mud pump handbook pdf free sample

abstractNote = {Based on extensive research, development, and field testing of mud pumps and accessory equipment, this book offers cost-saving methods in operation and maintenance of triplex and duplex pumps. It covers practical engineering concerns such as pressure losses from friction in the piping and inertia in the drilling mud; suction dampeners in pump operation; charging the suction pipe for greater efficiency and smoother operation; hydraulic and mechanical knocking; hydraulic pressure losses; discharge lines.},

abstractNote = {Based on extensive research, development, and field testing of mud pumps and accessory equipment, this book offers cost-saving methods in operation and maintenance of triplex and duplex pumps. It covers practical engineering concerns such as pressure losses from friction in the piping and inertia in the drilling mud; suction dampeners in pump operation; charging the suction pipe for greater efficiency and smoother operation; hydraulic and mechanical knocking; hydraulic pressure losses; discharge lines.},

13 Special Tools List For HHF-1300 / 1600 Mud Pump, delivered together with the pump...5214 Spare Parts Lift For HHF1300 / 1600 Mud Pump, delivered together with the pump.. 5315 Recommended spare parts . 55

HHF-1300/1600 Mud Pumps are horizontal, triplex single acting reciprocating pumps. It feedshigh-pressure circulated drilling fluid to bottom hole, which flushes the bore-hole bottom andcrushes rocks; furthermore, cools and lubricates drill- bits and carries the cuttings (rock chips) tothe surface.The Pump mainly consists of two components, power and fluid ends. The power end includes theassemblies of frame, pinion shaftcrankshaftcrossheads etc.

assemblies of hydraulic cylindervalves, cylinder liner, piston, suction and discharge manifolds andso on. It is designed and manufactured that all parts and components of the pump conform with therequirements specified by the Specification for Drilling and Well Servicing Equipment (API Spec7K). All easily worn parts at the fluid end such as cylinder liner, piston and valve assemblies etc areuniversal and interchangeable and could be replaced with the same type parts and components inconformity to the above-said API Specification. To avoid air hammer and reduce outlet pressurefluctuationa suction stabilizer and discharge pulsation dampener were respectively installed at thesuction pipes and one side of pump outlet. At the other side of pump outlet, a reset safety valve isinstalled to guarantee that the pump pressure would not excess the rated working pressure. Eachmud pump is equipped with a charging pump to ensure good suction performances for the pumpwhile operating at high strokes.A combination of splash and forced lubrication systems has been used to lubricate all gears,bearings and crossheads in the power end. The cylinder liners and pistons in the fluid end will belubricated, cleaned and cooled by water supplied from a spray pump.For conveniences of daily maintenance, a set of special removers/tools will be delivered togetherwith the pump.Except for differences in the gears and bearings at the power end of the pumps., Frame, fluid endand so on for pump HHF1300 are the same as pump HHF1600. For convenience of usersunderstanding and use, the two pumps are introduced simultaneously in the following texts.

2.2 Performance parametersThe performance parameters for pump HHF1300/1600 are shown in the following table II:Table II Performance parameters for pump HHF1300/1600Diameter of cylinder liner and rated pressureStrokenumbers

The mud pump HHF-1300/1600, manufactured by our company, has been completely assembledand test-operated under full load and then discharged all lube oils from power end before beingdelivered to our customers. The pump must be checked and operated according to the followingmethods and measures before being put into formal services. In order to prevent personal injuryduring the performance of any checking and maintenance processes, it must be shut down and notoperating, all safety and protection facilities installed on the prime mover and drive device shouldbe put in safe positions.

The skid under the HHF-1300/1600 pumps is fit for all types of installations, but it is worth to bementioned that although the frame with box structure at the power end has high resistances tobending, but relatively lower resistances against twist; therefore, the supports under the frame mustbe level and with enough strength to bear the pumps dead load and dynamic forces exerted uponduring operation.3.2

In land installation, it is suggested that a mat base with, at least eight pieces of 31276mm305mmboards be placed under the pump skids along the entire length the positions as shownin the Figure 2. The board under the pump skids must, at least, be 12305mmwider than thewidth of the pump skid runner. More solid foundations are required in case of the installation beinglocated in wet or marshy land.

