wsp quintuplex pump manual

Doc No: OMM50000888 Rev: C of 62

Subject to contractual terms and conditions to the contrary, this document and all the information contained herein are the confidential and exclusive property of FMC Technologies, and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by FMC.

OPERATION AND MAINTENANCE MANUAL, WQ2700, WELL SERVICE QUINTUPLEX PUMP

Rev ECN No. Date Reviewed By Approved By Status

C 5021267 24-MAR-2009 Taylor, Justin McKelroy, Rondall RELEASED

Summary:

This is the first of three manuals for the FMC Well Service Quintuplex pump. This manual details general information regarding the pump and how to maintain the pump. The others are Power End Parts and Fluid End Parts.

The pump has a 10 inch stroke, a 250000 pound rod load and an input of 2700 BHP.



WQ2700 WELL SERVICE QUINTUPLEX PUMP

OPERATION AND MAINTENANCE MANUAL



Table of Contents

Section Title Page

1.0 Introduction ....................................... .......................................... 9

2.0 Warnings and Safety Instructions ................... ........................ 10

3.0 Nomenclature ....................................... ..................................... 13

4.0 Specifications and Features........................ ............................. 14

5.0 Storage Instructions ............................... .................................. 15

5.1 Short Term Storage..................................................................... 15

5.2 Short Term Storage for Severe Environments ............................ 16

5.3 Long Term Storage ..................................................................... 16

5.4 Freezing Weather Conditions Precautions.................................. 18

6.0 Installation Guidelines............................ .................................. 19

6.1 General Mounting........................................................................ 19

6.2 Lifting Requirements ................................................................... 19

6.3 Suction Piping Recommendations .............................................. 21

6.3.1 General Suction Piping and Joint Recommendations ................. 21

6.4 Discharge Piping Recommendations .......................................... 22

7.0 Lubrication Requirements / Recommended Lubricants.. ...... 24

7.1 Connections ................................................................................ 24

7.2 Lubrication Pressures and Flow rates ......................................... 25

7.2.1 Power End Pressures and Flow Rates........................................ 25 7.2.2 Power End Lubrication Temperature Parameters ....................... 25 7.2.3 Plunger Oil Pressure Parameter ................................................. 25 7.2.4 Packing Grease (if used)............................................................. 25

7.3 Recommended Lubricants .......................................................... 26

8.0 Special Tool Requirements .......................... ............................ 26

8.1 Tool Kits ...................................................................................... 26

8.2 Tool Descriptions ........................................................................ 27



8.2.1 Fluid End Drain (P532156).......................................................... 27 8.2.2 Cover Wrench (P532158)............................................................ 27 8.2.3 Cover Wrench Speed Tool (P534014) ........................................ 28 8.2.4 Valve Seat Puller (P532161) ....................................................... 28 8.2.5 Valve Seat Installation (P532162) ............................................... 29 8.2.6 Retainer Removal (P532163)...................................................... 29 8.2.7 Discharge Flange Wrench Adapter (P535797)............................ 30 8.2.8 Lift Devices.................................................................................. 30 8.2.9 Tie bolt Tightening Kit (P533079)................................................ 30

9.0 Service Procedures................................. .................................. 31

9.1 Replacing Covers........................................................................ 31

9.2 Replacing Valves ........................................................................ 34

9.2.1 Wing Guided Valves.................................................................... 34 9.2.2 Stem Guided Valves ................................................................... 35 9.2.3 Remove Suction Valve Retainer ................................................. 36 9.2.4 Remove Valve Seat and Lower Valve Guide .............................. 37 9.2.5 Valve Inspection and General Maintenance................................ 40 9.2.6 Install Valve Seat and Valve Guide ............................................. 41 9.2.6.1 Suction Valve Installation .................................................................................. 41

9.2.6.2 Discharge Valve Installation .............................................................................. 42

9.3 Replacing Plungers and Packing ................................................ 44

9.4 Replacing Stuffing Boxes ............................................................ 48

9.5 Replacing Plunger Rod Seals ..................................................... 49

9.6 Replacing Discharge Flanges ..................................................... 51

9.7 Tie bolt Tightening Procedure ..................................................... 52

9.7.1 Clamp Nut Description ................................................................ 53 9.7.2 Installing and Applying Torque to the Clamp Nut ........................ 53

9.8 Power End Scheduled Maintenance Service Recommendations .................................................................... 55

9.9 Replacing Crankshaft Oil Injector Seals...................................... 55

10.0 Fastener Torque Requirements ....................... ........................ 56

11.0 Trouble-Shooting Pumps ............................. ............................ 57

12.0 Ordering Information ............................... ................................. 59

13.0 Reference Drawings................................. ................................. 60



14.0 Lifting Arrangement ................................ .................................. 62



List of Tables Tables Page

Table 1: Specifications and Features..............................................................................14

Table 2: Plunger Sizes – Max Flow Rate and Pressures ................................................15

Table 3: Recommended Lubricants ................................................................................26

Table 4: Power End Recommendation Service Schedule...............................................55

Table 5: Fastener Torque Requirements ........................................................................56

Table 6: Trouble-Shooting Chart.....................................................................................57



List of Figures Figures Page

Figure 1: Pump Lifting Arrangement ...............................................................................20

Figure 2: Swivel Lifting Device........................................................................................20

Figure 3: Fluid End Drain Tool........................................................................................27

Figure 4: Cover Wrench .................................................................................................27

Figure 5: Cover Wrench Speed Tool ..............................................................................28

Figure 6: Valve Seat Puller .............................................................................................28

Figure 7: Valve Seat Installation Tool .............................................................................29

Figure 8: Retainer Removal Tool ....................................................................................29

Figure 10: Valve cover, retainer, seal cross-section........................................................32

Figure 11: Valve Cover / Valve / Fluid End Illustration ....................................................33

Figure 12: Exploded View - Wing Guided Valve Components ........................................34

Figure 13: Exploded View – FMC Stem Guided Valves ..................................................35

Figure 14: Valve Retainer Lock Spring Compressing Illustration.....................................36

Figure 15: Valve Retainer w/ Removal Tool Illustration...................................................36

Figure 16: Valve Seat Puller Installed on Fluid End ........................................................37

Figure 17: Valve Retainer Lock Spring Compression Illustration.....................................41

Figure 18: Wing Guided Valves Installed to Fluid End ....................................................43

Figure 19: FMC Stem Guided Valves Installed to Fluid End ...........................................43

Figure 20: Single Packing Cross-Section........................................................................45

Figure 21: Double Packing Cross-Section ......................................................................46

Figure 22: Stuffing Box Face Seal Orientation ................................................................48

Figure 23: Plunger Rod Oil Seals ...................................................................................49

Figure 24: Flange Seal Orientation .................................................................................51

Figure 25: Hytorc Tie bolt Nut Assembly.........................................................................53



1.0 Introduction

The WQ2700 Well Service Pump is made for fracturing and other stimulation treatments. It was designed to address the demands of high pressure, high power mobile applications.

The pump has separate assemblies for the crankcase, crosshead and gearbox. The gearbox has a planetary gear reducer with an offset gear to bring the input shaft and driveshaft closer toward the center of the pumping unit, while keeping the driveshaft angle acceptable.

The crosshead is a unique design that maximizes the bearing areas on the power stroke and on the suction stroke.

The fluid end is held on the pump with tie bolts that run through the fluid cylinder, through the spacer rod and into the crankcase bearing support rings. By bolting directly to the support rings, the front plates, welds and other failure-prone components are eliminated from the load path.

