02 - Triplex Pumps

JET Module 2
Triplex Pumps
Provisory
TABLE OF CONTENTS TOC
1 Introduction pg 04
2 Introduction to triplex pumps pg 05
3 Triplex pump main components pg 06
3.1 Pump types pg 08
3.1.1 Cementing/completion services pg 08
3.1.2 Mixed cement/frac- services pg 12
3.1.3 Fracturing services pg 15
3.3.4 Coiled tubing services pg 18
4 Pump rate calculations pg 20
5 Specifications & ratings PG Series triplex pump pg 21
5.1 Chain case pg 21
5.2 Power end pg 22
5.3 Fluid end pg 23
5.3.1 Specifications pg 24
6 Routine maintenance pg 26
6.1 Pump cavitation pg 27
6.2 Power end pg 29
6.2.1 Temperature pg 29
6.2.2 Noises pg 29
6.2.3 Pony rod seals pg 30
6.2.4 Sludge and cement pg 30
6.2.5 Chemical and salt water corrosion pg 31
6.2.6 Power end lubrication system pg 31
6.2.7 hydraulic pump types pg 33
6.3 Fluid End pg 34
6.3.1 Fluid end lubrication system pg 34
6.3.2 Plungers and packing assembly pg 38
6.3.3 Fluid end cover retainers pg 39
6.3.4 O-ring and backup ring pg 40
6.3.5 Valves (MacClatchie valves) pg 42
6.3.6 Valve Seats (MacClatchie valve seats) pg 44
JET 2 - Triplex Pumps v1.0 (Provisory) 2

TABLE OF CONTENTS TOC
6.3.7 Packing pg 46
6.3.7.1 Fluid end repacking procedure pg 47
6.3.7.2 Valve seat removal and installation pg 54
6.3.7.3 Header ring packing installation pg 59
6.3.7.4 Repacking the header ring pg 62
6.4 Chain case lubrication system pg 65
7 Servicing pg 66
7.1 STEM 1 and operation of the triplex pump pg 66
7.1.1 Triplex pump STEM 1 pg 66
7.2 Triplex pump STEM 2 pg 69
7.2.1 Chain case pg 69
7.2.2 Power end pg 70
7.2.3 Fluid end pg 71
7.2.4 Packing oilers (Alemite) pg72
7.2.5 Triplex pump annual inspection - every 12 months pg 72
8 Troubleshooting pg 73
9 Appendix 1 - prime-up procedures pg 75
9.1 Priming triplex pumps using gravity feed pg 76
9.2 Priming triplex pumps using a pressurizer pump pg 77
10 Appendix 2 - hydraulic horsepower test (HHP) pg 78
11 References pg 79
12 Check your understanding pg 80
JET 2 - Triplex Pumps v1.0 (Provisory)

3
INTRODUCTION 1.0.0
The purpose of any pump is to convert mechan- When working on the pump, follow the proce-
ical energy provided by motors, engines, tur- dures in Well Services Safety Standard 4 -
bines, and other prime movers into fluid energy Facilities and Workshops.
as efficiently as possible. The pump should be
light, compact, simple, and easy to operate and When conducting function testing on the pump,
maintain while providing the efficiency and the follow the procedures in Well Services Safety
power required. Standard 5 – Location Safety.
Schlumberger Well Services uses low-pressure
and high-pressure pumps (also called positive Terms used in this training
displacement pumps). High-pressure pumps Reciprocating pump
use plungers to displace fluid. A mechanical device consisting of single acting
This training introduces you to one of the most positive displacement elements, such as pis-
common high-pressure pumps in the oilfield tons or plungers and is used to impart a pulsat-
industry, the triplex pump. ing flow to a liquid. The reciprocating pumps
used by Well Services are single acting triplex
Learning objectives: (three plungers) and quintuplex (five plungers)
Upon completion of this training, you should be units.
able to:
· explain the function of a triplex pump Single acting
· identify the various components of the A pump in which the liquid in each plunger is
triplex pump discharged only during forward stroke for one-
half of the crank revolution.
· describe how the triplex pump operates
· identify different pump models
Positive displacement pump
· identify the sizes and ratings on the A pump utilizing a plunger or cylinder to dis-
triplex pump place fluids, usually under pressure. Closing a
· maintain the triplex pump valve on the discharge side results in overpres-
· troubleshoot common pump problems sure.
· maintain the triplex pump
· service the triplex pump.
Safety warning:
Proper supervision is required during hands-on
training. Request assistance from your supervi-
sor if you are unfamiliar or uncomfortable with
the operation.
Ensure that all safety devices are in place and

operational before using a triplex pump. This
includes overpressure shutdowns and rupture
disc valves.

4
INTRODUCTION TO TRIPLEX PUMPS 2.0.0
Triplex pump is the general name given to any type of pump assembly consisting of three
plungers.
The reciprocating plunger pump is the most efficient pump for pumping abrasive fluids at high
pressure (1,000 psi and above) and requires the least amount of maintenance.

TRIPLEX PUMP MAIN COMPONENTS 3.0.0
Most types of pump assemblies have three
main components: b) Converts a low-torque, high-rpm engine
output to a high-torque, low-rpm output
Chain case, also called a speed reducer: more suited to the power end require-
Reduces the input shaft rpm. Well Services ments. The prime mover drives the chain
uses chain cases on PG series pumps and over the upper and lower sprockets that
gear reducers on most other pumps. are mounted on the pump pinion shaft.
Chain case When the prime mover rotates the lower
shaft, the chain transmits the power to the
upper shaft and rotates as well. This shaft
then transfers the rotation to the power
end pinion shaft. The different diameters
of the two sprockets in the chain case
reduce the prime mover output speed
increasing the torque input to the pump.
The chain case has two important functions:

a) Provides flexibility when mounting the
A typical twin P.G. pump layout
pump assembly in different locations
with respect to the prime mover output
shaft center-line. You can mount the To prevent the chain case from moving when
chain case on either side of the power power is applied, secure the chain to the chas-
end. sis or skid using a pair of torque rods.

Power end: Converts rotational power into Fluid end: Receives the power from the power
reciprocating power. The power end functions end. This part of the triplex pump receives fluid
the same way as a crankshaft in a motorcar at low pressure, applies horsepower to the
engine. The pinion shaft drives the crankshaft fluid, and discharges fluid at a high pressure.
using bull gears. The eccentrics of the crank- The mechanical pumping action is similar to a
shaft change the rotation of the mainshaft into conventional piston-type internal combustion
a reciprocating action. The reciprocating force engine or a reciprocating piston-type air com-
is then transferred to the connecting rods and pressor.
crossheads, moving the plungers in the fluid
end. As the plunger is drawn toward the power end
during the suction stroke, it reduces the pres-
sure inside the chamber between the suction
and discharge valves. This causes the suction
valve to lift and allow the fluid to flow into the
suction manifold through the suction port,
around the suction valves, and into the cham-
ber.
When the plunger moves in the opposite direc-

tion toward the fluid end, also called discharge
stroke, the fluid inside the chamber is forced
out. The suction valve closes immediately and
the fluid lifts the discharge valve from its seat
and flows into the discharge chamber.
Flow through fluid end
7
PUMP TYPES 3.1.0
Triplex pumps are used in cementing services, mixed cement/frac services, fracturing services,
and coiled tubing services.
3.1.1 Cementing/completion services

3.1.1.1 Pump types
5-in Stroke PG series

The PG series pump was the main pump for all cementing services equipment until recently.
This pump was available in a magnesium frame (truck mounted) and steel frame (offshore).
Power end gear reduction is internal using a bull gear and pinion shaft. The pump is usually cou-
pled to a chain case to
provide additional
reduction and driveline
offset.
8
6-in Stroke SPM TWS600S
This pump uses stuffing box construction in the fluid end. The plunger size can be varied over
a limited range. This can be done by only changing the stuffing box.
This pump is used as a replace-

ment for the PG series pump on
new completion/cementing equip-
ment designs. It features a crank-
shaft style power end with a bolt-on
gear reducer.
This pump is a much more compact

design and is rated at 600 hp input
as compared to 250 hp rating for
the PG series pump. This is also
advantageous for the new higher
horsepower cementers being devel-
oped and more suitable for continu-
ous pumping operations associated
with coiled tubing services.

3.1.1.2 Components
Valves and seats

There are no special valves and seats for
cementing/completions services. Several
vendors can supply these components.
Some locations use valves with stretch-on rub-

ber inserts for better results during pressure
testing since they tend to hold pressure better.
Rupture disc suction valves of the correct rat-

ing are required for all completions/cementing
pumping applications.
Packing
Using a universal header ring packing is rec-
ommended for completions services.
Suction stabilizers
Suction stabilizers are not used in completions
services.

3.1.2 Mixed cement/frac services
GD1250
The GD1250 is a lightweight
design offering high horse-
power per pump weight. It
was originally used on the
Pumper Pod, which is a frac
pump and blender combina-
tion. It is also used on high-
horsepower offshore skids as
a replacement for MD1000.
Three series of fluid ends are

available. Two of these fluid
ends can be fitted with multi-
ple plungers and have inter-
changeable stuffing boxes.