3.3 Permanent installationsWhile the pump being permanently installed on the structural base or concrete slab on a barge ordrilling platform and the pump skid being fixed by bolts, it is essential that the skid be properlyshimmed to prevent the power frame from possible distortion or twists. The pump skid must besolidly sat down on all shims when all bolts are tightened.In case of barge installation, the pump skid is usually bolted to T-beam, the positions for installingshims are shown in the Figure 2 and 3. Properly shimming should be noted to avoid possible twistor distortion. All shims must exceed the full width of the skid beam flanges and have a minimumlength of 12 (305mm).When integral installations for power unit or electric motor and pump skids are required thepump must be fixed on the skids of the T beam, with retention blocks rather than bolts in thisway the pump could be a bit floating so as to reduce greatly the possible deformation of thepump frame caused by the deformation of barge deck or platform.

Whether to use V- belt or multi-strand chain or universal shaft for the drive between power sourceand the pump, it must be very careful during the whole installation to ensure the longest service lifeand minimize the shut- downs caused by failures from the drive.Upon installation of drive sheave or sprocket, make sure all rust preventatives or greases in the huband on the shaft are removedBurs and rough spots on the keyskeyways and shaft must beremoved so that all keys fit properly in the keyways on the shaft and drive elements. The shaft ofthe pinion gear should be coated with light lube oil or anti-seize oil, and then fit the hub of sheaveor sprocket, tighten all bolts according to the following requirements:Tightening bolts with wrench or wrench with extension pipe may lead to exceeding torque,therefore, it is imperative to adhere to the torque value given in the following table to tighten allbolts, otherwise, it may damage the hub and the sheave by the exceeding tightening force, which isagain multiplied by the wedging action of the tapered surface. In addition, all bolts of hub must betightened alternately and gradually.

3.4.1.1 Checking sheave groove statusBefore installation, check that the sheave grooved are not worn out and getting rounded, otherwise,the V-belt will be damaged quickly. The groove sidewall must be level and straight and there are nodusts, rusts.3.4.1.2 Checking sheave alignmentHaving installed all sheaves and tightened them to working status check their alignment. If thedistances from one side of the two sheaves to the centerline of sheave groove are equal, check thealignment with two tightened strings (for fishing or better for piano) along one side of the twosheaves; one is put above the sheave center and another below the center, and then move one oftwo sheaves until the strings have touched 4 points of the sheave rim; in this way determining thetwo centerlines of the drive sheaves are parallel and their side face be vertical with their axle line.3.4.1.3 adjustment of V-belt pretension forceTo adjust the belt tension, change/increase the central distance between two sheaves until no sag tobe found on the tightening belt side, and the slack side is also tightened but has a bit of sags. Andthen increase a certain of central distance again, for example, if the center distance is 100(2540mm), 1/2 (13mm) is to be increased after completion of adjustment of the central distance;again if the center distance is 150 (3810mm), 3/4 (19mm) is to be increased.Note: Dont obtain belt tension by lifting the pump or by lowing the pump below ground level toallow the belt to be tensioned by pumps weight.3.4.2 Chain drive3.4.2.1 InstallationInstallation and maintenances correctly are important means to extend the service life of chaindrive and chains and sprockets themselves. Many factors such as the width of chain, center distance,speed and load etc. are to be considered when determining the allowable alignment tolerance ofsprockets; since there is no perfect operating method to be applied, therefore, what we can do isto make the chain alignment as exactly as possible. As mentioned above in 3.4.1.2, a more precisealignment can be made with two stretching steel wires (better for piano) along one side of the bothsprockets; one is put above the centerline and another below the centerline, and then move one oftwo sprockets until the strings have touched 4 points of the sprocket rim; in this way, to determine

the two centerlines of sprockets are parallel and their end face be vertical with their axle line.3.4.2.2 Lubrication of chain driveThe lubrication system used for all chain drive in HHF series pumps is an independent one, whichhas its own lube oil pump, reservoir and drive. Filling the lube oil into the chain case must be up tothe indicated height. The lube oil to be used are as follows:Ambient temperature above 32 F 0C