The tie bolts are pre-loaded with a hydraulic tensioning tool. The long tie bolts and torque tool maximizes fatigue life of the tie bolts.

The stuffing boxes are made separately from the fluid cylinder. This allows for replacement of the stuffing box in the event of fatigue or packing bore wear. For most sizes, it allows for the use of more than one plunger size to be used for each fluid cylinder size.

Plunger packing is a commonly available configuration using v-packing and header rings. It is available with single and double rings of v-packing.

The retention of the suction valves is designed to eliminate the usual groove in the fluid cylinder wall that is a common source of fatigue.

All fluid ends can use commercially available wing-guided valves and seats or FMC stem guided valves and seats.

Discharge connections are bolted flanges. The outlets are Weco® male or female connections.

The manuals for the WQ2700 are broken down into three volumes.

Operation and Maintenance – General specifications and regular maintenance requirements.

Power End Parts – Parts listings and exploded views of the crankcase, spacer frame and gearbox assemblies.

Fluid End Parts – Parts listings and exploded views of the fluid end including the various size options.



2.0 Warnings and Safety Instructions

Many accidents occur through careless use of mechanical equipment. You can avoid hazards associated with high-pressure equipment by always following the safety precautions listed below. FMC Technologies cannot anticipate all of the situations a user may encounter while installing and using FMC products. Therefore, the user of FMC products MUST know and follow all applicable industry specifications and practices on the safe installation and use of these products. For additional safety information, refer to FMC Technologies product catalogs, product brochures and installation, operating and maintenance manuals, which can be accessed at www.fmcfluidcontrol.com, or contact FMC Technologies at 800/772-8582.

The application of FMC products are in working environments and systems which must be properly designed and controlled. Safety procedures and policies MUST be clearly established by the user and followed. Always use appropriate protective equipment.

WARNING

FAILURE TO FOLLOW THESE SAFETY WARNINGS COULD RESULT IN DEATH, SERIOUS PERSONAL INJURY, AND/OR SEVERE PROPERTY DAMAGE

• NEVER MIX OR ASSEMBLE COMPONENTS, PARTS OR END CONNECTIONS WITH DIFFERENT PRESSURE RATINGS. Mismatched conditions, including but not limited to that of a 2” Figure 1502 male sub end connected to a 2” Figure 602 female sub, may fail under pressure resulting in death, serious personal injury or severe property damage.

• NEVER USE OR SUBSTITUE NON-FMC COMPONENTS OR PARTS IN FMC PRODUCTS OR ASSEMBLIES.

• NEVER MODIFY OR REPAIR FMC PRODUCTS IN A MANNER NOT SPECIFICALLY DIRECTED IN INSTRUCTIONS PUBLISHED BY FMC TECHNOLOGIES.

• ALWAYS SELECT ONLY APPROPRIATE PRODUCTS AND MATERIALS FOR THE INTENDED SERVICE. Never expose standard service products to sour gas fluids. (Refer to NACE MR0175). Do not interchange sour gas with standard service components. Always use appropriate safety precautions when working with ferrous products in below freezing temperatures. Freezing temperatures lower the impact strength of ferrous materials.



• WHENEVER LEAKAGE IS DETECTED FROM FMC TECHNOLOGIES PRODUCTS, REMOVE THEM FROM SERVICE IMMEDIATELY to prevent death, serious personal injury, and/or property damage.

• TO PREVENT LEAKAGE OR MALFUNCTIONS RESULTING FROM INTERNAL WEAR OR SEAL DEGRADATION, THE USER MUST ESTABLISH A PREVENTATIVE MAINTENANCE AND INSPECTION PROGRAM. THIS PROGRAM MUST INCLUDE:

• Inspection of parts to detect loss of wall thickness which may result in decreased pressure capacity.

• Routine replacement of seals and inspection of proper operation.

• NEVER USE SEVERLY WORN, ERODED OR CORRODED PRODUCTS. Contact FMC Technologies for more information on how to identify the limits of erosion and corrosion.

• ALWAYS MAKE CERTAIN THAT PERSONNEL AND FACILITIES ARE PROTECTED FROM RESIDUAL HAZARDOUS FLUIDS BEFORE DISASSEMBLY OF ANY PRODUCT.

• USE EXTREME CAUTION WITH SOLVENTS used to clean or degrease equipment. Most solvents are highly flammable. Observe all safety instructions on packaging. Always follow manufacturer’s instructions and Material Safety Data Sheet directions when using solvents.

• SHUT DOWN OR DISENGAGE the pump and all accessory equipment before attempting any type of service. Failure to do this could cause electrical shock or injury from moving pump parts or components under high pressure.

• BLEED OFF ALL PRESSURE to the pump and piping before attempting any maintenance to the pump. Failure to do so may spray water or chemicals at high pressure onto service personnel.

• NEVER OPERATE THE PUMP WITHOUT A PRESSURE RELIEF VALVE, burst disc, or other type of properly sized overpressure safety device installed.

• ALWAYS USE A PRESSURE GAGE OR TRANSDUCER when operating the pump. The pressure must never exceed the maximum pressure rating of the pump or damage may occur. This damage may cause leakage or mechanical damage resulting in injury to personnel.

• ENSURE THAT NO VALVES ARE PLACED BETWEEN THE PUMP AND PRESSURE RELIEF VALVE. If the pump is started with a closed or restricted valve in line before the pressure relief valve, the pump may build up pressure in excess of its rated limits and burst causing injury to personnel.

• USE SHIELDS OR COVERS AROUND PUMPS. This precaution can prevent the exposure of service personnel to these fluids should leakage occur. The shields and covers are required for preventing injury due to moving parts. A customer



supplied drip tray is required to enclose the bottom of the spacer frame to prevent injury.

• ALWAYS USE GUARDS on all belt drives and couplings. Guards can prevent personnel from becoming entangled and injured in rotating parts.

• The preload of the tie bolt nuts holding fluid end to the power end are critical to the life of the bolts. These nuts must be installed using the prescribed procedure. A STUD GUARD SHOULD BE IN PLACE AFTER THE TIE BOLTS ARE TENSIONED.

• THE PUMP MUST BE EQUIPPED WITH OVER-PRESSURE AND OVER-TEMPERATURE PROTECTION. The pump should be equipped with monitoring devices or an automatic shutdown device to prevent damage to the pump or its surroundings in the event that the pump discharge pressure exceeds the design pressure limits or in the event that the pump lubrication temperature exceeds temperature limits.

• NEVER MODIFY THE PUMP TO PERFORM BEYOND ITS RATED SPECIFICATIONS.

• NEVER EXCEED THE RATED WORKING PRESSURE OF THE PRODUCT.

• COMPLETE AND PROPER MAKE-UP OF COMPONENTS AND CONNECTIONS IS REQUIRED TO ATTAIN RATED WORKING PRESSURE. Always apply essential care, attention, handling and inspection to threaded components before, during and after make-up.

• NEVER STRIKE, TIGHTEN, LOOSEN OR ATTEMPT REPAIRS ON PRESSURIZED COMPONENTS OR CONNECTIONS.

• NEVER STRIKE WING UNION NUTS OR COVER RETAINERS HAVING SEVERLY FLATTENED AND EXTRUDED EARS. This condition can result in flying debris leading to serious personal injury and must immediately be addressed by either grinding off extruded material or removing the nut from service.

• ALWAYS FOLLOW SAFE PRACTICES WHEN USING OR MAINTAINING PRODUCTS OVERHEAD. Products not properly secured could fall.

• Never exceed the load rating of lifting devices on products or lifting equipment.