MD1000
The MD1000 type triplex pump gets its
name from its developer, Michel Drevet
and its maximum hydraulic horsepower
(hhp) output, which is 1000 hhp. Unlike the
other two types of triplex pumps, the
MD1000 type of pump uses a single
swashplate rather than separate wheels to
operate the three plungers.
The MD1000 pump consists of three, 120-

degree thrust rods connected to an oscil-
lating plate. Each thrust rod is, in turn,
attached to a crosshead, which operates a
plunger. As power turns the gears of the
power end, one thrust rod is at the
Maximum Forward Position (MFP),
while a second is in forward motion, and a · Weight/horse power ratio: The weight
third in backward motion. of the MD1000 type of pump with its
input horsepower has a ratio of 6.68.
The same ratio for a crankshaft pump
Advantages of the MD1000 pump varies from 8.33 to 19.82. This
means that the MD1000 pump provides
These models have many advantages over more hydraulic horsepower for the
traditional triplex pumps, but are commonly same pump weight. In fact, pump
used only in offshore applications. These weight can be reduced by up to one-
advantages include: third that of the crankshaft pump and
still delivers the same horsepower. This
· Global efficiency: While a traditional, means that more hydraulic horsepower
crankshaft-type pump typically has a and less dead weight can be transport
maximum efficiency of 80%, the ed. For offshore operations where
MD1000 type of pump has an efficiency transportation costs are significant, this
of 93%. This means that there is more is a great advantage.
hydraulic horsepower delivered to the
fluid being pumped, that intermittent · Plunger size: If the plungers on an
horsepower is closer to continuous MD1000 pump and a crankshaft pump
horsepower, and that less horsepower are the same, the MD1000 pump will
is dissipated in heat. This last point is have a higher working pressure and
especially important, because it means flow rate.
that the cooler operation requires a
smaller oil cooler, which saves in both
weight and size.

· Horsepower/volume ratio: The input · Balance: The swashplate design allows
horsepower of the MD1000 pump with the mainshaft assembly to be perfectly
its overall volume has a ratio of 13.52. balanced. This reduces vibrations in the
The same ratio for the crankshaft pump system and leads to longer bearing life
is between 3.5 and 10. This means that and reduced noise. Related to this, the
if the two pumps have the same vol- main center line of the MD1000 pump is
ume, the MD1000 pump will deliver aligned with the center line of the prime
more hydraulic horsepower. Or if the mover (motor or engine). This allows for
horsepower is the same, the MD1000 a better equipment layout design and
pump will require less overall volume. reduction in space required.
So, for any given application, the
MD1000 pump will be a smaller, more
compact unit than the crankshaft alter
native and will be easier to transport.

3.1.3 Fracturing services
3.1.3.1 Pump types
8-in stroke HD2250

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

SD2000 Crossbore pump
The 11-in stroke pump was originally developed to replace the in-line fluid ends. This pump has a
weight disadvantage for trailer units since it weighs approximately 4000 lbs more than the
HD2250.
3.1.3.2 Components
Valves and seats

Bonded insert valves are used in fracturing service. The proppant-laden fluids will get under the
snap on inserts and lead to valve failure.
Rupture disc suction valves of the correct rating are required for all pumping applications. Valves
and seats are available from several vendors.
Packing
Header ring packing is standard for all services. For more detailed refer to Section 6.3.7 -
Packing.

3.1.3.3 Special CO2 considerations
Commonly, CO2 is used with fracturing jobs. Special equipment specifications, such as CO2
rated suction manifold that are capable of handling high suction pressure, is required.
When pumping CO2, the suction stabilizer MUST be disconnected by blanking off the suction
header.
For CO2, you can use up to 5000 psi standard header ring packing and plunger lube. Pressure
above 5000 psi requires the use of special header rings.
At higher pressures, CO2 gas is entrained in the header ring during pumping and released after
the job. This causes the packing to fail when a conventional job is performed after a CO2 job.

3.1.4 Coiled tubing services
With coiled tubing services, different pump parameters are required. Due to the high friction pres-
sure through the coiled tubing, fluid can only be pumped at a limited maximum pump rates. Use
the dedicated coiled tubing triplex pumps for this type of application.
3.1.4.1 Pump types
6-in stroke OPI600

PG/Butterworth
To convert a standard PG pump for high-pres-
sure coiled tubing services, use a stainless steel
Duralife fluid end.
While the PG pump is not designed for continu-

ous pumping coiled tubing operations, the
Duralife fluid end performs better than a stan-
dard triplex in this application. The 2.5 plunger
size is well suited for low rate pumping, and this
pump offers replaceable fluid cylinders. The
stainless steel construction makes this pump
well suited for pumping sea water or brines.

PUMP RATE CALCULATIONS 4.0.0
EXAMPLE:
SPF 343
Allison 9800 series transmission - 4th gear
(1.77 : 1 ratio)
Engine rpm = 1900
HD2250 power end 6.353:1 ratio
IOPI fluid end (5 ½ plungers)

SPECS & RATINGS FOR PG SERIES TRIPLEX PUMP 5.0.0
CHAIN CASE 5.1.0
Most twin pump cement units, such as CPS and CPT, use a standard 23.15-in center-to-center
chain case for the downhole pump using a 90-in pitches long chain.
Mixing pumps use an extended chain case (6-in extension section to increases the chain case
length to 29.15-in center-to-center. They also use a 95 pitches long chain. To extend the chain
case, add a spacer and increase the chain length. Both chains are known as Quad 80 chain,
which means 80 pitch (length from pin to pin) and 4 links wide.
Chain case
Torque arms are designed to stabilize and control the reaction of the torque being applied
through the chain case. To adjust the torque arms, complete the following steps:
1 Rotate the torque arms using the left-hand threads to change their length.
2 Set one of the torque arms to the desired position.
3 Ensure that the driveshaft is clear from any obstruction.
4 Adjust the other torque arm in any direction to tighten and lock the chain case
into position.
5 Tighten all locking nuts in position.

POWER END 5.2.0
On PG pumps, you can configure the power end to be driven from the left or right-hand side.
These two configurations do not require different parts but is distinguished by the way the pinion
shaft is installed in the power end frame. When changing the position of the pinion shaft, retime
the timing gears.
NOTE: The district mechanic retimes the timing gears.
NOTE:
There are a few
instances where the
PG series power end
turns the opposite
direction. This is not
common, but you will
find it on units that
have two PG pumps
facing each other and
are driven by conven-
tional diesel engines.
Right-hand drive Left-hand drive

FLUID END 5.3.0
There are five different fluid ends available for
the PG series power end. The most common
ones are the G, L, and H ends. Those are
machined from forged AISI 4340 steel or better.
The R and S fluid ends are used for special

applications requiring extremely high pres-
sures, such as stimulation jobs. They are usu-
ally autofrettaged to lengthen their life.
Autofretagging is similar to the process used in
making artillery gun barrels to improve metal
resistance to fatigue. The material is heat-treat-
ed and stress-relieved simultaneously at high
pressure.

5.3.1 Specifications
*Calculate the maximum flow rate of a triplex pump based on 97% volumetric efficiency.
NOTE:
It is recommended to use both discharge ports for flow rates over 8.2 bpm to prevent the
erosion of the discharge port, bushing, and manifold. Maximum fluid end pressure limitations
are based on the power end maximum rod load rather than fluid end pressure limitations.
The assembly of the PG05 triplex pump weighs 5,250 lbs (2.4 tones). It is used on offshore skid
units, such as the CPS 362, where weight is not a critical factor. It is also used in corrosive envi-
ronments such as offshore areas where the PG03, which has a magnesium frame, is resistant to
severe corrosion. CPT 372, CPT 462, and CPS 310 Heli-units use PG03 because weight is an
important design factor.

ROUTINE MAINTENANCE 6.0.0
Like any equipment, maintaining the triplex
pump ensures many years of trouble-free serv-
ice. This section provides guidelines for the
proper steps for care, maintenance, and repair
of triplex pumps.

PUMP CAVITATION 6.1.0
Cavitation is the main damaging factor to a To prevent cavitation, perform the following
triplex pump during operation, especially when steps:
the pump pounds and the treating lines shake · Ensure that the triplex pump is properly
and jerk violently. Another cavitation reason is primed by bleeding all air from the
the premature rupture of burst disks (suction system.
valves) at much lower pressures than their
rated burst pressures. In either case, the result
NOTE:
is an operation failure.
Annually, inspect fluid ends for
cracks using the magnetic par-
Cavitation usually results from: ticle testing process. Contact
· using a worn or damaged pressurizing Gardner Denver for light serv-
pump that is not maintaining adequate ice. Check with your mainte-
pressure on the pump suction manifold nance supervisor for more
information.
· air leak in the suction manifold
· pumping too fast for the pressurizing
centrifugal pump to keep sufficient fluid
supply to the triplex pump.
· Ensure that the pulsation dampener is in
Cavitation occurs when the chamber is not full good operating condition and purged
of liquid and the plunger changes direction of air while priming a pump on a
from suction to discharge. The plunger does
fracturing unit.
not push fluid out the discharge, but compress-
es vapor causing a momentary change in the
pump loading and the plunger's velocity. This · When pumping high viscosity mud that
sudden change in velocity causes a tremen- is stored in displacement tanks for a
dous shock to the power and fluid ends, lead- long period of time, circulate the mud
ing to a mechanical failure or fatigue. back to the tanks before pumping it to
prevent the mud from becoming a gel or
Cavitation causes barrel counters and job restrict suction.
recorders to read incorrectly. These counters
measure the volume of fluid being pumped by
counting the number of revolutions on the pin-
ion shaft or engine output shaft. These coun-
ters continue to count as long as the pump is
turning even when nothing is being pumped.
Cavitation is more likely to occur when pump-

ing oil, even after proper priming, than when
pumping water since water has a much lower
vapor pressure than oil.