If Ambient temperature below 0F-18C, Please consult a reputable lube oil dealer forrecommendations. As for those approved lube-oil specifications and their supplements, referencesmight be made to the reports/bulletins usually used on lube oil, which are written and published byoil-manufacturer. If there is any discrepancy between manual and the reports/bulletins, thesuggestion from the reports/bulletins shall be prevailed.Owing to the chain lube system being an independent system, the maintenance must be carried outbased on equipments special requirements, which include:n Daily checking oil leveln Daily checking oil statusn Daily checking oil pressure (515psi 0.0350.103MPan Supplying some oils to chainn Checking nozzles working status on the spray tuben Checking the working conditions of the oil pumps drive (V-belts, or chain)Note:a. There is a pressure relief adjusting screw on the rear of the pump housing to adjust the oilpressure.b. When oil pressure is too high or too low, which indicate that the suction and discharge filterscreens need cleaning.

The design of pump suction system has been considered to install the system independently. Toobtain a satisfied suction performance, the HHF series pumps must have positive head (pressure);

the optimum pressure for suction manifold is 2030psi 0.140.21Mpa. Under this pressure,the pump could have the maximum volumetric efficiency and the longest service life forconsumable parts. This pressure can be obtained by 56 charging pump with a 40 hp, 1150-rpmelectric motor. A special kind of device is necessary to keep the charging pump and the triplexpump automatically and synchronously turned on and off. For drilling rigs driven by DC motor,usually a signal sending out from DC control panel actuates the electromagnetic starter; at this time,the air line of drilling pump clutch can provide a group of contactors when clutch is engaged,through which supply power to the electromagnetic starter.The suction pipeline should be arranged with a by pass for the charging pump, to facilitate thedrilling pumps continuous operation when the charging pump is in maintenance or failure. Whenthe drilling pump is operated without charging pump, usually replace a softer suction valve springto improve suction performances.Suction stabilizer is a very efficient supplementary device, which can fully charge the fluid intocylinder liner and greatly eliminate the fluid fluctuations in suction pipes resulting in a smootherflow in the discharge line.Note: Dont connect the discharge pipe of the safety valve to the suction pipeline, since when thesafety valve opens it causes a sudden rise to the system internal pressure; if the pressure is higherthan the rated pressure of the system, it will damage the manifold, suction stabilizer and centrifugalpump etc.

5 Preparation of power endBefore being shipped to the users, the HHF series pump manufactured by our company has beencompletely assembled and test operated. All lube oils have been drained. Before operating thepump, the following operations and checks must be carried out.5.1 Power end lubricationBefore filling lubricant, open inspection window on cover and check power end oil reservoir forpossible accumulation of condensation, and drain and flush the inner chamber by removing thepipe plugs on each side of the pump (see item 2, Fig.7). Fill in the proper brand and quantity oflubrication oil in the power end according to the requirements specified on the designation plate of

pump frame.Recheck oil level after pump has operated for a period of 15 minutes. Shut pump down for about 5minutes until oil stabilized, check oil level gauge (see item 1, Figure 7). It is usually necessary for afew more gallons (10 liters) of oil to be added due to a certain amount being retained in thecrosshead and frame cavities.5.2 Installation and inspection of Crosshead Extension Rods and Diaphragm Stuffing BoxSeals for HHF-1300/1600 PumpAs shown in Figure 4, remove the diaphragm stuffing box and splash- guard (1) and rotatepump so that crosshead is at the front of the stroke, check bolt-tightening status. If the cleanlinessof front part of crosshead and its extension rod and bolt- tightening are not up to the requirements,remove the extension rod and thoroughly clean the crosshead front and the end face of theextension rod; and then insert alignment boss on crosshead extension rod outer circle into thecrosshead bore and install the bolts (2) to the torque: 350370 ft.lbs, (475500N.M), finally lockit with steel wire.