• Use of FMC products in suspension applications can result in over-stress conditions leading to catastrophic failure. If externally applied loads are anticipated, consult factory.

• ALWAYS FOLLOW SAFE PRACTICES WHEN MANUALLY LIFTING AND CARRYING PRODUCTS.



3.0 Nomenclature

The pump is generally designated as the WQ2700.

• The plunger size is indicated by adding two digits to the name. For example, a pump with 5 inch plungers is a WQ2750. With 4½ inch plungers, it is a WQ2745.

• The numbering of the cylinders is 1 to 5 with 1 being closest to the gearbox.

• More than one plunger size may be used with a fluid cylinder. The fluid cylinders are referred to by letter; A, B, C, D, E.

• Suction covers are called out by fluid cylinder size. Discharge covers are referred to by valve size.

• The stuffing boxes are known by both plunger and fluid cylinder size. For example, a stuffing box may be known as a “B4.5”.



4.0 Specifications and Features

Table 1: Specifications and Features Power 2700 bHP Rod Load 250000 lbs Approximate Weight 18500 lbs Stroke 10 inch Maximum Crankshaft Speed 300 rpm Stroke Timing 1-5-3-2-4 Plunger centerline distance 10.5 inch Gear Reduction 6.95 to 1 Plunger Sizes 4, 4-1/2, 5, 5-1/2, 6, 6-1/2 Pressure at rated rod load 7500 to 20000 psi Outlet Connections Weco or customer specified Fluids . Common well service fluids containing proppants, additives, and CO2

(with use of CO2 Suction Manifold) Lubrication Dry sump, User supplied pump & filtration. See Table 3:

Recommended Lubricants Fluid cylinder type Monoblock, autofrettaged Stuffing Box Bolt-on, some fluid cylinders accept multiple sizes Packing ½” cross-section V-ring & header ring, adjustable Packing Lubrication User supplied grease or oil, pressure lubrication Valves / Seats Wing Guided Valves or Double stem-guided, removable seats Plungers Hard coated, non-collapsible Fluid End Attachment Tie rods through the fluid cylinder



Table 2: Plunger Sizes – Max Flow Rate and Pressures

Plunger Size Max Rate Max Pressure In. GPM BPM LPM PSI kPa 4 816 19.4 3089 20000 137167

4-1/2 1033 24.6 3909 15000 103422 5 1275 30.4 4826 12700 87787

5-1/2 1543 36.7 5840 10500 72551 6 1836 43.7 6950 8800 60963

6-1/2 2155 51.3 8157 7500 51945

5.0 Storage Instructions

FMC pumps come from the factory prepared for storage periods of up to six (6) months in proper environmental conditions. Indoor storage in a dry, temperature-controlled location is always recommended.

NOTE

Proper storage of your FMC pump will insure that it is ready for service when needed.

5.1 Short Term Storage

Application -

Pump will be stored indoor, in a temperature controlled environment for less than (6) months.

Instructions -

• No special steps are required to prepare it for storage.

• As a general rule for pumps in corrosive fluid applications, the fluid end should be drained, flushed with water or other non-corrosive cleanser and blown dry using compressed air whenever idle.



5.2 Short Term Storage for Severe Environments

Application -

Pump will be stored short term (less than six (6) months) in a severe environment (non-climate controlled).

Instructions -

• Drain any fluid from pump

• Flush the fluid end with water to clean out any of the remaining pumpage and blow dry with compressed air.

• Spray a fog of preservative oil into the suction and discharge ports of fluid end, and install pipe plugs in openings. See Table 3: Recommended Lubricants

• Remove the oil fill cap (or plug) and the power end breather vent.

• Spray a heavy fog of preservative oil into the oil fill hole until it can be seen coming out of the breather opening. See Table 3: Recommended Lubricants

• Coat all exposed, unpainted metal surfaces (for example, driveshaft) with preservative oil.

• Replace the oil fill cap and breather vent, and then cover the entire pump with a weather resistant covering such as a canvas or plastic tarp.

5.3 Long Term Storage

Application -

Long-term storage is defined as any period when the pump is in storage or idle in excess of six (6) months.

Instructions -

• Flush the fluid end with water to clean out any of the remaining pumpage

• Blow the fluid end dry using compressed air.

• Drain all remaining oil from the pump power end.



• Remove the rear cover to expose the drive components. Spray all internal parts with a rust preservative that is soluble in lubricating oil while rotating the driveshaft several turns by hand to insure complete coverage. See Table 3: Recommended Lubricants.

• Replace the rear cover and add a concentrated internal rust inhibitor per recommendations See Table 3: Recommended Lubricants.

• Spray a rust preventative onto all exterior machined surfaces paying careful attention to any unpainted areas like the crankshaft extension and plunger rods.

• Remove the power end breather cap and store in a dry place. Cap the breather opening with a plug or other suitable means in order to keep the preservative atmosphere sealed inside the power frame.

• Ensure the pump is stored on a shelf or pallet that is several inches above the ground.

CAUTION

Never store the pump on the floor or ground.

• Cover the entire pump with a canvas or plastic tarp.

• Periodically inspect the unit and rotate the crankshaft by hand several turns during each inspection.

• Drain and replace the rust inhibitor after every six (6) months of storage.

• Before operating the pump, drain the preservative and lubricating oil mixture from the power end. Reinstall the drain plug, breather/filler cap, and any other components that were removed for storage.

NOTE

FMC can factory prepare units for extended storage for a nominal fee if specified at the time of order.



5.4 Freezing Weather Conditions Precautions

Application –

Pump is stored or is idle in conditions that are near or below freezing.

Freezing weather can cause problems for equipment when pumping water based fluids that expand in volume when changing from a liquid to a frozen solid state.

WARNING

When water based fluids are left in a pump fluid en d and exposed to freezing temperatures, the expansion of the water as it free zes can rupture the fluid cylinder of the pump and cause permanent equipment damage. If dama ge is undetected, and the pump is operated, personnel injury could occur.

Instructions:

• Remove any water based fluids from the pump. The best way to do this is to run the pump for 10 to 15 seconds with the suction and discharge lines disconnected or open to atmosphere. This will clear the majority of the fluid from the pumping chamber as well as the suction and discharge manifolds.

• Blow compressed air through the fluid end to remove all traces of fluid. If possible, remove the pipe plugs and push open the suction valve seat to insure that all fluid is drained from the pumping chamber between the suction and discharge valves. The FMC drain tool (P532156) can be used press open the suction valve. See section 8.2 for tool description.

• As an alternative to draining and drying the fluid end, a compatible antifreeze solution can be circulated through the fluid end. RV antifreeze, propylene glycol, is recommended for this purpose.



6.0 Installation Guidelines

A proper installation is the key to optimum performance, long service life, and reduced maintenance requirements. Take time to thoroughly plan your installation.

6.1 General Mounting

• It is important to mount the pump so that vibrations are isolated from the trailer frame.

• Driveshaft rotation is clockwise looking at the input flange

• The pump must be mounted in a horizontal position only.

• For driveshaft or direct-coupled units, insure that the shafts are centered and parallel when the driver is mounted to the pump.

• The user must supply a drip tray under the stuffing boxes that functions as a guard beneath the spacer frame.

WARNING

Never operate the pump without a shaft guard secure ly in place.

Never operate the pump without guards around the sp acer frame between the power end and the fluid end.

It is recommended to install a guard on top and sid es of the spacer section.

6.2 Lifting Requirements

The WQ2700 Quintuplex pump utilizes a 3-point lifting arrangement.

• Two lift eyes are located on top of the power end.