· Do not suck slurry at a slow speed. If
the slurry is foamy and the job must be
completed at a high rate, use an
antifoam product to minimize foaming.
· If pumping out of two or more tanks or

when changing displacement tanks,
open the second tank valve before
closing the first one to prevent air from
entering the system.
· Ensure that all suction hoses used do

not have air leaks at the connections or
around the nipples. It is possible to
conduct a pressure test on suction
hoses and connections by carefully
pressurizing them with a centrifugal
pump like the RA45.
· If there are indications of cavitation,

reduce the pump rate immediately and
correct the problem before increasing
the pump rate again.
· If cavitation occurs when using a pump

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

POWER END 6.2.0
To ensure that the power end is operating cor-
rectly, inspect and check the following: 6.2.2 Noises
Listen for unusual noises such as clicking or
6.2.1 Temperature knocking. Noises are caused by:
During any job, frequently check the power end 1. loose eccentrics or damaged
lubrication pressure gauge and the frame tem-
perature. The power end is considered over- NOTE:
heated when you are unable to touch the frame If keys and keyways are loose, you
for more than few seconds. Overheating occurs will hear a knocking sound during
during extended pumping at or near maximum pumping under pressure.
horsepower levels. Shutdown the pump if the
power end is overheating. keys/keyways
2. damaged bull or pinion gears
WARNING: 3. worn or damaged main bearings,
The power end can catch fire if heated crosshead, or connecting rod bushings
excessively. If the power end has a 4. damaged main crankshaft
magnesium frame, it is impossible to
extinguish the fire.
BEST PRACTICE:
If a fresh water hose is available, run a
stream of cool water over the frame to
cool it down during extended pumping.
5. cracked eccentric
6. Problems with the fluid end can also be
mistaken for power end noises. Inspect
the fluid end carefully to eliminate this as
a source of noise or knocking.

6.2.3 Pony rod seals 6.2.4 Sludge and cement
The purpose of the pony rod seals is to keep During STEM 2 inspection, remove the rear
oil in and dirt out of the power end. If the power end cover or inspection plate and feel
exposed end of the pony rod shows signs of the bottom of the frame for cement or other
pitting or dullness, this is an indication that the sludge. Sludge can quickly wear out the bear-
pony rod seals would wear out quickly. ings and brass bushings inside the power end.
IMPORTANT:
Ensure that lock-out tag-out proce-
dures are followed before reaching
inside the power end.
Slinger rings are installed on the pony rod to

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

6.2.5 Chemical and salt water corrosion
Inspect the surface of the power end frame for
chemical and salt-water corrosion. Scrape or
wire brush any corrosion, then re-prime and
paint the power end.
IMPORTANT:
If you have a magnesium frame
power end offshore, take utmost
care to prevent corrosion (elec-
trolytic) from the salt environment.
It can quickly damage the power
end.
6.2.6 Power end lubrication system

Check each unit’s maintenance manual for the
proper lubricant.
When using a PG pump in high horsepower or

continuous pumping operations, an external oil
cooler may be required to keep the pump
below the maximum allowable operating tem-
perature.
Power ends in frac services have oil coolers

installed during manufacturing.
A pressure relief valve maintains the system

pressure from exceeding a set pressure.
There are two different styles of power end oil

filters and arrangements: internal bypass and
external bypass.
WARNING:
NOTE: Since pressure in a hydraulic system is
When checking oil level, always a result of resistance and the flow rate
remove the dipstick and allow air to varies with engine rpms, the pump is
sized so that it maintains adequate oil
escape from the tube. Replace the
pressure at low engine speeds.
dipstick and check for the correct However, oil pressure becomes low
oil level. when components wear. This can cre-
ate catastrophic power end failures,
A mechanically or hydraulically-driven pump especially when the following condi-
pumps the lubricating oil out of the power end. tions exist at the same time:
The oil then flows through a filter to the line’s
cross fitting, then to the mainshaft and
crossheads.
pressure on each pump.
· The power end is working at very To adjust a pressure relief valve, remove the
low rates and high discharge large cap. To increase pressure, turn the
adjustment screw clockwise. To reduce pres-
pressures.
sure, turn the screw counterclockwise.
· Rpm is low to create enough oil
pressure to maintain a good film
IMPORTANT:
of oil on the eccentric bearings.
There are oil seals inside the main
· The rod load is high. shaft-bearing cap of the power end.
ALWAYS watch and maintain the When these seals wear, oil pres-
power end oil pressure. Proper sizing sure drops. You can check oil pres-
of the fluid end prevents these types of sure using the gauge attached to
failure. the cap.
Remove and inspect the oil filter condition.

NOTE:
Clean and replace as necessary.
Always consult your supervisor
To check the oil’s color or clarity, compare a before tampering with any adjust-
sample from the power end with a new one. ments.
A bypass around the oil filter ensures continued
flow of oil in the event the filter becomes
clogged. A relief valve controls the bypass
process. On older styles, the valve is mounted
directly onto the filter and has a hose. The
valve directs any bypass flow to the down-
stream side of the filter.
On new styles, the bypass is internal of the fil-

ter housing and has a pre-determined differen-
tial setting. The new style filters have an indica-
tor that clearly indicates when and if the filter is
bypassing: green for good and red for bypass-
ing. This indicator works only when the oil is
flowing through the filter. During the job, check
and record the condition on a STEM I report.
A relief valve that is mounted directly to the

bottom of the power end frame controls oil
pressure. A pressure gauge mounted on the
control panel or directly on the power end lube
oil circuit allows the operator to monitor oil
IMPORTANT:
Keep oil clean at all times. A milky
color usually indicates water con-
tamination.

6.2.7 Hydraulic pump types
There are two different styles of power end
lube pumps: gear type hydraulic pump and
vane type hydraulic pump. When the Gear type
is mounted to the Auxiliary drive shaft, which
rotates twice the engine rpm, an angle drive
adapter is used to reduce the rpms. The Vane
type hydraulic pump is directly mounted to the
gear train on the engine through a splined input
shaft. In both cases, the engine oil pressure
increases if the shaft seal leaks.
CAUTION:
Since a Tyrone pump uses a straight Power end lube pump
input shaft, take special care when
installing the tapered drive adapter.
The spacing of the drive gear is critical
to ensure that the gear is set correctly
in the center of the driving gear of the
angle drive. Failure to do so lowers the
power end oil pressure in critical situa-
tions.
IMPORTANT:
Webster Brand pump is obsolete
and must be replaced with a Tyrone
pump. Order a complete replace-
ment kit.
Power end lube pump
This pump is directly mounted to the gear train

o

FLUID END 6.3.0
To ensure that the fluid end is operating cor-
rectly, inspect and check the following:
6.3.1 Fluid end lubrication system

The fluid end lubrication system uses an air-
driven pump to transfer packing oil to the
plungers. Check valves that are installed direct-
IMPORTANT:
For optimum packing life, it is
essential to properly lubricate the
plungers and packing. An improper-
ly lubricated packing leaks in few
seconds from pumping operation,
damaging the polished surface of
the plungers. It will also cause heat
generation and shorten the packing
life.
cycle. Plugging it in any hole stops the cycle
ly onto the fluid end prevent cement from and shuts down the lubrication system. If it
migrating into oil lines. A divider block is used becomes necessary to abort lubrication to a
centrifugal pump for example, reroute the hose
NOTE: to the reservoir.
The Alemite pump used for the fluid
end lubrication system is a grease The air-operated Alemite pump delivers lubri-
pump that allows pumping high cating oil to a McCord divider block, which in
viscosity oils. turn delivers oil equally to each plunger. The
CAUTION: NOTE:
Never reuse packing oil as dirt and The Alemite pump also provides
debris will contaminate the system, lubrication to the centrifugal pump
damage the pump, and plug the through a parallel discharge line or
divider blocks. divider block on older units.
in this system to distribute oil to the plungers. divider block outlet is connected through a
The recommended oil to use is 15W40 clean check valve to each fluid end-packing bore.
engine oil. From there, oil flows into the fluid end and
The Divider block uses two codes: Number 12 enters the lantern gland for even distribution to
to indicate that the block will discharge out of the packing.
one side, and number 24 to indicate that the The current Alemite pump used on the PG
block will discharge out of both sides. series cementing pumps is Model 9668 with a
medium pressure pump (5:1 ratio). The pump
These coded blocks cannot be used inter- section works in conjunction with the
changeably. Each block must complete its Pneumatic Logic Air Motor, Model 338066- A1.

