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www.pquip.com P-QUIP Ltd

[email protected] Units 2&3, River Place, Paddockholm Ind Est,
Kilbirnie, Ayrshire, KA25 7EN, Scotland U.K.

Tel: 01505 685434 Int. (44) 1505-685434

Fax: 01505 682756 Int. (44) 1505-682756

Instructions for the Safe Use of P-Quip Liner Retention Systems – Pt. No. 80000111
Revision date: August 9, 2006

Item Part No Description Qty. / Unit Qty./ ump Weight

0 80000111 Liner Retention Assembly. Includes parts 1,2,3,5,6,7,8,9,10, 1 3 180kg
1 80000011 Liner retention body complete with fitted piston assemblies 1 3 95kg
2 80000013 Retention flange 1 3 30kg
3 80000004 Retention Nut 4 12
4 80000121 Piston Rod Assembly. Includes parts 17,18,19,20,21,22,29. 4 12
5 80000010 Studded Adaptor plate. Includes parts 15,16, 1 3 45kg
6 80000015 Liner sleeve 1 3
7 80000016 Cap screw 1 ½” 8 24
8 80000017 Cap screw 1 ¼ ” 1 3
9 75001101 Liner retention Body Fixing Nut 5 15
10 71002210 Liner retention Body Fixing Nut 4 12
11 72000400 Pressure Fitting 1 3
12 59000112 ¾” A/F Hexagon socket wrench for Body Fixing Nut – not shown 1 per rig
13 59000114 7/8” A/F Hexagon socket wrench for Body Fixing Nut – not shown 1 per rig
14 59000115 1” A/F Hexagon socket wrench for Body Fixing Nut – not shown 1 per rig
15 80000018 Stud 1” 4 12
16 80000019 Stud 1 ¼ ” 5 15
17 80000022 Piston Rod 4 12
18 80000024 Cylinder Cover Nut 4 12
19 60000846 Large O’Ring 4 12
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20 72001600 Small O’Ring 4 12

21 72000300 Disc Spring 56 168
22 16001200 Spring Packer 4 12
23 59000113 Hand Operated Hydraulic Pump – not shown 1 per rig
24 59000116 Air Operated Hydraulic Pump – not shown 1 per rig
25 72000201 Pin Wrench For Cylinder Cover Nut– not shown 1 per rig
26 72000411 Dust Cap for Pressure Fitting– not shown 1 3
27 59001109 60mm AF socket for Retention Nut– not shown 1 per rig
28 10000002 Anti Rotation Dowel 4 12
29 80000025 M39 Washer 4 12

Specification:

1) This product is a direct replacement for the Original Equipment supplied for an Ideco T1300 or T1600 Mud Pump fitted with
OEM or Southwest Oilfield Products modules. It is intended to allow faster and safer liner changes than with the original
equipment.
2) The range of liners that this device will retain is 5 ½” through to 7 ½”.
3) This product is designed to work up to the maximum pump pressure / liner size combinations recommended by the Mud Pump
Manufacturer.
4) The working pressure of the Liner Retention Body (1) is 680bar / 10,000psi.
5) The weights of the various components are clearly marked on the product and on page 1 of this document.
6) The noise level of this product does not exceed 70dB(A).

Principles of operation:

1. Hydraulic pressure is applied through the Pressure Fitting (11)

2. Hydraulic pressure is fed to all 4 No. Piston Rods (17) simultaneously.
3. The Piston Rods (17) are thus forced against the Springs (21), causing them to be compressed.
4. The liner is retained against the wear plate by the Retention Flange (2) and the Liner Sleeve (6).
5. The 4 No. Retention Nuts (4) are tightened on to the Retention Flange (2).
6. When the pressure is released the springs (21) will apply their force to the liner through the Piston Rod (17), the Retention Nut
(3) the Retention Flange (2) and the Liner Sleeve (6).
7. In the operational situation the springs are fully compressed and the internal pressure is zero.

Labeling:

The following label will be seen on the product. Should this label become worn or defaced it should be replaced.