• Fluid End A: A swivel lift eye with a 2 FIG 2002 male connection is used to connect to the 2 FIG 2002 female connection on top of the fluid end, which serves as a the third lift point. (FMC p/n P536554).

• Fluid End B – E: A swivel lift eye with a 2 FIG 1502 male connection is used to connect to the 2 FIG 1502 female connection on top of the fluid end, which serves as a the third lift point. (FMC p/n P534439).



WARNING

Approximate weight is 18,500 lbs. Ensure lifting e quipment is properly rated and is certified for use. Ensure that personnel performin g the lift are trained in heavy lift applications. Failure to use properly rated liftin g equipment by trained personnel can lead to serious personal injury or death.

Figure 1: Pump Lifting Arrangement

Figure 2: Swivel Lifting Device



6.3 Suction Piping Recommendations

Poor suction piping practices are a very common source of pump problems. To ensure proper operation, it is very important to follow good design practice in the installation of the suction system before the pump is operated. A small amount of extra time and money invested in the piping system usually provides for better pump performance and longer periods between service requirements.

6.3.1 General Suction Piping and Joint Recommendati ons

• The suction line from the fluid source to pump should be as short and direct as possible.

• Use rigid piping, non-collapsible hose or a combination of both as circumstances require in your installation.

• The suction pipe size should be at least equal to or one size larger than the pump inlet.

• Long piping runs, low suction heads, or indirect pipe routing may require even greater over-sizing of the suction line for proper operation of the pump. In some cases it may be necessary to install a booster pump in the suction line of the pump to obtain sufficient pressure for the pump to operate successfully.

• The suction line must be laid out so that there are no high spots in the line where gas or air pockets could collect. These pockets can make the pump difficult to prime and cause rough, erratic operation.

• A drain valve or plug should be installed at the low point of the suction line to allow for drainage during freezing conditions or for maintenance.

• All piping is supported independently of the pump. By supporting the piping this way, vibrations are reduced and stress on the pump is kept to a minimum. The use of elbows, nipples, unions, or other fittings should be minimized.

• Make sure that all joints and connections are airtight. Air leaks reduce the capacity of the pump and can result in cavitation, rough operation, and/or loss of prime. To help isolate mechanical and hydraulic vibrations, FMC recommends the use of flexible hose connections between the pump and any rigid piping.



CAUTION

FMC does not recommend using the pump in static lif t conditions without prior approval.

6.4 Discharge Piping Recommendations

• Route the discharge piping in as short and direct a route as possible.

• Use the same pipe size as the outlet of the pump.

NOTE

On installations where the discharge piping is in e xcess of 50 feet (15 meters), it is suggested to use the next larger size pipe to minim ize friction losses downstream of the pump.

WARNING

Always use piping that is designed for your particu lar pressure requirements. Inadequate pressure ratings can allow hose or pipe failure res ulting in personal injuries or equipment damage.

NOTE

See FMC Engineering Bulletin EB124C for Line Layout Recommendations.

• Install a glycerin filled pressure gauge in the pump discharge line. It is

recommended to install gauges at the pump and upstream of valves in the discharge line. A gauge dampener should be installed to lengthen the life of the gauge.



• Ensure that all piping is supported independently of the pump to reduce vibrations and strain on the pump itself.

• Minimize the use of elbows, nipples, unions, or other fittings.

• Use a sufficient number of swivel connections between the pump and any rigid piping to help isolate mechanical and hydraulic vibrations. Pulsation dampeners are recommended as well to reduce such vibrations.

• A properly adjusted pressure relief valve or rupture disc must be installed directly downstream of the pump to prevent damage or injuries resulting from over pressure or deadhead conditions.

• The relief valve by-pass line must be as large as the pipe outlet of the relief valve.

WARNING

Never install valves in the by-pass line or between the pump and relief valve.

• FMC recommends that the by-pass be returned to the suction tank or drain, not back into the pump suction line.

• FMC Fluid Control Flowline Engineering recommends not exceeding velocities in excess of 40 ft/sec in the line.



7.0 Lubrication Requirements / Recommended Lubrican ts

The power end is designed to have a dry sump with a customer supplied sump, pump, cooling and filtration system.

Few factors can influence the life of a pump more than the power end lubricant and its condition. Careful selection of the right type of oil for your particular application will help insure optimum performance from your pump. Maintaining correct flow, pressure, and temperature conditions is necessary to provide proper power end lubrication.

The proper lubricant is gear oil formulated with an EP (Extreme Pressure) additive. For the FMC Well Service Pump, an ISO grade 220 is adequate for most ambient conditions. At very low ambient temperatures, use an ISO Grade 150 lubricant or synthetic with a low pour point. FMC recommends the use of synthetic lubricants in high ambient conditions.

7.1 Connections

There is one lube oil inlet connection.

• It is a 2 inch SAE Code 61 four bolt flange connection located on the bottom of the lube oil manifold. The manifold is located on the side of the crosshead structure between the power end and the gearbox.

There are 4 outlet (drain) connections.

• Beneath the crankcase, there are two 4 inch pipe coupling.

• At the lowest point the offset gearbox, there is a 2 inch pipe coupling.

• The last connection is a 2 inch pipe coupling located at the bottom of the adapter between the power end and planetary gearbox.

• FMC recommends that all four connections be made without a reduction in size. The drain lines should be routed directly to the lube reservoir with as little restriction as possible.

• The tank vent should be adequate for the return flow.



7.2 Lubrication Pressures and Flow rates

7.2.1 Power End Pressures and Flow Rates

• The recommended minimum flow rate is 65 GPM at the pump inlet. The lube oil pump will need to be rated to 70 GPM at engine or drive speed.

• The lube system should be fitted with a power end mounted relief valve set at 120 psi (100 psi – 150 psi max) to prevent over pressurization at start-up.

• The lube system should be equipped with a 20 micron filter located between the lube pump and the power end. The outlet from the reservoir should include a strainer.

• The recommended lube oil pressure is 100 psi. The minimum allowable pressure is 80 psi.

7.2.2 Power End Lubrication Temperature Parameters

• The unit cooling system should be adequate to cool the lube oil to 140 degrees Fahrenheit (F).

• The maximum inlet temperature should not exceed 180 degrees Fahrenheit (F).

• A minimum lube temperature of 80 degrees Fahrenheit (F) is required before loading up the pump.

7.2.3 Plunger Oil Pressure Parameter

• The plunger lubrication applied pressure recommendation is 30 – 35 psi.

• The maximum plunger lubrication pressure should not exceed 60 psi.

7.2.4 Packing Grease (if used)

• Packing lubrication grease should be a non-moly product to avoid particles hanging up in distribution blocks if used.

• Grease should be selected to accommodate ambient conditions.



7.3 Recommended Lubricants

Table 3: Recommended Lubricants

Application Lubricant

Exxon Spartan EP 220 Conventional EP Gear Lubes

Exxon Teresstic N EP 220

Mobil SHC 629

Power End

Gear Lube w/ EP Additive Synthetic EP Gear Lubes

Conoco Syncon EP 150

Rock Drill Oil

Exxon Arox 150

Shell Torcula 150

Packing Lube

Grease or Rock Drill Oil

Mobil Almo 529

Rust Inhibitor Internal Cortec® VCI 329

External Texaco Metal Protective Oil

8.0 Special Tool Requirements

A number of special tools are required for performing overhaul and maintenance. Below are descriptions of the various kits and tools.

8.1 Tool Kits

P532157 – Frac Pump Tool Kit

• Includes all special tools required. Order this kit when a new maintenance location is being outfitted.

