EFTA00795782.pdf

9 NATIONAL OILWELL VARCO Reciprocating Plunger Pumps Installation, Care and Operation Manual Covering the following pumps: 103Q-3 59T-3 103Q-3 110Q-3 Print Index i 110Q-3 Sales r Technical Information USA Tol!free: I (800) 324 4706 Phone: 1 (918)447 4600 Fax: 1 (9181 44 7 4677 Internet: REVISED: September 2, 2010 M. Box 4638 Houston, Texas 77210-4638 ISSUE: September 26, 2005 EFTA00795782  KW NATIONAL OILWELL VARCO SUPPLEMENT FOR ALL PUMP MANUALS A! WARNING !A PRESSURE RELIEF VALVES AI NOTICE I A Our technical publications relative to reciprocating pumps state that pressure relief valves must be installed in the discharge systems from these units. This supplement is issued to emphasize the importance of relieving the discharge system of all pressure which exceeds the rated working pressure applied by the manufacturer to the specific pistons and liners (or plungers and packing) in any particular unit. •Print4 Some I Index I Next I EFTA00795783  A! WARNING ! A For the protection of persons and property the discharge system from each Reciprocating Pump must be equipped with a device which relieves the system of all pressures which exceed the pressure rating applied by the manufacturer to each particular piston or plunger diameter. Allowances will be made for pressure surges which are inherent with the reciprocating action of piston and plunger pumps. The percentage of pressure allowance appears later in this publication and in the "Standards of the Hydraulic Institute" (131h edition). The relieving device must provide for instantaneous pressure relief, it may be a valve designed for automatic or manual resetting; however, if preferred, rupture discs or burst discs may be installed. FAILURE to comply with the procedures outlined in the Warning may result in damage to the pump and related equipment and more importantly may cause serious bodily injury or death! THE PRESSURE RELIEF VALVE: 1. This valve must be a full opening type. 3. The relief valve must be between the pump fluid end and any valve in the discharge 2. It must have a working pressure rating, equal system. to or greater than, the maximum working pressure of the pump. 4. There must be no restricting device(s) between the relief valve and the pump fluid 3. The through capacity of the valve, when fully end. opened, must be sufficient to relieve the full capacity of the pump without excessive THE RELIEF VALVE DISCHARGE LINE: overpressure. 1. The relief valve discharge line should not RUPTURE DISC OR BURST DISC: terminate in the pump suction line. 1. These discs must have a diameter which is 2. The line should terminate in the supply tank, not less than the pipe size of the pressure if possible. relief flange. 3. The line must be securely anchored. 2. These discs must have a rupture or burst pressure rating consistent with the 4. The line must be the same pipe size as, or specifications tabulated later in this may be larger than, the discharge connection publication. on the relief valve. LOCATION OF THE RELIEF VALVE: 5. If the line is of great length, this must be taken into consideration in sizing the relief 1. The relief valve must be placed in the valve. discharge line as close as possible to the pump fluid end or it may be mounted on the 6. There must be no restrictions or valves in the pump discharge manifold. relief valve discharge line. 2. The relief valve must be on the pump side of NOTE: Follow the foregoing instructions if any discharge strainer. rupture discs or burst discs are installed. SUGGESTED SET PRESSURES FOR THE PUMP RELIEF VALVES: PUMP TYPE: OPERATING PUMP PRESSURE: Double Acting - Duplex Piston Pressure Rating - Plus 25% Double Acting - Triplex Piston Pressure Rating - Plus 10% Double Acting - Quintuplex Piston Pressure Rating - Plus 10% Single Acting — Triplex Piston Pressure Rating - Plus 10% Single Acting — Simplex Plunger Pressure Rating - Plus 25% Single Acting — Duplex Plunger Pressure Rating - Plus 20% Single Acting — Triplex Plunger Pressure