6 Spray pump assemblyThe spray pump assembly consists of spray pump, water tank and spray pipe with nozzles etc. Thefunction of spray pump is to supply water in the form of spray to the cylinder liner and piston toflush, lubricate and cool them to extend the service life of the cylinder liner and piston.

The spray pump is a centrifugal pump, which is electric motor driven and uses water as cooling andlubrication fluid. Attention must be paid to assure the cooling fluid is supplied to the cylinder linerand piston, otherwise immediate damage of piston rubber parts and cylinder liner will occur.The HHF series mud-pumps manufactured by our company use a stationary spray pipe, as shown inFigure 5, which consists of a fixture (1), connecting pipe (2) and spray nozzle pipe (3). It sprays thecooling fluid to inner holes of cylinder liner and piston. The spray nozzle pipe should be checkedoften as the pump works. Through adjustment of water supply to the manifold, to assure enoughcooling fluid to be sprayed directly to piston.

Figure 5Cooling fluid will be transfused by pump (item3, Figure 7), and sucked from water tank (item 5,Fig.7), to the manifold located in the left (right) wall plate of the frame. By regulating the ballvalve (item 4, Fig.7), the pump will supply water to the inside of the cylinder liner withoutsplashing back on the crosshead extension rod. Water should not splash on the extension rodotherwise some of water will spray into the power end contaminating the lube oil.The cooling fluid is returned from frame drainage hole to water tanks setting chamber, and as thefluid flows through the filter screen, the solids settle as shown in Fig. 6.

7 Assembly of fluid end partsThe cross-section of the fluid end is shown in Figure 8, clean and install all parts of the fluid endmust follow the methods as follows.Note: The parts in the fluid end are designed for metal to metal installations to reduce wearcaused by high-pressure fluid which is used in modern high-pressure-pump operations. Based onthis consideration, in order to ensure a reliable sealing between parts in the fluid end, it is requiredto clean all parts thoroughly and have no burs, scores or rusty spots etc7.1 Valves and seatsRemove all three valves pot cover (18), three cylinder heads (16) and plugs (15), andthoroughly clean all machined surfaces in the fluid end with a good cleaning solvent.Make sure all valve seat bores are very clean and dry (free of dirt, grease, anti-rust additivesetc.), and remove all burs and nicks with a fine emery cloth. Clean and dry thoroughly the valveseats and install suction and discharge valve seats into the valve cavity bores and then install thevalve body; knock the upper part of the guidepost with a copper hammer to drive the valve seats inplace, finally install valve springs and other parts.7.2 Cylinder linerInsert liner- seal- rings (1) into the counter-bore of the cylinder. Install the wear plate (2) in placewith stud bolt, and then install liner flange (3), be sure that the liner lock starting point is at the 5oclock position; and coat the inner bore of nut with Locktite gelatin 277, and finally tighten the nutto torque 470510ft.lbs640690N.m.Note: the purpose of putting the thread start point at the position of 5 oclock is to keep the linerlock threads from being damaged. Insert liner seal rings (1) into the counter-bore of the wear plate(2). Coat inner surface of cylinder liner lock (4) with grease and then put the two-half liner-latchingring on the liner and hold them with the O-ring. Lift the cylinder liner and coat cylinder liner lockthreads with grease and put the lead thread start point at the position equivalent to 7 O clock andpush while turning the liner into the liner flange (3). Tighten the liner lock (4) and press the linerend face into position and knock the liner lock tightly with a hammer.

