Home

Reciprocating Plunger Pumps Installation, Care and

1. SS N N CN IS Sj Z 7 Y 14 Figure 15 NOY uar TONAL OILWELL VARCO www nov com Installation Care and Operation WERTEN e NATIONAL OILWELL VARCO Plunger Pump Valves Continued lil TAPERED SEAT VALVES A SPHERICAL VALVES and SEATS 1 VALVE REMOVAL PROCEDURE a Both suction and discharge valves are removed from the top of the cylinder It is necessary to pull the discharge valve prior to pulling the suction valve Remove the spring retainer by pressing downward on the puller head and turn counter clockwise about 1 8 of a turn or until retainer stops Remove the retainer with the retriever See Figure 17 Remove spring s and valve with the retriever See Figure 18 Remove seat by placing the puller head through the seat opening and engage lugs to the underside of the seat Pull seat or bump seat loose and remove See Figure 19 2 INSTALLATION PROCEDURE a e NATIONAL OILWELL VARCO Make certain cylinder tapers are clean and dry Inspect for corrosion or damaged areas Repair or replace as required Clean and dry spherical seat tapers and with retainer and spring s removed place seat in place making certain it is straight With a bar and a driver tap seat in place with 2 or 3 strokes NOTE Seat does not have to be completely seated Pump start up pressure will drive seat home See
2. lt 4 x 20 10 NOTES Assumes 100 WI single grade ails Read across horizontally SAE grades based upon viscosity at 100 C ISO and AGMA grades based upon viscosity at 40 C Equivalence is in terms only of viscosity Quality requirements are a separate consideration viscosity limits are approximate For precise data consult ISO AGMA and SAE specifications grades define only in terms af 100 C viscosity For low temperature limits consult SAE specifications 50 International Standardization Organization AGN American Gear Manufacturers Association SAE Society of Automotive Engineers Print Home 79 Index Next www nov com waviowat oitwELL VARCO NATIONAL OILWELL With over 120 locations worldwide National Oilwell Varco is located near you To find the nearest Distribution Service Center machinery center or repair facility please give us a call at our main office listed below Or you can access our website at the URL listed below where you may search by location or country http www nov com contactus Sales Technical Information National Oilwell Varco is a leading USA Tollfree 1 800 324 4706 manufacturer of reciprocating plunger pumps Mission Fluid King centrifugal pumps and fluid replacement parts Internet hitp www nov com We also offer a complete set of solutions to your fluid transfer challenges For
3. CORROSION 1 MANUFACTURED UNDER ONE MORE UNITED STATES PATENTS 3 146 724 5 276 659 3 599 694 4 487 222 4 667 697 1 26 c 14 ATEX 0004 ee 1 NO nanona owe varco 10000 RICHMOND HOUSTON TEXAS 77042 U S A MAX MIN AMBIENT TEMP C o 2407904 Lr Print Home 10 Index Next e NATIONAL OILWELL VARCO www nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual ATEX Warning Statements I PUMPS AND PUMP UNITS A 80T PUMP Continued 2 DECLARATION OF INCORPORATION amp Declaration of Incorporation Machinery EC Declaration of Conformity ATEX MANUFACTURER National Oilwell Varco 6750 S 57 West Avenue Tulsa Oklahoma 74131 PRODUCT DESCRIPTION 80T Pump APPLICABLE EUROPEAN DIRECTIVES Machinery 98 37 EC ATEX 94 9 EC PED 97 23 EC APPLICABLE HARMONIZED STANDARDS Machinery EN 12100 1 EN 12100 2 ATEX EN 1127 1 EN 13463 1 EN 13463 5 PED Exempt per Article 1 Clause 3 10 NOTIFIED BODY Bureau Veritas ATEX NB 0081 retains a copy of the Technical File ATEX 0004 II2G c The equipment described in this Declaration of Incorporation complies with the Applicable European Directives and relevant sections of the Applicable International Standards Integration instruction are provided that contain requirements and specifications that must be implemented prior to putting this equipment into serv
4. gear reducer housing is equipped with magnetic drain plug that will collect any steel particles prevent them from being recirculated with oil This plug should be cleaned every six months b The gear reducer should be drained flushed and refilled every six months or as often as required to maintain clean sludge free oil of the proper viscosity c Clean air breather with a non explosive solvent Print Home 69 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation Manual e NATIONAL OILWELL VARCO Gear Reducer Continued ll OVERHAUL AND REPAIR A GENERAL The bearings and other working parts in the plunger pump gear reducers have been designed for continuous duty service and if proper maintenance is given will provide years of trouble free service If overhaul and repairs are necessary disassembly and assembly procedures are discussed below 1 DISASSEMBLY a Remove housing cover bolts and using threaded jackscrew holes pull the cover and tapered dowel pins b Remove pinion shaft and Timken bearings from housing c Remove blind cover plate d Tap out Timken outer cup and mark all parts for correct replacement position e Pull crankshaft gear Gear is a 001 005 shrink fit to shaft Puller holes are provided in gear for pulling 5 8 holes 165T and 300Q 1 holes Heat should be used when pulling gears but a combination of dry heat and dry ice c
5. e NATIONAL OILWELL VARCO Installation Care and Operation NATIONAL OILWELL VARCO TIE TA Operation I GENERAL ATTENTION THE FOLLOWING POINTS SHOULD BE CHECKED FOR THE PREVENTION OF TROUBLE OR TO CORRECT TROUBLE THAT MAY ARISE A OPERATION CHECKLIST 1 WWW nov com Pump must be a set level for proper lubrication If an auxiliary lubrication pump is used for slow speed operation make sure it is connected and is operating properly Make sure pump is filled with clean oil of the proper viscosity see above Do not over speed the pump Do not use a smaller diameter sheave than is recommended for the pump Make sure all safety shutdown switches are operating properly Keep all suction and discharge line valves fully open If a bypass is used to regulate output make sure it is set properly Make sure the pressure relief valve is set properly Do not exceed the pressure rating of the pump for the particular plunger size Make sure the suction line is tight as air entering the suction line will cause severe hammering and knocking of the pump Make sure plunger and intermediate rod connections are tight and locked Check the plunger packing for correct adjustment refer to the Assembly Fluid End Plunger Packing Installation section of this manual Check the suction and discharge dampeners for proper charge as this is very important for long dampener life and good pump
6. 16 www nov com Remove threaded cover The covers should be tight enough to require an extension on a 24 pipe wrench to loosen Inspect threads for wear which could occur if cover was loose Remove retainer with hook on a magnetic retriever Some retainers are tapped with a lifting thread for removal Remove cover seal from top of cage with hook on magnetic retriever This hook is rough ground at the plant and should be finished to a flat sharp edge to be most effective See Figure 4 Before removing spring observe amount of pre load Spring should extend about 1 8 to 3 16 above the top of the cage It is not recommended that you stretch a spring to secure the correct pre load as this causes physical damage to the spring This should be done only on these cases where a new spring is not available Remove the spring with hook See Figure 6 Remove cage with puller as illustrated Under normal conditions these cages are readily removed If the fluid being pumped makes mineral deposits gyp in the cage bore this will immediately alert the customer that he should start some type of treating program to protect his complete system Using magnet or hook remove valve disc See Figure 6 Insert valve seat driver in discharge seat and rock back and forth This action will loosen the seat and allow it to be removed with the hook See Figure 7 Assemble upper valve as removed to keep parts together Remove seal from top of lower
7. After the bearings have been brought up to temperature and with the crankshaft firmly supported install the cone and roller assemblies on the crankshaft The large O D must go on first and be positioned next to the shoulder on the crankshaft Make sure the cone and roller assemblies are firmly against the shoulders on the crankshaft Allow the crankshaft and bearing assembly to cool before installing in the power end Make sure the main bearing openings in the frame are clean and free of burrs NOTE The crossheads and connecting rods on old J 30 pumps prior to S N 3854 and J 60 pumps prior to S N 7476 must be installed prior to replacing the crankshaft assembly With the cone and roller assemblies of the main bearings in place on the crankshaft slide the crankshaft from either side through the main bearing openings in the power end frame with No 1 throw forward Install the crankshaft main bearing outer races or cups the thin edge of the tapered race leading into the bore over the cone and roller assembly Place the crankcase main bearing shims amounting to approximately 050 1 27 mm in thickness on either crankshaft bearing retainer f the old bearings and retainers are being re installed use the same amount of shims as before NOTE The following steps 9 10a and 10b are necessary only if new bearings are being installed When the same crankshaft main bearings are being reassembled use the same amount of shims as were prev
8. Each cage that is removed should be inspected at the following points referred to in the drawing Figure 8 a Inspect for wear in this area It is best to do this with the valve and seat in the cage therefore a more accurate decision can be made The wear in this area which can be judged by the sideways movement of the disc should not exceed 1 2 the width of the seating surface of the disc valve or more than 1 8 to 3 16 for the ball valve These are maximum figures and could result in poor valve action and some loss of efficiency If in doubt change the cage b Inspect the valve seat shouldering area for signs of wear or hammering If this portion of the cage is cracked or battered the cage should be replaced This will only happen if the cage is allowed to move in the bore due to loose covers PAA S AA S SS KX L C Figure 8 c Inspect cage bore for excessive spring In most cases this area will wear only if there is poor valve action or extremely corrosive water that attacks the cage material in this wear zone d Inspect O D of cage for nicks burrs or washers Clean cage thoroughly before replacing Print Home 55 Index Next WWW nov com e NATIONAL OILWELL VARCO Installation Care and Operation VEEL e NATIONAL OILWELL VARCO Plunger Pump Valves Il CAGE TYPE VALVES D VALVE PARTS INSPECTION Continued 2 VALVE BOTTOM GUIDED AND SEAT The standard 25 NATIONAL O
9. EN 13463 1 EN 13463 5 PED Exempt per Article 1 Clause 3 10 NOTIFIED BODY Det Norske Veritas ATEX NB 0575 retains a copy of the Technical File ATEX 0003 Ex II 2G c T4 The equipment described in this Declaration of Incorporation complies with the Applicable European Directives and relevant sections of the Applicable International Standards Integration instruction are provided that contain requirements and specifications that must be implemented prior to putting this equipment into service this equipment must not be put into service before the machinery into which it is to be incorporated has been declared in conformity with the provisions of the Machinery Directive The EHSR s related to this equipment have been addressed a Technical Construction File is available for inspection by designated bodies ATEX product marking Authorized Signature Date I Matthew Bryce March 1 2007 Important safety information is contained in the installation operation and service manuals read and understand this information prior to installing or using this equipment This Document applies only to the equipment described above and is invalid if not reproduced in its entirety Print Home 15 Index Next www nov com naT onAL oitwELL VARCO Installation Care and Operation Manual e NATIONAL OILWELL VARCO Installation I GENERAL Careful planning of the plant layout will save considerable time and expen
10. plunger forward d Remove intermediate rod and intermediate rod seal retainer from pump as one assembly e Remove plunger and old packing making sure stuffing box is clean Plungers and boxes may be removed as an assembly by rotating the pump so the intermediate rod is all the way back disconnecting the plunger and sliding the stuffing box back and out f Starting with the first Phenolic ring seat each ring individually in the order packaged Eliminate the No 1 Phenolic ring when using a sleeve washer with ceramic plungers g Install plunger and make up the adjusting nut tight to ensure the entire packing set is properly seated The nut should be loosened and adjusting hand tight h Install intermediate rod and retainer Connect plunger and torque properly as outlined in the Power End Intermediate Rods and Oil Seat Retainers section of this manual i Start the pump and run with normal system pressure Tighten the adjusting nut carefully watching for excessive heat build up Continue to tighten the nut until it is a good snug fit and the nut shows no movement in the threads IMPORTANT IF THE ADJUSTING NUT LOCKS AND CANNOT BE MOVED IMMEDIATELY REMOVE THE PRESSURE FROM THE PUMP BACK OFF THE NUT ONE HALF 1 2 TURN AND START AGAIN j This packing may or may not leak depending on the circumstances and it does not require continuous adjustment It should be checked and re tightened the first day or two after installation