Rating - Plus 10% Single Acting — Quintuplex Plunger Pressure Rating - Plus 10% Single Acting — Septuplex Plunger Pressure Rating - Plus 10% Note: The above set pressures are to be observed when installing rupture discs or burst discs. Print Home Index Next I EFTA00795784  Installation, Care and Operation Manual e NATIONAL OILWELL VARCO Foreword... This manual is published as a guide for the normal operation of your NATIONAL OILWELL VARCO equipment. Because of the many factors, which contribute to the function or malfunction of this machinery, and not having complete knowledge of each factor or combination of factors, we cannot detail all facets of this subject. We must therefore confine the scope of this presentation and when situations encountered are not fully encompassed by complete, understandable instructions. these situations must be referred to the manufacturer. When other than routine servicing is necessary, it can be most efficiently performed if the unit is removed to an area of adequate space where an over-head crane, hydraulic lift, bearing pullers, impact tools, etc., are accessible. The dimension and tolerances specified in this publication are those desirable for the most efficient operations of the equipment. When components become worn or when new parts are introduced into a worn unit, it may not be possible or economically feasible to reestablish such strict alignment and correct all dimensional deviations. Improvements in design, engineering, materials, production methods, etc., may necessitate changes in these products and result in inconsistencies between the content of this publication and the physical equipment. We reserve the right to make these changes without incurring any liability or obligation beyond that which is stipulated in the purchase contract. The pictures. photographs, charts, diagrams, drawings. verbal contents and specifications are not to be construed as giving rise to any warranty on the part of NATIONAL OILWELL VARCO. National Oilwell Varco makes no warranty, either expressed or implied beyond that which is stipulated in the purchase contract. NATIONAL OILWELL VARCO pumps are manufactured by National Oilwell Varco at the Tulsa, Oklahoma plant. The serial number, assigned each pump is stamped on the power end. Please refer to this serial number when ordering parts for the pump. The right and left sides of the pump are determined by viewing the pump from the back of the power end, looking toward the fluid end. This position is also used to identify the plungers and their related parts as being number one, two and three, beginning at the left side of the pump. A! CAUTION! CAUTION! CAUTION!A EXERCISE SAFETY IN ALL PERFORMANCES: DO NOT IGNORE ANY WARNINGS; USE ONLY APPROVED METHODS, MATERIALS AND TOOLS. DO NOT PERMIT ANY FUNCTION OF QUESTIONABLE SAFETY; ACCIDENTS ARE CAUSED BY UNSAFE ACTS AND UNSAFE CONDITIONS. SAFETY IS YOUR BUSINESS AND YOU ARE INVOLVED. A! WARNING! WARNING! WARNING! A BEFORE PERFORMING ANY SERVICE FUNCTION, BE CERTAIN THAT THE UNIT IS SEPARATED FROM ITS POWER SOURCE OR THAT THE POWER SOURCE IS LOCKED-OUT TO PREVENT ANY FORM OF ENERGY FROM ENTERING THE EQUIPMENT. THIS WOULD INCLUDE ELECTRICAL OR MECHANICAL ENERGY INTO OR FROM THE PRIME MOVER(S), PNEUMATIC ENERGY FROM THE COMPRESSOR/AIR SYSTEM. ETC. Print j Home 2 Index I Next e NATIONAL OILWELL VARCO EFTA00795785  Installation, Care and Operation NATIONAL OILWELL VARCO Manual A! WARNING ! WARNING ! WARNING !A FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS PUBLICATION CAN RESULT IN PROPERTY DAMAGE. SERIOUS BODILY INJURY. OR DEATH. A! ATTENTION - NOTICE - IMPORTANT !A THESE TERMS ARE USED TO DRAW ATTENTION TO ACTION THAT WILL CAUSE DAMAGE TO THE PUMP. COMPONENTS OR ATTACHMENTS. A! ATTENTION !A PUMP NOMENCLATURE: ALL PUMP SIZES WITHIN THIS MANUAL WILL BE DESCRIBED WITH THE NEW OR CURRENT NOMENCLATURE. THE OLD PUMP NOMENCLATURES DESCRIBED ON THE FRONT COVER, BUT NOT INCLUDED IN THIS MANUAL EXCEPT AS NEEDED, ARE TO BE UNDERSTOOD AS BEING INCLUDED WITH THE NEW NOMENCLATURES. A! WARNING ! WARNING ! WARNING !A BEFORE SERVICING PUMPS: 1. SHUT DOWN OR DISENGAGE THE PUMP POWER SOURCE. 