standard 4: Facilities and Workshops, InTouch Content ID# 3313678

Safety Standard 5: Pressure Pumping and Location Safety, InTouch Content ID# 3313681

Safety Standard 15: Lockout/Tagout, InTouch Content ID# 3313691

Safety Standard 26: Air Tanks and Receivers, InTouch Content ID# 3313706

Safety Standard 27: Inspection and Testing of Pressure Relief Valves and Gauges, InTouch Content ID# 3313707

Maintenance Bulletin 625E “MUST DO” - Pressure Vessel, and Relief Valve Inspection and Test Procedures, InTouch Content ID# 3998770)

Maintenance Bulletin 1103 - Header Ring Packing For All Services, InTouch Content ID# 2023279)

Maintenance Bulletin 982 - Alemite Fluid End Pacing Lube Sysyem, InTouch Content ID# 3770448)

Maintenance Bulletin 1085 - Air-Over-Oil Fluid End Packing Lubrication System, InTouch Content ID# 2023265)

Header ring packing ordering information:

Gardner Denver Tulsa Customer ServicePhone: 800 637 8099Fax: 918 664 6225email: [email protected]

CDICustomer Service contacts:Beatriz Trevinoemail: [email protected] Robertsemail: [email protected]: 281 446 6662Fax: 281 446 7034

UTEXWeimar Molded Products605 UTEX Dr.Weimar, TX 78962Phone: 979 725 8529 or 877 469 2829Fax: 800 924 8277

76 |References


12.0 Check Your Understanding

77JET 02- Triplex Pumps |

1. The power end converts energy from _________.A. hydraulic energy to mechanical energyB. reciprocal power to rotational energyC. rotational power to reciprocal powerD. mechanical energy to pressure energy

2. Is the volumetric efficiency of all triplex pumps the same value?A. trueB. false

3. What important functions do chain cases have? Select two that apply.A. Lubricate and cool the chains.B. Secure the power end from flexing

during pumping.C. Provide flexibility in mounting.D. Convert rpm to torque.E. Provide storage of power end

lubrication.

4. A triplex pump is a _________.A. low-pressure positive displacement

pumpB. high-pressure pump using the gear

principleC. high-pressure positive displacement

pump consisting of three plungers

5. The maximum fluid end pressure limitations is based on _________.A. metal used in the construction of the

fluid endB. power end maximum rod loadC. AJSI steel gradesD. autfretaging processes

6. For coiled tubing operations, use a _________ .A. MD1000 pumpB. 8-in stroke HD2250 pumpC. 6-in stroke OPI600 pumpD. PG/Butterworth pump

7. The correct level for oil in the power end is _________.A. ok as long as oil is visible in the bottom of the power end.B. ½ in below the bottom of the main

bearing’s caps.C. ½ in above the top of the main bearing’s caps.

8. The maximum flow rate of a triplex pump is calculated on _________.A. 88% volumetric efficiencyB. 92% volumetric efficiencyC. 97% volumetric efficiencyD. 100% volumetric efficiencyE. does not depend on volumetric

efficiency

78 | Check Your Understanding

9. Low-pressure in the power end is caused by _________, _________ and _________.A. high discharge pressureB. low engine rpmC. rod load is lowD. worn componentsE. all of the above

10. Crosshead seals are used to _________ and _________. A. prevent leakage of oil from the power

end via the pony rodsB. keep oil in and dirt out of the power endC. supporting the crossheads (pony rods)D. backing up the O-rings in the power

end

11. Reusing packing oil is recommended to reuse packing oilA. trueB. false

12. The divider block _________.A. divides equal oil to each plungerB boosts, the oil pressure to the lantern

glandsC. prevents the lubrication system from

failing when one of the discharge ports is blocked

D. controls the discharge rate from the Alemite pump

13. A block divider that is coded 24 has _________.A. one outlet: must discharge from one

endB. two outlets: must discharge from both

endsC. cannot be used with a divider block

coded 12

14. A discharge stroke occurs when the plunger is drawn toward the power end.A. trueB. false

15. One of the most damaging factors for a pump fluid end is _________.A. pump cavitationB. excessive pressureC. pumping inhibited acidsD. excessive rates

16. Cavitation can be the result of _________, _________, or _________.A. keeping the pump chambers full of

sandB. worn or damaged pressurizing pump

not maintaining adequate pump suction manifold pressure

C. pumping too fast for the pressurizing pump to keep up

D. not keeping the fluid end chambers full of fluid

79JET 02- Triplex Pumps |

17. During a STEM 1 inspection, it is essential to_________, _________ and ________.A. tighten the packing before pumping operationsB. drain all water in cold weather after

washing the pumpC. check for oil leaks in the crosshead

sealsD. check the oil level in the chain cases,

power ends, and packing lubricant reservoir

E. all of the above

18. Unusual noises in the power end could indicate _________.A. damaged bull or pinion gearsB. worn or damaged main bearingsC. crosshead, or connecting rod bushingsD. damaged crankshaftE. cracked eccentricF. all of the above

19. Cavitation is more likely to occur when pumping oil than water.A. trueB. false

20. Burst disk valves are designed to last at least 500,000 pressure cycles.A. trueB. false

21. Using dull or scored plungers does not reduce packing life.A. trueB. false

22. The shelf life of urethane inserts is _________.A. 1 yearB. 6 monthsC. 2 yearsD. 1 month

23. A 5-in stroke PG series pump is primarily used for _________.A. Fracturing servicesB. Coiled tubing servicesC. Cementing/completion services D. Mixed cement/frac services

24. A hydraulic horsepower test is performed to confirm the unit performance level and to reveal potential mechanical problems.A. trueB. false

25. The power end can catch fire from excessive heat.A. trueB. false

26. Excessive greasing of the suction and discharge cover and retainer threads can cause a grease or hydraulic lock.A. trueB. false

27. The triplex pump annual inspection is performed by the _________.A. unit operatorB. field specialistC. mechanicD. field engineer


80 | Check Your Understanding

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