General Safety:

1) These safety notes should be read in conjunction with local rules and working procedures, particularly where permit to work
systems are in place.
2) Prior to working on the mud pump the unit must have its motive power isolated and locked off and hydraulic flow lines isolated
and locked off. The pump valve modules should be vented to atmosphere.
3) The following protective clothing should be worn while working with this equipment.
• Eye protection suitable to protect from inadvertent discharge of pressurized oil.
• Foot protection suitable to protect the operator from accidental dropages.
• Hand protection suitable to protect against the effect of mineral oil on the skin.
• Coveralls to allow more efficient lifting and handling.
4) Great care should be taken when handling this equipment as various components are over 25kg (N.B. all items heavier than
25kg are marked with their weights) and it may not be practical to use mechanical lifting aids. During regular use it will be
necessary to man handle the Retention Flange (2). Care must be taken during these operations to position the body over the
component being lifted by standing in the cofferdam.
5) Extra care must be taken when manually handling these components, as they are prone to become slippery due to the spillage of
oil and mud.
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Regular Safety Checks:

1) Check that the appropriate protective clothing warning signs are posted in the pump room or workspace and are clearly legible.
2) Check that these equipment operating instructions are posted in the pump room or workspace and are clearly legible.
3) Check the hydraulic hose and pressure gauge on the pump is undamaged.
4) Test the hydraulic pump for safety and efficiency by removing the adaptor from the Liner Retention System and energizing the
hose to 10000psi / 680bar. Check that the gauge holds the pressure for one minute and that there are no visible leaks. This
action will prove the integrity and efficiency of the pump.

Installation and Preparation Instructions:

1) Assembling a liner Retention System in to the pump is a two-person job.

2) Prior to starting to fit the Liner Retention System, remove and set aside the rod system except for the Power End Rod (Pony
Rod / Crosshead Extension Rod), and the liner. If an Original Ideco Liner Retention system is fitted to the mud pump then this
should be completely removed, following the instructions given in the Ideco instruction manual. The parts to be removed and
discarded are the Threaded Liner Retainer, Threaded Ring and the 8 No. 1 ½” studs and nuts. Lay the original parts safely to
one side for disposal.
3) The liner aperture in the pump frame and the mounting surface of the pump frame must be thoroughly cleaned. The bore of the
pump frame must be cleaned to bare metal using wire brushes and emery. This is essential or the future removal of the Liners
will be very difficult.
4) Reinstall 2 of the 1 ½” studs hand tight to assist with fitting the Adapter Plate (5).
5) Coat 8 No. Cap Screws (7) with a good quality thread lubricant.
6) Slide the Studded Adapter Plate (5) on to the studs. Note that there is a “top” mark.