2. SHUT DOWN ALL PUMP ACCESSORY EQUIPMENT. 3. RELIEVE OR "BLEED OFF" ALL PRESSURE FROM THE PUMP FLUID CYLINDER(S). FAILURE TO SHUT DOWN POWER AND RELIEVE PRESSURE FROM THE PUMP BEFORE SERVICING CAN RESULT IN SERIOUS PERSONAL INJURY AND PROPERTY DAMAGE. Print Home 3 Index Next it NATIONAL OILWELL VARCO EFTA00795786  Installation, Care and Operation Manual e NATIONAL OILWELL VARCO Plunger Pump Nomenclature Example.... 59 T-3 M F RATED INPUT HORSEPOWER T = TRIPLEX = QUINTUPLEX F - FLANGED L = LOW PRESSURE M = MEDIUM. H = HIGH STROKE LENGTH (IN.) *NOMENCLATURE MAY BE SHORTENED IN PARTS LISTS OR OTHER INSTANCES TO LEAVE OFF THE MATERIAL, VALVE TYPE, ETC. THIS FULL NOMENCLATURE DESCRIPTION IS GIVEN FOR INFORMATIONAL PURPOSES. Print I Home 4 Index I Next I e NATIONAL OILWELL VARCO EFTA00795787  Installation, Care and Operation NATIONAL OILWELL VARCO Manual Table of Contents... INSTALLATION PAGE I. GENERAL A. Suction Line 8 B. Discharge Line 8-9 C. Power End 9 D. Fluid End 9 E. Plunger Packing 10 F. Plunger Packing Lubrication 10 G. Suction Pulsation Dampener 1. Low Pressure - Plastic Body 10 2. High Pressure - Aluminum Body 11 LUBRICATION I. GENERAL A. Oil 12 OPERATION I. GENERAL A. Operation Check List 13 MAINTENANCE I. GENERAL A. Daily Maintenance 14 B. Monthly Maintenance 14 C. Storage 15 D. Start-Up After Storage 15 II. TROUBLE SHOOTING GUIDE 16-18 OVERHAUL AND REPAIR I. GENERAL A. Tools Required 19 B. Check Points and Adjustments 1. 59T-3 19 2. 103O-3 19 3. 59T-3, 103Q-3. 110O-3 19-20 Print 1 Home) 5 Next e NATIONAL OILWELL VARCO EFTA00795788  Installation, Care and Operation Manual e NATIONAL OILWELL VARCO Table of Contents (continued)... DISASSEMBLY PAGE I. POWER END A. Plunger/Intermediate Rods and Oil Wiper Retainers 21 B. Crankshaft Assembly 59T-3 21-22 103O-3,110O-3 22 C. Crankshaft Bearings (All Pumps) 22-23 D. Lubrication Oil Pump (110Q-3) 24-25 E. Integral Gear Reducer 26 II. FLUID END A. Fluid Cylinder Removal All Pumps 26 B. Plunger Removal All Pumps 27 C. Stuffing Box Removal 27 D. Fluid End Valve Removal 27 ASSEMBLY I. POWER END A. Connecting Rod and Crosshead Assembly 59T-3, 103O-3 28 110O-3 29 B. Crankshaft Main Bearings and Center Support Bearings 59T-3 30-31 10343,1100-3 31-32 C. Connecting Rod to Crankshaft Assembly All Pumps 33 D. Intermediate Rods and Oil Seal Retainers All Pumps 33 II. FLUID END A. Stuffing Boxes and Plungers All Pumps 34 B. Power End/Fluid end Adapters All Pumps 35 C. Fluid Cylinders All Pumps 35 D. Fluid Valves —Tapered Seat All Pumps 35 E. Piping Installation All Pumps 35 F. Plunger Packing Installation 1. 838 Packing 36-37 2. Braided Packing 38-39 3. 1068-4 Spring Loaded Packing 40-41 rr Print Home I Next I 6 e NATIONAL OILWELL VARCO EFTA00795789  Installation, Care and Operation e NATIONAL OILWELL VARCO Manual Table of Contents (Continued)... PLUNGER PUMP VALVES PAGE I. OPERATIONAL MAINTENANCE A. Suction and discharge 42 B. Valve Covers 42 C. Valve Cover Seals 42 D. Valve Springs 42 E. Valve and Seat 42 II. TAPERED SEAT VALVES A. Severe Duty Valve 1. Nomenclature 43 2. Valve Removal Procedure 44 3. Valve Inspection Procedure 45-46 4. Valve Installation Procedure 46-47 B. Disc Style Valve 1. Nomenclature 48 2. Valve Removal Procedure 49 3. Valve Inspection Procedure 50 4. Valve Installation Procedure 50-51 C. Spherical Valve 1. Nomenclature 52 2. Valve Removal Procedure 53 3. Valve Inspection Procedure 53 4. Valve Installation Procedure 54-55 D. Spherical Valve — Severe Duty 1. Nomenclature 56 2. Valve Removal Procedure 57 3. Valve Inspection Procedure 57-58 4. Valve Installation Procedure 58 P-55U LUBRICATOR I. PUMP OPERATING INSTRUCTIONS A. Operating Instructions 59 1. Box Suction Pumps 59 2. Flow Rate Adjustment 59 3. Sight Glass 59 4. Overfilling of Sight Glass 59 5. Reservoir Oil Level 59 6. Pump Displacement 59 Revisions effective September 2, 2010 - replaced the word multiplex with reciprocating. Print Home 7 Next e NATIONAL OILWELL VARCO EFTA00795790  Installation, Care and Operation Manual e NATIONAL OILWELL VARCO Installation... I. GENERAL Careful planning of the plant layout will save considerable time and expense, both initially when the installation is made and later during the operation of the plant. In selecting the location for the pump, consideration should be given to the fact that a positive suction head at the pump inlet contributes toward the pump efficiency. However, the layouts of the piping, the arrangement of the fittings, and restrictions in the suction and discharge lines have even more effect. For this reason, all fittings and valves should be full opening; all bends should be of long radius or should be eliminated where possible. Long radius 45° ells should be used, particularly if installed near the fluid cylinder. The following points outline the basic requirements for an installation that will contribute greatly toward good pump operation. A. SUCTION LINE 1. The suction line must not be smaller than the suction intake of the fluid cylinder and may be larger. The length of the suction line should be held to a minimum and should run straight from the supply tank to the pump. 2. When bends are required, they should be made with long radius 45° ells. Do not use a bend directly adjacent to the fluid cylinder. Avoid using any 90° bends if at all possible. 3. Provide a full opening gate valve in the suction line adjacent to the supply tank to permit the line to be drained when necessary. Do not use any type of restricting valve. 4. Do not use meters or other restrictions in the suction line. Eliminate any rise or summit in the suction line where air or vapor can collect. 5. Pulsation dampening devices are strongly recommended. 6. When necessary to manifold a number of pumps to a common suction, the diameter of the manifold and suction pipe leading from the supply tank must be such that it has a cross-sectional area equal to, or greater, than the area of the combined individual suction pipes. 7. When a charging or booster pump is used in the suction line, it must have a capacity equal to twice that of the pump output. This is necessary to provide a charging pump with an output great enough to meet the peak volume requirements of the plunger pump during the suction stroke and not act as a restriction in the line. 8. All piping, both suction and discharge must be solidly and independently supported. The first support must be as close to the pump as practical. This is necessary to prevent placing the pump in a strain and to keep any vibration in the system from acting directly on the pump. B. DISCHARGE LINE 1. Use a pulsation dampener or a desurger in the discharge line. It should be placed in the line as near the fluid cylinder as possible and ahead of any bend in the line. 2. Do not reduce the size of the discharge line below that of the pump outlet until the line has passed through the desurger, and is away from the pump approximately 20 feet (6m). 3. Any bend in the discharge line should be made with a long radius 45° ell. Do not use a bend directly adjacent to the fluid cylinder, particularly a 90° bend. Print Home I Index I Next I 8 de NATIONAL OILWELL VARCO EFTA00795791  Installation, Care and Operation S NATIONAL OILWELL VARCO Manual Installation... I. GENERAL B. DISCHARGE LINE (Continued)... 4. A pressure relief valve should be installed in the discharge line. The relief valve should be set to operate at a pressure no greater than 25% above the maximum rated pressure for the plunger size being used. It should be installed in the line ahead of any valve and be piped so that any flow is returned to the supply tank rather than the suction line. This will prevent possible damage to the suction line and suction dampener. 