To adjust the Alemite pump rate, set the air Current-generation pump units have a lube oil
pressure regulator between 110-120 psi. filter installed downstream of the Alemite pump.
Regulate the metering valve on the discharge
side of the pump to control the desired amount Unlike the old Alemite pumps, you cannot rely
of lubrication oil. on the air motor sound to determine the lubri-
cation rate. Install a pressure gauge in the dis-
charge side of the pump to determine air pres-
sure. Typical pressure is between 30 - 40psi.
IMPORTANT:
On Model 338066-A1 Pneumatic
Logic Air Motors, do not use an air
lubrication system. These motors
are packed with Teflon lubricant and
do not require any additional lubri-
cation except during service or
repair. However, it requires clean
dry air.
NOTE:
A blockage in any of the oil delivery
lines indicates failure of the entire
plunger lubrication system. The
McCord divider block does not
operate if any of its outlet ports is
blocked.

6.3.1.1 Air-over-oil lubrication system · Reduces oil consumption.
The air-over-oil lubrication system is a highly- · Lessens the amount of wasted
reliable, low-maintenance lubrication system. It plunger lubricant.
replaces conventional Alemite systems in both · Does not affect packing life.
cementing and fracturing services. In 1999, this · Is compatible with all packing types.
system became the standard plunger lubrica-
· Simplifies operations in environmentally
tion system for new cementing and fracturing
sensitive areas, including offshore.
units. It can also be retrofitted on existing
pumping equipment in the field. · Uses air pressure to force lubricant to
the plunger packing and centrifugal
This new lubrication system uses an air-pres- pumps.
sured oil reservoir that forces oil through the · Has no moving parts to jam or fail.
delivery lines to each packing bore. Adjusting · Reduces maintenance costs.
the metering valves regulates oil flow. The · Provides annual operating savings that
metering valve is located between the oil reser- are estimated at $2,500 per unit.
voir and the packing bore check valve.
To convert existing units to the air-over-oil lubri-
This system is simple and easy to maintain due cation system, remove the entire existing
to the limited number of components. plunger lubrication system except for the waste
oil catch tank. Parts for the new system
CAUTION: include:
This system uses a pressure ves- · an ASME-coded, pressurized, oil tank
sel. Pay special attention to the and mounting bracket
operating and refilling procedures. · distribution manifold and hoses
All users must be familiar with the · new check valves at the fluid end
system’s pressure relief mecha-
nisms.
· wiper rings behind the lantern ring to
contain lubrication oil.
NOTE:
The lubrication system provides the following Follow Schlumberger guidelines as
advantages when properly installed: described in Maintenance Bulletin
No. 625E and Well Services Safety
Standards, including Safety
Standard 26 – Air Tanks and
Receivers and Safety Standard 27 -
Inspection and Testing of Pressure
Relief Valves and Gauges.

Major Components 3. Distribution Manifold and Hoses
The distribution manifold simplifies hose rout-
1. Tank ing. All the hose connections are push-loc to
enable you to make field installations without
The tank must have the following characteris-
special tools or hose crimping.
tics:
· ASME-coded
4. Chain case
· certified to 200 psi/13.79 bar
The Chain Case requires minor maintenance if
· maximum capacity of 16.4 checked regularly. Check for the following:
US gallons/62 liters
· contaminated oil
· fill point at top sight plug of · torque rods with loose ends, which are
13.2 U.S. gallons/50 liters worn, improperly adjusted, or corroded
The tank has the following safety features:
NOTE:
· two-piece fill cap
Grease the torque rods when per-
· brass, three-way, pressure/bleed ball forming a STEM 2.
valve
· 150 psi pressure-relief valve
· 0-100 psi liquid-filled, pressure gauge Unusual sounds such as slapping noises indi-
· three liquid-level, sight plugs – 1,750 cate the following:
psi/119 bar maximum working pressure · The chain is hitting the inside of
the case.
WARNING: · The companion flange splines are worn.
To insure safe and reliable operation, · The chain case bearings are faulty.
you must use the specified replace-
ment tank. Do not make substitutions
or use locally manufactured tanks. IMPORTANT:
Any unusual noises that cannot be
precisely traced require immediate
attention.
2. Fluid End Modifications
Fluid end parts that must be modified are:
· three Haskel SS, 15,000 psi
check valves
· three wiper seals to be installed in the
packing nuts on fracturing units
IMPORTANT:
Packing nuts can be modified local-
ly or purchased. Cementing units
using the PG pump must have a
seal groove in the packing ring
between the packing nut and the
lantern ring.

6.3.2 Plungers and packing assembly 6. Carefully check the rubber diaphragms
to ensure that they have not been perfo-
rated. Perforated diaphragms could
The fluid end is rugged and requires little atten-
cause cement to flow into the lines
tion. Detailed repacking procedure will be
leading to the overpressure shutdowns
described in Section 6.3.7.1.
(OPSD) and console gauges.
Complete the following before each job:
1. Tighten the plungers and check the

packing.
2. If the packing is double stack or header

ring, verify that the packing gland nuts
did not back off.
3. On conventional Alemite systems, adjust
the oil flow from the Alemite pump to the
packings. Check for leaks along the air
and lubrication lines.
4. In air-over-oil systems, ensure that the
three-way pressure valve is on and the
lube level in the tank is correct.
5. Inspect the Martin Decker gauge
protectors to ensure that they are
pumped up and working properly.
CAUTION:
Do not over tighten the packings.
Never re-tighten the header ring
packing.

7. Check the OPSD at this point to protect · Electronic engines: electrical
the equipment and most importantly the power to the engine electronic
operators on: control modules throttle connection is
· CPS-361 units with air throttles: cut off to set the engine to the idle posit-
OPSD cuts off air supply for the tion.
throttle and transmission to set
the engine to idle position and to 6.3.3 Fluid end cover retainers
return the transmission shift cylin- Use a pipe wrench to remove or reinstall retain-
der to the neutral position. ers, then top them with a heavy hammer to
ensure proper seating.
There are two ranges available
for OPSD: 0-10,000 psi and
0-15,000 psi. Calibrate the OPSD
when performing a pressure test
on the triplex pump using an
accurate pressure gauge or other
instrument as follows:
1. Adjust the OPSD to

1000 psi.
2. Bring the pressure up to
the OPSD trips, which
should be 1000 psi
+/- 500 psi.
3. Check OPSD accuracy.
4. Adjust the calibration plate
to coincide with the OPSD
trip pressure.
5. Perform steps 1 through 4
at different pressure rates Tightening the cover retainer with a pipe
to ensure the OPSD wrench is only to prevent the nuts from being
accuracy on the unit. backed-out due to vibration. The actual seal
NOTE: efficiency will not improve by over-tightening
the nuts.
Do not exceed the
maximum allowable
working pressure of
the fluid end.
· Units with standard transmission:

cutting off air disconnects the
clutch to disable the transmission
and set the engine to the idle position.

6.3.4 O-ring and backup ring
After removing the suction or discharge covers, remove the O-rings and back-up rings to inspect
and clean the groove from cement or other debris. After the O-rings and backup rings are rein-
stalled in the groove, sparingly grease the cover and retainer threads. Excessive greasing caus-
es a grease lock, which prevents properly tightening the cover or extrudes the O-rings and back-
up rings from the groove. Extruded O-rings are easily cut or nicked. If this happens, remove the
cover and replace the damaged seals.
NOTE:
Grease lock occurs when grease acts like an incompressible hydraulic fluid in a jack.
Grease caught between threads and an O-ring prevents tightening the threads. When
pressure is applied on the cover retainer, the O-ring may give way. Generally, this
happens with the suction and discharge covers as the O-ring seal is entering the
sealing bore of the fluid end. When pushing excess grease ahead of the threads on
the retainer, grease gets trapped as the O-ring begins to seal. Excess grease does
not squeeze past the O-ring and prevents tightening the cover
Suction cover Discharge cover

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

6.3.5 Valves (MacClatchie valves)
Valves are manufactured in the following forms:
Discharge Valves Suction valves (burst disk)
Burst disk valves (Frangible suction valves)

were designed for two reasons:
1. To protect the treating equipment and

power end from damage due to
accidental and violent over
pressuring of the fluid end.
2. To avoid injury or death of personnel

due to a rupture of treating equipment
resulting from over pressurizing the
triplex pump. There were instances of premature failure of
burst disk valves, and in almost all cases, the
WARNING: causes have been attributed to:
Never use Burst disk valves in
the discharge
Suction side(burst
Valves of thedisk)
fluid · Circulation at excessively high rates
end, or discharge valves in the during the priming of pumps while using
suction side.
gravity feed: This causes pressure
peaks that are not visible on pressure
Burst disk valves are designed to last at least gauge and exceeds the pressure ratings
500,000 pressure cycles. This is equal to
of burst disk valves. To prime a pump,
approximately 8,300 barrels pumped per
plunger in a TG (3-3/4-in) fluid end to 14,700 use a rate no more than 50% of the
barrels per plunger in a TH (5-in) pump. Given rated volume output of the pump
the cross-section of the jobs we perform, the being primed.
valves or packing would be worn out long · High Pressure testing of lines: When the
before this volume is reached. pump is not properly primed, it
causes the plunger to accelerate and
NOTE: jerk creating water-hammer effect. If
A pressure cycle is defined as 1 possible, pump at a low rpm using a
plunger stroke at the maximum larger pump to build some pressure in
pressure rating of the fluid end. the system, then change to the smaller
pump as required.