7.5 Lower valve rod guide and cylinder headInstall the lower valve rod guide (12) and slip it on valve body, through flashboard (13) press downthe valve rod guide and press the valve spring simultaneously. Install the locating disk (11) into thecylinder bore; install cylinder head O-ring (14) on the cylinder head plug (15). Coat the O-ring andouter circle of the cylinder head plug with lightweight oil. And push the cylinder head plug andknock the end lightly into the cylinder front-end inner bore. Coat the threads of the cylinder headwith grease; rotate the cylinder head (16) in against and on the plug (15), and then tighten thecylinder head with a force-multiplier tool and hammer provided together with the pump.If the fluid is leaking through the bleeder holes it indicates that the O-rings are damaged or thecylinder head is loose. Never block the bleeder. Once the O-ring fails it will cause the head threadsand other parts be washed out and damaged.

The reset relief valve (3) is installed on the accessory manifold for the purpose of protecting thepump from pressure exceeded the rated value and discharge all the fluids to guarantee safety of themud pump. The reset relief valve must be installed to be able to contact directly to the mud tanks;and no valves may be installed between the relief valve and the discharge line. Pipe the outlet of therelief valve directly to the mud tank by seamless steel pipe and with as few turns in this line aspossible. If a turn is necessary, the elbow bend should be > 120. It is not allowed to pipe theoutlet of the relief valve to the suction pipes of the pump.The flange on the bottom of the KB-75 pulsation dampener (1) is supplied together with R39 ringgasket(6); before installation of pulsation dampener , clean the ring gasket and groove thoroughlyand after installation, tighten the nuts (7) to the torque: 750850ft.lbs10201150N.m. Toensure balanced forces to be exerted, all nuts should be tightened alternately cross ways.Before starting the pump, pre-charge the pulsation dampener to not be more than 2/3 of the pumpdischarge pressure. Maximum pressure is not to exceed 650 psi (4.5 Mpa). The pulsation dampenerwill be charged with nitrogen only.Do not charge with air, oxygen, hydrogen or other easily-burnt and explosion gases.The charging will be conducted with a set of charging equipment (pulsation dampener charginghoses assembly) provided together with the pump, as shown in Figure 10 and the operationsequences are as follows:

To achieve the best results, the dampener pre-charging pressure must not be more than2/3 of the pump discharge pressure, and the maximum charging pressure is 650 psi (4.5Mpa).

For maintenance of the dampener, the pressure in the dampener must be zero and thepump pressure also is zero. Be careful that dont fully rely on the pressure gaugereadings. The vent valve cap must be open to release pressure, the remaining pressuremay be low and the pressure gauge may not read correctly. This low pressure may stillcause an accident.

systems is adopted for HHF series pumps. When a gear oil pump is driven mechanically (exceptdriven by a electric motor), the types of pressure system adopted, in fact, govern the minimumSPM, at which the pump being operated. As for the pressure lubrication systems adopted for HHFseries pumps, they could operate at a minimum 25 SPM; at this time, the lowest oil pressure is 5 psi(0.035 Mpa).Big gear rim

Figure 11Note: The pressure lube oil pump could be installed outside of mud- pump and driven by v-belt orinstalled inside of mud- pump and driven by big gear rim. When the later installation is used, therotating direction of the pinion gear should be as shown in figure 11.