5. A by-pass line should be installed to permit the pump to be started without load. This allows oil to circulate and reach all parts in the power end before they are loaded. C. POWER END 1. The pump must be mounted level and should be grouted in and be free of strain. This applies to a skid-mounted pump or a pump mounted directly on a concrete base. 2. The sheave of a belt driven pump must be correctly aligned with the prime mover sheave. Care must be used to prevent over-tightening as this will shorten belt life, place the pump in a strain, and cause undue additional loads on the crankshaft and bearings. Sheave sizes should not be smaller than the minimum approved diameter. 3. When connecting a direct-driven pump, the shafts must be correctly aligned. Couplings should not be expected to compensate for avoidable misalignment. With Thomas Flexible Couplings, angular misalignment should not exceed one-half degree. Offset misalignment of the centerlines of the two shafts should not exceed .015" (.381 mm). Actually, misalignment should be as small as practical. 4. Provision should be made to stop the pump automatically in the event of supply fluid failure. A pump should not be run dry, as this causes wear on the packing. 5. Adequate plunger chamber drains have been provided in the pump and should not be plugged. Drain lines should never be reduced in size from the connection provided. 6. The pump has been drained of oil after testing at the factory and MUST be filled with the proper oil (see page 12) before starting. The rust inhibiting oil coating inside the power end need not be removed before filling; however, it is recommended that the power end be checked to make sure dirt or contamination has not entered during shipment. D. FLUID END 1. The fluid cylinder is shipped assembled to the pump complete with valves and cover plates. The stuffing boxes, plungers, and related items have also been assembled and tested with the pump (unless otherwise specified) and require no further assembly. Before the pump is started, these parts should be checked for tightness as well as for possible damage during shipment. 2. Thoroughly clean the suction line piping before starting the pump. Weld spatter, slag, mill scale, etc., will damage a pump in a short time. Print Home I 9 Index I Next I NATIONAL OILWELL VARCO EFTA00795792  Installation, Care and Operation Manual e NATIONAL OILWELL VARCO Installation... I. GENERAL (Continued)... E. PLUNGER PACKING The recommended style of packing has been installed and run at the plant. It does, however, require further "setting up" as the pump is started and brought up to pressure. Refer to pages 36 through 41 for correct procedure for packing used. F. PLUNGER PACKING LUBRICATION 1. Automatic packing lubricators are beneficial on all installations and are required on pumps operating at high pressure (1200 psi [85kg/cm 2] and up) to obtain good packing life. 2. When an automatic lubricator is used in water and power oil service, use Rock Drill (Air Drill) oil of proper viscosity. For butane-propane service, use NATURAL castor oil. Set lubricator to feed 5 to 7 drops per minute. G. SUCTION PULSATION DAMPENERS 1. Low Pressure - Plastic Body a. Some National Oilwell Varco plunger pumps are equipped with suction pulsation dampeners. These dampeners do an excellent job when properly charged and should be kept filled during operation. A! ATTENTION ! A At suction pressures over 10 psi (.7kg/cm2), the dampener should be deflated prior to bleeding off the suction pressure to prevent damage to the diaphragm. b. The plastic dampener body has an instruction decal attached, which lists the following installation and charging procedures. A! ATTENTION ! A HANDLE WITH CARE. This is a plastic part and can be broken. c. Tighten capscrews with 10 to 12ft-lbs. of torque. A! ATTENTION ! A Use thread-sealing compound on check valve and tighten until snug. OVERTIGHTENING WILL DAMAGE BODY. d. With pump operating - Charge dampener until bottom of diaphragm is visible through sight glass. Proper charge is when bottom of diaphragm is between center and top of sight glass. Print Home Index I Next I 10 e NATIONAL OILWELL VARCO EFTA00795793  Installation, Care and Operation S NATIONAL OILWELL VARCO Manual Installation... I. GENERAL G. SUCTION PULSATION DAMPENERS (Continued)... 