P533084 – Frac Pump Tool Kit (w/o Tie bolt Torquing Wrench)

• Order this kit when a new set of tools is needed and the torquing wrench set is already available.



8.2 Tool Descriptions

8.2.1 Fluid End Drain (P532156)

This tool is a bar that is shaped to reach through the pipe couplings on a FMC suction header and lift the suction valve up, allowing fluid to drain from above the valve.

Figure 3: Fluid End Drain Tool

8.2.2 Cover Wrench (P532158)

This wrench is a hammer wrench fitted with a hex bar. It fits into the internal hex of the cover retainers.

Figure 4: Cover Wrench



8.2.3 Cover Wrench Speed Tool (P534014)

This wrench is a hex bar fitted with a handle. It fits into the internal hex of the cover retainers. It is designed to speed the removal of the cylinder cover retainers.

Figure 5: Cover Wrench Speed Tool

8.2.4 Valve Seat Puller (P532161)

The valve seat puller is used to remove the valve seats from the fluid cylinder. A setting sleeve inside the puller jaws enables the jaws to positively engage the valve seat while fitting around the lower valve guide.

Figure 6: Valve Seat Puller



8.2.5 Valve Seat Installation (P532162)

This is a punch type tool. After the seat are placed in the fluid cylinder. The tool is placed on top of the valve seat and is used to hammer to seat into the tapered bore.

Figure 7: Valve Seat Installation Tool

8.2.6 Retainer Removal (P532163)

This tool, with a 3/8” extension, fits over the suction valve retainer. The tool is used to twist the retainer away from the retaining lugs of the fluid cylinder.

Figure 8: Retainer Removal Tool



8.2.7 Discharge Flange Wrench Adapter (P535797)

This tool is used in conjunction with a torque wrench to access and properly tighten the nuts on the discharge flange.

Figure 9: Discharge Flange Wrench Adapter

8.2.8 Lift Devices

The swivel lift devices are used to interface with the hammer union female connection on top of the fluid end assembly. The lift device is used in conjunction with the two lift eyes on the power end to lift the pump assembly.

• P536554 - 2 FIG 2002 MALE CONNECTION (used for WSP with Fluid End A Assembly)

• P534439 - 2 FIG 1502 MALE CONNECTION (used for WSP with Fluid End B – E Assembly)

8.2.9 Tie bolt Tightening Kit (P533079)

The Tie bolt tightening kit provides a means to adequately torque the tie bolts to the proper specified torque values. The kit is made up of 3 main components listed below.

• Hydraulic Power Pack (P533076)

The power pack provides the power to operate the torque wrench. It is shop-air driven.

• Torque Wrench (P533077)

The torque wrench is used to tighten the attaching nuts onto the tie bolts, providing the extreme preload necessary for long-life and safe operation.

• Clamp Nut Driver (P533078)

This is the adapter that fits the torque wrench to the clamp nut. This is the only part of the tie bolt tightening kit provided in Tool Kit P533084.



9.0 Service Procedures

FMC Pumps are designed to simplify all required maintenance. The plungers, valves, and oil seals are all normal expendable items that wear out and require replacement. Read and understand each section completely before attempting to service the pump.

9.1 Replacing Covers

1. Using the cover hammer wrench (P532158), remove the suction and discharge cover retainers.

2. Lift the cover from the bore using the handle in the cover.

3. Inspect the sealing surface at the base of the fluid cylinder thread. Inspect the bottom of the grooves in the covers. The surfaces should be free of corrosion or scratches extending radially across the sealing surface. The sealing surface may be repaired by machining the surface to clean up. Contact FMC engineering to determine machining dimensions.

4. Inspect the threads on the retainers and on the fluid cylinder. Check for galling or deformation of the threads.

5. Inspect the threads in the fluid cylinder and on the retainers for cracks.

6. Inspect the seal. Use of a new seal is recommended whenever the covers are removed. Install the seal into the cover. Use heavy grease to hold the seal in place. The anti-extrusion ring molded into the seal must face the sealing surface on the fluid cylinder.



Figure 10: Valve cover, retainer, seal cross-section

7. Ensure that no proppant or other contaminants are present in the threads or sealing surfaces.

8. Lubricate the threads and sealing surfaces.

9. Install the covers into the fluid cylinder. Ensure that the valve, the valve spring and the cover are properly positioned as shown

NOTE

For the discharge covers, the valve guide of the co ver must fit over the valves’ spring if using Wing Guided Valves or the valves’ spring and stem if using Stem Guided Valves.

Cover Face Seal

Fluid End Body

Cover Retainer

Cover



Figure 11: Valve Cover / Valve / Fluid End Illustration

10. Install the retainer hand tight, making sure that the counter bore in the retainer faces the cover.

11. IMPORTANT: Using the hammer wrench, tighten the retainer. Tighten until a distinct ring is heard when hammering. For maximum life of the fluid cylinder and the retainers, it is important to fully tighten the retainers.

NOTE

For gauge covers, the instructions are the same exc ept for the use of the hammer wrench. Be sure that the hammering surface of the retainer is not overly rounded over from previous use. The flat of the hammer lugs shou ld have a minimum width at the OD of .25 inch.

CAUTION

Any burrs on the hammering surfaces of the gauge co ver retainer or the hammer wrench should be ground away prior to installation.



9.2 Replacing Valves

The following instructions describe how to replace valves and their respected components. The FMC Well Service Pump can accept commonly available Wing Guided Valves or FMC Stem Guided Valves. Wing Guided Valve parts and Stem Guided Valve parts are not interchangeable. Therefore, it is important to reference the FE parts manual to ensure the correct parts are used for a given configuration.

9.2.1 Wing Guided Valves

Wing guided valves and seats are commonly available from FMC and supply stores. All other parts are of FMC manufacture. The standard springs, valve guides, and suction valve retainers must be removed and replaced with FMC parts unique to the wing-guided valve installation. Refer to the FE manual for specific part numbers.

The wing guided valve seats can be pulled using the FMC valve seat puller or a commercially available valve seat puller.

Figure 12: Exploded View - Wing Guided Valve Components

Discharge Cover Retainer

Cover Seal

Valve Spring

Valve Retainer Spring

Suction Valve Retainer

Valve Seat O-ring

Valve Seat

Valve Retainer Boot

Valve Body

Upper Valve Guide

Discharge Cover



9.2.2 Stem Guided Valves

The FMC Well Service Pump also accepts FMC’s Stem Guided Valves. The Stem Guided Valve features an upper and lower stem that is designed to promote longer valve life by achieving better valve to seat alignment.

Figure 13: Exploded View – FMC Stem Guided Valves

Discharge Cover Retainer

Cover Seal

Valve Spring

Valve Retainer Spring

Suction Valve Retainer

Valve Seat O-ring Valve Seat

Lower Valve Guide

Valve Retainer Boot

Valve Body

Upper Valve Guide

Discharge Cover



9.2.3 Remove Suction Valve Retainer

1. Rotate the crankshaft as needed to bring the plunger to bottom dead center.

NOTE

If changing the packing, remove the plungers at thi s time per section 9.3.

2. Remove the suction and discharge covers as described in section 9.1.

3. Insert a pointed rod or screwdriver into the hole or slot on the side of the suction valve retainer and lift the detent spring.

Figure 14: Valve Retainer Lock Spring Compressing Illustration

4. Using the suction valve retainer removal tool with a 3/8” extension, twist the suction valve retainer 90° CCW and remove from the fl uid cylinder.

Figure 15: Valve Retainer w/ Removal Tool Illustration

5. Remove the suction spring and the valve from the fluid cylinder



9.2.4 Remove Valve Seat and Lower Valve Guide

The FMC valve seat puller kit (P532151) is required to pull the valve seats.