11. 20 220 194 20 220 327 NUT 75 518 308 75 510 330 Print www nov com Home amp Index Next e NATIONAL OILWELL VARCO e NATIONAL OILWELL VARCO Installation Care and Operation Manual Plunger Pump Valves TAPERED SEAT VALVES A SPHERICAL VALVES AND SEATS Continued ZELDA 2 y vi lt 2 e ES M N N NS NM K SN 5 N e INN KINN SS N N N Ve NN N KN SN N gt ANS NNN SZ VANS EN lt LS N NY ANO NUN 4 LANN KN NN NNNNNI EN O ZZ m ES N un Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Print Home 64 Index Next www nov com e NATIONAL OILWELL VARCO Installation Care and Operation NATIONAL OILWELL VARCO TIE TA Plunger Pump Valves Continued TAPERED SEAT VALVES B TAPERED SEAT BOTTOM GUIDED VALVES 1 VALVE REMOVAL PROCEDURE a Using hex head wrench as shown in Figure 23 remove retainer and spring Bottom guided valves can be removed with a magnet or special valve retriever b Screw puller head on valve seat until tightly shouldered Valve seat can be pulled or bumped as shown in Figure 24 2 INSTALLATION PROCEDURE a Make certain fluid end tapers are clean and dry Inspect for corrosion or damaged areas to see if repair is required b Clean and dry valve seats
12. 250T amp 300Q Maximum Torque Value 15 ft lbs 15 ft lbs 21 3 8 1 bolt clamp 30 ft lbs 45 1 2 2 bolt clamp 5 Adjust stuffing box nut Adjusting nut should be tightened with the bar furnished with the pump Refer to the Assembly Fluid End Plunger Packing Installation section of this manual for proper packing procedure and lubrication practices Print Home 43 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation TIE TA e NATIONAL OILWELL VARCO Assembly Il FLUID END Continued B FLUID CYLINDER ALL PUMPS 1 Install fluid cylinder check stuffing box seals as cylinder is moved into place 2 Tighten nuts alternately pulling fluid cylinder up evenly torque nuts to the following values THREADS 165 200T 250T amp 300Q Dry ft Ibs 800 Lubricated ft Ibs 640 3 When installing the suction discharge piping always use the capscrews furnished with the pump as they are special high strength and double heat treated C FLUID VALVES SPHERICAL TAPERED SEAT BOTTOM GUIDED AND CAGE TYPE ALL PUMPS See Valve section of this manual D PIPING INSTALLATION ALL PUMPS 1 Install flanges on fluid cylinder with special high carbon double heat treated capscrews furnished with the pump 2 Install suction and discharge lines to flanges Print Home 44 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care a
13. BELT LENGTH DRIVE SPROCKET CHAIN SIZE CHAIN LENGTH COUPLING MAKE COUPLING SIZE PRESSURE VOLUME PUMP SPEED DRIVE SPEED PLUNGERS PACKING PISTONS LINERS VALVES SEATS LUBRICANTS CRANK CASE FLUSHING SYSTEM GEAR UNIT LUBRICATOR PRIME MOVER COUPLING NOTES All of the above entries are not applicable to a specific unit therefore completion of this form must be confined within the limits of each pump and the specified optional accessory equipment Print Home 77 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation VEEL e NATIONAL OILWELL VARCO Typical Waterflood Pump Installation Suction and Discharge Piping Arrangement HORIZONTAL PLUNGER PUMP WITH DUAL SUCTION AFO OISCHAMOE COMMECTIONS MAS THE AOVAMTAGES OF A LOR SUCTION CONECTION MINIMIZES SUCTION FOR ACCEPTABLE PERFORMANCE THE PUMP MUST Pan HEAD MEQUIRENENTS BE PROVIDED im ACEQUATE SUCTION PRESSURE CUAL COMECTIONS SIMPLIFIES THE DESIGN OF A MINDAM OF A TO 5 FEET OF RATER OW ITS SUCTION AMD DISCHARGE PIPING EQUIVALENT OF OTHER 10 ABOVE THE PUMP C LOR CENTER OF GRAVITY REDUCES VIBRATIONS SUCTION IS USUALLY SUFICIENT HIH TEP D LON PROFILE EASES MAINTENANCE AND REPAIR ERATURE ALTITUDE VAPOR PRESUME LINE FRICTION PUMP SPEED ANO ACCELERATION HEAD WILL INCREASE THIS REQUIRDENT PRESSURE RELIEF
14. FOOT FROM TANK TO PUMP IS RECOMMENDED NORK AREA AROUND FIRE INIT 2 A FLEXIBLE HOSE AND OR EXPANSION JOINT IN THE SUCTION III CARE AND OPERATIONS SHOULD INCLUDE CLEANLINESS LIME ALSO DISCHARGE LINE PROVIDES FOR THERMAL EXPAN DAILY INSPECTIONS PERIODIC INSPECTIONS ROUT SION AND TENDS TO DAMPEN VIBRATIONS INE MAINTENANCE AND PREVENTIVE MAINTENANCE 3 DIRECT THE DISCHARGE LINE USING 45 LONG RADIUS ELLS TO GRADE OR BELON GRADE LEVEL AS SOON AS POSSIBLE TO RELIEVE STRAIN AND REDUCE VIBRATIONS THE LINE SIZE SHOULD BE SUFFICIENT NOT TO EXCEED A MAXIMUM FLUID VELO CITY OF 8 TO 10 FEET SECOND i 4 IF CHARGING PUMP IS USED IT SHOULD BE LOCATED NEAR THE SUPPLY IN ITS SELECTION GIVE CONSIDERATION THE FLUID PUMPED VELOCITY PLUNGER PUMP VALVING LINE FRICTION ETC SIZE CHARGE PUMP TO 1 1 2 TIMES RECIPROCATING PUMP VOLUME CAPACITY MINIMUM SUE DATE TYPICAL WATERFLOOD PUMP INSTALLATION SUCTION amp DISCHARGE PIPING ARRANGEMENT C GSK3886P DRAWING NO Print Home 78 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Viscosity Equivalents SAE SAE 60 AGMA CRANKCASE GEAR e VG GRADE OILS OILS 70 O a 9 1000 2 800 g 600 9 500 o 400 x i 300 CS a 5 E s Z EN 100 5 55 9 0 60 mE i 2 50 EA 50 F i 6 E Cas 30 190 5
15. GUIDE PROBLEM POSSIBLE CAUSE e NATIONAL OILWELL VARCO CORRECTION KNOCKING OR POUNDING IN FLUID END AND PIPING Print e NATIONAL OILWELL VARCO SUCTION LINE RESTRICTED BY 1 2 3 4 1 TRASH SCALE BUILD UP ETC LOCATE AND REMOVE 2 PARTIALLY CLOSED VALVE IN SUCTION LINE LOCATE AND CORRECT 3 METERS FILTERS CHECK VALVES NON FULL OPENING CUT OFF VALVE OR OTHER RESTRICTIONS RE WORK SUCTION LINE TO ELIMINATE 4 SHARP 90 BENDS OR 90 BLIND TEES RE WORK SUCTION LINE TO ELIMINATE AIR ENTERING SUCTION LINE THROUGH CUT OFF VALVE TIGHTEN OR REPACK VALVE STEM PACKING AIR ENTERING SUCTION LINE THROUGH LOOSE CONNECTION OR FAULTY PIPE LOCATE AND CORRECT AIR OR VAPOR TRAPPED IN SUCTION LINE LOCATE RISE OR TRAP AND CORRECT BY STRAIGHTENING LINE PROVIDING ENOUGH SLOPE TO PERMIT ESCAPE AND PREVENT BUILD UP LOW FLUID LEVEL INCREASE SUPPLY AND INSTALL AUTOMATIC LOW 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 POOR INLET AND OUTLET ARRANGEMENT AT SUPPLY TANK INLET TO BE AT TOP OF TANK AND BAFFLED TO BREAK OUT GAS AND PREVENT CHANNELING OUTLET TO BE 12 FROM BOTTOM OF TANK AND AS FAR FROM INLET AS POSSIBLE NEVER CLOSER THAN 902 LOOSE PACKING ADJUSTING NUT TIGHTEN AND OR REPLACE PACK
16. Install left hand bearing retainer and gasket as described previously NOTE If pump is to have a gear reducer it is necessary to replace the left hand bearing retainer with a retainer that has a double drain back area in the labyrinth seal area Do not use dirt excluder inside the gear reducer Install dirt excluder tightly against each bearing retainer except as noted above Print Home 38 Index Next www nov com Installation Care and Operation NATIONAL OILWELL VARCO TIE TA Assembly I POWER END Continued C CONNECTING ROD AND CROSSHEAD ASSEMBLY ALL PUMPS 1 Press the crosshead pin bushing into the connecting rod 2 Ream bushing to size refer to the tables shown the Overhaul and Repair Check Points and Adjustments section of this manual for dimensions Apply bluing with crosshead pin and scrape bushing to reveal high spots If service bushings are used reaming will not be necessary in most cases 3 Install the crosshead pin by pressing into crosshead or to facilitate assembly the crosshead may be heated to no more than 300 F 149 C in an electric oven or bath NOTE Crossheads are marked TOP on extension rod end Connecting rods and bearing caps are match marked as units Install connecting rod in crosshead so match marks on top of crosshead correspond D CONNECTING ROD TO CRANKSHAFT ASSEMBLY e 4 30 and J 60 With Old Style Straight Cut Aluminum Connecting Rods 1 Thoroughly
17. RESULT IN PROPERTY DAMAGE SERIOUS BODILY INJURY OR DEATH ATTENTION NOTICE IMPORTANT 4 THESE TERMS ARE USED TO DRAW ATTENTION TO ACTION THAT WILL CAUSE DAMAGE TO THE PUMP COMPONENTS OR ATTACHMENTS ATTENTION PUMP NOMENCLATURE ALL PUMP SIZES WITHIN THIS MANUAL WILL BE DESCRIBED WITH THE NEW OR CURRENT NOMENCLATURE THE OLD J MODEL 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 AA WARNING WARNING WARNING 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 www nov com waviowat oitwELL VARCO Installation Care and Operation Manual e NATIONAL OILWELL VARCO Plunger Pump Nomenclature Example ji T 3 L14 d 4 L FLANGED T THREADED HORSEPOWER S SPHERICAL SEAT VALVES T TRIPLEX A CAGE VALVES Q QUINTUPLEX B NEW CAGE VALVES TAPERED SEAT VALVES CYLINDER MATERIAL NUMBER L LOW PRESSURE M MEDIUM H HIGH STROKE LENGTH IN NOMENCLATURE MAY BE SHORTENED IN PARTS LISTS OR OTHER INSTANCES TO LEAVE OFF THE MATERI
18. Spherical Valves and Seats 1 Valve Removal Procedure AAA 62 2 Installation Procedure AAA 62 64 B Tapered Seat Bottom Guided Valves 1 Valve Removal Procedure AAA 65 2 Installation Procedure I L L tns L L L L L 65 67 Print Home 7 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation B NATIONAL OILWELL VARC WERTEN Table of Contents Continued GEAR REDUCER PAGE LUBRICATION AND MAINTENANCE General en EE 68 o UE 68 69 2 Maintenarice au u u ER c in aska ege 69 OVERHAUL AND REPAIR Le EE 70 J Disassembly ein 70 2 EE 71 73 EM UE e RTE 73 P 55U LUBRICATOR I PUMP OPERATING INSTRUCTIONS A Operating seen euren 74 BOX PUMPS ET 74 2 Flow Rate e EE EE 74 SESISNBeErccce 74 pe lNseeser 74 5 Reservoir Qil Level 74 6 PUMP le Ee 74 STORAGE OF PUNPS I GENERAL General 75 Recommended Protection and Initial Storage nanas 75 Six Month 76 D Pre Installation Check After Storage 76 OWNERS ee 77 TYPICAL WATERFLOOD PUMP INS
19. air faster than others When the quality of air becomes excessive it can eventually air lock the pump For this reason it is recommended that an oil level in the sight glass be maintained When level drops remove the vent screw and fill sight glass to top replace vent screw and operate flushing unit manually observing that an oil in the sight glass is free from air If air is not expelled it may be necessary to loosen union nut on pump outlet and expel air at this point It is desirable to maintain level below the drip tube so drops can be seen during operation Print Home e NATIONAL OILWELL VARCO e NATIONAL OILWELL VARCO 4 OVERFILLING OF SIGHT GLASS In a vacuum type sight feed it is not uncommon to See a reverse action whereas sight glass fills with oil and the drops cannot be observed Overfilling is caused by oil absorbing air in the sight glass and normally does not affect the operation of the pump Remove the vent screw from sight glass and allow level to drop below drip tube Tighten vent screw and check to see that air free oil from drip tube can be observed in the sight glass If overfilling continues it may be caused by plunger wear and oil slippage is being drawn back to sight glass If this is the problem the feed setting in drops per stroke will then automatically be reduced by the amount of slippage 5 RESERVOIR OIL LEVEL LOSS OF PRIME If reservoir runs low on oil at a point below the suction inl
20. an 44 C Fluid Valves Spherical Tapered Seat Bottom Guided and Cage 44 D Piping Installation 44 E Plunger Packing Installation EK Ree ia 45 2 1045 PACKING EE 46 3 699 PACKING EE 47 4 Spring Loaded Kevlar Reciprocating Packing 47 48 PLUNGER VALVES I OPERATIONAL MAINTENANCE Suction and discharge uu e rh EAA a ie i ie nc delet 49 B Valve COWS IS tao u u L EE 49 C Valve Cage and Cover Seal I L L L L suu 49 STEIER lte EE 49 Valve Cages iii EE 50 P Valve ANG EE 50 ll CAGE TYPE VALVES A Nomenclature 51 B Valve Servicing Tools Cats u ritu retinere ert rere ratos n ERI Alien aan 52 C Disassembly Procedure 53 54 D Valve Parts Inspection 1 Cage Bottom Guide Disc Ball or 2 2 0 1 0 55 2 Valve Bottom Guided and Geat 56 3 Valve Spherical and 56 A Valve DISC and EE 57 5 Valve Ball and Seat EE 58 NEI EE 58 7 Seals Valve and E01 m 58 E Assembly Procedure L L 59 61 TAPERED SEAT VALVES A
21. and Discharge interchangeable Y 7 OLD DISC TYPE PREVIOUS NEW WING GUIDED TYPE SPHERICAL TYPE Figure 3 Print Home 51 Index Next e NATIONAL OILWELL VARCO Installation Care and Operation INERTITEIN e NATIONAL OILWELL VARCO Plunger Pump Valves Il CAGE TYPE VALVES Continued B VALVE SERVICING TOOLS charts The valve servicing tools referred to on the following pages are listed below CAGE TYPE VALVES SPHERICAL BOTTOM GUIDED BALL amp DISC Valve Cage Cage Seat Magnet Pump Size Kit Puller Bumper Drive Retriever 30T 2H 60T 3H 80T 3H 1710292 1710249 1790080 1790040 1790034 30T 2L 60T 3M 80T 3M 100T 4H 130T 4H 1711251 1711249 1790080 1790041 1790034 100T 4M 130T 4H 130T 4M 165T 5H 165T 5HA 200T 5H 200T 5HA 250T 5H 1712342 1712242 1790080 1790042 1790034 250T 5HA 165T 5M 200T 5M 250T 5M 300Q 5M 1713068 1713069 1790085 1790043 1790034 1790053 375T 7H 1715338 1715339 1790085 G 1790062 1790034 G 1715342 165T 5HB 200T 5HB 250T 5HB 300Q 5H 1713351 1713352 1790085 G 1790064 1790034 Print Home 52 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Plunger Pump Valves TYPE VALVES Continued C DISASSEMBLY PROCEDURE 1 10 11 12 13 14 15
22. cage Remove spring with hook Note Notice if spring had proper pre load Remove cages using same procedure as No 4 Using magnet remove valve disc Insert valve seat driver in suction seat and rock back and forth This action will loosen the seat and allow it to be removed with the hook Assemble lower valve as removed to deep parts together Remove bottom seal Inspect cylinder bore with flashlight paying particular attention to sealing areas f necessary repeat the above steps in the remaining cylinder bores Print Home 53 Index Next e NATIONAL OILWELL VARCO Installation Care and Operation amp NATIONAL OILWELL VARC Manual Plunger Pump Valves ll CAGE TYPE VALVES C DISASSEMBLY PROCEDURE Continued Figure 4 Figure 5 x Figure 6 Figure 7 Print Home 4 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Plunger Pump Valves Il CAGE TYPE VALVES Continued D VALVE PARTS INSPECTION 1 CAGE Bottom Guide Disc Ball or Spherical The cages used in the National Oilwell Varco Valve Assembly are precision machined and designed for long trouble free service Erratic valve action associated with poor suction conditions can cause accelerated wear on this part ATTENTION A LOOSE COVER WILL ALLOW CAGE MOVEMENT AND WILL CAUSE EXTENSIVE DAMAGE TO CAGE AS WELL AS FLUID END