2. High Pressure - Aluminum Body a. In pressures in excess of 20 psi (1.406 kg/cm?) and up to 70 psi (10.545 kg/cm2), it is necessary to use the National Oilwell Varco high-pressure suction dampener. b. The high-pressure dampener is charged in a similar manner to the low-pressure plastic dampener, using air or nitrogen to charge the diaphragm and maintain its position in relation to the sight glass. c. The following procedures should be used to service this dampener: (1) The dampener is fitted to an adapter that may be either welded into an existing line or be a part of a separate dampener housing. Place a gasket on each side of the diaphragm retaining plate and place on the adapter. (2) The dampener spacer is then placed on top of the retainer plate with the grooved side up and the flat side against the retainer gasket. (3) The diaphragm fits into the groove on the spacer with the curved portion of the diaphragm above the spacer. (4) Apply a continuous 1/8" diameter bead of silicone rubber on the outer edge of the diaphragm after it has been positioned into the spacer. This silicone rubber (GE Silicone Rubber or Dow-Corning Silastic) is readily available at most hardware stores. Assemble the body cover within ten minutes after applying the silicone rubber. (5) Fit the dampener cover over the diaphragm and assemble the capscrews. Tighten these capscrews evenly to approximate 80 ft-lbs. of torque. (6) Install the sight glasses, one in each side of the cover. Be sure to seat the sight glass packing carefully into the groove on the cover, as this must be an airtight connection. (7) The air check valve has a pipe thread and must be made up into the cover airtight. Use a good pipe thread sealant to promote sealing. Print I Home I 11 Index I Next I NATIONAL OILWELL VARCO EFTA00795794  Installation, Care and Operation Manual • NATIONAL OILWELL VARCO Lubrication... I. GENERAL NATIONAL OILWELL VARCO models 591-3 and 103O-3 reciprocating pumps are "splash" lubricated. The main bearings and crankshaft bearings are fed by splash. Crossheads and crosshead pin bushings are fed through holes in the crossheads and crosshead reservoir. Intermediate rods are lubricated from the splash they receive from the crosshead. NATIONAL OILWELL VARCO model 110Q-3 reciprocating pump is pressure lubricated via a small gear pump direct driven by the crankshaft. The gear pump provides oil to the crankshaft, connecting rod bearings and crosshead pin bushings. The main bearings and crossheads are splash lubricated from the main oil reservoir and crosshead oil reservoir. A. OIL Use "extreme pressure" gear oil. The chart below shows the recommended grades for various temperatures surrounding the pump. U.S. UNITS OF MEASURE Temperature AGMA Industrial EP Gear Oil +50°F to +155°F AGMA No. 6 EP or ASTM/ISO Grade No. 320 (viscosity 1335 to 1632 SSU 100°F) +20°F to +100°F AGMA No. 5 EP or ASTM/ISO Grade No. 220 (viscosity 918 to 1122 SSU 100°F) -20°F to + 60°F AGMA No. 2 EP or ASTM/ISO Grade No. 68 (viscosity 284 to 347 SSU 100°F) Crankcase Capacity - Quarts: 59T-3 - 10 103Q-3 - 20 110O-3 - 20 METRIC UNITS OF MEASURE Temperature i AGMA Industrial Gear Oil +10°C to +68°C AGMA No. 6 EP or ASTM/ISO Grade No. 320 (Viscosity 228-352 cSt at 37.8°C) -7°C to +38°C AGMA No. 5 EP or ASTM/ISO Grade No. 220 (Viscosity 198-242 cSt at 37.8°C) -29°C to +16°C I AGMA No. 2 EP or ASTM/ISO Grade No. 68 (Viscosity 61-75 cSt at 37.8°C) Crankcase Capacity - Liters: 591-3 — 9.5 103Q-3 - 18.9 110Q-3 — 18.9 Oil must pour freely at minimum operating temperature. Change oil every six months or as frequently as operating conditions require maintaining a clean, sludge-free oil of proper viscosity. Print I Home I Index I Next I 12 • NATIONAL OILWELL VARCO EFTA00795795  Installation, Care and Operation NATIONAL OILWELL VARCO Manual Operation... I. GENERAL A! ATTENTION !A THE FOLLOWING POINTS SHOULD BE CHECKED FOR THE PREVENTION OF TROUBLE OR TO CORRECT TROUBLE THAT MAY ARISE. A. OPERATION CHECKLIST 1. Pump must be a set level for proper lubrication. 