· Cavitation during pumping: Maintain a minimum of 20-30 psi suction at all times on the
suction side of the triplex pump. If cavitation becomes imminent, immediately slow down
the pump. The larger the fluid end, the more vulnerable it becomes to suction problems,
especially at high rates.
NOTE:
Old style high-strike valve body is obsolete and no longer manufactured. High
strike is the amount of metal contact between the valve body and seat when the
valve is closed.
Three types of valve inserts are available depending on the service requirements:
1. Rubber inserts (black color) are used for basic cementing and acid jobs. However, they
have poor resistance to abrasives, such as sand, and hydrocarbons.
2. Urethane inserts (yellow color) is used for sand fracture stimulation. They have poor
resistance to acids. They last approximately one year in hot/humid conditions.
3. Urethane Bonded inserts (yellow color) are supplied as one integral piece of urethane
insert bonded to a steel valve body. This type is used in high pressure fracturing jobs
using proppants. The insert prevents abrasives from working their way between the valve
body and the insert. If the insert becomes damaged, remove it using a low-heat cutting
torch. Once removed, install either a standard rubber or urethane inserts. You can use the
valve for cementing or general pumping only.
NOTE:
If using a cement pumping unit in sand control service, the bonded insert valve
must be used.
Urethane inserts deteriorate with time while being stored. Their shelf life is approximately one
year when not stored properly. Ideal storage area is a cool, dark place with low humidity. The
insert turns yellow along the edges when it starts to deteriorate. Later, the whole insert begins to
change to yellow and starts to crumble like old bread.
To install an insert, soak it in hot water for few minutes and then force the insert over the indenta-
tion.
NOTE:
When stocking inserts, take into account factors such as average con-
sumption.
6.3.6 Valve Seats (MacClatchie valve seats)

Two valve seat types were previously available: tapered and straight-hole. The straight-hole type
is obsolete and no longer available. Only the tapered type is currently used.
When pumping at a high pressure or when a plunger makes a complete pressure cycle, the clos-
ing valves hammers the seat. Constant hammering effect presses the valve seats tightly into the
fluid end.
Use a valve seat gauge to determine the degree of wear on the seat. Replace the seat when
the indicator becomes flush with the top of the gauge or when you see signs of pitting, corrosion,
and wash-outs.
Straight-hole and tapered valve seat
Check the valve seat for pitting, erosion, wash-outs, and cracks
when the fluid end is opened.

To install new valve seats, complete the following steps:
Clean the bore and remove any Set the seat in the bore, ensuring
STEP 01 rust, scales, and cement. STEP 02 that the O-ring is seated correctly
Inadequate removal of these scales causes the in its groove
O-ring to hang up and get cut or bruised on the
valve seat bore.
Place the seat squarely in the

STEP 03 bore.
IMPORTANT:
Do not use any lubricant on the
seat or in the valve seat bore.
Drive the seat into the bore.
Place an old valve, without an

STEP 04 insert, on the seat.
Strike the center of the valve with

STEP 05 a steel bar to drive the seat into
the bore.

Complete repacking of the pump
STEP 06 Remove the old valve. STEP 07 and pressure test the fluid end to
the rated pressure.
6.3.7 Packing
Field testing conducted has demonstrated the
superior life of the header ring packing system
over conventional single stack (hard and soft
ring assembly) and elastoplast packing in
cementing service, and over the double stack
packing in fracturing services. This new system
also provides superior results in drilling (Mud)
systems.
Single-stack (rubber/fiber or hard/soft assem-

bly) and double-stack (Elastoplast) packing
assemblies are now replaced with the header
ring packing for cementing, fracturing, and
coiled tubing services. Refer to Maintenance
Bulletin 1103, InTouch content ID 2023279, for
details on ordering and installing new header
ring packing assemblies.

6.3.7.1 Fluid end repacking procedure
TOOLS SPARES
· a piece of hardwood · O-rings
(not the handle of the hammer) · backup rings
· a short piece of broomstick or · valve inserts
old hammer handle · springs
· plunger puller tool
· a 4 lb (2 kg) hammer WARNING:
· C wrench for the gland nuts Wear safety equipment. Turn off air or
electric supply to the pump. Ensure
· an 18-24 in pipe wrench
that the pump cannot be started.
· on older fluid ends, a hex nut and steel Display warning signs prominently on
bar may be required the controls, following the Lock Out-
· rags or other clean-up material Tag Out procedure in Well Services
Safety Standard 15.
NOTE: NOTE:
Use the packing tool kit (P/N Whenever working above ground
570376000). It is recommended to level, use a purpose-built platform.
use this kit if available in the A proper platform provides enough
location. space for laying out pump parts in a
logical order if troubleshooting is
required.
STEP 01 Tap the ears of the fluid end cover

with a hammer until the cover
starts to loosen up.

Use a pipe wrench to unscrew Extract the suction valve retainer
STEP 02 the cover from the fluid end body. STEP 03 and place the cover and retainer
The suction valve retainer is in a logical order on the platform
removed with the cover. or pallet.
Remove the suction valve. Remove the discharge cover. If a

STEP 04 Inspect its condition then place STEP 05 Martin Decker Sensor is
it with the other parts from the same cham- attached, remove it first. Place all parts togeth-
ber. er with those from the same chamber.

Using a wrench and hammer, Unscrew the plungers completely
STEP 06 break the plungers from the STEP 07 from the pony rods using the pipe
pony rods. wrench. Do not damage the
threads on the pony rods.
NOTE:
Do not put a wrench on the pony
rod. Use the tapered end on the
plunger for screwing or unscrewing
the plunger as required.
If a plunger is covering the suction valve, rotate the drive shaft to the chain case
STEP 08 using a pry bar in the u-joint to retract the plunger.
The correct way The wrong way
WARNING:
Using a pipe wrench can cause drive shaft tube damage. Any pipe wrench marks on the drive
shaft creates a crack and causes a catastrophic failure or twist-off during a job.

Use the C spanner to unscrew Install the plunger remover by
STEP 09 the packing gland nut and STEP 10 carefully screwing it with a turning
release the packing compaction. motion. Slowly remove the
plunger from the chamber.
Completely unscrew the pack-

STEP 11 ing gland nut and place it with
the other parts.
NOTE:
If the pony rods are not fully with-
drawn as close to the power end as
possible, it may be difficult to with-
draw the packing gland nuts.
CAUTION:
While removing the plunger, ensure
that it does not fall out and cause
an injury. Do not drop or nick the
plunger on the chromed surface.

Using a piece of hardwood, gen- Carefully remove the male pack-
STEP 12 tly and evenly tap the brass on STEP 13 ing adapter. Cement might be
the opposing sides. The brass is close to the stuck around it making it difficult
packing bore. Any slight misalignment makes to remove.
the brass difficult to remove.
IMPORTANT:
Do not use excessive force.
Repeat the previous steps for

STEP 14 all chambers.
STEP 15 Inspect the parts as follows:
a. Wipe the O-rings and backup rings to

inspect them for stretching, bruises,
or cuts.
IMPORTANT:
Do not use diesel or solvent on rub-
ber parts. O-rings may swell on con-
tact with diesel or solvents.
b. Clean and inspect the O-ring c. Inspect the valve bodies for washouts,
grooves for foreign particles. pits, and corrosion. Check the valve
Inspect the coarse ACME threads inserts for abrasion damage or cracks.
for damage or cracks. Replace as necessary. Check the burst
Use a file to fix small thread disk to ensure that it is intact.
bruises. Replace the springs if they are distorted
or corroded.
Clean and inspect O-ring grooves Inspect the valve bodies

d. Inspect and change the plungers if
they are dull or show score marks.
Using dull or scored plungers
severely reduces the packing life.
CAUTION:
Do not reuse the packing.
e. Inspect the fluid end

body by ensuring that
the valve seats are not
washed out or pitted.
Check the ACME
threads and packing
bores.
Thoroughly clean out
cement, sand, rust, or
dirt using a wire brush,
emery cloth, or steam
cleaner.
f. Clean and inspect the brass for any sign

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

g. Check the oiling system (Alemite or air- WARNING:
pressure type) to ensure that a positive Turn off the power or air supply after
flow of oil is coming through the oiling checking the oil system and hang
hole at the top of the packing bores. warning signs.
Start the unit and turn on the lube
system.
NOTE:
Perform repacking according to
Maintenance Bulletin 1103. Always
verify the packing assembly order
before repacking.
IMPORTANT:
If the packing is not the header ring
packing, remove older packing and
install a conversion kit. Obtain and
install the correct conversion kit
according to Maintenance Bulletin
1103.

6.3.7.2 Valve seat removal and installation
Valve seat puller types:

Valve seat puller assembly Valve seat puller assembly
TYPE 01 P/N 428024000: TYPE 02 P/N 902857000:
This type is designed for use on conventional This type is designed for MD1000 fluid end and
triplex pump fluid ends, especially stimulation can be used in conventional fluid ends that
pumper fluid ends that do not have suction have suction caps. This puller allows the inser-
caps and require the lug to swivel. By rotating tion of a split washer onto the tie rod once it
the assembly to the vertical position, it passes passes through the valve seat from above.
through the valve seat from above and subse-
quently rotates freely into the engaged position
below the valve seat.

Clamshell-type puller assembly
TYPE 03 P/N 902857000:
You can machine this type approximately 0.040-in at each

pulling shoulder for a total of 0.080-in for an 0.080-in
reduction in circumference. This is necessary when pulling
suction seats in the small bore SPM fluid ends, to fit the
puller through the seat.
NOTE: IMPORTANT:
The following steps provide a Pulling a valve seat requires two
guideline for pulling a valve seat, people. If you have questionable
but not necessarily the only method valve seats, pull them before failure
used in the field. occurs.