23. mechanical contact or temperature rises due to mechanical or electrical overload or slipping of drive belts Regular inspection of these parts must be carried out to ensure they are in good condition and replacement of any suspect part must be carried out immediately Seals should be suitably rated for the environment The seal and any associated equipment such as a flushing system must be installed operated and maintained in accordance with the manufacturer s instructions Where a packed gland seal is fitted this must be correctly fitted and adjusted This type of seal relies on the process liquid to cool the shaft and packing rings so a constant drip of liquid from the gland section is required Where this is undesirable an alternative seal type should be fitted Failure to operate or maintain the pump and ancillary equipment in line with the manufacturer s instructions may lead to premature and potentially dangerous failure of components Regular inspection and where necessary replacement of bearings and lubrication is essential The pump and its components have been designed to ensure safe operation within the guidelines covered by legislation Accordingly National Oilwell Varco has declared the machine safe to use for the duty specified as defined by the Declaration of Incorporation or Conformity that is issued with this instruction manual Print Home 9 Index Next e NATIONAL OILWELL VARCO Installation Care and Opera
24. rod and cap and keep halves of inserts together 2 Connecting rod and crosshead can be removed through cradle chamber without disturbing the crankshaft Interference with plungers and stuffing box nuts is possible depending on plunger size Remove plungers if necessary Remove crankshaft bearing oil seal retainers and gasket Use puller screws in crankshaft bearing cage back out holes if necessary and remove crankshaft assembly with main bearing cage from the left side of the pump During removal have No 1 throw on crankshaft forward e J 100 Prior to S N 9568 and J 150 1 2 e NATIONAL OILWELL VARCO Remove all the connecting rod bearing caps and both inserts Keep halves inserted together Connecting rod and crosshead must be moved all the way forward with intermediate rods removed to clear crankshaft Remove crankshaft bearing oil seal retainers and gasket Use puller screws in crankshaft bearing cage back out holes if necessary and remove crankshaft assembly with main bearing cage from the left side of the pump During removal have No 1 throw on crankshaft forward Print Home 32 Index Next WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO TIE TA Disassembly L POWER END B CRANKSHAFT ASSEMBLY Continued 100T 130T 165T 200T 250T and 3000 1 2 Remove connecting rod bearing cap and both inserts Keep halves of inserts together Co
25. 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 Lubrication Section in this manual 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 Print Home 19 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation Manual e NATIONAL OILWELL VARCO Installation I GENERAL Continued G 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 H PLUNGER PACKI
26. systems are required except on the 300Q Initial filling should be into the crosshead reservoir on top of the crossheads 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 to 100F 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 ASTM ISO Grade No 68 viscosity 284 to 347 SSU 100 F Crankcase Capacity U S Gallons 30T 1 1 2 100T 5 1 2 200T 8 60T 2 130T 5 1 2 250T 8 80T 2 165T 8 300Q 12 METRIC UNITS OF MEASURE Temperature 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 AGMA No 2 or ASTM ISO Grade No 68 Viscosity 61 75 cSt at 37 8 C Crankcase Capacity Liters 5 7 100T 20 8 200T 30 3 60T 7 6 130T 20 8 250T 30 3 80T 7 6 165T 30 3 300Q 45 4 Oil must pour freely at minimum operating temperature Change oil every six months or as frequently as operating conditions require to maintain a clean sludge free oil of proper viscosity Print Home 22 Index Next www nov com
27. the seat into seal until it is solid with bottom of bore Check seat be certain top side is up See Figure 12 Place valve disc on magnet with spring in position on top of valve disc and lower into place on top of seat Leave magnet standing in bore NOTE Valve discs are interchangeable between suction and discharge seats See Figure 13 Insert cage in bore using handle of seat driver tap cage gently to the bottom NOTE The cages fit the bores very closely Use care when inserting the cage to be sure it is not cocked Work the cage gently it will slide into the bore when correctly aligned Lift the valve disc with the magnet to make certain it is not caught under the cage and using a hammer gently drive the cage down until solid See Figure 14 Check disc springs to see that they are free in the cage Pull magnet loose See Figure 15 Using a flashlight check the spring for correct positioning on valve disc and for proper pre load Check valve disc to be certain top side is up See Figure 15 Place seal in cylinder bore and push to top of suction cage with hook Gently tamp seal into position Drop discharge seat using handle as described in No 4 Drive seat solid on top of cage In some cases the pre load from the suction spring will push the seat up after it is driven this is normal Print Home 59 Index Next e NATIONAL OILWELL VARCO Installation Care and Operation INERTITEIN e NATIONAL OILWEL
28. 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 relief valve must be between the pump fluid end and any valve in the discharge 2 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 overpressure THE RELIEF VALVE DISCHARGE LINE 1 The relief valve discharge line should not RUPTURE DISC OR BURST DISC These discs must have a diameter which is not less than the pipe size of the pressure relief flange These discs must have a rupture or burst pressure rating consistent with the specifications tabulated later in this publication LOCATION OF THE RELIEF VALVE The relief valve must be placed in the discharge line as close as possible to the pump fluid end or it may be mounted on the pump discharge manifold The relief valve must be on the pump side of any discharge strainer terminate in the pump suction line The line should terminate in the supply tank if possible The line must be securely anchored The line must be the same pipe size as or may be larger than the discharge connection on the
29. way forward at the end of the discharge stroke Remove the intermediate rod to crosshead lock screw remove the plunger clamp assembly and brake the intermediate rod loose from the crosshead one fourth 1 4 turn ATTENTION A BACK UP WRENCH MUST BE USED ON THE CROSSHEAD 2 With the intermediate rod in the forward position slide the plunger forward in the stuffing box 3 Rotate the crankshaft until the intermediate rod is in the back position of its stroke Unscrew at the intermediate rod and the intermediate rod wiper retainer capscrews then remove the rod and retainer as one assembly 4 The plunger can now be slid back out of the stuffing box and removed through the cradle chamber 5 Remove the stuffing box nut lube fitting copper tubing if lubricator is used and packing C FLUID END VALVE REMOVAL Refer to valve section located in the middle of this manual Print Home 35 Index Next WWW nov com waviowat owe VARCO Installation Care and Operation WERTEN e NATIONAL OILWELL VARCO Assembly I POWER END A CRANKSHAFT AND MAIN BEARINGS 60T and 80T 1 10 e NATIONAL OILWELL VARCO Thoroughly clean and remove all burrs from the 1 0 of the cone and roller assembly and from the bearing seating surfaces on the crankshaft Heat the cone and roller assembly in an electric oven or oil bath to 300 F 149 C It is recommended that a thermometer be used to prevent overheating
30. 5 Fluid Valve Removal teret neu Ru e ERR rer 35 ASSEMBLY I POWER END A Crankshaft Main Bearings 307 60T amp 80T e 36 100T 130T J 150 165 200 250T amp 3000 37 B Crankshaft and Center Support Bearings 2001 2501 ul e EE 38 100T 130T 165 200T 2501 amp 3000 38 C Connecting Rod and Crosshead 39 D Connecting Rod to Crankshaft Assembly J 30 and J 60 with Old Style straight cut connecting 39 J 100 J 150 with Old Style straight cut connecting rode 39 60T 80T 130T 165T 200 250 amp 3000 with New Style connecting rods 40 41 E Intermediate Rods and Oil Seal Retainers GOT 80T 100T and 190T 000000000000 00 000 41 100T 130 165T 200T 250T amp 3000 41 Puget 42 Print Home 6 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO TIE TA Table of Contents ASSEMBLY Continued PAGE ll FLUID END A Stuffing Boxes and PIUNgE S misinis 42 EN 42 43 1007 1307 1657 2007 250 8 3000 43 B Cylinders All Pumps iiiter u areas
31. 5 Fluid cylinders can be removed without disturbing the stuffing boxes or plungers But it is recommended that the stuffing boxes and plungers be removed for easier access to the lower cylinder studs and nuts Disconnect piping Remove nuts holding stuffing box retainer in place Slide retainer clear of the cylinder studs Remove fluid cylinder retaining socket head capscrews B STUFFING BOXES AND PLUNGER REMOVAL 60T and 80T 1 e NATIONAL OILWELL VARCO Rotate crankshaft until the intermediate rod is in the back position of its stroke Loosen the plunger lock screw if used and disconnect the plunger from the intermediate rod ATTENTION USE BACK UP WRENCH ON THE CROSSHEAD TO PREVENT DAMAGE TO CONNECTING ROD Slide the plunger forward in the stuffing box Unscrew the intermediate rod Remove the clip holding the intermediate rod wiper retainer remove the rod and retainer as one assembly The plunger can now be slid back out of the stuffing box and removed through the cradle chamber Remove stuffing box nut and packing For removal of the stuffing box the fluid cylinder must be first removed Print Home 34 Index Next WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO TIE TA Disassembly II FLUID END B STUFFING BOXES AND PLUNGER REMOVAL Continued e 100T 130 165T 200T 250 and 3000 1 Rotate the crankshaft until the intermediate rod is all the
32. 81 WRENCH 1790082 RETRIEVER 1790034 SUPPORT 1713109 NUT 6300160 FLANGED NUT Print e NATIONAL OILWELL VARCO Home 66 6314002 Index Next www nov com Installation Care and Operation NATIONAL OILWELL VARCO TIE TA Plunger Pump Valves II TAPERED SEAT VALVES B TAPERED SEAT BOTTOM GUIDED VALVES Continued REMOVAL NS N NN N NS NS RNs d RES C E NN S SNS SS SI Figure 22 Figure 23 Figure 24 INSTALLATION Figure 25 Figure 26 Figure 27 Print Home 67 Index e NATIONAL OILWELL VARCO www nov com Installation Care and Operation TIE TA e NATIONAL OILWELL VARCO Gear Reducer I LUBRICATION AND MAINTENANCE A GENERAL NATIONAL OILWELL VARCO plunger pump gear reducers are splash lubricated The rotation of the gears provides adequate lubrication to all working parts The gear reducer housing and the plunger pump power end are separated by a labyrinth oil seal on the 30T and a labyrinth oil seal retainer on the 60T 80T 100T 130T 165T 200T 250T and 300Q These seals separate the lubricating oils and prevent contamination Initial filling should be through the hand hole cover and can be gauged by the high and low level oil plugs in the housing Correct level is at the bottom of the high level plug 1 OIL Use extreme pressure gear oil The following chart shows t
33. ACK PER INSTRUCTIONS SCALE OR BUILD UP ON PLUNGER TREAT FLUID AS REQUIRED SHORT PACKING LIFE Print www nov com WORN OR PITTED PLUNGERS AND OR STUFFING BOX REPLACE AS REQUIRED ABRASIVES IN FLUID FILTER AS REQUIRED PUMP OPERATED WITHOUT FLUID CHECK SYSTEM FOR FAULTY LOW LEVEL SHUT DOWN CONTROLS OR CLOSED VALVES AND CORRECT AS REQUIRED ABNORMALLY HIGH FLUID TEMPERATURES CHECK WITH MANUFACTURER FOR RECOMMENDATIONS ON TYPE OF PACKING WRONG TYPE OF PACKING FOR PARTICULAR FLUID BEING HANDLED CHECK WITH MANUFACTURER FOR RECOMMENDATIONS ON TYPE OF PACKING CAVITATION KNOCKING AND POUNDING IN FLUID CYLINDER AND PIPING Home 27 REFER TO CORRECTION OF KNOCK IN POWER END ABOVE Index Next e NATIONAL OILWELL VARCO Installation Care and Operation TIE TA e NATIONAL OILWELL VARCO Maintenance Il TROUBLE SHOOTING GUIDE Continued PROBLEM POSSIBLE CAUSE CORRECTION INSTALL NEW PLUNGER USING CARE TO AVOID FEDERE SS TREES ANY SHARP BLOW OR FORCE ON PLUNGER CHECK SYSTEM TO ELIMINATE ANY SHARP OR SUDDEN TEMPERATURE DIFFERENCES TEMPERATURE EXTREMES ON THE PLUNGER CAN BROKEN OR PITTED PLUNGER CRACKED FROM THERMAL OCCUR FROM PACKING AS DISCUSSED UNDER FROM IMPLOSIONS SHORT PACKING LIFE PROBLEM PR FROM CAUSED BY IN TEMPERATURE CHANGES IN THE FLUID ITSELF EXCESSIVE GAS OR AIR ENTRAINED PLUNGER PITTED FROM IMPLOS
34. AL VALVE TYPE ETC THIS FULL NOMENCLATURE DESCRIPTION IS GIVEN FOR INFORMATIONAL PURPOSES CYLINDER MATERIAL NUMBER EXAMPLES INCLUDE 14 9D NICKEL ALUMINUM BRONZE 12 FORGED STEEL 06 2 316 S S Inquire about other material numbers Print Home 4 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO TIE TA Table of Contents ATEX WARNING STATEMENTS PAGE I PUMPS and PUMP UNITS A 80T Pump 1 ENITJ T 10 2 Declaration of Incorporation cceccceceeeeeeeeeeeeeeceeeeeeeaeeeeaeeeceaeeeceaeeeeaaeseeeecaeeesaaeseeaeeseeeescaeessaeseeeessaees 11 B 200T Pump TeiIName plate SR 12 2 Declaration of Incorporation esses eene enne 13 C 300Q Pump 1 E 14 2 Declaration of Incorporation A nenn ln shell 15 INSTALLATION I GENERAL DEE 16 17 B P mp Mounting TEE 18 le ln ET 18 LEE 18 Discharge TT 19 F Power End EE 19 Ge le BEE 20 H Pl nger PACKING WEE 20 Plunger PackingEubrieation sauna anne 20 J Suction Pulsation Dampener T Low Pressure Pl stic BOdy 20 21 2 High Pressure Aluminum Body air 21 LUBRICATION I GENERAL WO M 22 OPERATION I GENERAL A Operation Check EISE aiit ai itu at