2. Make sure pump is filled with clean oil of the proper viscosity (see page 12). 3. Do not over-speed the pump. 4. Do not use a smaller diameter sheave than is recommended for the pump. 5. Make sure all safety shutdown switches are operating properly. 6. Keep all suction and discharge line valves fully open. 7. If a bypass is used to regulate output, make sure it is set properly. 8. Make sure the pressure relief valve is set properly. 9. Do not exceed the pressure rating of the pump for the particular plunger size. 10. Make sure the suction line is tight, as air entering the suction line will cause severe hammering and knocking of the pump. 11. Make sure plunger and intermediate rod connections are tight and locked. 12. Check the plunger packing for correct adjustment (see pages 36 to 41). 13. Check the suction and discharge dampeners for proper charge, as this is very important for long life and good pump operation. 14. Make sure the hex nuts holding the cylinder in place are tight. Print Home I 13 Index I Next I NATIONAL OILWELL VARCO EFTA00795796  Installation, Care and Operation Manual • NATIONAL OILWELL VARCO Maintenance... I. GENERAL The following points are intended as a guide to be used in setting up a maintenance program. Good preventive maintenance will pay big dividends in the form of reliable service with a minimum of trouble. A. DAILY MAINTENANCE 1. Check power end oil level daily. Do not attempt to check the oil with the pump running. Inspect the oil for dirt or contamination and change if necessary. An increase in oil level indicates fluid end leakage into power end. Change oil immediately and check intermediate rod wipers and surface smoothness of rod. Check for plunger packing leakage. 2. Lubricate plunger packing frequently. Packing life can be greatly increased by greasing every four (4) hours with a small amount of grease. Grease is not recommended at pressures above 1200 psi. Use an alternate packing lubricator to drip the proper oil on the plunger for lubrication. (See page 10 for further details). 3. Check lubricator for proper level and operation. 4. Check plunger packing for excessive leakage. Replace packing as required. 5. Check stuffing box adjusting nuts for tightness. 6. Drain plunger leakage sump tanks if required. 7. Flush plunger chamber drain lines with kerosene on power oil pumps and fresh water on salt pumps. This may be done weekly unless salt and paraffin accumulation is severe. 8. Make sure suction and discharge line valves are fully open. 9. Check for leakage between the fluid cylinder and frame or stuffing box to fluid cylinder packing if required. 10. Check all seals for leakage. 11. Check belts or clutch for slippage. If either condition exists, correct immediately. B. MONTHLY MAINTENANCE 1. Drain and refill crankcase every six (6) months or as often as required to maintain a clean, sludge-free oil of the proper viscosity. 2. Clean crankcase air breather with a non-explosive solvent. 3. Check all studs, nuts and capscrews for tightness. Inspect gaskets for leaks; tighten or replace as required. 4. Clean pump. Good housekeeping is a prerequisite to good maintenance. Print Home Index I Next I 14 • NATIONAL OILWELL VARCO EFTA00795797  Installation, Care and Operation t NATIONAL OILWELL VARCO Manual Maintenance... I. GENERAL (Continued)... C. STORAGE If the pump is to be idle for longer than one (1) week, it should be prepared for storage as follows: 1. Drain and clean crankcase thoroughly. Leave drain open and install 90° elbow, pointing downward, to permit air circulation and prevent condensation build-up. 2. Coat all bearings, finished surfaces. and entire inside surface of crankcase with a rust inhibiting oil. 3. Remove plungers and packing, clean and coat with rust inhibiting oil. 4. Remove fluid cylinder valves allowing cylinder to be thoroughly cleaned and drained. 