8.2 Flow- controlled splash lubrication systemThe flow- controlled splash lubrication systems are the same for all HHF series pumps, regardlessof the types of oil pump provided for the lubrication system. In the flow-controlled splash system,the big gear rim brings up the oil from the sump; and when its teeth mesh with the pinion, the oil issqueezed out and splashed to various oil troughs and oil cavities in the frame. With reference tofigure 13, the oils are thrown into the trough (7) and flow through pipe (8), to the bearings on thetwo sides of the pinion shaft.The passage that oil flow from the top of the crosshead guide into the crosshead bearings is shownin figure 12. The oils accumulated in oil chamber above the crossheads flow through oil nozzle (1),into the crosshead pin baffle, and then to oil passages (5) to lubricate crosshead bearing. There are- 24 -

8.3 Pressure lubrication systemThe pressure lubrication systems used for HHF series mud- pumps have installed a lube oil pump,as shown in Figure 13; in this system, the filtered oil is sucked in, through the suction filter (1), bythe pump, and then through the block II (2), distributed to the pinion shaft nozzle (3A), mainbearing oil-pipe (4) and the block I (4A) in crosshead chamber again through the block I (4A),distribute oil to the crosshead, its bearing and extension rod.

Figure 13A pressure gauge (5) is mounted on the back base plate of the frame to show oil pressure inthe block oil-distributor, which is obviously changing with the speed of the pump. However, if asudden pressure drop or increase occurs, the reasons caused must be found according to the sectionon Maintenance of lubrication system.A pressure relief valve (6) is mounted on the block II (2) to prevent the pump and its drivefrom possible damage caused by excessive pressure. The relief valve is preset to 80 psi (0.55 Mpa)and then locked down to avoid the preset pressure changing.

Upon built-in installation of the lube oil pump, as shown item 9 in Figure 13, the pump must bewell positioned according to the requirements as shown in the Figure. The side face of the oil pumpgear must be flush and parallel with the side edge of the mud pump main gear rim, and the gearteeth have 0.024-0.0355 (0.60-0.90 mm) backlash.A typical layout for oil pump driven by pinion shaft is shown in Figure 14. The oil pump (1) ispipe-connected to the lube oil pipes system through the suction and discharge adapters mounted onthe bottom inside walls of the power end. Dont over-tighten the V-belt (2) to prevent the pumpfrom premature damage. To avoid possible injury, the V-belt guard, as shown item 3 in Figure 14,must be installed before the pump being operated.

8.4 Maintenance of lubrication systemSufficient lubrication of all moving parts is the most important factor to extend the service life ofthe pump; being meticulous in maintenance of the lube oil system is a duty for all operators. In fact,a good or poor maintenance of the lube oil system determines a long or short trouble-free servicelife of the pump.The recommended lubrication oil is as follows; and also shown on nameplate fixed on the pumpside. All data recommended are the results of long-period tests in the oil field; therefore, anysubstitution of oil recommended could only be used for emergency conditions.

Every shift should make their rounds to check the oil level and maintain the level at the FULLposition; in view of oil level compensation, it is allowed to drive the pump for 5 minutes at a slowspeed and make sure the oil level at the specified position.Check once every 6-month if the oil has any sand and corrosive compounds in it or not; it shouldbe drained. Drain all the oil and flush the oil reservoir before adding new oil. The oil drains arelocated on either side of the pump frame. During flushing, thoroughly clean the oil troughs and thechambers under the crosshead guides, and also clean or replace the filter element in the suction oilfilter, and clean the suction filter screens. Before filling new oil remove the drain cover from settingchamber and clean out contaminants.Regularly check the condition of the lube oil and replace if contaminated ;moisture in the air,ingress of water and mud, and dirt may enter and contaminate the oil.The settling chamber (deposit chamber) is located in the crosshead guide area of power end; thecontamination in the oil splashed into this area is allowed to settle and be drained out by removingthe drain cover that located on the two sides of the frame under crosshead inspection cover.Check once every month. Remove drain covers at pump two sides to drain out the contaminated oilfrom the settling chamber. This will lose about 15-gallons of oil and must be compensated byadding the same amount of oil to the main reservoir.Check once every week. Remove the 2 1/2 plugs below the frame and drain out the accumulated

water. Every shift makes their round of inspection of oil level once and keep the level to the fullposition.In case of oil pressure drop occurs; check the following items:--- Suction filter screen may be blocked--- Oil level may be too low--- V-belt slipped--- Connections or joints may be broken or loosen--- Oil pump may be worn or damaged--- Relief valve may be failedIn case of oil pressure increase occurs; check the following items:--- Oil pass-way may be blocked--- Contaminations may make the oil be viscous--- Relief valve may be inoperative--- Pressure gauge may be defective--- Other abnormal conditions