35. D OUTPUT Tom AT 20 F TO 100 F AGMA 5 EP OR ISO 220 20 TO 60 F AGMA 2 OR ISO 68 DO NOT EXCEED MAXIMUM DISCHARGE PRESSURE BELOW PLUNGER SIZE GPM AT MAX RATED CRANKCASE OIL CAPACITY _ Jus GALLONS RATED RPM PSI BAR OIL MUST POUR FREELY AT MINIMUM OPERATING TEMPERATURE CHANGE OIL AS FREQUENTLY AS REQUIRED TO MAINTAIN A SLUDGE FREE OIL OF 1 PROPER VISCOSITY CHECK LEVEL PERIODICALLY WITH PUMP AT REST ROTATE IDLE PUMP OCCASIONALL AVOID CORROSION 1 MANUFACTURED UNDER ONE OR MORE UNITED STATES 1 PATENTS 3 146 724 3 276 639 3 399 694 4 487 222 4 667 697 1 1 CE Gl 26 c 4 ATEX 0003 MAX MIN FLUID TEMP C sid nanona OILWELL VARCO 10000 RICHMOND HOUSTON TEXAS 77042 0 5 MAX MIN AMBIENT TEMP C Print 14 Index Next e NATIONAL OILWELL VARCO www nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual ATEX Warning Statements I PUMPS AND PUMP UNITS C 300Q PUMP Continued 2 DECLARATION OF INCORPORATION Declaration of Incorporation Machinery EC Declaration of Conformity ATEX MANUFACTURER National Oilwell Varco 10000 Richmond Houston Texas 77042 PRODUCT DESCRIPTION 300Q Pump APPLICABLE EUROPEAN DIRECTIVES Machinery 98 37 EC ATEX 94 9 EC PED 97 23 EC APPLICABLE HARMONIZED STANDARDS Machinery EN 12100 1 EN 12100 2 ATEX EN 1127 1
36. European Directives and relevant sections of the Applicable International Standards Integration instruction are provided that contain requirements and specifications that must be implemented prior to putting this equipment into service this equipment must not be put into service before the machinery into which it is to be incorporated has been declared in conformity with the provisions of the Machinery Directive The EHSR s related to this equipment have been addressed a Technical Construction File is available for inspection by designated bodies ATEX product marking Authorized Signature Date 4 44 Chris Cackler February 20 2008 Important safety information is contained in the installation operation and service manuals read and understand this information prior to installing or using this equipment This Document applies only to the equipment described above and is invalid if not reproduced in its entirety Print Home 13 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation Manual e NATIONAL OILWELL VARCO ATEX Warning Statements I PUMPS AND PUMP UNITS Continued C 300Q PUMP 1 NAMEPLATE A DATE or MANUFACTURE PLUNGER PUMP end PUMP Wel sme CRANKCASE LUBRICATION INSTRUCTIONS RATED MAX INPUT AIR TEMPERATURE INDUSTRIAL EP GEAR OIL 50 F TO 155 F AGMA 6 EP OR ISO 320 EP RATE
37. FT TO HUB FACE 30T 1 3 4 60T 80T 2 5 15 100T 130T 4 1 4 165T 4 3 8 200T 250T 300Q 6 1 2 q Insert key with beveled side next to shaft and allow to cool in place Print Home 72 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Gear Reducer 1 OVERHAUL AND REPAIR A GENERAL 2 ASSEMBLY Continued IMPORTANT e MAKE SURE GEAR IS HOT ENOUGH AND INSTALLATION IS PERFORMED QUICKLY ON THE SHAFT BEFORE IT IS POSITIONED e MAKE SURE KEYWAYS ARE ALIGNED WHEN SHRINKING GEAR ONTO SHAFT r Position high speed pinion in housing supporting same with rope or cloth through the hand hole in top of housing s Apply liquid gasket between cover and housing Install the housing cover and secure with capscrews and taper pins L Place remaining shims on open retainer and install with screws making certain the drain slot is at the bottom Adjust with shims and retainers until the endplay of the pinion shaft is from 003 to 005 loose on all reducers except 200T and 300Q where the end play is from 005 to 007 loose Check clearance of Labyrinth seal to shaft There should not be any metal to metal contact IMPORTANT e MAKE CERTAIN THE BEARING OUTER CUPS ARE SOLID AGAINST THE RETAINERS AND THE OUTSIDE RETAINER IS INSTALLED CORRECTLY u Check meshing of pinion and crankshaft gear v Install pinion shaft dirt ex
38. Figure 20 Install valve spring s and spring retainer See Figure 21 Print Home 62 Index Next WWW nov com NATIONAL OILWELL VARCO Plunger Pump Valves TAPERED SEAT VALVES A SPHERICAL VALVES and SEATS Continued Installation Care and Operation Manual VALVE COMPLETE Consists of ITEMS INCLUDED 2 1 2 3 3 1 2 4 5 VALVE COMPLETE SUCTION 1792520 25 1793020 25 1793520 25 1794020 25 1795020 25 DISCHARGE 1792522 25 1793022 25 1793522 25 1794022 25 1795022 25 SEAT SUCTION 1792521 25 1793021 25 1793521 25 1794021 25 1795021 25 DISCHARGE 1792523 25 1793023 25 1793523 25 1794023 25 1795023 25 VALVE ONLY 1792527 25 1793027 25 1793527 25 1794027 25 1795027 25 SPRING SUCTION 1792525 1793025 1793525 1794025 1795025 RETAINER 1792524 6 1793024 6 1793524 6 1794024 6 1795024 6 SPRING DISC 1792526 1793026 1793526 1794026 NONE 1792525 1793025 1793525 PULLER KIT Consists of 1794025 1795025 ITEMS INCLUDED 2 1 2 3 3 1 2 4 5 PULLER KIT 180104119 180104127 180104135 180104143 180104151 PULLER HEAD 181205709 181259300 181259359 181259409 181259410 RETRIEVER 1790034 SPACER 181205709 181205710 WASHER
39. ILWELL VARCO bottom guided disc and seat is made from a specialty stainless steel which is strictly resistant to corrosion An optional heat treated stainless steel 4 valve is available for less corrosive fluids that contain solids The standard valve is non magnetic so a loop is provided for removal from the fluid cylinder The following inspection points should be observed a The valve seat and sealing surface should be closely inspected for evidence of excessive wear and or washed areas The amount of wear can be determined by comparison with a new valve and seat Worn valves and seats should be replaced b Inspect the valve guides and seat bores for guide wear Valves with excessively worn or broken guides and grooved seats should be replaced c Inspect the outside surface of the valve and seat for nicks burrs or washers and thoroughly clean before assembly 3 VALVE SPHERICAL AND SEAT The standard NATIONAL OILWELL VARCO spherical valve amp seat is made from a specialty stainless steel which is strictly resistant to corrosion The valve is non magnetic so a loop may be provided for removal from the fluid cylinder The following inspection points should be observed a The valve seat amp sealing surface should be closely inspected for evidence of excessive wear and or washed areas The amount of wear can be determined with a new valve amp seat Worn valves amp seats should be replaced b Inspect the outside surface of th
40. ING INADEQUATE SIZED SUCTION LINE REPLACE WITH INDIVIDUAL SUCTION LINE OF NEXT SIZE LARGER THAN INLET PUMP LEAKAGE PRESSURE RELIEF VALVE THAT HAS BEEN PIPED BACK INTO SUCTION LINE REPAIR VALVE AND RE WORK PIPING TO RETURN 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 BROKEN PLUNGER Home INSPECT WHEN ROTATING PUMP BY HAND AND REPLACE AS REQUIRED Index Next www nov com NATIONAL OILWELL VARCO Maintenance Il TROUBLE SHOOTING GUIDE Continued PROBLEM POSSIBLE CAUSE Installation Care and Operation Manual CORRECTION KNOCK IN POWER END VALVE WEAR OR DAMAGE CHECK FLUID END FOR BAD VALVES WORN MAIN BEARINGS REPLACE AS REQUIRED LOOSE PLUNGER INTERMEDIATE ROD CROSSHEAD CONNECTION INSPECT FOR DAMAGE REPLACE AS REQUIRED AND TIGHTEN WORN CROSSHEAD PIN OR CONNECTING ROD LOCATE AND REPLACE AS REQUIRED RAPID VALVE WEAR OR FAILURE CORROSION TREAT FLUID AS REQUIRED ABRASIVES IN FLUID FILTER AS REQUIRED IMPROPER INSTALLATION INSPECT AND INSTALL PER INSTRUCTION SHEET IN PACKING BOX IMPROPER LUBRICATION EITHER INSUFFICIENT OR EXCESSIVE OR INCORRECT TYPE CHECK INSTRUCTIONS IN MANUAL AND CORRECT AS REQUIRED LUBRICATOR NOT OPERATING INSPECT AND CORRECT AS REQUIRED ADJUSTING NUT LOOSE INSPECT AND REP
41. IONS CHANGE SUCTION SYSTEM TO ELIMINATE OR FLUID CAUSED BNY EXCESSIVE GAS OR AIR CHECK WITH MANUF REGARDING USE OF ENTRAINED IN FLUID SPECIAL PACKING ARRANGEMENT CHECK AND CORRECT PER RECOMMENDATIONS RAPID WEAR OF PACKING FAILURE UNDER SHORT PACKING LIFE PROBLEM HARD COATED P LUNGER NOT SUITABLE FOR PLUNGER PARTICULAR SERVICE CHECK WITH MANUF FOR RECOMMENDATION PLUNGER NOT SUITABLE FOR PARTICULAR SERVICE PUMP NOT LEVEL CHECK AND CORRECT AS REQUIRED CHECK AND CORRECT AS REQUIRED WORN CORRODED PITTED OR OTHERWISE DAMAGED SEALING SURFACE CHECK AND CORRECT AS REQUIRED OIL SEAL LEAKS WORN OR DAMAGED SEALS CHECK AND CORRECT AS REQUIRED OIL LEVEL TOO HIGH CHECK AND CORRECT AS REQUIRED Print Home 28 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Overhaul and Repair GENERAL The bearings and other working parts in the power end have been designed for continuous duty and if properly lubricated will provide years of trouble free service However after the pump has been in service for a long period of time the bearings and other working parts will gradually loosen and if not corrected will lead to more serious trouble The time to overhaul the pump will vary depending on the operating conditions and is therefore a matter that must be left to the good judgment of the operator Comple
42. Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Installation GENERAL J SUCTION PULSATION DAMPENERS 1 Low Pressure Plastic Body Continued d ATTENTION Use thread sealing compound on check valve and tighten until snug OVERTIGHTENING WILL DAMAGE BODY 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 2 High Pressure Aluminum Body a In pressures in excess of 20 psi 1 406 kg cm2 and up to 70 psi 10 545 kg cm2 it is necessary to use the National Oilwell Varco high pressure suction dampener 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 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 t
43. L VARCO Plunger Pump Valves ll CAGE TYPE VALVES E ASSEMBLY PROCEDURES Continued 13 Place valve on magnet with spring in position and lower into place on top of seat Leave magnet standing in the bore 14 Insert cage and drive using the same procedure as No 7 15 Inspect using same procedure as No 7 16 Check valve assembly with flashlight using same procedure as No 8 17 Place seal on retainer and install in cylinder Screw threaded cover down by hand until threads are fully engaged Torque center bolts to following values TORQUE Dry TORQUE Lubricated PLUNGER PUMP SIZE 30T 2H 30T 2L 60T 3H 60T 3M 80T 3H 80T 3M 500 ft lbs 400 ft lbs 100T 4H 100T 4M 130T 4H 130T 4M 165T 5M 3000 5HA 200T 5H 250T 5H S50 ibs 165T 5M 3000 5 200 5 250T 5M 650 ft lbs 525 ft lbs 165T 5H 200T 5H 250T 5H 300Q 5HB 900 ft lbs 735 ft lbs 375 7 1300 ft lbs 1060 ft lbs Print Home 60 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NOV wationar OILWELL VARCO TIE TA Plunger Pump Valves Il CAGE TYPE VALVES E ASSEMBLY PROCEDURES Continued
44. LL VARCO g D TT Lifting Arrangement Lifting Arrangement With Gear Reducer Without Gear Reducer Rear View Rear View Print Home 16 Index Next e NATIONAL OILWELL VARCO www nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Installation I GENERAL A LIFTING Continued Lifting Arrangement Lifting Arrangement With Gear Reducer Without Gear Reducer Side View Side View VT Lifting Arrangement Lifting Arrangement With Gear Reducer Without Gear Reducer Top View Top View Print 17 Index Next WWW nov com waviowat oi weLL VARCO Installation Care and Operation WERTEN e NATIONAL OILWELL VARCO Installation 1 GENERAL Continued B PUMP MOUNTING 1 The skid or foundation must be level Angular installation and operation may be detrimental to the lubrication of equipment and may impose high stresses causing equipment failure 2 The skid or foundation must be of sufficient strength to prevent flexing of the equipment 3 The skid or foundation must be of sufficient size and design to maintain the equipment free of strain 4 The equipment must be adequately secured to the foundation High strength bolts or capscrews with locking devices are generally employed 5 Consideration should be given to the location of the equipment with its proximity to the associated equipment fluid supp
45. LL VARCO pumps are manufactured by National Oilwell Varco at the McAlester 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 CAUTION CAUTION CAUTION 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 WARNING WARNING WARNING 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 SAIR SYSTEM ETC Print Home 2 Index Next e NATIONAL OILWELL VARCO www nov com Installation Care and Operation NATIONAL OILWELL VARCO AA WARNING WARNING WARNING 4 FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS PUBLICATION CAN
46. NG 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 the Assembly Fluid End Plunger Packing Installation section of this manual for correct procedure for packing used I 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 J 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 ATTENTION 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 ATTENTION HANDLE WITH CARE This is a plastic part and can be broken c capscrews with 10 to 12ft lbs of torque Print Home 20
47. NING OR WITH PRESSURE IN THE CYLINDER Bleed off the discharge pressure and check the tightness of the covers as outlined under the assembly procedure for the type of cover used C VALVE CAGE AND COVER SEALS 1 Cage Type Valves There are three identical seals in each valve stack The seals perform a very important function in this design valve and we recommend that they be changed any time they are removed from the pump 2 Cover Seals The cover seals should be replaced as required D VALVE SPRINGS The springs used with the NATIONAL OILWELL VARCO valves are made of inconel alloy stainless steel ATTENTION THESE SPRINGS SHOULD BE CHANGED APPROXIMATELY ONCE A YEAR IN ORDER TO ASSURE PROPER VALVE ACTION AND ELIMINATE THE POSSIBILITY OF A SPRING BREAK Print Home 49 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation VEEL e NATIONAL OILWELL VARCO Plunger Pump Valves 1 OPERATIONAL MAINTENANCE Continued E VALVE CAGES The cages are normally made from aluminum bronze stainless steel or hardened steel depending on the type of service These cages are precision machined to give long continuous service F VALVE AND SEAT 1 Cage Type Valves There are four basic valve and seat assemblies available depending on the type of service They are the disc type the ball type the wing guided type and the spherical type These valves can be made available in a variety o