Open the fluid end as described
TOOLS STEP 01 in the Fluid end repacking proce-
· valve seat puller dure section. After removing the suction and
· hammer discharge covers, check and replace, if neces-
· 24-in pipe wrench sary, the valve seat by feeling the seating area.
· chisel or old screwdriver Use the proper seat wear gauge for your fluid
· bucket and cleaning solvent end as defined in the Treating Equipment
· rags Manual.
· grease
· other spares like O-rings
or backup rings
Using puller assembly P/N Insert the collar and threaded rod
STEP 02 428024000, install the collar onto STEP 03 through the pressure plate.
the threaded rod. Adjust the placement of the
collar by estimating the length of threaded rod
required to reach the valve seat.

Thread the nut under the pres- Attach and hand-tighten the head
STEP 04 sure plate from the bottom of the STEP 05 to the threaded rod without the
threaded rod to secure the collar lug and pin components.
and pressure plate.
Lift and insert the complete Install the lug and pin compo-
STEP 06 assembly into the top of the fluid STEP 07 nents onto the head.
end. Ensure that it is centered so that the head
passes readily through the valve seat. The
head should now be visible below the valve
seat that will be pulled
NOTE:
Follow the correct safety proce-
dures when lifting heavy objects.
JET 2 - Triplex Pumps v1.0 57

STEP 07 Continued from previous page.
IMPORTANT:
Do not attempt to make replacement lugs or pins at a local machine shop. These
parts are made of high strength steel. Using the wrong material will result in lug or pin
failure when pulling seats.
Making sure that the lug is horizontal, rotate the connecting rod until the lug
STEP 08 makes contact with the lower side of the valve seat.
Continue to rotate the connection rod, slowly continuing to pull the valve, until
STEP 09 completely extracted.

6.3.7.3 Header ring packing installation
Complete the following steps to install the header ring packing:
Use a disc or puller to remove Clean and lubricate the packing

STEP 01 the old packing and brass. The STEP 02 nut threads.
steel junk ring has a stepped
bore.
Clean any cement and proppant

STEP 03 from the bore and Inspect it for
damage.
STEP 04 Install the junk ring. STEP 05 Install the header ring.

Install the female adapter - brass
STEP 06 Install the pressure ring. STEP 07 and PEEK
STEP 08 Install the lantern ring. STEP 09 Install the packing nut.
a. Tighten packing nut to seat the packing.

b. Loosen the packing nut a ½ turn.
c. Hand-tighten until it touches the packing.
d. Tighten a ¼ turn and paint the alignment
marks on the packing nut and fluid end.
e. Loosen the packing 1 turn.

Lubricate the packing and Coat the pony rod pin with Never-
STEP 10 plunger. STEP 12 Seize thread compound and then
tighten the plunger onto it. Snap
Drive the plunger through the tight with a sharo blow using a
STEP 11 packing with a slide hammer or hammer and a pipe wrench.
using a large piece of wood, tap
the end of the plunger to ensure
that the plunger and the pony rod
are conected.
Start the pump and check the

STEP 13 installation. Note that the packing
IMPORTANT:
Change the plungers when they
does not require further adjustment. become dull or show score marks.
Using dull or scored plungers
severely reduces the packing life.

6.3.7.4 Repacking the header ring
To repack the header ring, complete the following steps:
Since one of the fluid end Install the O-rings and backup
STEP 01 chambers is repacked, install STEP 02 rings. Using excess grease cre-
the valve springs and cover retainer assem- ates a grease lock during the installation of
blies. Clean, inspect, and replace these retainers and covers.
parts if necessary.
CAUTION:
Do not soak the O-ring in solvents.

Coat the retainer with a thin layer Once the suction spring is under
STEP 03 of grease and install the suction STEP 04 the cover, tighten the assembly
valve. Screw in the suction valve cover/retainer by hand or with a pipe wrench. Tighten the
assembly until it touch the springs. Use a retainer with a few hammer strikes.
piece of wood to compress and engage the
spring under the cover, while simultaneously CAUTION:
screwing the retainer in. Ensure that the suction cover is
properly installed with the flat side
holding the valve spring com-
CAUTION: pressed. Covers are sometimes
Do not tie the springs with rope installed 90-180° out of the proper
or wire. position. It is crucial that the flat
portion of the wedge that com-
presses the suction spring be
exactly perpendicular to the valve.
To check the position, ensure that
the two screw holes in the suction
cap are perpendicular to the wedge
surface.
Ensure that the O-ring and backup ring are in good condition and clean the groove.
STEP 05 Lightly grease the groove. Excessive grease prevents the rings from properly seat-
ing.
Carefully install the discharge
STEP 06 cover and retainer. Ensure that
the discharge valve spring is properly centered
so that it engages the spring retainer stub on
the bottom of the discharge cover.
CAUTION:
You must never put a burst disc valve
in the pump discharge.

63
Hand-tighten the discharge cover Perform a STEM I, then check
STEP 07 then hammer it to properly seat
STEP 08 that you have installed all the
the cover. parts. Start the unit and observe for correct
operation of the Alemite lubricator.
Engage the pump in low gear and After tightening the packing
STEP 09 tighten all the packing nuts with STEP 10 assembly, circulate water for 15-
the C spanner 20 minutes at different rates to verify that the
packing and lubrication systems are performing
CAUTION: properly.
Any moving piece of equipment
could become a hand trap. CAUTION:
Do not use an extension handle on
a packing gland nut wrench. It will
damage or over tighten the packing
nut and assembly. Remove any nut
that becomes hard to tighten.
Check the packing nut and fluid
end threads for damage or hard-
ened cement.

CHAIN CASE LUBRICATION SYSTEM 6.4.0
Each chain case is equipped with either a sight

glass or a dipstick to indicate the oil level in the
case. The oil level indicator should be center-
lined with the bottom of the input shaft.
NOTE:
When checking oil level, always
remove the dipstick and allow the
oil level to settle. Reinsert and
remove the dipstick to check the
correct oil level.
Ensure that you have only the required amount

of oil to prevent the chain case from overheat-
ing. When a chain case is overheated, the
bearing grease seals become damaged. If
overheating continues, oil breaks down chemi-
cally, losing its viscosity, lubricating, and cool-
ing properties, which will severely damage the
bearing and chain case.
SERVICING 7.0.0
STEM 1 AND OPERATION OF THE TRIPLEX PUMP 7.1.0
Before starting up, properly STEM the unit using the following:
Tightly screw the plungers to the Ensure that the oil level in the
STEP 01 pony rods (crossheads) with a STEP 02 chain cases, power ends, and
pipe wrench. Do not overtighten. packing lubricant reservoir is correct and that
the specified lubricants are used.
For the Alemite pump to operate and deliver
lubricant to the plunger's packing, open the air
supply valve.
With pressure on the power end Ensure that the power end oil
STEP 03 lube circuit, verify that the AlemiteSTEP 04 pressure is correct while the
pump is functioning. Adjust the oil flow as pump is running. At 1000-rpm pinion speed
described in Maintenance Bulletin 982. (2/3 of the maximum pumping rate), oil pres-
sure should be approximately 50 psi for cold oil
NOTE: and 40 psi for warm oil (above 100 deg F).
Refer to Maintenance Bulletin 1085
(InTouch ID: 2023265) for air-over-
oil lubrication system.
Put the pump back in neutral For single stack (cementing),

STEP 05 gear and ensure that the packing STEP 06 tighten the packing gland nuts
gland nuts are snug. If the header ring packing before each job.
is installed, regular tightening in not required.
Verify that the gland nuts have not backed off.
For elastoplast (cementing), tight- For double stack (fracturing), per-
STEP 07 en the packing gland nuts before STEP 08 form periodic adjustment per
each job. Maintenance Bulletin 1103
(InTouch ID: 2023279).
For header ring packing with a Ensure that the pump is ready for
STEP 09 teflon back-up ring, verify that the STEP 10 priming and operations.
nuts did not back off. Once adjusted, the head-
er ring packing does not require additional
adjustment.
After completion of any pumping
NOTE: STEP 11 operation, pump clean water
Do not overtighten the header ring
packing. through the discharge piping until you see
clean water flowing from the pump, then stop
pumping.
Refer to Maintenance Bulletin 1103 for part
CAUTION:
replacement information.
Never loosen the fluid end packing
gland nut during this operation.
Remove the suction manifold Check under the pony rods

STEP 12 caps and flush the manifold out STEP 13 (behind the fluid end) to ensure
with water. If the weather is cold and there is a that the drip pan drain is not blocked. Flush out
chance of freezing, drain all water from the the drip pan with water.
pump by fanning the pump and prying up the
suction valves.

Check and replace the pony rod Before starting a job, per-
STEP 14 seals on the power end if there is
SUMMARY form STEM 1 (pre-job
an oil leak. Ensure that the slinger rings are not inspection):
loose. These rings prevent any high pressure
fluid that leaked past the packing from damag- · Check plunger tightness.
ing the pony rod seal and entering the power · Check condition and lubricant level of
the power end. the chain case.
· Check condition and lubricant level of
the power end.
· Check the condition and lubricant level
of the packing oil (Alemite) reservoir.
· Check the operation of the packing
oiler (Alemite).
· Check the power end lube oil pressure:
50 psi for cold oil
40 psi for hot oil
· Check that the gland nuts are tight.
· Proceed to prime the pumps.
· Clean the pump and manifold by pump-
ing clean water through it.
· Flush out the suction manifold.
· Drain the pump if there is cold weather.
· Check the crosshead seals.
· Check that the slinger rings are
not loose.