5. Coat entire cylinder, valves and parts, with a rust inhibiting oil. 6. Thoroughly inspect pump and rotate crankcase once each month. Re-coat with rust inhibiting oil where necessary. D. START-UP AFTER STORAGE Any pump that has been in storage, either after field use or as shipped from the plant, will need a thorough inspection to make sure it has not been damaged in any way and that all parts are properly in place. A! ATTENTION !A FAILURE TO OBSERVE THE FOLLOWING POINTS CAN RESULT IN SERIOUS DAMAGE. 1. Remove all covers on both power end and fluid end; thoroughly clean and inspect all parts and finished surfaces. 2. Check all bearings to make sure they are clean and in good condition. 3. Make sure valves, plungers and packing are properly installed and in good condition. 4. Carefully tighten all bolts, nuts, studs and working connections. 5. Fill power end to the proper level with clean oil of the proper viscosity. Make sure oil is poured into the crosshead reservoir and is worked into all bearings. 6. Fill packing lubricator and pump lines full. Check by breaking connection at stuffing box, working lubricator plunger until oil appears. Print Home I 15 Index I Next I S NATIONAL OILWELL VARCO EFTA00795798  Installation, Care and Operation Manual e NATIONAL OILWELL VARCO Maintenance (Continued)... II. TROUBLE SHOOTING GUIDE PROBLEM POSSIBLE CAUSE CORRECTION SUCTION LINE RESTRICTED BY: (1,2,3,4) 1. TRASH, SCALE BUILD UP, ETC. LOCATE AND REMOVE 2. PARTIALLY CLOSED VALVE IN SUCTION LOCATE AND CORRECT LINE 3. METERS, FILTERS, CHECK VALVES, NON-FULL-OPENING, CUT-OFF VALVE OR RE-WORK SUCTION LINE TO ELIMINATE OTHER RESTRICTIONS. 4. SHARP 90° BENDS OR 902 BLIND TEES. RE-WORK SUCTION LINE TO ELIMINATE. AIR ENTERING SUCTION LINE THROUGH TIGHTEN OR REPACK VALVE STEM PACKING CUT-OFF VALVE AIR ENTERING SUCTION LINE THROUGH LOCATE AND CORRECT LOOSE CONNECTION OR FAULTY PIPE KNOCKING OR POUNDING IN FLUID LOCATE RISE OR TRAP AND CORRECT BY END AND PIPING STRAIGHTENING LINE, PROVIDING ENOUGH AIR OR VAPOR TRAPPED IN SUCTION LINE SLOPE TO PERMIT ESCAPE AND PREVENT BUILD- UP INCREASE SUPPLY AND INSTALL AUTOMATIC LOW LOW FLUID LEVEL LEVEL SHUT-DOWN SWITCH SUCTION DAMPENER NOT OPERATING INSPECT AND REPAIR AS REQUIRED WORN VALVES INSPECT AND REPAIR AS REQUIRED ENTRAINED GAS IN FLUID PROVIDE GAS BOOT OR SCRUBBER FOR FLUID INLET TO BE AT TOP OF TANK AND BAFFLED TO BREAKOUT GAS AND PREVENT CHANNELING. POOR INLET AND OUTLET ARRANGEMENT OUTLET TO BE 12" FROM BOTTOM OF TANK AND AT SUPPLY TANK AS FAR FROM INLET AS POSSIBLE, NEVER CLOSER THAN 902. LOOSE PACKING ADJUSTING NUT TIGHTEN AND/OR REPLACE PACKING REPLACE WITH INDIVIDUAL SUCTION LINE OF INADEQUATE SIZED SUCTION LINE NEXT SIZE LARGER THAN INLET PUMP LEAKAGE PRESSURE RELIEF VALVE THAT REPAIR VALVE AND RE-WORK PIPING TO RETURN HAS BEEN PIPED BACK INTO SUCTION LINE TO SUPPLY TANK - NOT SUCTION LINE. BY-PASS PIPED BACK TO SUCTION REWORK TO RETURN BY-PASSED FLUID BACK TO SUPPLY TANK - NOT SUPPLY LINE INSPECT WHEN ROTATING PUMP BY HAND AND BROKEN PLUNGER REPLACE AS REQUIRED Print Home Index I Next 16 NATIONAL OILWELL VARCO EFTA00795799  Installation, Care and Operation t NATIONAL OILWELL VARCO Manual Maintenance... II. TROUBLE SHOOTING GUIDE (Continued)... PROBLEM POSSIBLE CAUSE CORRECTION VALVE WEAR OR DAMAGE CHECK FLUID END FOR BAD VALVES WORN MAIN BEARINGS REPLACE AS REQUIRED LOOSE PLUNGER - INTERMEDIATE ROD INSPECT FOR DAMAGE - REPLACE AS KNOCK IN POWER END CROSSHEAD CONNECTION REQUIRED AND TIGHTEN WORN CROSSHEAD PIN, OR LOCATE AND REPLACE AS REQUIRED CONNECTING ROD CORROSION TREAT FLUID AS REQUIRED ABRASIVES IN FLUID FILTER AS REQUIRED INSPECT AND INSTALL PER INSTRUCTION IMPROPER INSTALLATION SHEET IN PACKING BOX IMPROPER LUBRICATION (EITHER INSUFFICIENT OR EXCESSIVE OR CHECK INSTRUCTIONS IN MANUAL AND CORRECT AS REQUIRED. INCORRECT TYPE) RAPID VALVE WEAR OR LUBRICATOR NOT OPERATING INSPECT AND CORRECT AS REQUIRED FAILURE ADJUSTING NUT LOO