48. RANKSHAFT AND CENTER SUPPORT ROLLER BEARING ASSEMBLY 200T 250T and 3000 1 2 8 Check the crankshaft bearing surfaces for nicks or burrs and remove Install snap ring in groove nearest left hand bearing cage Heat inner race of roller bearing to not more than 300 F 149 C in electric oven or oil bath and install against snap ring Install second snap ring on first bearing Install snap rings in the frame bearing support areas Install rings in inner grooves Install snap rings in the frame bearing support areas Install rings in inner grooves Roller bearing assembly is a possible light press fit into the frame bore Slide or gently tap the bearing assemblies into place against the snap rings Install outer snap rings e 100T 130T 165T 200T 250 and 3000 1 e NATIONAL OILWELL VARCO Install the crankshaft assembly in pump locating the crankshaft bearing cage at the left side with the TOP mark up and the plastic gasket in its proper location Use care when passing the bearing inner race through the first roller assembly NOTE The crossheads and connecting rods on the old J 100 pumps prior to S N 9568 must be installed prior to replacing the crankshaft assembly Check Timken lock nuts and lock washers and tighten securely Install right hand bearing retainer and gasket Make certain TOP mark is facing upwards Check clearance of Labyrinth seal to shaft There should not be any metal to metal contact
49. Reciprocating Plunger Pumps http www nov com NATIONAL OILWELL VARCO SUPPLEMENT FOR ALL PUMP MANUALS WARNING 4 PRESSURE RELIEF VALVES NOTICE 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 Print Home Index Next WARNING 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 13 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
50. TALLATION SUCTION and DISCHARGE PIPING ____ _ __ 78 VISCOSITY EQUIVALENTS 79 Revisions effective August 27 2010 replaced the word multiplex with Print Home 8 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual ATEX Warning Statements I PUMPS AND UNITS 1 www nov com Where a pump or pump unit is to be installed in a potentially explosive atmosphere ensure that this has been specified at the time of purchase and that the equipment has been supplied accordingly and displays an ATEX nameplate or is supplied with a certificate of conformity If there is any doubt as to the suitability of the equipment please contact National Oilwell Varco before commencing with installation and commissioning Process liquids or fluids should be kept within specified temperature limits otherwise the surface of pump or system components may become ignition source due to temperature rises Where the process liquid temperature is less than 90 C the maximum surface temperature will not exceed 194 F 90 C provided the pump is installed operated and maintained in accordance with this manual Electrical installation and maintenance work should only be carried out by suitably qualified and competent persons and must be in accordance with relevant electrical regulations All electric
51. The bushings are pressed into the connecting rod and must be reamed to size The pin and bushings must then be blued to check the fit High spots in the bushings must be scraped Print Home 29 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation TIE TA e NATIONAL OILWELL VARCO Overhaul and Repair GENERAL B CHECK POINTS AND ADJUSTMENTS Continued CRANKSHAFT O D MAXIMUM CLEARANCE MINIMUM CLEARANCE in mm i i 2 500 63 500 2 499 63 475 3 250 82 550 3 249 82 525 4 125 104 775 4 124 104 750 5 000 127 000 126 975 CROSSHEAD PIN O D MAXIMUM CLEARANCE MINIMUM CLEARANCE mm 34 963 34 950 47 663 47 650 65 113 65 100 76 238 76 225 Print Home 30 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Disassembly POWER END It is not necessary to remove the fluid end when disassembling the power end The plungers may be disconnected from the intermediate rods and left in the stuffing boxes A INTERMEDIATE RODS AND OIL WIPER RETAINERS ALL PUMPS 1 Loosen the plunger lock screws if used disconnect the plunger from the intermediate rod and remove the baffle plate ATTENTION A BACK UP WRENCH MUST BE USED FOR REMOVAL OF PLUNGER AND INTERMEDIATE ROD TO PREVENT DAMAGE TO THE CONNECTING ROD 2 T
52. UL AND REPAIR A GENERAL 2 ASSEMBLY Continued i After taper pins are fitted and driven re check tightness of special capscrews by torquing to following values and wire them in place PUMP SPECIAL TORQUE SIZE CAPSCREW 30T 2402010 60T 80T 2402850 100T 130T 2405029 165 2403190 200T 250 3000 2405018 j Check high speed pinion for nicks and burrs in bearing areas and remove same k Heat pinion tapered roller assemblies in electric oven or bath to 300 F and install on pinion shaft Make sure bearings are shouldered on shaft Install outer race of tapered roller assemblies in housing and cover m With half the shims on the blind retainer install and secure with screws n Check crankshaft extension keyway crankshaft gear and key nicks and burrs remove same o Heat the crankshaft gear to 350 F in an oil bath or furnace to ensure even and uniform heating If these methods are not available heat the gear with a large top torch as described in Dissassembly paragraph 1 e of this section of the manual It is of prime importance that the gear be heated slowly and evenly from the gear rim to the hub Use a tempil stick and micrometers to assure a correct fit Allow gear to cool slowly p Slip gear on shaft with under cut area on hub facing toward pump puller holes facing out Position gear on shaft so that distance from end of shaft to outside face of hub is as follows PUMP END OF SHA
53. UR FREELY AT MINIMUM OPERATING TEMPERATURE CHANGE OIL AS FREQUENTLY AS REQUIRED TO MAINTAIN A SLUDGE FREE OIL OF PROPER VISCOSITY CHECK OIL LEVEL PERIODICALLY WITH PUMP AT REST ROTATE IDLE PUMP OCCASIONALL TO AVOID CORROSION MANUFACTURED UNDER ONE OR MORE UNITED STATES PATENTS 3 146 724 5 276 659 3 599 694 4 487 222 4 667 697 26 c T4 TCF ATEX 0005 MAX MIN FLUID TEMP C OILWELL V 10000 RICHMOND HOUSTON TEXAS 77042 U S A ON MAX MIN AMBIENT e 2407905 Print 12 Index Next e NATIONAL OILWELL VARCO www nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual ATEX Warning Statements I PUMPS AND PUMP UNITS 200T PUMP Continued 2 DECLARATION OF INCORPORATION amp Declaration of Incorporation Machinery EC Declaration of Conformity ATEX MANUFACTURER National Oilwell Varco 6750 S 57 West Avenue Tulsa Oklahoma 74131 PRODUCT DESCRIPTION 200T Pump APPLICABLE EUROPEAN DIRECTIVES Machinery 98 37 EC ATEX 94 9 EC PED 97 23 EC APPLICABLE HARMONIZED STANDARDS Machinery EN 12100 1 EN 12100 2 ATEX EN 1127 1 EN 13463 1 EN 13463 5 PED Exempt per Article 1 Clause 3 10 NOTIFIED BODY Bureau Veritas ATEX NB 0081 retains a copy of the Technical File ATEX 0005 II2G c The equipment described in this Declaration of Incorporation complies with the Applicable
54. VALVE SET M HIGHER FULL OPENING VALVE THAN 1 25 TIMES THE MAXIMUM PLUNGER LOCATED NEAR TANK LUBRICATION OF PACKING IS WORKING PRESSURE BY PASS LINE AND RELIEF LINE TO REDUCE FRICTION AND EXTEND THE LIFE RETURNING TO THE SUPPLY OF THE PLUMGERS AND PLUNGER PACKING CHARGING PUMP NOTE 4 BY PASS VALVE PERMIT STARTING WITHOUT LOAD DISCHARGE PULSATION DAMPENER LOCATED x 5 mne SUPPORTS HERE NECESSARY TO RELIEVE STRAINS AMO MINIMIZE VIBRATIONS PRESSURE GAUGE mW SMUBBER OR 30 DISCHARGE LIME 3 LOW POINT ONAINS PUMP SUCTION STABILIZER LOCATED IN THE SUCTION LINE AS CLOSE AS POSSIBLE TO THE PUP SPN B FUL OPENING CHEEK VALVE GENERAL RECOMMENDATIONS S FUL OPENING GATE OR BALL VALVE I PROVIDE SAFETY SHUT DOWN CONTROLS FOR ALL MAL FUNCTIONS OF THE SYSTEM PUMP AND PRIME MOVER INCLUDING A LOW SUCTION PRESSURE OR LOW TANK LEVEL NOTES B LOW DISCHARGE PRESSURE 1 A SEPARATE SUCTION LINE IS RECOMMENDED FOR EACH PUMP C HIGH DISCHARGE PRESSURE THE LINE SHOULD BE A MINIMUM OF ONE SIZE LARGER THAN D LOW OIL PRESSURE OR LOW OIL LEVEL PUMP SUCTION FLANGE OR OPENING TO PROVIDE A MAX E HIGH TEMPERATURE EXCESSIVE VIBRATIONS IMM OF 1 TO 2 FEET SECOND FLUID VELOCITY IF BENDS _ OVERLOADING OF PRIME MOVER ARE NECESSARY USE ONLY 45 LONG RADIUS ELLS A SLOPE II FCR SERVICING ANO SAFETY PROVIDE ADEQUATE OF 1 4 PER
55. al equipment including control and safety devices should be suitably rated for the environment in to which they are installed Where there may be a risk of an accumulation of explosive gases or dust non sparking tools should be used for installation and maintenance To minimize the risk of sparking or temperature rises due to mechanical or electrical overload the following control and safety devices should be fitted A control system that will shut the pump down if the motor current or temperature exceed specified limits An isolator switch that will disconnect all electrical supply to the motor and ancillary electrical equipment and be capable of being locked in the off position All control and safety devices should be fitted operated and maintained in accordance with the manufacturer s instructions All valves on the system should be open when the pump is started otherwise serious mechanical overload and failure may result It is important that the pump rotates in the direction indicated on the nameplate This must be checked on installation and commissioning and after any maintenance has been carried out Failure to observe this may lead to dry running or mechanical or electrical overload When fitting drives couplings belts pulleys and guards to a pump or pump unit it is essential that these are correctly fitted aligned and adjusted in accordance with the manufacturer s instructions Failure to do so may result in sparking due to unintended
56. an also be used The puller should be attached to the gear and a heavy strain should be applied The gear should be heated with a large tip torch starting at the outside gear rim below the root of the teeth and working in a circular motion heat the gear slowly and evenly toward the hub The torch should be kept in constant motion to prevent hot spots The gear rim should always be kept at a temperature above the hub area to eliminate tensile stresses in the gear rim which causes the gear to crack The gear will break loose from the shaft when enough heat has been applied The puller should then be able to remove the gear Do not exceed 350 F at any time on the surface of the gear Use a tempil stick to gauge the temperature f A gear removed in this manner will be a serviceable gear ATTENTION EXCESS HEAT OR SPOT HEATING WILL CAUSE THE GEAR TO CRACK OR DISTORT ALLOW GEAR TO COOL SLOWLY Print Home 70 Index Next e NATIONAL OILWELL VARCO www nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Gear Reducer 1 OVERHAUL AND REPAIR A GENERAL Continued 2 ASSEMBLY NOTE Items 1 through 4 may be omitted if the pump is equipped with a new style main bearing cage 100T amp 130T Part Number 1711617 Omit items 1 through 4 for all 30T 60T 80T 165T 200T 250T and 300Q a Remove crankshaft assembly and left hand main bearing and cage assembly as per pump service manual b Install a ne
57. ccur 3 Insert seals stuffing box to fluid cylinder into grooves in the face of the stuffing boxes Grease lightly to hold in place until fluid cylinder is installed 4 Assemble packing in stuffing box bore as per instructions included with each set of packing or as described in the Assembly Fluid End Plunger Packing Installation section of this manual 100 130T 165T 200T 250T and 3000 1 Rotate crankshaft until the intermediate rod is at the end of the suction stroke 2 With the stuffing box packing and plunger installed slide the assembly into the pilot bore If properly aligned and lubricated the stuffing box will slide easily into place When a flanged retainer is used with the stuffing box make certain the lubrication fitting hole is at the top 3 Tighten stuffing box hex nuts to the following torque values 165T 200T 250T amp 300Q Dry ft lbs 400 800 Lubricated ft lbs 325 640 Threads 100T 130T 4 Install rubber baffle if used on intermediate rod and connect plunger to intermediate rod with threaded connection or clamped connection Make sure the mating surfaces are clean and free from nicks and burrs Tighten plunger rod using the following torques threaded plungers Threads 100T 130T 165T 200T 250T amp 300Q Dry ft lbs 400 480 Lubricated ft lbs 325 385 Tighten capscrew in plunger clamp assembly as follows clamped plungers PUMPS 100T 130T 165T 200T
58. clean and remove all burrs and nicks from connecting rod and crankshaft journals 2 The connecting rod journals are a precision fit and require no adjustment Make sure the match marks on connecting rod and cap are the same and on the same side 3 Install connecting rod bolts and lock type nuts Use torque wrench and tighten to torque specified in chart below e eJ 100 and J 150 With Old Style Straight Cut Connecting Rods The connecting rod bearings are precise fitting inserts requiring no adjustment When reinstalling the same inserts assemble them in pairs at their original location Make sure the match marks on connecting rod and cap are the same and on the same side 1 Install rod half of bearing seat connecting rod on the shaft and install bolts 2 Install other half of bearing and bearing cap making sure dowel pins in the bearings are properly joined Using a torque wrench tighten to the torque specified in the chart below TORQUE FT LBS PUMP 30T Straight Cut Rod w Bolts amp Locknuts 45 Straight Cut Rod w Capscrews Slant Cut Rod w Capscrews 75 60T 165T 200T 80T 250T 300Q Print Home 39 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation VEEL e NATIONAL OILWELL VARCO Assembly I POWER END D CONNECTING ROD TO CRANKSHAFT ASSEMBLY Continued 60T 80T 130T New Style 165 200T 250T 3000 The conn