TRIPLEX PUMP STEM 2
EVERY 6 MONTHS OR 300 HOURS 7.2.0
It is the responsibility of the equipment operator · Carefully grease the barrel counter right
to perform STEM 2 with assistance from the angle drive if a grease zerk is installed.
mechanic. Most barrel counters use a proximity
switch to determine pump rate. No
7.2.1 Chain case lubrication is required.
· Check the condition of the torque-rod
end bushings and lock nuts. Replace
worn bushings. NOTE:
· Grease the torque-rod ends and adjust Size the ratio of the right angle
the length as necessary. drive specifically for the fluid end on
that pump.
· Inspect the retaining pin.
Grease Zerk
NOTE: EXAMPLE:
End bushings are no longer avail-
TRO uses a 0.249 ratio,
able as separate items. You must
change the torque-rod assembly TGO - .385, TLO - 0.466 and
when replacing the bushings. THO - 0.555 gear ratio. When using
Check the Equipment Parts Manual incorrect ratio, the mechanical bar-
(InTouch ID 3015447). rel counter will not be accurate.
This ratio coincides with the bbl/per
· Grease the chain case bearings. Check revolution for each fluid end
the condition of the oil filler cap/breather. (InTouch ID 3015637)
If necessary, wash the filler cap/breather
in solvent and blow dry.
· Switch the end caps to reverse the right
angle drive and to change the rotation of
· On older units remove the oil and rein-
the cable.
stall the barrel counter drive cable.

7.2.2 Power end Ensure that slinger rings fit snugly on the pony rods.
· Inspect the power end mounting for

loose, worn, or broken bolts. · Inspect the power end lubrication oil
· Inspect the frame for cracks or suction hoses. If a suction hose is col-
broken sections. lapsing, it indicates that the oil is
severely contaminated and the lube
pump does not have enough oil. To
IMPORTANT:
clean the lubrication system:
The power end frame and mount-
ings are exposed to extreme load- 1. Drain the oil.
ing and vibration during pumping 2. Analyze a sample in a lab.
operations. Fix damaged mountings 3. Remove the power end back
or loose bolts immediately to avoid cover.
expensive repairs. Bolts should be 4. Clean and flush inside the power
torqued 600lb-ft (+ 10%). end with a solvent.
5. Flush and clean the hoses.
NOTE: 6. Clean the lubrication system, oil
Never weld a magnesium power
pump, and filter.
end.
· Check for oil leaks, and take oil samples

to inspect for metal particles or water
contamination and determine the cause.
Ensure that the slinger rings fit snugly
on the pony rods. Replace broken or
missing slinger rings.

7. Install the fluid end’s back cover 7.2.3 Fluid end
and fill with new oil to the speci- · Inspect the packings, packing glands,
fied level. and plungers for any wear,
NOTE:
leaks, or looseness.
Oil volume for the power end is 17 CAUTION:
gallons in addition to the oil It is unnecessary to remove the
required for hoses, pump, and filter. packings for inspection unless there
are indications that the packing
The maximum pressure differen- assembly is leaking or failing.
tial across the filter is 75 psi. If Packings are usually damaged dur-
pressure becomes higher, a relief ing removal from the fluid end bore.
valve in the system opens and Do not over tighten the packing
the oil bypasses the filter and gland nut. Refer to Maintenance
Bulletin 1085 for more information.
continues to supply the
power end.
· Open the fluid end and inspect the
NOTE:
valves, valve seats, inserts, and springs
Prime new or reassembled lubricat-
ing pumps before operating the unit for cracks, wear, or damage. Compare
by opening the lines and filling the them to new components if in doubt.
pump with oil. Reconnect the hoses Replace as necessary.
then crank the engine for 30 sec-
onds with the engine Stop button
pressed down.
· Listen for any unusual noises and per

form a Hydraulic Horsepower (HHP) test
to reveal any potential mechanical
problems. Record the test results for
future reference and place a copy with
the STEM 2 report. Refer to Appendix 2
in this training for the HHP test
procedure.

· Replace any damaged backup rings and 7.2.4 Packing oilers (Alemite)
O-rings on the discharge and suction Check that the lube tank is clean. Drain, flush,
covers. Remove all hardened cement and refill as necessary.
from the O-ring groove.
NOTE:
Water can easily enter the tank
· Inspect the ACME threads of the fluid where the Alemite pump is mount-
end and cover retainers for cracks. ed and become mixed with the
Ground off the first or last thread if lubrication oil giving a false indica-
cracked no more than 1/2 of a thread. If tion that the packing is leaking.
more than 1/2 of a thread is cracked,
replace the fluid end. Notify your
maintenance department before
repairing threads.
7.2.5 Triplex pump annual inspection -
· If the packing is failing prematurely, every 12 months
tighten or replace the plungers and The mechanic performs annual Inspection;
packing gland nuts as necessary. Check however, it is essential for the operator to
for proper lubrication from the understand the requirements as well as the
Alemite pump. importance of the mechanic's responsibilities.
(Procedure for annual inspection is covered in
NOTE:
the fluid end section of the Treating Equipment
Signs of wear on the bottom of a
failing packing indicate excessive Manual)
crosshead wear on the power end.
· Check tightness of the tie rod nuts

(900 ft-lbs). Tighten as required.
NOTE:
Loose tied rod nuts can cause the
fluid end to crack due to uneven
stress.

72
TROUBLESHOOTING 8.0.0

APPENDIX 1 – PRIME-UP PROCEDURES 9.0.0
Refer to Safety Standards for Well Services
Operations for recommended procedures
(InTouch content ID 3038426).

PRIMING TRIPLEX PUMPS USING GRAVITY FEED 9.1.0
To prime the triplex pumps using gravity feed, complete the following steps:
Place the first pump in high gear Increase the triplex pump rate to
STEP 01 at idle speed. Make sure there
STEP 02 3 bpm (0.5 m3/min.). Continue
are fluid returns in the displace- pumping until you have a steady
ment tank. continuous return of the fluids.
Return the pump to neutral gear

STEP 03 and run the engine at idle speed. STEP 04 Repeat Step 1 through Step 3 for
the second pump.
Close the gravity feed lines. Open the pressure feed lines to
STEP 05 STEP 06 the pumps.

PRIMING TRIPLEX PUMPS USING
A PRESSURIZER PUMP 9.2.0
To prime the triplex pumps using the pressurizer pump, complete the following steps:
Start the prime up procedure Place the pump in high gear at

STEP 01 using the engine pressuring and-
STEP 02 idle speed.
make up centrifugal pumps.
Make sure there are fluid returns Increase the pump rate to 3 bpm
STEP 03 in the displacement tank.
STEP 04 (0.5 cubic m/min.), and run the
engine at a fast enough speed to operate the
hydraulic system. Continue pumping until you
have a smooth return of fluids.
Return the pump to neutral gear Repeat step 2 through step 5 for
STEP 05 and maintain engine speed at the
STEP 06 the second pump.
same rpm.
Prime each pump through the

STEP 07 mixing equipment.

Appendix 2 – hydraulic horsepower test (HHP) 10.0.0
Follow all applicable Well Services Safety Standards for rig-up, priming, and pumping.
Hydraulic horsepower tests are generally conducted at the district to verify unit performance.
To perform a hydraulic horsepower test, complete the following steps:
Obtain the performance curve for Rig up following Well Services

STEP 01 your unit to get the actual
STEP 02 Safety Standards 5 – Location
hydraulic performance for the unit. Safety. You will need a water supply, charge
pump (if the unit does not have a pick-up
pump), and a discharge choke.
IMPORTANT:
This procedure assumes that you
have a remote-actuated choke. If
not, you must shutdown while mak-
ing adjustments to the choke. Rig
up the choke to allow isolation and
bypass.
Pressure test the discharge pip-

STEP 03 Conduct a STEM 1 of the unit. STEP 04 ing and verify that the unit over-
pressure shutdowns are functioning using Well
Services Safety Standards 5.
Referring to the unit performance Open the choke, select the

STEP 05 curve, select a gear in the mid-
STEP 06 appropriate gear, and establish
range that results in pumping pressure of 5,000 the desired rate at full engine rpm. If using a
psi or lower and rates of 8 bpm or lower remote choke, slowly close the choke until the
(assuming full engine rpm) for units rated under engine droops the correct amount. If the
1000 HHP. For large frac units, select a gear engine’s full-load droop is not known, droop the
that results in a maximum pumping pressure of engine 25-50 rpm.
10,000 psi or lower, and rates of 8 BPM or
lower.
If you are using a manual choke, Note the rate and pressure and
STEP 07 shutdown the unit and adjust the
STEP 08 calculate the hydraulic
choke in small increments until the correct horsepower.
droop is obtained.

