IIIII

lubricated at least once a day. lt is bestto instal l a spring loaded grease cup toautomatical ly lubricate the packing. Asyou f i l l t he g rease cup a sp r ing i scompressed and a stem rises. As thegrease is used the spring forces newgrease to the pack ing and the s temlowers. When the stem is low the cupneeds refilling. Grease should be pumpedinto the box while turning the shaft unti li t comes out around the packing gland(approximately 20 shots).

lf the packing leakeage is excessive, athick water pump grease should be usedrather than the general purpose grease.l n mos t cases genera l pu rpose i sacceptable.

Water LubricationIt is best to inject water into the lantern ring

from an external source when pumpingdrilling mud. This will keep most of the solidsout of the packing. PACKING AND SHAFTLIFE WILL BE INCREASED UP TO 5OO%.Also, water leakage from the packing will notbe as objectionable as mud.

PART IV MAINTENANCE

DisassemblyThe fluid end of the pump is so constructed

that those parts subject to wear may bereadily replaced in the field. To replace thecasing, wear plate, and impeller, thefollowing procedures should be followed.

1. Stop the pump and drain al l the l inesleading to the pump..

2. Loosen the bolts at the suction anddischarge flanges of the pump andmove the pipe clear of the pump casing.Remove the pump from the system.

3. Separate the coupling and loosen thecoupling half mounted to the PumPshaft.

4. Remove the casing stud nuts andremove the casing.

5. Loosen the packing gland nuts andswing the packing gland bolts clear ofpacking gland. Remove the packinggland.

6. Sl ide the water sl inger along the shaftaway from the bearing cap.

7. Loosen the bearing cap bolts on bothends and slide the bearing caps alongthe shaft. This will expose the bearings,

which are locked to the shaft by aneccentric locking ring and set screw.

8. Loosen the bearing set screw and tapthe bearing locking ring with a punchand a small hammer so that it turns inthe direction opposite to that of the shaft.When the bearing locking ring hasturned Tt revolution the bearing is freedfrom the shaft. Both bearings must bereleased. File off any upset caused bythe collar set screw before attempting toslide the shaft through the bearings.

9. Remove the impeller and shaft from thepedestal, thus freeing the lantern ring,water slinger, bearing caps, bearingsand couplings.

10. Remove the impeller nuts and washer.11. Remove the lantern ring and packing.12. Remove the wear plate by using the jack

bolts in the stuffing box. The wear plateis pressed into the stuffing box andforms the bottom of the stuffing box.

13. The bearings may now be removed fromthe pedestal for inspection by tappinglightly with a wooden or brass rod.

InspectionImpeller: Replace if, impeller shows

excessive erosion (especially on the pump-out vanes on the back of the impeller),corrosion, extreme wear, or vane breakage.Shaft: Check for runout to see that the

shaft has not been bent. lf runout exceeds0.002 inch, replace the shaft. Bearing seatsand oil seal area must be smooth and free ofscratches or grooves. Shaft threads must bein good condition. Replace shaft, ifnecessary.Ball Bearings: Replace if worn, loose, orrough and noisy when rotated. New bearingsshould not be unwrapped until ready for use.Replacement bearings must be of the propersize and type as supplied with the originalequipment.Seals: lt is recommended that all O-ring

and gasket seals be removed duringdisassembly and replaced. In those caseswhere new seals are not available, the oldones can be reused if they are not torn orotherwise damaged.General: All parts should be clean before

assembly. This is especially important forretaining rings and O-ring grooves, threads,gasket surfaces, bearings, and bearingsurfaces. Any burrs should be removed withcrocus cloth.