7) Fit the 8 No. Cap Screws (7) and tighten using the Socket Wrench (14). Prior to final tightening, confirm alignment with the
pump frame bore by sliding a liner in to position. If the liner does not easily clear the Adapter Plate (5), the cap screws should
be slackened off and the unit moved as necessary. Final torque the Cap Screws to 1800 lb.ft. / 2400N.m. (Note that this figure
is the theoretical “dry thread” figure. The figure must be adjusted by the lubrication factor given by the thread lubricant
manufacturer. Typically, if Molybdenum Disulfide was used the torque could be reduced to approximately 600 lb.ft. /
800N.m.).
8) The hexagon sockets should then be filled with general purpose grease and the plastic caps re-fitted. This action will preserve
the integrity of the hexagon sockets, until it is necessary to use them for loosening. Replacement plastic plugs will be supplied
upon request.
9) Lift the Liner Retention Body (1) with a mechanical lifting device that is configured such that it will allow the Body (1) to be
suspended in the mouth of the pump frame bore. The body (1) should be lifted using a suitable endless soft sling, with a
balanced bite taken around the outside. The weight is indicated on the unit and on the parts list above.
10) Once the Body is suspended in place the operative should squat in the cofferdam facing the Body and adjust the lift until the 8
No. holes in the Body line up with the 9 No. studs on the Adapter Plate (5).
11) Coat 4 No. studs (15), the 5 No. studs (16) and the 1 No. Cap Screw (8) with a good quality thread lubricant.
12) When the Body (1) is finally lined up with the 9 No. studs, push it on to the studs while adjusting the mechanical lift.
13) Coat the 5 No. Fixing Nuts (9) with high temperature grease (Copper coat / Mollyslip etc.) and screw on to studs (16), utilizing
Hexagon Socket Wrench (13). Final torque the Cap Screws to 1100 lb.ft. / 1500 N.m. (Note that this figure is the theoretical
“dry thread” figure. The figure must be adjusted by the lubrication factor given by the thread lubricant manufacturer.
Typically, if Molybdenum Disulfide was used the torque could be reduced to approximately 370 lb.ft. / 500 N.m.).
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14) Coat the 1 No. Cap Screw (8) with high temperature grease (Copper coat / Mollyslip etc.) and screw in to the remaining hole,
utilizing Hexagon Socket Wrench (13). Final torque the Cap Screws to 1100 lb.ft. / 1500 N.m. (Note that this figure is the
theoretical “dry thread” figure. The figure must be adjusted by the lubrication factor given by the thread lubricant
manufacturer. Typically, if Molybdenum Disulfide was used the torque could be reduced to approximately 370 lb.ft. / 500
N.m.).
15) Coat the 4 No. Fixing Nuts (10) with high temperature grease (Copper coat / Mollyslip etc.) and screw on to studs (15), utilizing
Hexagon Socket Wrench (12). Final torque the Cap Screws to 580 lb.ft. / 870 N.m. (Note that this figure is the theoretical “dry
thread” figure. The figure must be adjusted by the lubrication factor given by the thread lubricant manufacturer. Typically, if
Molybdenum Disulfide was used the torque could be reduced to approximately 200 lb.ft. / 300 N.m.).
16) The hexagon sockets should then be filled with general purpose grease and the plastic caps re-fitted. This action will preserve
the integrity of the hexagon sockets, until it is necessary to use them for loosening. Replacement plastic plugs will be supplied
upon request.
17) Prepare the hydraulic pump (23 or 24) by removing the transport plug and replacing with the vented filler plug. Top up the
hydraulic pump with hydraulic oil (preferably EP32 but any grade will be adequate).
18) When an air driven hydraulic pump (24) is used, connect the pump to a suitable air supply using a length of standard air hose.
The air supply should be fitted with a water separator, a lubricator and a pressure regulator set to 110 psi / 7.5bar.

Operating Instructions: Fitting A Liner to the Pump

1) Assembling a liner in to the pump is a two-person job. Note carefully that no hammering will be necessary.
2) Select the appropriate size of Liner to be fitted to the Pump. Clean the bore of the liner and check its condition. Liners that
have excessive wear, blow holes, grooves etc. should be discarded.
3) Clean all paint from the portion of the outer surface of the liner that enters the pump frame. If any nicks or burrs are noticed
they should be carefully removed by filing and rubbing with emery.
4) Fit a fresh seal into the groove on the liner and coat the seal area and bore with a good quality non-metallic grease.
5) Thoroughly coat the bore of the Body (1), the bore of the pump frame, the bore and outer surface of the Liner Sleeve (6) and the
outer surface of the liner, with high temperature grease (Copper coat / Mollyslip etc.).
6) Lift the liner in to position using a mechanical lifting device if possible and enter the liner in to the bore of the Body (1).
7) Once the liner is safely entered, remove the lifting tackle and push the liner fully home to contact with the wear plate.
8) Slide the Liner Sleeve (6) over the liner and push home until it locates against the flange of the liner.
9) Thoroughly coat the 4 No. Piston Rod (17) threads with high temperature grease (Copper coat / Mollyslip etc.).
10) Lift the Retention Flange (2) on to the 4 Piston Rods (17). This Retention Flange is “reversible”. Slide the Retention Flange
along the Piston Rods (17) until it is hard up against the end of the liner.
11) Screw 4 No. Retention Nuts (3) on to the 4 No. Piston Rods (17) by hand, evenly, so that the Retention Flange (2) is squarely
butted against the end of the liner.
12) Connect the Hydraulic Pump (23 or 24) hose to the Pressure fitting (11) on the Body (1). Ensure that the connector is fully
screwed together or the fluid will not flow through the connector. Energize the system to 680bar / 10,000psi.
13) When the system is energized it will be possible to observe the 4 No. Retention Nuts (3) moving away from the Retention
Flange (2) by approximately 5-7mm. This movement is the result of pressure being applied to the Piston Rods (17) and forcing
them to compress the Springs (21).
14) The 4 No. Retention Nuts (3) should now be tightened on to the Retention Flange (2). Tighten the 4 No. Nuts (3) evenly as if
bedding a pipe flange. The Socket Wrench (27) should be used with a 24” ratchet. Final tighten the nuts to approx 600 lb.ft. /
800N.m.
15) The hydraulic pressure should now be released while the assembly is being observed. There should be almost zero movement
as the pressure is relieved as the assembly should be all “metal to metal” leaving no room for movement. If a measurable
movement is seen to take place then the Retention Springs (21) will become uncompressed and loose their retention force. If
movement takes place then the pressurizing and nut tightening operation should be repeated until there is no obvious movement
upon release of the pressure.
16) The liner is now correctly retained and ready to work. Disconnect the pump hose from the Body.
17) Refit the pump rod system as per separate instructions.