References 11.0.0
Treating Equipment Manual (InTouch ID 3013931)
Safety Standards for Well Services Operations (ID# 3038426)
Well Services Safety Standard 4 - Facilities and Workshops
Well Services Safety Standard 5 – Location Safety
Well Services Safety Standard 15 – Lock Out-Tag
Well Services Safety Standard 26 – Air Tanks and Receivers
Well Services Safety Standard 27 - Inspection and Testing of Pressure Relief Valves and Gauges
Maintenance Bulletin 625E
Maintenance Bulletin 1103, InTouch ID 2023279
Maintenance Bulletin 982
Maintenance Bulletin 1085, InTouch ID 2023265
Header ring packing ordering information:
Gardner Denver Tulsa

Customer Service
Phone: 800 637 8099
Fax: 918 664 6225
email: [email protected]
CDI
Customer Service contacts:
Beatriz Trevino
Scarlett Roberts
Phone: 281 446 6662
Fax: 281 446 7034
UTEX
Weimar Molded Products
605 UTEX Dr.
Weimar, TX 78962
Phone: 979 725 8529 or 877 469 2829
Fax: 800 924 8277
CHECK YOUR UNDERSTANDING 12.0.0
Q 01 The power end converts energy from: Q 06 For coiled tubing operations, use
Hydraulic energy to mechanical energy (Select all that apply)
Reciprocal power to rotational energy MD1000
Rotational power to reciprocal power 8-in stroke HD2250 pump
Mechanical energy to pressure energy 6-in stroke OPI600 pump
PG/Butterworth pump
Q 02 The main components of a triplex pump

are: (Select all that apply) Q 07 The correct level for oil in the power end is
Engine ½ full
Shaft ok as long as oil is visible in the
Chain case bottom of the power end
Power end ½-in below the bottom of the main
Fluid end bearings caps
½-in above the top of the main
bearings caps
Q 03 Chain cases important functions are
(Select all that apply)
Lubricate and cool the chains. Q 08 The maximum flow rate of a triplex pump
Secure the power end from flexing during is calculated on
pumping 88 % volumetric efficiency \
Provides flexibility in mounting 92 % volumetric efficiency
Converts rpm to torque 97 % volumetric efficiency
Provides storage of power end lubrication 100 % volumetric efficiency
Does not depend on volumetric efficiency
Q 04 A triplex pump is
Low-pressure positive displacement Q 09 Low-pressure in the power end is caused by:
pump
High-pressure pump using gear principle high discharge pressure
High-pressure positive displacement Engine rpm is low
pump consisting of three plungers Rod load is low
Worn components
All of the above
Q 05 The maximum fluid end pressure limita-
tions is based on Q 10 Crosshead seals are used for:
Metal used in the construction of the fluid (Select all that apply)
end Preventing leakage of oil from the power
Power end maximum rod load end via the pony rods.
AJSI steel grades Keep oil in and dirt out of the power end
Autfretaging processes Supporting the crossheads (pony rods)
Backing up the O-rings in the power end

Q 11 It is recommended to reuse packing oil Q 17 During STEM 1, it is essential to:
True Tighten the packing before pumping
False operations.
Drain all water in cold (typo) weather after
washing the pump
Q 12 The divider block functions to: Check for oil leaks in the crosshead seals
Divide equally oil to each plunger Check oil level in the chain cases, power
Boost the oil pressure to the lantern ends, and packing lubricant reservoir
glands All of the above
Prevent the lubrication system from failing
when one of the discharge ports are
blocked Q 18 Unusual noises in the power end could
Control the discharge rate from the indicate: (Select all that apply)
Alemite pump Damaged bull or pinion gears
Worn or damaged main bearings,
crosshead, or connecting rod bushings
Q 13 A block divider that is coded 24 has Damaged crankshaft.
One outlet Must discharge from one end Cracked eccentric
Two outlets Must discharge from both All of the above
ends
Cannot be used with a divider block
coded 12 Q 19 Cavitation is more likely to occur when
pumping oil than water.
True
Q 14 A discharge stroke is when the plunger is False
drawn toward the power end.
True
False Q 20 Burst disk valves are designed to last at
least 500,000 pressure cycles.
True
One of the most damaging factor for a False
Q 15 pump fluid end is:
Pump cavitation
Excessive pressure Q 21 Using dull or scored plungers does not
Pumping inhibited acids reduce the packing life.
Excessive rates True
False
Q 16 Cavitation can be the result of:

Q 22 Urethane inserts shelf life is
Keeping the pump chambers full of sand 1 year
Worn or damaged pressurizing pump not 6 months
maintaining adequate pump suction mani- 2 years
fold pressure. 1 month
Pumping too fast for the pressurizing
pump to keep up
Not keeping the fluid end chambers full of
fluid

Q 23 5-in stroke PG series pump
is primarily used for
Frac services
Coiled tubing services
Cementing/completion services
Mixed cement/frac services
Q 24 A Hydraulic Horsepower Test (HHP) is

performed to confirm the units perform-
ance level, and reveal potential mechani-
cal problems
True
False
Q 25 The power end can catch fire due to

excessive heat.
True
False
Q 26 Excessive greasing of the suction and

discharge cover and retainer threads can
cause a grease or hydraulic lock
True
False
Q 27 Triplex pump annual inspection is per-

formed by:
Unit operator
Field specialist
Mechanic
Field engineer

CHECK YOUR UNDERSTANDING: ANSWERS 12.0.1
A 01 Rotational power to reciprocal power A 16 Worn or damaged pressurizing pump

not maintaining adequate pump
A 02 Chain case suction manifold pressure.
Power end Pumping too fast for the
Fluid end pressurizing pump to keep up
Not keeping the fluid end chambers full
A 03 Provides flexibility in mounting of fluid
Converts rpm to torque
A 17 Drain all water in clod (typo) weather
A 04 High-pressure positive displacement after washing the pump
pump consisting of three plungers Check for oil leaks in the crosshead
seals
A 05 Power end maximum rod load Check oil level in the chain cases, power
ends, and packing lubricant reservoir
A 06 6-in stroke OPI600 pump
PG/Butterworth pump A 18 All of the above
A 07 ½-in below the bottom of the main A 19 True

bearings caps
A 20 True
A 08 97 % volumetric efficiency
A 21 False
A 09 Power end is working at a low rate
and high discharge pressure A 22 1 year
Engine rpm is low
Worn components A 23 Cementing/completion services
A 10 Preventing leakage of oil from the A 24 True

power end via the pony rods.
Keep oil in and dirt out of A 25 True
the power end
A 26 True
A 11 False
A 27 Mechanic
A 12 Divide equally oil to each plunger
A 13 Two outlets Must discharge

from both ends
A 14 False
A 15 Pump cavitation

ANSWERS
83

02 - Triplex Pumps

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What are the main components of a triplex pump?

What are the main components of a triplex pump?

What are some common applications of triplex pumps?

What are some common applications of triplex pumps?

JET Module 2

2 Introduction to triplex pumps pg 05

3 Triplex pump main components pg 06

3.1 Pump types pg 08

3.1.1 Cementing/completion services pg 08

3.1.2 Mixed cement/frac- services pg 12

3.1.3 Fracturing services pg 15

3.3.4 Coiled tubing services pg 18

4 Pump rate calculations pg 20

5 Specifications & ratings PG Series triplex pump pg 21

5.1 Chain case pg 21

5.2 Power end pg 22

5.3 Fluid end pg 23

6.1 Pump cavitation pg 27

6.2 Power end pg 29

6.2.3 Pony rod seals pg 30

6.2.4 Sludge and cement pg 30

6.2.5 Chemical and salt water corrosion pg 31

6.2.6 Power end lubrication system pg 31

6.2.7 hydraulic pump types pg 33

6.3 Fluid End pg 34

6.3.1 Fluid end lubrication system pg 34

6.3.2 Plungers and packing assembly pg 38

6.3.3 Fluid end cover retainers pg 39

6.3.4 O-ring and backup ring pg 40

6.3.5 Valves (MacClatchie valves) pg 42

6.3.6 Valve Seats (MacClatchie valve seats) pg 44

JET 2 - Triplex Pumps v1.0 (Provisory) 2

JET 2 - Triplex Pumps v1.0 (Provisory)

Ensure that all safety devices are in place and

JET 2 - Triplex Pumps v1.0 (Provisory)

JET 2 - Triplex Pumps v1.0 (Provisory) 5

The chain case has two important functions:

JET 2 - Triplex Pumps v1.0 (Provisory) 6

When the plunger moves in the opposite direc-

3.1.1 Cementing/completion services

5-in Stroke PG series

This pump is used as a replace-

This pump is a much more compact

JET 2 - Triplex Pumps v1.0 (Provisory) 10

Valves and seats

Some locations use valves with stretch-on rub-

Rupture disc suction valves of the correct rat-

JET 2 - Triplex Pumps v1.0 (Provisory) 11

Three series of fluid ends are

JET 2 - Triplex Pumps v1.0 (Provisory) 12

The MD1000 pump consists of three, 120-

JET 2 - Triplex Pumps v1.0 (Provisory) 13

JET 2 - Triplex Pumps v1.0 (Provisory) 14

8-in stroke HD2250

JET 2 - Triplex Pumps v1.0 (Provisory) 15

Valves and seats

JET 2 - Triplex Pumps v1.0 (Provisory) 16

JET 2 - Triplex Pumps v1.0 (Provisory) 17

3.1.4.1 Pump types

6-in stroke OPI600