MCM 1 78 Maintenance Page 6

-----

i

AssemblyTo reassemble the pump, follow the

disassembly instructions in reverse order.New gasketS should be used throughout.Gaskets should be 1/16 inch thick andshould be made of a material suitable to thepump operating conditions.1. lnstall the bearings in the pedestal.2. Install new grease seals in the bearing

caps .3. With the impeller installed on the shaft

and rigidly keyed in place, insert theshaft from the front through the shafthole in the wear plate. Feed on parts inthe following order:

Water SlingerFront Bearing CapBearing Cap GasketFront Eccentric Lock Washer

Then feed the sheift through the front andthen rear bearing and add the remainingparts in the following order:

Rear Eccentric Lock WasherRear Bearing Cap GasketRear Bearing Cap

lmpeller Adjustment With TheCasing Off The Pump1. Push the rear against the shoulder with

the rear bearing cap.2. Push the impeller back against a 0.020

inch shim between the rear impellerpump-out vanes and the front of thewear plate.

3. Push the rear bearing in again to besure it is against the shoulder. Lock thebearing eccentric lock ring in thedirection of rotation.

4. Tighten the set screw in the eccentriclock.

lmpeller Adjustment With TheCasing On The Pump

1. Put on the casing with the casinggasket and tighten the casing stud nutsuniformly. 5.

2. Push the shaft forward until theimpeller hits the casing. Mark the shaft.Pull the shaft back until the impellerhits the wear plate. Mark the shaftagain.

3. The shaft should be set halfwaybetween the shaft marks so that theclearance between the impeller and the

casing is approximately the same asthe distance between the impeller andthe wear plate.

4. Make sure the rear bearing is seatedagainst the pedestal shoulder and thenlock it against the shaft with thebearing eccentric lock ring. The lockring should be set in the same directionof rotation as the shaft. Lock the ringwith the set screw.The front bearing should not seatagainst the housing shoulder. Thebearing should be free to float alongwith the shaft to compensate forexpansion and contraction of causedby temperature changes. The outerrace clearance is about 1/16 inch oneach side. Push the bearing in until itseats against the shoulder and pull itout 1/16 inch.Lock the front bearing to the shaft inthe same manner as the rear bearing.

Packing The Pump1. Make sure the box is cleaned of all old

packing and the plastic lantern ring.2. Grease all five shaft packing rings (5).

Insert three packing rings alternating thesplits in the rings from top to bottomstarting with the split on the first ring onthe bottom. lf King type packing is beingused the rings should be installed withthe lips toward the impeller.

3. Installthe lantern ring with the split in thevertical position. The two halves of thepacking gland may be used to push thepacking and the lantern ring togetherand to the bottom of the box.lnsert the final two packing rings. Theobjective is to have the last split down sothat leakage will drip down and not,haveto go over the shaft and possibly in thebearings. lf King packing is being used,insert the final King ring with the liptowards the outside and split on top, andfollow with the single ring of squarepacking split down.With the packing gland in position, swingthe gland bolts into place. Initially tightenthe gland hard to compress the packing.Then back off the gland bolts andretighten only finger tight. Caution:Tighten the gland against the packingfinger tight only. lf packing is over-tightened it may be burned when thepump is started.

5.

o .

4.

MCM 178 Maintenance PageT

Excessive Packing Leakage AndRapid Packing WearMost early packing failures are caused byover{ightening or poor installation.

Packing Appearancelf the packing being removed is hard and

brittle, it has been run dry some time in itslife. This is often done in the first hour ofservice. The packing has more ability togrow with heat during its early life. Even ifthe packing is adjusted just right beforestarting the pump, in the first few minutes ofoperation the packing will grow with heat andbecome over{ight. It will then run droptightand the packing wi l l burn. ONCE THEPACKING IS BURNED IT WILL NEVERSEAL PROPERLY AGAIN. Let new packingleak more in the first few hours and thenadjust it to 10-12 drops per minute.

Installing Water Flush SYstem ToBe Acceptable By Oil GomPaniesMany oil operators will not allow water to be

put on the packing because of excess watergetting into the mud, a result of poorlydesigned and maintained systems. Twomajor problems cause this complaint:1. Too much l ine pressure2. Not turning water off when pump is not

in use.