Operating Instructions: Removing a Liner from the Pump

Removing a liner from the pump is a two-person job. Note carefully that no hammering will be necessary.
1) Remove and set aside the rod system except for the Power End Rod (Pony Rod / Crosshead Extension Rod),
2) Connect the Hydraulic Pump (23 or 24) hose to the Pressure fitting (11) on the Body. Ensure that the connector is fully
screwed together or the fluid will not flow through the connector. Energize the system to 680bar / 10,000psi.
3) The 4 No. Retention Nuts (3) should now be loosened. The Socket Wrench (27) should be used with a 24” ratchet. The torque
required to loosen the Nuts should be similar to that to which they were initially tightened.
4) Screw 4 No. Retention Nuts (3) off of the 4 No. Piston Rods (17) by hand.
5) Slide the Retention Flange along the Piston Rods until it is approximately 50mm from the end of the liner, lift the Retention
Flange (2) off the Piston Rods (17) and lift clear of the cofferdam.
6)
7) Using a pinch bar at the groove at the end of the Liner Sleeve (6), free the Sleeve from the Body. Slide the liner out until there
is approximately 100mm remaining in the Body (1) bore.
8) Connect a mechanical lifting device safely to the liner and slide completely clear of the Body bore. Care should be taken to
ensure that the liner remains balanced during the lifting process.
9) If a liner is going to be reinstalled immediately then the unit may be left pressurized in preparation. If not the pressure should
be released and the pump hose disconnected.
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Operating Instructions: Removing A Liner Retention Body for Any Operational Reason.

1) Removing a Liner Retention System from the pump is a two-person job. Note carefully that no hammering will be necessary.
2) Remove the liner as above.
3) Slide the Alignment tool (21) into the Body and pump frame.
4) Loosen and remove the 8 No. Cap Screws using the Socket Wrench (16).
5) Lift the Liner Retention Body (1) with a mechanical lifting device that is configured such that it will allow the Body (1) to be
suspended in the mouth of the pump frame bore. The body (1) should be lifted using a suitable endless soft sling, with a
balanced bite taken around the outside. The weight is indicated on the unit and on the parts list above.
6) Lift the Body clear.

Maintenance / Troubleshooting

1) Preferable hydraulic oil; ISO grade 32; ISO oil type HM. – This material has no known hazard as defined by local laws. This
material if discarded is not expected to be a characteristic hazardous waste. Disposal should be in compliance with federal, state
and local laws. All components are in compliance with EC Seventh Amendment Directive 92/32/EEC. Toxic fumes or vapors
may evolve on burning.
2) Liner Retention Body (1) Corrosion protection: The Body (1) is manufactured from carbon steel and as such will rust. The
unit, except for its bore should be painted regularly. Do not paint over the label. The piston rods, where they extend from the
Body should not be painted but must be generously coated with high temperature grease. The bore of the body must be
generously coated with high temperature grease. The Pressure Fitting (11) should be oiled or lightly greased and the Dust
Cover (26) must be fitted to protect the threads and attachment mechanism.
3) Liner Retention Body (1) Pressure Integrity: The Body (1) will have its ability to retain its working pressure tested at each
use. It will not be necessary to carry our regular pressure tests. Each time the device is used, a leak check should be carried
out. If the pressure in the system leaks off slowly it is probably due to one of the following reasons:-

1. Hydraulic pump is not retaining pressure (Refer to manufacturers instructions).

2. Leak at the Pressure Fitting (11) Refit fitting using new bonded washers and PTFE tape etc.
3. Leak at one of the 1/8” BSP porting plugs on the outside of the body. This will probably require the unit to be removed to
the bench for repair. The leaking plug should be removed and replaced utilizing PTFE tape to seal the threads. The unit
should then be tested at working pressure for 15 minutes prior to refitting.