9.1 Power endRegular inspection of the power end is the most important way to conduct preventive maintenance;it could find various failures in time, small or big and enable the mud pump to be repairedaccording to plan or in the normal shutdown time.a.

Oil pipe-lineCheck all oil pipelines and make sure that they are complete and free of obstructions. Checkthe pump suction pipelines are free of damage.

Teeth of main and pinion gearCheck the condition of the main and pinion gear teeth for any abnormal wear. During therunning-in period there will be some pitting on the face of the gear teeth. This is referred to asinitial pitting and is not harmful to the life of the gears; however, during the regular check ifthe pitting is expanding, immediately contact the pump manufacturer to inspect the gearsthoroughly.

9.2 Roller bearingRoller bearings are used for all HHF series mud- pumps. As very precise mechanical parts, allroller bearings must be carefully maintained to ensure that higher load capacity and longer servicelife to be obtained.

9.6 Installation of crosshead guide9.6.1Clean thoroughly the surfaces of the guide and frame bore used for installation of the guideand remove all burs or rough edges.9.6.2If an old guide is to be reused, check the friction surface for wear and scoring etc. If it is notup to the requirements, replace it.Note: As for HHF 1300/1600-mud pumps, the upper and lower crosshead guides are notinterchangeable. The guides are differently machined so that the lower one places the crosshead on

9.7.1Thoroughly clean all dirt or contaminations and remove all burs or rough edges from OD,pinhole of the crosshead and guide inner bore etc. Wipe and dry crosshead pinhole so that theconnection with the pin taper bore is made up as metal to metal one. See following note.9.7.2 Position the small end of the link at the side hole of the crosshead guides. Support the linkwith a piece of wood so that the crosshead pin can pass through the bore of link small end whilesliding the crosshead into the pinhole at the aligned positions. See Figure 18.9.7.3 Install the left side crosshead first and then rotate the crankshaft assembly to make themiddle link hole into the middle crosshead; at this time the right link hole backs, remove thesplash guard disk (see item1, Figure 19); push the right crosshead to the middle extension rodchamber so that enough clearances are provided for installation of middle crosshead, and theninstall the right crosshead.Note: If an old guide is to be reused, check the wearing surface for wear and scoring etc. Thecrosshead might be installed to opposite side of the pump if necessary i.e. the left and rightcrosshead could be exchange- installed into the bores. However, dont install the pin into the taperhole until the crosshead pin baffle (2) is mounted.9.7.4 Install crosshead pin baffle (2) and bolts (3), (4); align the taper hole of crosshead with thelink small end hole, and push the pin by hand or knock the big end of the pin lightly by a hammerto install the pin into the taper bore. Put the adjusting shims between crosshead pins and baffle(note: as to a set of pin and its hole, the thickness of shims needed are determined and notexchangeable with other shims, otherwise, failures may occur); rotate crosshead pin until the 8bolt- holes on the pin baffle align with the holes below and install 6 bolts (4) and 2 bolts (3)separately and tighten them by hand (refer to Figure 19 and 19A). The oil catcher of crosshead pinbaffle should be upwards.