59. cluder 3 INSTALLATION Since the plunger pump gear reducer is attached to the pump and becomes a part ofthe pump package the installation should receive the same careful consideration that the pump itself does Careful installation practices will greatly increase trouble free operation and reduce maintenance costs For general installation recommendations see Installation Section of the pump manual Print Home 73 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation WERTEN P 55U Pump A OPERATING INSTRUCTIONS 1 BOX SUCTION PUMPS VACUUM FEED Fil reservoir with oil Loosen union nut on pump outlet Remove the vent screw and fill the sight glass with oil Prime by manually pumping flushing unit until air free oil is observed from the drip tube and oil level drops in the sight glass Replace vent screw and tighten union nut e Maintain oil level in sight glass below the drip tube so drops can be observed 2 FLOW RATE ADJUSTMENT Loosen locknut on flushing unit Turn flushing unit counter clockwise to increase flow Turn flushing unit clockwise to decrease flow Tighten locknut when desired flow rate is achieved 3 SIGHT GLASS In a vacuum type sight feed it is not uncommon for oil level in the sight glass to drop during operation Absence of a level indicates air is being taken in with the oil Some oils due to viscosity conditions will release
60. ding 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 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 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 Print Home 18 Index Next WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Installation I GENERAL Continued E DISCHARGE LINE 1 Use 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 4 pressure
61. e properly as outlined in the Power End Intermediate Rods and Oil Seat Retainers section of this manual j For 850 N packing start pump and operate under pressure retighten adjusting nut After pump has been running for two 2 or three 3 hours under pressure packing will seat itself and the adjusting nut should be tightened as much as possible to eliminate any movement of the packing in the stuffing box Use the bar furnished with the pump Do not use a cheater k The adjusting nuts should be checked and each tightened for the first 2 or 3 days until the packing is completely seated and the adjusting nuts cannot be tightened any further Use the bar furnished with the pump Do not use a cheater Print Home 45 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation VEEL e NATIONAL OILWELL VARCO Assembly Il FLUID END PLUNGER PACKING INSTALLATION Continued 2 1045 PACKING also called No 265 It is important that the following procedure be observed when replacing old packing to prevent rapid packing wear a Remove crosshead reservoir and rotate crankshaft to bring plunger forward b Back off locking set screw if used at intermediate rod crosshead connection and intermediate rod plunger connection Using back up wrench loosen this connection one fourth 1 4 turn c Rotate crankshaft until plunger is all the way back unscrew plunger or remove clamp assemblies and slide
62. e valve amp seat for nicks burrs or washes and thoroughly clean before assembly Print Home 56 Index Next e NATIONAL OILWELL VARCO www nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Plunger Pump Valves I CAGE TYPE VALVES D VALVE PARTS INSPECTION Continued 4 VALVE DISC AND SEAT The NATIONAL OILWELL VARCO disc type valve is made from heat treated stainless steel An optional 316 stainless steel valve is available for severe corrosive service The 316 stainless steel valve is non magnetic and cannot be picked up with a magnet The heat treated valve is magnetic The following inspection points should be observed See Figure 9 a The valve and seat sealing surfaces should be closely inspected for evidence of excess wear and or washed areas The amount of wear can be determined by comparison with a new valve and seat or by observing the amount of undercut still remaining on the disc seating surface If this face is flat the valve disc and probably the seat should be replaced Small washes or cuts in the seating surface can sometimes be removed with emery cloth The seating surfaces should then be ground or polished to a smooth finish A good field method is to lay the fine emery cloth or crocus cloth on the milled top of the cylinder and polish the disc and seat on this surface b Inspect the outside surface of the disc and seat for nicks burrs or washes and thoroughly clean bef
63. ecting rod bearings are precision fitting inserts requiring no adjustment When re installing the same inserts assemble them in pairs at their original location Make sure the match marks on the connecting rod and cap are the same on the corresponding sides Figure 1 NOTE It is possible to install these bearing shells incorrectly Please follow instructions carefully Print Home 40 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Assembly POWER END D CONNECTING ROD TO CRANKSHAFT ASSEMBLY 60T 80T 130T New Style 165T 200 250T and 3000 Continued 1 5 Check bearing halves for pin engagement and fit over the dowel pin in the cap half of the connecting rod Please note the drawing and match marks Install both bearing halves on the crankshaft with the dowel pins engaged as shown Position crankshaft throw to the rear With bearing shells in position as shown in drawing pg 38 fit the cap half of the connecting rod over the bearing shells Make certain the dowel pin is seated properly and the lubrication hole in the bearing is toward the front so as to match the oil hole in the connecting rod NOTE Later model connecting rods have the dowel pin located in the rod half With this pin the location of the rod is positioned first on the bearing shell Slide the connecting rod back over the crankshaft throw us
64. erchanged 1 Right Hand Bearing Short Shaft Extension a b Install chain sprocket on 165T With a bearing cone and roller assembly at proper temperature install on the crankshaft with the thick edge of the taper against the shoulder Assemble the bearing spacer and outer race on the crankshaft and against the inboard cone and roller Install outboard cone and roller assembly thin edge against the bearing spacer Tighten the lock nut and lock with lock washer prong This can best be done after the shaft is in the pump Make sure cone and roller assemblies are tight against the bearing spacer 2 Left Hand Bearing Long Shaft Extension a With bearing cone and roller at proper temperature install on the crankshaft with the thick edge of the taper against the shoulder Assemble the bearing spacer against the inboard cone and roller Drive outer race into the bearing cage against bottom shoulder Install the outer race and cage assembly and gasket against inboard cone and roller Install outer cone and roller assembly thin edge against the bearing spacer Assemble lock nuts and lock washer Tighten lock nut and lock with prong of lock washer Make sure cone and roller assemblies are tight against the bearing spacer Print Home 37 Index Next www nov com e NATIONAL OILWELL VARCO Installation Care and Operation WERTEN e NATIONAL OILWELL VARCO Assembly I POWER END Continued B C
65. et of the pump it may be necessary to prime individual pumps after filling using procedure listed above 6 PUMP DISPLACEMENT Maximum output per stroke 1 4 Plunger 018 Cubic Inches 3 8 Plunger 038 Cubic Inches The cubic volume for a pint of oil is 28 9 cubic inches and average drop size is 002 cubic inches Pump Outlet 1 8 NPT Vent Screw i Sight Glass s Union Nut Flushing Unit Lock Nut Suction Inlet Index Next www nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Storage of Pumps I GENERAL All machinery units require protection from corrosion erosion natural attrition which causes deterioration of the surface as well as the working parts Generally units in operation are frequently inspected cleaned painted and lubricated while idle units are often more or less neglected Any degree of neglect is costly especially if continued over a sufficient period of time to make restoration of the equipment impossible It is recommended that preventive measures of protection be established and the following will guide you in the minimum requirement A GENERAL Preferably units should be stored in clean climatically controlled buildings This would require the minimum inspection but since storage in older environments is sometimes necessary more frequent inspections and additional protection is necessary T
66. every time the valves are removed from the pump If it is absolutely necessary to re use these seals install the best seal in the middle stack the next best at the bottom and the worst seals on the top covers Replace used seals with new ones as soon as possible Print Home 58 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Plunger Pump Valves CAGE TYPE VALVES Continued E ASSEMBLY PROCEDURES 1 10 11 12 www nov com After all parts have been thoroughly inspected and cleaned assemble each valve unit on top of the pump leaving off the seals Make certain the seat is shouldered up in the cage and the spring is correctly positioned on the disc Now check the spring for correct pre load which should be with 1 8 to 3 16 of spring extending above top of cage See Figure 10 Check cylinder bores for nicks scratches cuts or washed areas with flashlight Fluid end should be reworked if these are too deep for seal to work effectively Place new seal in cylinder bore and push to bottom with hook Gently tamp the seal into the bottom of the bore See Figure 11 Using handle of seat driver as a guide drop a suction seat on top of gasket The handle will prevent the seat from turning over when dropped NOTE Suction seat has a larger bore I D than the discharge seat Insert seat driver in suction seat and using a hammer tap
67. f materials on special order 2 Tapered Seat Valves There are two basic OEM valve amp seat assemblies available depending on the type of service They are the bottom guided BG tapered seat valves and the spherical tapered seat valves The BG valve and seat are available in a variety of materials depending on the type of fluid being pumped The spherical valves are made of Nitronic 50 material Print Home 50 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Plunger Pump Valves continued CAGE TYPE VALVES The NATIONAL OILWELL VARCO valve is patented design valve This manual will assist in performing the normal maintenance requirements of the valves A NOMENCLATURE www nov com 1 2 3 4 5 6 7 8 9 1 0 Acme threaded valve cover with center bolt One piece solid cover used on 30T 60T or 80T Retainer not used 30T 60T or 80 Cover and Cage Seal Suction or Discharge interchangeable Disc Valve Cage Suction or Discharge interchangeable Valve Spring Suction or Discharge interchangeable Stop Valve Disc 30 Taper Cut in Cage not used in Ball Valve Cages Valve Disc Valve suction or Discharge interchangeable Valve Seat Discharge only Small bore I D used to retain Suction Spring Valve Seat Suction Only Large Bore I D same as Suction Throat Bore Valve Seat Suction
68. ff the nut one half turn If stuffing box has been removed re install assembly onto reciprocating Connect plunger to intermediate rod and tighten Insert stop pin into stuffing box nut Fill lubricator with Rock Drill Oil for normal temperature or steam cylinder oil for high temperature fluids Fill lubricator lines by pumping it manually Check its operation Start pump at slow speed and low pressure if possible tighten stuffing box nut and insert stop pin in hole Watch for a short period of time Oil if needed Set lubricator to twice normal rate After 24 hours resume normal operation Check stuffing box for excessively high temperatures and abnormal leakage Figure 2 Print Home 48 Index Next WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO TIE TA Plunger Pump Valves 1 OPERATIONAL MAINTENANCE A SUCTION AND DISCHARGE As with any plunger pump the necessity for having an adequate suction head and proper piping design of both suction and discharge cannot be over emphasized ATTENTION NOISY VALVES DUE TO IMPROPER FILLING CAN LEAD TO SHORT LIFE AND RAPID MECHANICAL WEAR OF THE POWER END PARTS B VALVE COVERS CAUTION THE VALVE COVERS AS USED WITH THE NATIONAL OILWELL VARCO PLUNGER PUMPS MUST BE KEPT TIGHT AT ALL TIMES DUE TO THE DISCHARGE PRESSURE APPLYING A CONSTANT LOAD TO THE COVERS IT IS NOT POSSIBLE TO CHECK THEIR TIGHTNESS WITH THE PUMP RUN
69. hat will boil water back off stuffing box nut and repeat run in until temperature remains after nuts are re tightened Teflon is DuPont s registered trademark for TFE Fluorocarbon fiber 4 SPRING LOADED KEVLAR RECIPROCATING PACKING Recommended Packing Procedure a b Before re packing determine cause of failure Remove plunger stuffing box nut and all internal parts in stuffing box Remove stuffing box itself if necessary to clean Clean all parts and determine if parts are worn or reusable Replace all worn parts Soak new packing elements in oil Lubricate all other parts Note the depth of stuffing box bore If greater than four inches 4 install appropriate spacer See appropriate parts list for applicable spacer Install parts into stuffing box in the following order spacer if needed spring follower small end first Kevlar ring and brass ring with care alternate these items three 3 times twice for 30T and then add the bushing gland ring Screw on the nut hand tight Insert plunger into packing assembly Print Home 47 Index Next www nov com e NATIONAL OILWELL VARCO Installation Care and Operation VEEL e NATIONAL OILWELL VARCO Assembly Il FLUID END E PLUNGER PACKING INSTALLATION 4 SPRING LOADED KEVLAR RECIPROCATING PACKING Continued e NATIONAL OILWELL VARCO Tighten packing nut Bushing should seat and shoulder against stuffing box face Back o
70. he 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 Home 24 Index Next www nov com e NATIONAL OILWELL VARCO Installation Care and Operation TIE TA e NATIONAL OILWELL VARCO Lubrication GENERAL NATIONAL OILWELL VARCO Plunger Pumps are splash lubricated The main bearings receive oil through ports in the frame Crankshaft bearings are fed by splash and at low speed through roll pins from the crosshead reservoir 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 At speeds under 200 rpm special auxiliary oil