If the pressure in the system leaks off rapidly then it is probably due to the failure of one of the Large O’rings (19) on the
Piston Rod (17). This will be confirmed when oil is seen to emit from the area of the Cylinder Cover Nut (18). If this is
proved to be the case it will be necessary to remove the Body from the pump (see; “Operating Instructions: Removing a Liner
Retention body for Operational Reason.” Above) and carry out the following procedure on the bench: -

1. Confirm that there is no pressure retained within the body.

2. Remove the cylinder cover nut (18) using the pin spanner part no (25)
3. Remove the Pressure Fitting (11) to prevent a vacuum being created behind the piston as it is being removed.
4. Lay the body on its back and stand over it.
5. Grasp the Piston Rod (17) and pull until it comes clear of the body.
6. Check that the springs (21) are not rusted or broken and replace as required. Assemble springs exactly as shown in
drawing herein.
7. Check that the anti rotation dowel (28) is glued in place in the hole in the body (you will observe 2 holes in the bottom of
the cylinder. The dowel (23) should be fitted to the hole that does not connect with the internal oil-ways). Glue it in using
Locktite 638 or similar.
8. The cylinder should be inspected for damage in its bottom 1" / 25mm of its bore. The outside surface of the piston (17)
should also be checked for scores in the area around the O’ring (19)
9. Fit new O’rings (12 & 13)
10. Ensure that the threads in the Body and on the Cylinder Cover Nut (18) are in perfect condition and are clean. Immerse
the assembled Piston Rod In hydraulic oil. Stand over the Body and aim the Piston into the bore so that the hole in the
bottom of the Piston lines up with the Dowel (28).
11. Push the Piston into the bore using your own body weight. The piston will slide easily in the bore until the final 1” /
25mm. Tap the piston fully home with a soft hammer while turning it slightly in order to locate the Dowel. Ensure that
the unit is fully home by comparing its height above the Body, with the others.
12. Coat the Cylinder Cover Nut (18) with a copper-based grease and screw in to the Body. It should be possible to screw the
Cylinder Cover Nut down on to the Springs easily, using the Pin Spanner (25). If the threads become tight before the
Cylinder Cover Nut is flush with the top of the Body the nut must be removed, cleaned and checked. On no account must
undue force be used when screwing the Cylinder Cover Nut into the Body. The Cylinder cover nut should be screwed
down until it is just bearing on the Springs.
13. The Pressure Fitting (11) should then be refitted and the unit pressure tested at 680bar / 10,000psi. The test pressure
should be held for 15 minutes. During the test oil will be observed seeping out from the threads of the cylinder cover nut.
This will almost certainly be residue of the oil used in assembly, and should not be assumed to be a leak. Remember that
if the unit holds its test pressure then there is no leak.
14. The Cylinder Cover Nut should then be screwed down again until it is just bearing on the Springs. Finally the Cylinder
Cover Nut should be turned a further ¼ turn by light hammering on the Pin Spanner (25)
15. Finally fit the Body back in to the pump as per “Installation and Preparation Instructions:”
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4) Liner Retention Body (1) Loss or reduction of Retention force:

After a long period of use (Generally around 3-4 years) the retention force will drop off due to spring fatigue. If spring fatigue is
suspected then the Liner Retention System must be removed from the pump (see; “Operating Instructions: Removing a Liner
Retention body for Operational Reasons.” Above) and the following procedure carried out on the bench.
1. Confirm that there is no pressure retained within the body.
2. Remove the cylinder cover nut (18) using the pin spanner part no (25)
3. Remove the Pressure Fitting (11) to prevent a vacuum being created behind the piston as it is being removed.
4. Lay the body on its back and stand over it.
5. Grasp the Piston Rod (17) and pull until the Piston (17) comes clear of the body.
6. Check that the anti rotation dowel (28) is glued in place in the hole in the body (you will observe 2 holes in the bottom of
the cylinder. The dowel (28) should be fitted to the hole that does not connect with the internal oil-ways). Glue it in using
Locktite 638 or similar.
7. The cylinder should be inspected for damage in its bottom 1" / 25mm of its bore. The outside surface of the piston (17)
should also be checked for scores in the area around the O’ring (19)
8. Fit new O’rings (19 & 20)
9. Assemble the new Springs (21) on to the Piston (17) exactly as shown on the drawing below.
10. Ensure that the threads in the Body and on the Cylinder Cover Nut (18) are in perfect condition and are clean. Immerse
the assembled Piston Rod In hydraulic oil. Stand over the Body and aim the Piston into the bore so that the hole in the
bottom of the Piston lines up with the Dowel (28).
11. Push the Piston into the bore using your own body weight. The piston will slide easily in the bore until the final 1” /
25mm. Tap the piston fully home with a soft hammer while turning it slightly in order to locate the Dowel. Ensure that
the unit is fully home by comparing with the height of the others above the Body.
12. Coat the Cylinder Cover Nut (18) with a copper-based grease and screw into the Body. It should be possible to screw the
Cylinder Cover Nut down on to the Springs easily, using the pin spanner (25). If the threads become tight before the
Cylinder Cover Nut is flush with the top of the Body, the nut must be removed, cleaned and checked. On no account must
undue force be used when screwing the Cylinder Cover Nut in to the Body. The Cylinder cover nut should be screwed
down until it is just bearing on the Springs.
13. The Pressure Fitting (11) should then be refitted and the unit pressure tested at 680bar / 10,000psi. The test pressure
should be held for 15 minutes. During the test oil will be observed seeping out from the threads of the cylinder cover nut.
This will almost certainly be residue of the oil used in assembly, and should not be assumed to be a leak. Remember that
if the unit holds its test pressure then there is no leak.
14. The Cylinder Cover Nut should then be screwed down again until it is just bearing on the Springs. Finally the Cylinder
Cover Nut should be turned a further ¼ turn.
15. Finally fit the Body back in to the pump as per “Installation and Preparation Instructions:”

5) Liner Retention Body (1) Failure to release: In the event of the hydraulic system failing while the liner is retained, it will
still be possible to remove the liner. It should be understood that the tension applied to the Retention Nut (3) by the springs is
no more than would be applied by fully torquing the nut in the conventional manner. The nuts (3) may be removed using
conventional tools such as impact wrenches and torque multipliers. The wrench (27) is of impact quality and will be suitable
for this job.
6) Retention Flange (2) : Re-paint as necessary.
7) Liner Retention Body Fixing Cap Screws and Nuts (7,8,9,10): These should have their external surface protected from
corrosion so that they are in a sound condition when it is required to remove them. It is recommended that they are removed,
cleaned, lubricated and re-fitted every 6 months if they are not removed for operational purposes more frequently.
8) Retention Nut (3). These Nuts should be discarded after 6 months use. They should be liberally coated with grease during
use to limit corrosion.
9) Pressure Fitting (11) If these fittings are damaged and require replacement special note should be taken of the fact that they
are NOT standard quick release couplers. The units fitted are altered to avoid hydraulic fluid being trapped within the body.
Should fluid be trapped in the body it will expand with temperature rise and energize the system thus lowering the retention
force.
10) Piston Rod (17) This item is produced from carbon steel and as such should be protected from corrosion by liberal coating
with grease. The threads (M39x4) can generally be recovered following impact damage by hammering on the nut in order to
reform them.
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11) O’rings (19 or 20) O’rings are made from Viton and as such are suitable for all temperatures that are likely to be experienced
on a mud pump.
12) Hydraulic Pump (23 or 24) Refer to manufacturer instructions.

Recommended Spares

The following parts should be held on the rig as spares. The life expectation of all parts other than “consumables is many years.

Quantity Part Number Description Reason

20 80000004 Retention Nut Consumable
2 80000121 Piston Assy For Damage Spare
2 72000400 Pressure Fitting For Damage Spare
2 80000016 Fixing Cap Screw For Loss Spare
1 80000017 Fixing Cap Screw For Loss Spare
2 75001101 Fixing Cap Nut For Loss Spare
2 71002210 Fixing Cap Nut For Loss Spare

Modifications
Under no circumstance must this equipment be modified without the express written permission of P-Quip Ltd.