Control l ing Water Pressure To ThePackingThe water pressure is usually too high. The

brake cooling pump is normally used whichoperates at pressures from 50 to 75 psi.Only 5 to 10 psi water is needed to cool andlubricate the packing. A pressure regulatorshould be installed to reduce the pressureon the packing. One regulator can supply allcentrifugal pumps from a central system.

Contrott ing When To Use Water OnPackingLARGE VOLUMES of water get into the

mud when the pumP is NOT OPERATING'When the pump is running, the shaft deflectsand when stopped, the shaft straightens upand a gap occurs down one side of the shaftbetween the packing and the shaft. Thisallows a stream of water to enter the mud'You can manually turn off the water whenthe pump is shut down but a better way is to

install a solenoid valve in the water supplyline that turns the water on and off as themotor is turned on and off. ONLY a smallamount of water (a few drops per minute)which gets into the mud while the pump isrunning should not be objectionable to the oilcompanies.

Bearing FailuresExcept for cavitation problems, bearingfailure is the greatest cause of increasedpump operating cost. lf you continue to runa pump when bearing failures occur, thereis an excellent chance the entire pump willbe destroyed. Therefore it is very importantto change the bearings when failure starts.lf you wait for complete failure other fluid endparts will be damaged. Bearing failure ismore often caused by lubrication failurethan by normal bearing wear.

Misalignment Between Pump AndDriverA major cause of bearing failures is

misalignment. Alignment between the pumpand motor should always be checked aftershipment and periodically rechecked.

Detection Of Bearing Failure WhenPump ls RunningThe first indication of lubricant and bearing

failure is a rapid rise in operatingtemperature. You should feelthe frame oncea week to get a feel for how hot the bearingsnormally run. A sudden high increase intemperature normally means the bearingsare beginning to failand need changing.You cannot hold your hand for very long on

unsatisfactory temperatures. lf you can keepyour hand on the housing for 5 seconds thetemperature is about 160' F. which issuitable for most pumps. lf you cannot holdyour hand on the housing for five seconds orif the bearing housing is so hot you do notwant to touch it, there is most likely lubricantand/or bearing failure.

PART V MISGELLANEOUS

Suction line velocity should not exceed 10feeUsecond for reasonable pump life. Thismeans the maximum flow for a 6 inch

INFORMATION

Suction Line Velocity

MCM I 78 Mainte'nance Page 8

suction is 900 GPM and an 8 inch suction is1600 GPM. lf you want to flow more than1600 GPM a 10 inch or larger suction lineshould be installed.

Net Positive Suction Head (NPSH)The system must have enough NPSH for

the pump requirements or the pump willcavitate, greatly reducing its life.r.lt appears that most installations do nothEve enough NPSH to run a 5x6 pump atflows above 1400GPM even with an I inchsuction. (This does not mean that no onehas enough NPSH). The result ofinadequate NPSH is cavitation and earlypump failure. Through observation, thegreatest problem with NPSH is encounteredwith mud mixing pumps. Most companies donot change the nozzles in their mud gunsoften enough. On a 1 inch noz::le,l/16 inchwear per side will increase flow by 26%.Example: Volume required increases from1500 GPM to 1890 GPM. A wear of 1/8 inchincreases flow by 56% (from 1500 GPM to2340 GPM). lf sized correctly when new, themud mixing pumps will soon be required tofurnish a greatly increased volume andperhaps more than the maximum limit of thepump. We have found customers running6x5 pumps on mud mixing experiencingmuch higher operating costs than thoserunning 8xO pumps. Companies running 6x5pumps at 1750 RPM on mud mixing oftenhave high maintenance every six months,while customers running 8x6 pumps at 1150RPM often do not require major repair fortwo years. Looking at the failures, it appearsthe problem is inadequate NPSH at highervolumes, most likely clused by nozzle wear.