Figure 16: Valve Seat Puller Installed on Fluid End

Valve Seat

Jaws

Puller Bar

Hydraulic Jack

Jack Nut

Jack Plate

Knob

Upper Collar

Setting Sleeve



1. Ensure the valve covers, valve retainer, and springs have been removed.

2. Insert the valve seat puller into the valve bore. If using FMC Stem Guided Valves, orient the jaws through the valve seat bore and then over the arms of the lower valve guide. The jaws must be correctly oriented around the lower guide for proper engagement of the tool to the valve seat.

3. Hold the puller bar up against the lower valve guide. By pushing on the knob, slide the sleeve down. The knob will be approximately ¾” from bottoming out on the top of the puller bar. The knob position indicates a fully engaged setting sleeve.

CAUTION

Excessive force or hammering on the knob is not nec essary to slide the sleeve down and could cause damage to the puller. It is more likel y that the puller is not seated and that the jaws are not far enough down to engage below th e seat. Attempt to maneuver the puller to properly seat it.

NOTE

If the valve seat has mushroomed due to excessive w ear, use a grinder to remove material protruding into the ID before inserting th e puller. This will help to ensure the jaws will fully engage to the valve seat.

4. Place the jack plate, hydraulic jack and jack nut over the puller bar. There are different nuts used depending on whether a suction or discharge valve is being pulled. This is due to the height difference. Make sure that the puller bar, jack plate, hydraulic jack and jack nut are centered in the valve bore.

5. Pull up on the puller bar to seat the jaws on the bottom of the lower valve guide. Tighten the jack nut, while keeping the bar pulled up tightly against the jaws.

6. Check that the puller bar, jack plate, hydraulic jack, jack nut are centered in the valve bore.

7. Ensure that the setting sleeve is pushed down with the knob bottoming out on the top of the puller bar. The jaws should fully engage the valve seat. Note: If using FMC Stem Guided Valves, the jaws should fully engage to the lower valve guide below the seat. There is no lower valve guide when using wing guided valves. The upper collar should fully engage the top of the jaws holding them against the puller bar.



CAUTION

If the knob is not all the way down with the puller bar pulled up, the puller is not ready for the application of pressure.

Excessive force or hammering on the knob is not nec essary to engage the tool to the seat and could cause damage to the puller. It is more l ikely that the puller is not seated and that the jaws are not far enough down to engage bel ow the seat. Attempt to maneuver the puller to properly seat it.

CAUTION

The puller will fail if the valve seat puller is no t centered in the valve bore or if the jaws and setting sleeve are not fully engaged.

CAUTION

Do not exceed 8000 psi when applying pressure to th e valve seat remover. Pressure in excess of 8000 psi could cause failure to the valve puller.

8. Apply pressure using the Enerpac pump to hydraulically pull the valve seat.



9.2.5 Valve Inspection and General Maintenance

1. Check the valve seats, valves, guides and retainer for excessive wear or erosion. The seats should be free of any erosion on the OD of the seat. Replace the O-ring on the valve seat.

2. Check the lock spring to be sure that it fits in a tight fashion. If it is loose, remove the spring. Place the spring in a vise and bend the spring so that it binds when re-inserted into the retainer.

3. Inspect the valve seat taper. Ensure it is free of major scoring and contaminates.

4. If using the FMC stem guided valve, use the following as a guide for wear allowance:

• Refer to the illustration below. Normal valve wear shows itself as a loss of material in the dashed areas shown, symmetric with the valve and seat bodies. To determine whether or not to replace the valves and seats, take measurements for dimensions “A” and “B” as shown.

• FMC’s recommendations for maximum wear allowance are

A = 0.045 inches (1.1 mm)

B = 0.060 inches (1.5 mm)

* This is typical case depth of surface hardening. Beyond the wear limits detailed above, rapid wear is expected.



9.2.6 Install Valve Seat and Valve Guide

9.2.6.1 Suction Valve Installation

1. Inspect and clean the suction valve seat taper. Do not lubricate the valve seats. The OD of the valve seat must be clean of grease or other contaminants.

2. If using FMC Stem Guided Valves, place a lower valve guide in the fluid cylinder, Wing Guided Valves do not require a lower guide.

3. Install a new o-ring on the seat. Do not use any grease on the seat or o-ring.

4. Place the seat in the valve seat bore.

5. Hammer the seat in place using the valve seat installation tool (P532162).

6. Install the suction valve and spring.

7. Compress the lock spring upward and restrain it in the upward position using a bent pointed rod.

Figure 17: Valve Retainer Lock Spring Compression Illustration



8. Place the suction valve retainer over the valve and spring.

9. Orient the retainer valve so that the retainer lock spring tip is facing toward the plunger.

10. Pressing downward with the installation tool, turn the valve 45° CCW onto the fluid cylinder.

11. Remove bent rod used to compress the retainer valve lock spring.

12. Once the bent rod is removed, continue to turn the valve retainer CCW approximately 45° to lock it to the fluid cylinder. A click can be heard when the spring finds it’s locking groove in the fluid cylinder.

13. Ensure that the retainer and its spring are not sticking up in the path of the plunger.

14. Install the suction valve cover and cover retainer per section 9.1.

9.2.6.2 Discharge Valve Installation

1. Install the discharge lower valve guide and seat as described above for the suction valve.

2. Install the discharge valve and spring.

3. Using a permanent thread locking compound, thread the upper valve guide to the discharge valve cover. Properly position the valve guide / valve cover assembly to the discharge valve and fluid end assembly. Reference section 9.1 for valve cover and cover retainer installation steps.



Figure 18: Wing Guided Valves Installed to Fluid End

Figure 19: FMC Stem Guided Valves Installed to Fluid End



9.3 Replacing Plungers and Packing

1. Remove suction valve covers as described in Section 9.1.

2. Remove the clamps holding the plungers to the plunger rods.

3. Rotate the crankshaft to bring each plunger to top dead center.

4. Remove the plunger through the front of the fluid cylinder

5. Remove the packing adjusting nut and the packing from the stuffing box.

6. Inspect the plunger for scratches, voids, corrosion or lost hard-facing. Replace the plunger if damage or wear is found.

7. Inspect the individual packing parts for wear. If the hardware is undamaged, simply replace the soft parts. Ensure that the hole for lube flow is unobstructed.

8. Inspect the stuffing box bore for scratches or wash-boarding. Inspect the lube port to be sure that there is free flow of oil or grease from the plunger lube system.

NOTE

If the stuffing box needs replacing, see section 9. 4.

9. Replace the packing. Be careful to orient the packing correctly. Lubricate the packing bore and packing components with packing lube. Install the packing in the following order and as shown:

NOTE

There are two packing arrangements listed below: S ingle packing V-ring arrangement and a double packing V-ring arrangement.

On the single packing v-ring arrangement, a rear ad apter is used between the v-ring and the lantern ring.

On the double packing v-ring arrangement, two packi ng v-rings are stacked and interfaced directly to a lantern ring which feature s a groove to accept the v-ring packing. There is no rear adapter on a double packing stack- up.



Single Packing V-ring Arrangement:

a) Throat ring

b) Header ring

c) Packing v-ring

d) Rear adapter

e) Lantern ring with o-ring and packing seal installed. Lantern ring will have a flat surface that faces to the rear adapter.

Figure 20: Single Packing Cross-Section

Power End

Fluid End



Double Packing V-ring Attachment:

a) Throat ring

b) Header ring

c) Packing v-ring

d) Packing v-ring

e) Lantern ring with o-ring and packing seal installed. Lantern ring will have a V-groove present in the face to accept the packing V-ring.