71. he oil wiper retainer is piloted into the frame and held in place by two capscrews or a metal clip 3 Remove the intermediate rod from crosshead lock screw if used and using a back up wrench on the crosshead unscrew the rod Remove the rod and oil wiper retainer as one assembly B CRANKSHAFT ASSEMBLY e J 30 Prior to S N 3854 J 60 Prior to S N 7476 1 Remove connecting rod bolts and cap NOTE Match marks and deep halves together 2 Connecting rod and crosshead must be moved all the way forward to clear crankshaft 3 Remove crankshaft bearing retainers and seals and shims These shims should be tied together and marked for reassembly at their original location ATTENTION COVER KEYWAYS TO PROTECT OIL SEALS DURING REMOVAL 4 Rotate No 1 throw to front support the crankshaft and remove it from either side tapping it out with a brass bar to prevent damage to the end This will automatically remove one of the main bearing outer races The other race may be removed by knocking it out with a brass bar Tag the outer bearing races so they may be reassembled with the same bearing cone and roller assembly Print Home 31 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation Manual e NATIONAL OILWELL VARCO Disassembly L POWER END B CRANKSHAFT ASSEMBLY Continued e 60T and 80T 1 Remove connecting rod bearing cup and both inserts NOTE Match marks on
72. he 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 10 1632 SSU at 100 F 20 F to 100 F AGMA No 5 EP or ASTM ISO Grade No 220 Viscosity 918 to 1122 SSU at 100 F 20 F to 60 F AGMA No 2 EP ASTM ISO Grade No 68 Viscosity 284 to 347 SSU 100 F METRIC UNITS OF MEASURE Temperature AGMA Industrial EP Gear Oil 10 C to 68 C AGMA No 6 EP or ASTM ISO Grade No 320 Viscosity 288 to 352 cSt at 37 8 C 7 C to 38 C AGMA No 5 EP or ASTM ISO Grade No 220 Viscosity 198 to 242 cSt at 37 8 F 29 C to 16 C AGMA No 2 EP or ASTM ISO Grade No 68 Viscosity 61 to 75 cSt at 37 8 F Oil must pour freely at a minimum operating temperature Change oil every six months or as frequently as operating conditions require to maintain a clean sludge free oil of proper viscosity Print Home 68 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation D NATIONAL OILWELL VARCO TIE TA Gear Reducer I LUBRICATION AND MAINTENANCE A GENERAL 1 OIL Continued GEAR REDUCER OIL CAPACITY Pump Ratio 30T 3 83 4 20 60T 80T 34 2 77 3 035 3 50 100T 130T 60 3 15 3 42 3 89 4 269 165T 22 3 46 4 38 4 78 4 96 5 74 200T 2501 3000 2 MAINTENANCE
73. he schedule for inspection and protection can be determined only at the point of storage A protection and storage log is recommended Tropical areas require the maximum protection arid regions require the least amount of protection The frequency of inspection is determined after noting the rate of deterioration Take positive action immediately when corrosion erosion appears do not wait until large areas are covered because usually the larger the area the deeper the penetration B RECOMMENDED PROTECTION INITIAL STORAGE 1 Drain all oil and thoroughly clean inside of Power Frame 2 Coat pinion shaft oil seals with grease 3 Remove breathers for later installation on pump Seal all breather holes with greased solid pipe plugs Remove extension rods and diaphragm sealing housing be sure to protect the rods and housings storing them separately for later installation on the pump Seal diaphragms with wooden covers Mate the wood cover and diaphragm faces together thoroughly coating with Rust Veto 342 or its equivalent 4 Spray two gallons of Shell VSI 100 vapor phase inhibitor or equivalent into power end of pump 5 Remove valves and valve springs Clean and wrap in corrosion inhibiting paper Remove liners and pistons Clean and wrap in corrosion inhibiting paper Clean and dry fluid end bores and thoroughly coat all internal surfaces with Tectyl 506 or equivalent 6 Thoroughly coat all threads and end of valve cover and screw into fl
74. i id EE di Hd RE ee OP Heb dug Pe e ut Due PL a eec ce a Ced E de 23 MAINTENANCE I GENERAL A Daily Olne 24 B Monthly Maintenance cise ccc L S eds 24 fe 25 D Start Up After Storage 25 Il TROUBLE SHOOTING 26 28 Print Home 5 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation Manual e NATIONAL OILWELL VARCO Table of Contents Continued OVERHAUL AND REPAIR PAGE GENERAL A ools Req Ired PEE 29 B Check Points and Adjustments 1 308 601 crt n ua eege aa eer 29 2 100T 130T 165T 200T 250T amp 300Q I n L n n nsn 29 30 DISASSEMBLY I POWER END A Intermediate Rods and Oil Wiper 31 B Crankshaft Assembly ME 31 GOT BOTs BOD oo aeaa a E aaa Ena 32 NEUE Eu NT 32 100T 130 165T 200T 250T amp 3000 33 Crankshaft Bearings All Pumps 4 eiit ee eisen nee 33 II FLUID END A Fluid Cylinder Removal 307 HERE 34 100T 130T J 150 165T 200T 250T amp 3000 34 B Stuffing Boxes and Plunger Removal BOT GOT amp BOT urn 34 100T 130T J 150 165T 200T 250T amp 2000 3
75. ice this equipment must not be put into service before the machinery into which it is to be incorporated has been declared in conformity with the provisions of the Machinery Directive The EHSR s related to this equipment have been addressed a Technical Construction File is available for inspection by designated bodies ATEX product marking Authorized Signature Date 4 44 Chris Cackler October 4 2007 Important safety information is contained in the installation operation and service manuals read and understand this information prior to installing or using this equipment This Document applies only to the equipment described above and is invalid if not reproduced in its entirety Print Home 11 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation Manual e NATIONAL OILWELL VARCO ATEX Warning Statements I PUMPS AND PUMP UNITS Continued B 200T PUMP 1 NAMEPLATE DATE or MANUFACTURE PLUNGER PUMP mem CRANKCASE LUBRICATION INSTRUCTIONS RATED MAX INPUT AT AIR TEMPERATURE INDUSTRIAL GEAR 50 F 155 F 6 EP OR ISO 320 EP RATED oureur Juan nev 20 F TO 100 F 5 EP OR ISO 220 20 F TO 60 F 2 EP OR ISO 68 DO NOT EXCEED MAXIMUM DISCHARGE PRESSURE BELOW ZE AT MAX RATED CRANKCASE OIL us GALLONS RATED RPM PSI BAR OIL MUST PO
76. in 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 Make sure suction and discharge line valves are fully open 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 e NATIONAL OILWELL VARCO Drain and refill crankcase every six 6 months or as often as required to maintain a clean sludge free oil of the proper viscosity Clean crankcase air breather with a non explosive solvent Check all studs nuts and capscrews for tightness Inspect gaskets for leaks tighten or replace as required Clean pump Good housekeeping is a prerequisite to good maintenance Print Home 24 Index Next www nov com Installation Care and Operation 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 c
77. ing caution so the outer surface of the aluminum insert is not damaged Note the match numbers of the cap and rod to be certain the rod is assembled correctly Install the two 2 capscrews and torque as shown in chart Lockwire the capscrews securely E INTERMEDIATE RODS AND SEAL RETAINERS e 60T 80T 100T and 130 Install two oil wipers lips facing the power end Open one from the power end side and one from the fluid side On the power end side the wiper O D should be flushed with the face of the retainer On the fluid end side the wiper should be pressed in the retainer until it contacts the shoulder in the middle of the retainer Install the third wiper on the fluid end side of the retainer with lip facing the fluid end NOTE Make sure O D wiper and I D of retainer are clean and dry before installation of the wiper e 100T 130T 165T 200T 250T and 3000 Install two 2 oil wipers lips facing the power end and two 2 oil wipers with lips facing the fluid end The inner wipers should shoulder against the raised area in the center of the retainer Make certain the retainer and wipers are clean and dry before installation An oily or greasy surface can cause the wipers to become loose Print Home 41 Index Next www nov com e NATIONAL OILWELL VARCO Installation Care and Operation TIE TA e NATIONAL OILWELL VARCO Assembly I POWER END E INTERMEDIATE RODS AND OIL SEAL RETAINERS Co
78. iously used and use the steps as a check for adjustment Assemble the crankshaft bearing retainer and shims less oil seal to the main frame and tighten in place with the proper capscrews Install the other crankshaft bearing retainer less oil seal in the same manner as in step nine 9 above To determine the correct amount of shims when installing new bearings the following steps are recommended a When first installing shims use only enough shims to produce a slight drag when the crankshaft is rotated Tap shaft on each end sufficient to ensure that the bearing outer race is tightly against the retainer b Then add enough shims to remove the slight drag or pre load approximately 005 127 mm to 007 178 mm depending on the amount of pre load The bearings are correctly adjusted when there is 003 to 005 end play of the crankshaft and the crankshaft will rotate freely Do not pre load bearings Print Home 36 Index Next www nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Assembly POWER END A CRANKSHAFT AND MAIN BEARINGS Continued e 100 130T 165 200T 250 and 3000 The crankshaft should be clean and free of burrs The cone and roller assemblies are to be heated in an electric oven or oil bath to 300 F 149 C The use of a thermometer is recommended Bearing parts are match marked and should be noted prior to heating Make sure parts are not int
79. ly fuel supply environmental contamination etc 6 Avoid environmental contamination by providing the proper disposition of drainage from the crankcase gear case chain case sludge sump and any other lubrication reservoirs as well as from the flushing media sump the pump cradle the suction line and the discharge line C ALIGNMENT 1 Itis most important that the pump be accurately aligned with the prime mover 2 Follow the recommended alignment procedures provided by the manufacturer of the belts and sheaves or couplings D SUCTION LINE 1 e NATIONAL OILWELL VARCO 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 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 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 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 Pulsation dampening devices are strongly recommended When necessary to manifold a number of pumps to a common suction the diameter of the manifold and suction pipe lea
80. more Information contact National Oilwell Varco directly at the Headquarters in Houston Texas All National Oilwell Varco products are available throughout the U S and around the world from service centers authorized distributors and representatives Copyright 1999 by National Oilwell L P All Rights Reserved NATIONAL OILWELL NATIONAL and OILWELL are registered trademarks of NATIONAL OILWELL L P Houston Texas USA All other trademarks used are registered to their respective companies The information and data in this brochure including but not limited to pictures photographs charts diagrams drawings lists written comments and specifications are accurate to the best of our knowledge and belief but are intended for general information only Applications suggested for the materials and other information are described only to help readers make their own evaluations and decisions and are neither guarantees nor are they to be construed as express or implied warranties of suitability for these or other applications National Oilwell makes no warranty either express or implied beyond that stipulated in National Oilwell s Standard Terms and Conditions of Sale which are available upon request
81. nd Operation NATIONAL OILWELL VARCO Manual Assembly II FLUID END Continued E PLUNGER PACKING INSTALLATION 1 850 N Packing It is important that the following procedure be observed when replacing old packing to prevent rapid packing wear a Remove front crosshead reservoir cover plate and rotate pump to bring the desired plunger to the forward position b Back off locking setscrew if used at intermediate rod crosshead connection and intermediate rod plunger connection Using back up wrenches loosen connection one fourth 1 4 turn c Rotate crankshaft until plunger is all the way back Unscrew plunger or remove clamp assembly and slide plunger forward d Remove intermediate rod and intermediate rod seal retainer from as one assembly e Remove plunger and old packing making sure stuffing box is clean Plungers and boxes may be removed as an assembly by rotating the pump so the intermediate rod is all the way back thereby disconnecting the plunger and sliding the stuffing box back and out f Oil each ring with light DO NOT GREASE and install packing per sketch included with the packing Make sure the lips on the sealing rings face pressure shown g Install gland and pull down hand tight against packing h Install plungers then pull adjusting nut down as tight as possible with bar furnished with the pump DO NOT USE A CHEATER i Install intermediate rod and retainer Connect plunger and torqu
82. nnecting rod and crosshead can be removed through cradle chamber without disturbing the crankshaft Interference with plungers and stuffing boxes is possible depending on plunger size Remove stuffing boxes if necessary Remove oil wiper troughs 200T 250T and 300Q Remove right hand bearing retainer and gasket Remove left hand bearing retainer and gasket and remove capscrews from bearing cage Crankshaft can be removed from left side of pump only Puller holes are provided in the bearing cage if needed Extreme care should be used in removing the crankshaft so as not to damage the center support bearings or the bearing journals on the crankshaft of the 300Q C CRANKSHAFT BEARINGS ALL PUMPS The crankshaft main bearings may be inspected while on the crankshaft and should not be removed unless necessary A puller is required when replacement is necessary NOTE Keep the component parts of the bearings together if they are to be re installed They are match marked and must be correctly assembled as a unit Print Home 33 Index Next WWW nov com e NATIONAL OILWELL VARCO Installation Care and Operation Manual e NATIONAL OILWELL VARCO Disassembly Continued II FLUID END A FLUID CYLINDER REMOVAL 60T and 80T 1 2 Disconnect piping Remove the eight 8 fluid cylinder hex nuts and slide cylinder forward over the main frame studs 100 130 165T 200 250 and 3000 1