A t 1500 GPM a 6x5 pump a t 1750RPM requi res up to a 26 foot NPSHwhile a 6xB pump at 1150 RPM requireson ly a 7 foo t NPSH. Near l y eve rys y s t e m w i l l h a v e a 7 f o o t N P S Havai lab le whi le a lmost no system wi l lh a v e a 2 6 f o o t N P S H a v a i l a b l e ,e s p e c i a l l y i f t h e m u d t e m p e r a t u r eexceeds 140(, F.

We normally do not see cavitat ion asmuch wi th the desander and desi l terpumps because the rubber cones donot wear as rapid ly as s teel cones.Volume requirements are closer to 800to 1000 GPM.

Capacity Limits Of Pumps

Capacity limits for pumps listed below do notconsider suction line velocity or NpSHcalculations wtrich must be made for evervinstallation.

Capacity Requirements OfEquipment In Rig ApplicationsThe chart below lists the normal design

requirements when the equipment is newwith no wear.

PUMP SIZE3x2x134x3x135x4x146x5x148x6x14

MAXIMUM GPM450750

1 10018002400

EQUIPMENT4" CONE4H (s',) CONE6 'CONE8 'CONE12' ,CONE6'MUD HOPPER%" NOZZLE1'NOZZLE1 Y2" NOZZLE2'NOZZLEMECHANICAL BMKESELECTRIC BMKESSWACO DEGASSERWELCO DEGASSERBRANDT DGs DEGASSERBRANDT DGlO DEGASSER

Long Term PumpStorage1. Pump packages should be stored

indoors in a clean, dry and protectedenvironment.The storage area is to be free from anyvibration and temperature extremes.Motor and pump shafts are to be rotatedmanually every two months. A record ofthe rotation should be made.Grease in the motor and the pumpbearings is to be purged at the time ofremoval from storage and replaced withan ample supply of fresh grease in eachgrease cavity.

DESIGN VOLUME45 to 60 GPM

80 GPM125 GPM250 GPM

450 to 500 GPM550 GPM80 GPM

140 GPM3OO GPM

550 to 600 GPM40 to 50 GPM

50 to 200 GPM4OO GPM7OO GPM5OO GPM

lOOO GPM

And Motor

2.

3.

4.

llCt I 7 Mahtenance Page 9

5. Motor windings should be megged at thetime the equiprnent is placed in storage.At the time of removal from storage theresistance reading must not havedropped more than 50% from the initlalreading. Any drop below this Pointnecessitates electrical or mechanicaldrying of the motor windings.Condensation from hot days and cool

nights can fill the motor half full withwater. This is a greater pCtentialproDEm ln Oamp areas.

6. lf the pumps are to be stored outdoors,the pump suction and dischargeopenings should be sealed to preventany water from entering the pumphousing. This will prevent rust andcorrosion.

?ar* Oaaaa' Relcren& e4anrItmNo- Descrlpdon

QtvRcc MCM Mlrdon IIelco Hrrrbburr

I 178 Pcdcstal l FTl8PBD L3785 H3785 I.I7E.PED2 lT8Bcaring Cap 2 P788C 3790 H3790 2-t7g-BC3 178 Bcaring Cap Gaskct 2 r/SBCG t0399-23.r H10399-23-l 3-178-BCG4 I78 Bcrring Assm, 2 P78BA8 3944-3 H394/,-3 4A.I?E.BAE5 178 Oil & Grcasc Scal 2 r/SOGS 3943-14 H3943-t4 5.17E-OGS6 178 Bearinc Cap Bolt Assm, 4 FTl8BCBA 3861-1t3932-2 H386t-1t3932-2 6.178-BCBNA7 178 316-55 Shaft F/ 2x3-5x6 r/8SH3l65556 378644 H378644 7A-178.31655