Figure 21: Double Packing Cross-Section

10. Install each component, taking care not to damage the stuffing box or the individual components. Seat the packing parts fully in the packing bore.

CAUTION

Do not use hammers, screwdrivers or pry bars to sea t packing components to the stuffing box. This will increase the risk for dama ge to the components.

11. After all components are installed, tighten the adjusting nut hand tight plus an additional quarter turn, ensuring that all components are properly seated. Ensure that the inside surface of packing is lubricated.



12. Mark a reference line from the adjusting nut onto the stuffing box face using a permanent marker.

13. Back off the adjusting nut one full turn to unload the packing for plunger installation.

CAUTION

Failure to back off the adjusting nut one turn to u nload the packing prior to plunger installation could result in damage during installa tion.

14. Lubricate the leading edge of the plunger. Carefully insert the plunger into the

plunger bore and place it against the packing header ring.

15. Hold the plunger firmly against the header ring and carefully drive the plunger through using a rubber mallet. This can also be done by hammering on a block of wood placed against the end of the plunger. Drive the plunger back only far enough to engage the plunger rod when it is at top dead center.

CAUTION

Do not try to ram the plunger through the header ri ng as this will cause damage to the header ring.

Do not use a metal hammer or other hard object as t his will damage the plunger.

Take care not to damage the back end of the plunger (the clamping surfaces).

16. Reattach the plunger and plunger rod using the plunger clamps. It will be necessary to rotate the crankshaft to bring the rod and plunger together.

17. Find the marks previously made on the adjusting nut and stuffing box. Realign the marks to their original position, ensuring the proper compression of the pressure ring and optimizing packing life.

CAUTION

Do not excessively tighten the adjusting nut on the stuffing box. Over-tightening will substantially reduce packing life.

18. Once the packing is correctly adjusted, the packing should not be tightened further. If the packing begins to leak it is time to replace the packing or related parts.



9.4 Replacing Stuffing Boxes

1. Ensure that the packing lube system is not under pressure. Remove the plunger lube fittings from the stuffing box.

2. Remove the plunger and adjusting nut as described in sec 9.3.

3. Attach a lift eye to the top of the stuffing box in the tapped hole next to the plunger lube port. Attach a hoist to the lift eye. Remove slack from the hoist without pulling up on the stuffing box.

4. Remove the four stuffing box bolts.

5. Pull the stuffing box back from the fluid cylinder. Take care not to drop the stuffing box seal. Rotate the stuffing box 90° and lift out f rom between the spacer bars.

6. Check that the new stuffing box bore is clean and free of anything that might damage the packing. Replace the packing as described in section 9.3.

7. Inspect the sealing surface on the back of the fluid cylinder. The surface should be smooth and free of deposits, corrosion, debris or damage. Clean or repair as necessary.

8. Install a new face seal on the stuffing box. Use heavy grease to hold the seal in place until the stuffing box is fastened to the fluid cylinder. Be sure to observe the orientation of the new seal. The metal portion of the seal should be visible when it is installed in the groove. See Figure 22.

Figure 22: Stuffing Box Face Seal Orientation

Stuffing Box Assy

Fluid End Assy

Face Seal



9. Replace the stuffing box in the spacer frame. Insuring that the face seal is in place. Place the stuffing box into the counter bore on the fluid cylinder.

10. Replace the stuffing box bolts. Tighten the bolts sequentially in a criss-cross pattern. Torque to the values specified in the torque table. Reference Table 5 in section 10.

11. Reattach the plunger lube system.

12. Install the plungers and packing as described above in section 9.3.

9.5 Replacing Plunger Rod Seals

1. Remove the clamps holding the plungers to the plunger rods

2. Rotate the crankshaft until the plunger rods and plungers are separated.

3. Remove the screws holding the plunger rod seal holder to the spacer frame. Slide the holder off of the plunger rod. Remove the o-ring from the back of the holder.

4. Remove retaining ring from the seal holder. Remove the oil seals from the holder.

5. Replace the oil seals, ensuring that the seals are oriented properly. Both seals should be oriented so that the major lip faces the power end and the minor lip faces the fluid end.

Figure 23: Plunger Rod Oil Seals

Power End

Fluid End

Oil Seals



6. Replace the retaining ring.

7. Inspect the sealing surface on the spacer frame. The surface should be smooth and free of deposits, corrosion, debris or damage. Clean or repair as necessary.

8. Replace the o-ring seal on the back of the seal holder. Use heavy grease to retain the o-ring until it is installed on the spacer frame.

9. Slide the holder over the plunger rod and against the spacer frame.

10. Loosely, install the seal holder screws.

11. Reattach the plunger and plunger rod using the plunger clamps. It will be necessary to rotate the crankshaft to bring the rod and plunger together.

12. Tighten the seal holder screws sequentially in a criss-cross pattern.



9.6 Replacing Discharge Flanges

1. Remove the six nuts retaining the discharge flange.

2. Check the bottom of the counter bore in the fluid cylinder and the sealing face of the discharge flange boss. They should be smooth and free of corrosion, erosion or nicks.

3. Check the union sealing surfaces.

4. Install a new seal. The metal backup of the seal should be away from the bottom of the counter bore. It should be facing the discharge flange base as shown below in Figure 24.

5. Install the flange, tightening the nuts in a criss-cross pattern. Be sure that the flange is fully seated and flat against the fluid cylinder.

6. Torque the nuts as specified in the torque table. Reference Table 5.

Figure 24: Flange Seal Orientation



9.7 Tie bolt Tightening Procedure

IMPORTANT: FMC requires formal training on this tie bolt tightening procedure before non-FMC technicians should perform this operation.

The clamp nuts that attach the fluid end and hold the entire pump together are a critical part of the assembly. Care must be taken to install and tighten them correctly.

The relative measurement of the inner core and outer sleeve determines when the correct load is applied to the studs. The elongation of the stud and compression of the housings are measured as the offset between these two surfaces after they are loaded.

CAUTION

A single tie bolt cannot be replaced w/o completely relieving and re-torquing ALL studs according to this procedure.

WARNING

Applying too little load elongation can cause the s tuds to fail in fatigue. Applying too much load elongation can cause yieldin g of the studs. It is important to read the following instructions in their entirety, and follow each step correctly.



9.7.1 Clamp Nut Description

The clamp nut is made up of three pieces:

• Inner Core – threads to the stud

• Washer – splines onto the Inner Core

• Castellated Outer Sleeve - threads to Inner Core

Figure 25: Hytorc Tie bolt Nut Assembly

9.7.2 Installing and Applying Torque to the Clamp N ut

1. Ensure the fluid cylinder is properly aligned and seated to the spacer frame.

2. Thread nuts on the stud by hand. Ensure inner core extends slightly past the end of the washer.

NOTE

It is important that the inner core seats solidly a gainst the fluid end when first threaded into place.

3. Thread the outer sleeve down the core and drive the washer against the fluid end

face. The nut should be tightened to be considered snug. Do not use the hydraulic torque tool at this point.

Outer Sleeve

Inner Core

Washer



NOTE

At this point, the tip of the outer sleeve should b e flush with the top of the core.

4. Install all the remaining nuts to their respected studs as described above.

5. Set the Hytorc Avanti 8 hydraulic torque tool (P533077) to 1000 psi.

6. Start on a nut near the center and work diagonally across the pattern, while moving toward the outside.

CAUTION

Do not hand tighten any nuts further onto the studs during the loading sequence. This will cause different loading to be applied, which w ill make a difference when the final elongation measurement is taken.