0.015 (0.381mm), shims should be inserted under the lower guide to make the extension rodmove just towards the aligned center. In the meantime, enough clearance between the upper andlower guides should be ensured; in general, the lower guide is loaded heavily and a bigger force isexerted at the back part since the angle of link, thus the lower guide is fast worn; therefore, it ispermissible to shim the guides a bit skewed to take up the wear..During shimming, the clearance between the upper guide and crosshead upper surface must not beless that 0.020 (0.5mm). Larger clearances are acceptable since the characteristics of triplexpump operation and the crosshead pressure is always exerted on the lower guide when clockwiserotating.Note: When the pump must be driven anti-clockwise the crosshead pressure is exerted on theupper guide, therefore, the guide clearance must be controlled between 0.010.0160.250.40mm.9.8.5 Cut shims being long enough to make them completely pass through the guide; and cut tabson the shim side and exceeding over the frame supports (refer to installation of crosshead guide,9.6.3 and 9.6.4).

manifold must be open. While the valve are closed, the pump starting will exert an impact stress tothe pump and may cause fatigue cracks; and finally the pump head would be damaged by fatiguefailure if the situation continued.9.9.2

Properly maintain the fluid ends for storage. When a pump will not be used for 10 days more, it issuggested to remove the pistons. piston rods, liner etc and flush thoroughly the fluid end withclean water and then wiping them clean after flushing; grease all parts removed and all machinedsurfaces. This will not only extend the life of the fluid end parts but also protects them in goodcondition to be installed when the pump will be operated again.The fluid end assembly for triplex pumps consists of 3 forged fluid cylinder blocks, liner, valvepot cover and cylinder head cover, suction and discharge manifold etc.a.

10 Daily maintenances of PumpTo maintain the pump properly is a necessary measure to ensure the pump is working correctlyand extend its service life. Importance should be attached to this key task during operation.10.1 Daily maintenances10.1.1 Shut down the pump and check oil level at power end. Check once each day; if the pump isdriven by chain transmission the oil level in chain reservoir should also be checked. Duringoperation, the lube-oil pressure changes in the system shown on the oil pressure gauge should bechecked.10.1.2 Observe working status of the cylinder liner and piston; if a little bit mud-leakage is foundit is normal, but if mud leaked is excessive the piston needs to be replaced and the cylinder linerwear should also be carefully checked. If excessive wear is found replace the liner.10.1.3 Check the liner cavity of the frame and wash out the accumulated mud10.1.4 Check the cooling water quantity in the spray pump water tank. Replenish and replace thecontaminated cooling water if necessary

10.4 Maintenances every year10.4.1 Check the tightness of the crosshead guide and running clearance up to the requirements ornot, if not it could be adjusted by adding shims under the guide. If the crankshaft assembly isremoved for any reason it is recommended to rotate the crossheads 180for use again.10.4.2 It is recommended to inspect the pump fully every two or three years; check the wear anddamage status of the main bearings, eccentric bearings, crosshead and pinion bearings. Replacewith new if excessive wear on the old parts.10.4.3 Check all gears wear, if severely worn out in one face, the crankshaft and pinion shaft maybe turned to use the gears other unworn face.

10.5 Other points for attention in maintenance10.5.1 Wipe the 25taper face clean before installing the piston and extension rod clamps.10.5.2 While replacing the cylinder liner the liner seal rings must be replaced together.10.5.3 The pump was shut down or temporarily be shut down for more than 10 days.10.5.4 Close all inspection covers well to prevent the oil from being contaminated by sand or dirt.10.5.5 The pulsation dampener will be charged only with compressed nitrogen or other inert gases.- 50 -

12.1 If a mud-pump will not be used for a long period, it should be mothballed.12.2 Before mothballing, all fluids in the fluid end should be drained out, remove all dirt, washwith water and wipe clean. Coat all machined surfaces of all parts and components in the fluid endwith grease.12.3 Drain out all lube- oils in power end oil reservoir, crosshead guide at two sides, oil-settlingchamber and remove all accumulated dirt.12.4 Coat all machined surfaces on all bearings, crosshead, gears, piston rod, extension rod etcwith heavy oil.12.5 Block all suction and discharge flanges with blind plates.12.6 Seal all crosshead hole end cover, back cover, inspection-opening cover etc tightly.