178 416-55 Shaft F/ 2x3-5x6 P785H4l65556 4932-2tA H4932-2tA 7A-l784l6S5178 Ccramic CoatetEl 2x3-5X6 P785H4l65C56 17238-2rG-74 H 7238-2tG-7/| 78-l784l6SSC178 316-S5 Shaft F/ 6X8 I P78SH3l65568 t4928-4/' H 49284A 7F.r784-3l655178 416-55 Shaft F/ 6X8 I P78SH4l6S568 r4928-2rA H 4928-2lA 7C-1784-4l655178 Ccramic Coatcd F/ 6X8 I P785H4l6SC6E t7343-2tc-tA H 7343.2t.14 7D-1784-4l6SSc

8 178 Graphite Packing I PT8PMSG E264.17W-OBAH8264-l7W-OBA 8A.I?E.PMSG178 Kinc Packing I PTSPMSK 8474-t7W-7A H8474-l7W-7A' 8C-t78-PMSK178 Tcflon Packing I PTSPMST 8264-l7W-74 H8264-l7W-74 8D-178-PMST

9 178 Packing Gland I P78PG 7406-13A H7406-l3A 9.I?E.GPAt0 178 Gland Adjusting Bolt Assm' PTSCABA A370lA H370lA l0-178-GABAI t l?8 Wcar Platc Ductilc lron l P78WPD 3119-30 H3779-30 llB-178-wPDl 2 178-2X3 Ductilc RH ImPcllcr I P78D23MRXXX 4610-xx-30 H46t0-XX-30 t27823[RXXX

178-3X4 Ductilc RH ImPellcr I P78D34MRXXX 4605-XX.30 H4605-XX-30 l27834IRXXXneAXS Ductilc RH ImPcllcr I PTEDI5MRXXX 4105-XX-30 H4705-XX-30 I2TM5IRXXX178-5X6 Ductilc RH lmPcllcr l P78D56MRXXX 4710-xx-30 H47r0-XX-30 t27856IRXXX178-6X8 Ductilc RH ImPcller I P78D68MRXXX 5142.XX-30 H5142-XX-30 I2TE6EIRXXX

l 3 78 Housing Gaskct 2 r/SHG 10399.20.r Hr0399-20-l I3A-I7E.HGFl4 78-2X3 Ductilc Housing OnlY YI8D23H N/A N/A 147823HD

7R-?Y4 f)rrctilc Ho[3ine ()n P78D34H N/A N/A r47834HD784X5 Ductilc Housing OnlY FTEBISH N/A N/A r418r'isHD78-5X6 Ductilc Housing onlY P78D56H N/A N/A t47856HD78-6Xq Ductilc Housing OnlY P/8D68H N/A N/A r47E68HD

l 5 78-2X3 Ductilc Facc VI8D23F N/A N/A 26f1823HFD78-3X4 Ductitc Facc P78D34F N/A N/A 267834HFD784X5 Ductilc Facc Prl8Dt5F N/A N/A 2678/.s$FD78-SX6 Ducfilc Facc F78D56F N/A N/A 267E56HFD

78-6X8 Ductile Facc P78D6EF N/A N/A 267E68HFD

tat5 7&2X3 Housing Assm. RH Duct r8D23HFA G4676-304 H4676-30A l4TEZSDIrA78-3X4 Housing Assm. RH Duct r/8D34HFA. F4W-304 H46//'30A l47E34DltA1g-4XS Housing Assm. RH Duct P78DI5HFA F4732-304 H4732-30/| l47W'DHA

f8-5X6 HousingAssm. RH Duct F/8D56HFA. Fq+z-30A H4742-304 l,t7t56DHAlZg-6XA Houring Asm. RH Duct rTSD6tHFA F5t4-?0A H5t44.-30A l47868DHA

7 l ?f, Oil Slinacr Rinq FtSSRO N/A N/A l9-l7E-SRO

vt 178 Watcr Slingcr Ring F78SRW c3787A' HC37E7A 2Gl7E-SRWor Indicatcs Sizc

llGll I 78 Maimenance Page l0

1'flK

w

LOOK AND COMPARE .... WE'RE YOUR BEST CHOICE !

MCM 178 Maintenance Page ll