7. Measure the offset distance between the inner core of the clamp nut and the top of the outer sleeve using micrometers or calipers. The required elongation of the studs is .165 -.175 inches.

8. Increase the pressure incrementally as needed until the required elongation is achieved.



9.8 Power End Scheduled Maintenance Service Recommendations

Table 4: Power End Recommendation Service Schedule Item Description of Service Frequency (hrs)

Crankcase oil Drain and Replace 200 Oil Filters and Strainers Replace 100 Crankshaft Oil Seal Replace 200* Gear box Oil Seal Replace 200* Rod Bearings Inspect for significant wear and abnormalities 600 Crosshead Slides and Shoes

Inspect for significant wear, scoring, or burning

600

*Inspect both the crankshaft oil seal and gear box oil seal for leakage each time the crankcase oil is changed. Change the oil seals as necessary.

NOTE

When filters and strainers are removed, inspect the m for excess metal shavings. If excessive metal shavings are present, inspect the g earbox and crankcase for significant wear or non-conformance of internal parts.

9.9 Replacing Crankshaft Oil Injector Seals

1. Disconnect the hoses from the rotating union

2. Remove the union retainer plate by removing the six cap screws.

3. Pull the union free from its housing.

4. Remove the housing from the crankshaft by removing the retaining cap screws.

5. Remove the oil seal from the crankshaft cover.

6. Remove the union seal from the housing

7. Inspect all seal surfaces for non-conformances.

8. Lubricate the seals and seal surfaces.

9. Reinstall the oil seal and union seal.

10. Reattach the housing to the crankshaft, taking care not to damage the oil seal.



11. Insert the union into the housing. Reattach the retainer plate.

12. Reconnect the power end lube plumbing.

10.0 Fastener Torque Requirements

No pump service procedure is complete without ensuring that the fasteners have been properly torqued. Always use a calibrated torque wrench during the installation of all critical fasteners listed below. Values are in ft-lbs and Newton meters (N-m).

CAUTION

Failure to properly tighten the pump bolting could cause the pump to leak or possibly allow the bolts to fail.

Table 5: Fastener Torque Requirements

Fastener Fastener Size, in. Torque, ft-lbs

Torque, N-m

Tie bolt nuts 1-1/2 – 8UNS See Section 9.7 Connecting Rod 1 – 8UNS 450 610 Crosshead Trunnion Cap 3 / 4 – 10UNC 350 475 Crosshead Slide to Case 1 / 2 – 10UNC 60 81 Crosshead shoe to Crosshead 5 / 16 – 18UNC 15 20 Gearbox Adapter to Crankshaft Housing 3 / 4 – 10UNC 390 529 Gearbox Adapter to Ring Gear 5 / 8 – 11UNC (GR8) 200 271 Gearbox Housing Assembly to Ring Gear 5 / 8 – 11UNC 130 176 Suction covers Discharge Covers

* See note

Discharge Flange Nuts 1 – 8UNS 320 434 Suction Header Bolts 5 / 8 – 11UNC 80 108 Stuffing Box Bolts (Teflon-coated) 1-1/4 – 8UNS 600 813 Stuffing Box Bolts (non-coated, greased) 1-1/4 – 8UNS 900 1220

*Cover Installation – Covers are installed using a hammer wrench assembly available from FMC as a special tool. The exception is the gauge cover which uses a nut with hammer lugs. Both are installed by hammering. The cover retainers are installed to bottom out hand-tight in the fluid cylinder. The retainers are hammered up until a distinct ring is heard when hammered. See Section 9.1.



11.0 Trouble-Shooting Pumps

This chart is designed to aid in the solution of pump and pump system problems. Once the problem has been identified, work through the possible causes and solutions until the problem has been corrected.

Table 6: Trouble-Shooting Chart Symptom Possible Causes

No flow from pump Tank is empty

Suction valve is closed

Crankshaft is not turning Insufficient pump pressure ONLY Relief valve improperly adjusted and by-passing

fluid Worn pump valves Excessive leakage from pump seals

Insufficient flow OR pressure AND rough operation

Valve problem: - Valve is stuck in the open or closed position - Valve assembly is damaged or unseated - Valve seat is washed out All pump cylinders not primed Excessive gas in liquid due to: - Air leaks in suction line or fittings - High spots in suction line that allow formation of gas pockets - Vortex in tank near inlet pipe opening Pump is cavitating due to: - Fluid viscosity is too high - Inlet line is too long and/or too small diameter

Pump runs rough, knocks, or vibrates ONLY Loose plunger assembly Valve assembly is damaged or has unseated Pump is cavitating due to: - Fluid viscosity is too high - Inlet line is too long and/or too small diameter Worn or damaged power frame components Pump is sucking air across worn packing during suction stroke (usually only observed on pumps that do not have a booster pump)

Suction pressure fluctuates rapidly Pump is cavitating Air is entering into the suction piping

Fluid leaking from pump Plunger packing is wearing and about to fail Fluid cylinder seals are worn or damaged Stuffing box seal is leaking

Short plunger packing life High abrasive particle content in fluid Wrong style or type of packing for service Plunger is damaged Pump is cavitating (cylinders may run hot) Pump is allowed to run dry for extended periods of



time Packing lube system not properly maintained.

Short valve life High abrasive particle content in fluid Valve assemblies only partially rebuilt during previous service Valve assemblies damaged due to improper installation techniques Pump is cavitating

Leaking Between Fluid Cylinder and Cover, Discharge Flange or Stuffing Box

Seal is not oriented properly. The metal backup must be oriented as shown.

Cracked fluid cylinder Discharge pressure too high Pump exposed to freezing conditions without properly draining Hydraulic shock resulting from cavitation or entrained air Discharge valve is stuck shut Fluid cylinder fatigue life has been exceeded.

Power end overheats Discharge pressure too high Low oil level Improper oil viscosity, see Section 5.0 for proper selection of lubricants Contaminated power end oil Pump speed is too fast Worn or damaged crankshaft bearings, connecting rod bearing or crosshead slide

Broken crankshaft or connecting rod Pump exposed to freezing conditions without proper draining Discharge pressure too high Hydraulic shock due to cavitation

Broken Fluid End Bolts Nuts not properly torqued Discharge pressure too high

Power end oil is contaminated Use of high-pressure wash wand to clean near breather or oil seal areas Plunger rod oil seals are damaged or improperly installed



12.0 Ordering Information

Service parts are available through FMC’s worldwide network of distributors. If unsure where to purchase parts, contact FMC customer service for the location of an authorized parts retailer in your area. Always insist on genuine FMC replacement parts.

Use the Power End Parts Manual or the Fluid End Parts Manual for to determine the components and corresponding part numbers required to service the pump. Make sure that the part number on the drawing or bill of material matches the part number of the pump requiring parts.

Always reference the pump model, part number and serial number of the pump with the order. These numbers can be found stamped on the metal nameplate affixed to the power end of every pump. By referencing these numbers you can insure that the components you receive work as intended with your pump.

Be sure to inquire about any special service tools or complete maintenance kits.



13.0 Reference Drawings

2” NPT DRAIN FROM GEARBOX ADAPTER

2X 4” NPT DRAIN FROM SUMP



``

2” NPT DRAIN FROM GEARBOX AT THE BAFFLE



14.0 Lifting Arrangement

wsp quintuplex pump manual

Documents

express written authorization

swivel lifting device

lower valve guide

oil fill cap

fastener torque requirements

swivel lift eye

water based fluids

short term storage