83. ntinued e ALLPUMPS Rotate the crankshaft until the crosshead is all the way forward and install the retainer and rod as a unit NOTE sure retainer gasket is in place prior to installation Tighten rod and the crosshead using a back up wrench on the crosshead to the following torques Threads 165T 200T 250T amp 300Q Dry ft lbs 480 Lubricated ft lbs 385 ll FLUID END A STUFFING BOXES AND PLUNGERS Plungers are available in ceramic or steel ATTENTION NATIONAL OILWELL VARCO DOES NOT RECOMMEND THE USE OF CERAMIC PLUNGERS FOR PUMPING FLAMMABLE LIQUIDS 60T and 80T 1 Thoroughly clean and remove any nicks or burrs from all mating surfaces of the main frame fluid cylinder and stuffing boxes 2 Insert stuffing boxes into main frame NOTE The stuffing box is a press fit in the main frame and will have to be driven into position ATTENTION PREVENT DAMAGE BY PLACING A BLOCK OF WOOD OVER THE STUFFING BOX FACE Print Home 42 Index Next e NATIONAL OILWELL VARCO WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO EME Assembly II FLUID END A STUFFING BOXES AND PLUNGERS 60T and 80T Continued NOTE Stuffing box flange face should extend 001 to 004 025 mm to 102 mm beyond the frame face to assure proper crush on the stuffing box seal If this condition does not exist premature gasket failure will o
84. oat 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 ATTENTION 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 25 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation Manual Maintenance Continued ll TROUBLE SHOOTING
85. of new packing but should require very little attention after this k This packing can be used on hard coated or ceramic plungers without lubrication but as with any packing extended life is possible through the use of lubrication When using a mechanical or drip type lubrication system in water service use rock Drill Air Drill Oil of the proper viscosity Drip five to seven drops per minute Print Home 46 Index Next e NATIONAL OILWELL VARCO www nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Assembly II FLUID END PLUNGER PACKING INSTALLATION Continued 3 699 PACKING For top performance from the soft packing of Teflon fiber read and carry out the following instructions Use the above method to remove and re install intermediate rod and plunger a b Packing may be butt or diagonal cut Stagger joints in successive rings at least 90 Slide rings into stuffing box but do not tap or drive rings into place Tests have shown that this method gets maximum performance from soft packing of Teflon fiber Tighten stuffing box nut finger tight and start pump Packing should be leaking if not loosen stuffing box nut Remember install this soft packing with a minimum of gland pressure to minimize friction and heat build up Reduce leakage to desired level by tightening stuffing box nut about 1 6 turn at a time every few minutes If gland heats up to a temperature t
86. operation Make sure the hex nuts holding the cylinder in place are tight Print Home 23 Index Next e NATIONAL OILWELL VARCO Installation Care and Operation VEEL e NATIONAL OILWELL VARCO Maintenance 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 8 9 Check power end oil level daily by means of the dipstick in the rear cover 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 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 of the plunger for lubrication See Lubrication Section in this manual for further details Check lubricator for proper level and operation Check plunger packing for excessive leakage Replace packing as required Check stuffing box adjusting nuts for tightness Drain plunger leakage sump tanks if required Flush plunger chamber dra
87. ore assembly N B d 7 x SJ Disc amp Seat Spherical Valve amp Seat Figure 9 Print Home 57 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation VEEL e NATIONAL OILWELL VARCO Plunger Pump Valves IL CAGE TYPE VALVES D VALVE PARTS INSPECTION Continued 5 VALVE BALL amp SEAT The NATIONAL OILWELL VARCO ball and seat valve is composed of the same material as the Fluid Packed Supreme Ball and Seat The seat is reversible and the seating surfaces should indicate if replacement is necessary 6 SPRINGS The springs as used in the NATIONAL OILWELL VARCO cage type valve assemblies are designed for long trouble free service If installed correctly with the proper pre load and operated under normal conditions which include a good suction that provides a smooth valve action these springs will operate for a year or more ATTENTION IT IS BEST YOU CHANGE SPRINGS AND DESTROY THE OLD ONES APPROXIMATELY ONCE A YEAR IF THE SPRINGS FATIGUE AND BREAK THE RESULTING VALVE ACTION CAN DAMAGE THE CAGE AND VALVE HERE AGAIN IF INDOUBT CHANGE THE SPRING THEIR COST IS VERY MODERATE 7 SEALS VALVE CAGE The NATIONAL OILWELL VARCO cage type valves are of a stacked design and depend on the seal at the top middle and bottom of the stack to isolate the suction and discharge valves and their associated changes in pressure These seals should be changed
88. relief valve If the line is of great length this must be taken into consideration in sizing the relief valve There must be no restrictions or valves in the relief valve discharge line NOTE Follow the foregoing instructions if 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 2596 Double Acting Triplex Piston Pressure Rating Plus 1096 Double Acting Quintuplex Piston Pressure Rating Plus 1096 Single Acting Triplex Piston Pressure Rating Plus 1096 Single Acting Simplex Plunger Pressure Rating Plus 2596 Single Acting Duplex Plunger Pressure Rating Plus 2096 Single Acting Triplex Plunger Pressure Rating Plus 1096 Single Acting Quintuplex Plunger Pressure Rating Plus 1096 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 Installation Care and Operation INERTEIN 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
89. 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 F 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
90. se 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 LIFTING WARNING WARNING WARNING Extreme care must be made when lifting this pump to avoid property damage serious bodily injury or death 1 CHAIN SELECTION Minimum chain specification is as follows 3 8 size 31 32 pitch steel Rated 5000 Proof Test Use of chain below minimum requirements can result in damage serious bodily injury or death 2 CHAIN LOCATIONS The arrangement drawings below and following indicate the proper slinging method for handling this pump with chains Any deviation from this plan can result in damage serious bodily injury or death T NATIONAL gt 5 E OILWELL NATIONAL mE VARGO 00 OILWE
91. 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 OILWE
92. tapers and with retainer and spring removed place seat in place making sure it is straight c With bottom guided valve in place drive the seat as shown in Figure 25 until it stops driving d Check bottom guided valve to be sure it is free in the seat and install spring and retainer Torque retainer to values shown below using hex head wrench as shown in Figure 26 TORQUE ft Ibs Print Home 65 Index Next WWW nov com waviowat oitwELL VARCO Installation Care and Operation Manual Plunger Pump Valves TAPERED SEAT VALVES B TAPERED SEAT BOTTOM GUIDED VALVES Continued VALVE COMPLETE Consists of e NATIONAL OILWELL VARCO ITEMS INCLUDED 2 1 2 3 1 2 4 Suction VALVE Complete 1792500 4 1793000 4 1793500 4 1794000 4 Discharge 1792502 4 1793002 4 1793502 4 1794002 4 Suction 1792501 4 1793001 4 1793501 4 1794001 4 Discharge 1792503 4 1793003 4 1793503 4 1794003 4 VALVE Only 1790066 1713502 1790067 1790068 1792505 1793005 1793505 1794005 RETAINER 1792504 26 1793004 26 PULLER KIT Consists of 1793504 26 1794004 26 ITEMS INCLUDED 2 1 2 3 1 2 4 PULLER KIT 1792507 1793007 1793507 1794007 PULLER HEAD 1792506 1793006 1793506 1794006 BUMPER 1790080 BAR 17900
93. te disassembly and assembly procedures are discussed in their respective sections A TOOLS REQUIRED Most of the tools required to overhaul the pump will be found in an ordinary set of mechanics hand tools The special tools and equipment required and not furnished with the pump include a torque wrench bearing puller and a valve servicing kit Also a hot oil bath capable of reaching a temperature of 300 F 149 C will be needed B CHECK POINTS AND ADJUSTMENTS 1 60T amp 80T The crankshaft main bearings are single row shim adjusted tapered roller bearings They have been assembled and adjusted at the factory with proper clearance and will give long trouble free service The proper clearance is found by adjusting the amount of shims until the crankshaft has 003 to 005 endplay and will rotate freely 2 100T 130T 165T 200T 250T amp 300Q a The crankshaft main bearings are non adjustable double row tapered roller bearings factory set for the proper running clearance b The connecting rods or bearing inserts are solid aluminum alloy precision ground with the following tolerances see table next page c The minimum allowable clearance between the crosshead and crosshead bore is 012 305 mm The maximum allowable clearance including wear is 030 762 mm This is for all pumps d Maximum allowable clearances between the crosshead pin and connecting rod bushings are listed on the following table
94. tion Manual e NATIONAL OILWELL VARCO ATEX Warning Statements I PUMPS AND PUMP UNITS Continued 13 Failure to operate or maintain the pump and ancillary equipment in line with the manufacturer s instructions may lead to premature and potentially dangerous failure of components Regular inspection and where necessary replacement of bearings and lubrication is essential 14 The pump and its components have been designed to ensure safe operation within the guidelines covered by legislation Accordingly National Oilwell Varco has declared the machine safe to use for the duty specified as defined by the Declaration of Incorporation or Conformity that is issued with this instruction manual A 80T PUMP 1 NAMEPLATE p i MooeL DATE or MANUFACTURE PLUNGER PUMP CRANKCASE LUBRICATION INSTRUCTIONS RATED MAX INPUT HP w al ap TEMPERATURE INDUSTRIAL EP GEAR OIL 50 F TO 155 F 6 EP OR ISO 320 EP RATED oureur inaw aT rpm 20 F TO 100F AGMA 5 EP OR ISO 220 20 TO emt 2 EP ISO 68 EP DO NOT EXCEED MAXIMUM DISCHARGE PRESSURE BELOW Sinner tie npe RATED CRANKCASE capacity 05 GALLONS RATED RPM PSI BAR OIL MUST POUR FREELY AT MINIMUM OPERATING TEMPERATURE CHANGE OIL AS FREQUENTLY AS REQUIRED TO MAINTAIN A SLUDGE FREE OIL OF PROPER VISCOSITY CHECK OIL LEVEL PERIODICALLY WITH PUMP AT REST ROTATE IDLE PUMP OCCASIONALL TO
95. uid end 7 Protect all external machine surfaces using Rust Veto 342 or equivalent including pump pads 8 Inspect complete pump and record all details on the Protection and Storage Log Print Home 75 Index Next WWW nov com waviowat oitwELL VARCO Installation Care and Operation Manual e NATIONAL OILWELL VARCO Storage of Pumps I GENERAL Continued C SIX MONTH SERVICING 1 2 3 4 5 Rotate pump Renew internal rust inhibitors to specifications and quantities previously stated under the Initial Storage section Before replacing top and side covers inspect for any internal corrosion Inspect for soundness of external protection i e rust preventative and paint Renew as necessary Enter and record all details on the Protection and Storage Log D PRE INSTALLATION CHECK AFTER STORAGE 1 2 3 e NATIONAL OILWELL VARCO Repeat six month servicing procedure as stated above Ensure all necessary parts are complete and in a satisfactory condition for installation on pump Enter all records and close out the Protection and Storage Log Print Home 76 Index Next WWW nov com Installation Care and Operation NATIONAL OILWELL VARCO Manual Owners Record NAME LOCATION DATE OF DELIVERY DATE PLACED IN OPERATION PUMP MODEL PUMP SIZE SERIAL NO PRIME MOVER SERIAL NO GEAR UNIT SERIAL NO DRIVE DRIVE SHEAVE P D DRIVEN SHEAVE P D NO OF GROOVES
96. w cage and bearing per assembly instructions in pump service manual c Install new bearing retainer 100T amp 130T Part number 1711622 and gasket onto cage Check clearance of Labyrinth seal to shaft There should not be any metal to metal contact d Install crankshaft assembly per instructions in pump service manual e 60T amp 80T only replace left hand bearing retainer Part Number 1710011 with new bearing retainer Part Number 1710618 and re shim crankshaft as per instructions in service manual This retainer contains labyrinth oil seals but some older models use two 2 YS 3254 seals with the lips pointed in opposite directions f All other pumps contain labyrinth seal type retainers No oil seals are necessary Be sure seal grooves are clean before installing retainer g Apply liquid gasket to bearing cage and install gear reducer housing over pilot on bearing cage Insert special capscrews and tighten securely h Drill and ream for dowel pins two 2 holes Dowel pins are standard 25 per foot taper pins and are listed in the parts list section for each pump ATTENTION DO NOT DRILL THROUGH PUMP FRAME HOLES SHOULD BE REAMED DEEP ENOUGH TO ALLOW PINS TO BE DRIVEN UNTIL THE TOP OF THE TAPER ON PIN IS FROM FLUSH TO 1 8 STAND OFF Print Home 71 Index Next www nov com waviowat oitwELL VARCO Installation Care and Operation TIE TA e NATIONAL OILWELL VARCO Gear Reducer 1 OVERHA

Reciprocating Plunger Pumps Installation, Care and

Contents

Download Pdf Manuals

Related Search

Related Contents