maintenance of mud pump free sample

Many things go into getting the most life out of your mud pump and its components — all important to extend the usage of this vital piece of equipment on an HDD jobsite. Some of the most important key points are covered below.

The most important thing you can do is service your pump, per the manufacturer’s requirements. We get plenty of pumps in the shop for service work that look like they have been abused for years without having basic maintenance,  such as regular oil changes. You wouldn’t dream of treating your personal vehicle like that, so why would you treat your pump like that.

Check the oil daily and change the oil regularly. If you find water or drilling mud contamination in the oil, change the oil as soon as possible. Failure to do so will most likely leave you a substantial bill to rebuild the gear end, which could have been avoided if proper maintenance procedures would have been followed. Water in the oil does not allow the oil to perform correctly, which will burn up your gear end. Drilling mud in your gear end will act as a lapping compound and will wear out all of the bearing surfaces in your pump. Either way it will be costly. The main reasons for having water or drilling mud in the gear end of your pump is because your pony rod packing is failing and/or you have let your liners and pistons get severely worn. Indication of this is fluid that should be contained inside the fluid end of your pump is now moving past your piston and spraying into the cradle of the pump, which forces its way past the pony rod packing. Pony rod packing is meant to keep the oil in the gear end and the liner wash fluid out of the gear end. Even with brand new packing, you can have water or drilling fluid enter the gear end if it is sprayed with sufficient force, because a piston or liner is worn out.

There is also usually a valve on the inlet of the spray bar. This valve should be closed enough so that liner wash fluid does not spray all over the top of the pump and other components.

Liner wash fluid can be comprised of different fluids, but we recommend just using clean water. In extremely cold conditions, you can use RV antifreeze. The liner wash or rod wash system is usually a closed loop type of system, consisting of a tank, a small pump and a spray bar. The pump will move fluid from the tank through the spray bar, and onto the inside of the liner to cool the liner, preventing scorching. The fluid will then collect in the bottom of the cradle of the pump and drain back down into the collection tank below the cradle and repeat the cycle. It is important to have clean fluid no matter what fluid you use. If your liners are leaking and the tank is full of drilling fluid, you will not cool the liners properly — which will just make the situation worse. There is also usually a valve on the inlet of the spray bar. This valve should be closed enough so that liner wash fluid does not spray all over the top of the pump and other components. Ensure that the water is spraying inside the liner and that any overspray is not traveling out of the pump onto the ground or onto the pony rod packing where it could be pulled into the gear end. If the fluid is spraying out of the cradle area and falling onto the ground, it won’t be long before your liner wash tank is empty. It only takes a minute without the cooling fluid being sprayed before the liners become scorched. You will then need to replace the pistons and liners, which is an avoidable costly repair. Make a point to check the liner wash fluid level several times a day.

Liner wash fluid can be comprised of different fluids, but it is recommended to just using clean water. In extremely cold conditions, you can use RV antifreeze.

Drilling fluid — whether pumping drilling mud, straight water or some combination of fluid — needs to be clean. Clean meaning free of solids. If you are recycling your fluid, make sure you are using a quality mud recycling system and check the solids content often throughout the day to make sure the system is doing its job. A quality mud system being run correctly should be able to keep your solids content down to one quarter of 1 percent or lower. When filling your mud recycling system, be sure to screen the fluid coming into the tanks. If it is a mud recycling system, simply make sure the fluid is going over the scalping shaker with screens in the shaker. If using some other type of tank, use an inline filter or some other method of filtering. Pumping out of creeks, rivers, lakes and ponds can introduce plenty of solids into your tanks if you are not filtering this fluid. When obtaining water out of a fire hydrant, there can be a lot of sand in the line, so don’t assume it’s clean and ensure it’s filtered before use.

Cavitation is a whole other detailed discussion, but all triplex pumps have a minimum amount of suction pressure that is required to run properly. Make sure this suction pressure is maintained at all times or your pump may cavitate. If you run a pump that is cavitating, it will shorten the life of all fluid end expendables and, in severe cases, can lead to gear end and fluid end destruction. If the pump is experiencing cavitation issues, the problem must be identified and corrected immediately.

The long and the short of it is to use clean drilling fluid and you will extend the life of your pumps expendables and downhole tooling, and keep up with your maintenance on the gear end of your pump. Avoid pump cavitation at all times. Taking a few minutes a day to inspect and maintain your pump can save you downtime and costly repair bills.

Cavitation is an undesirable condition that reduces pump efficiency and leads to excessive wear and damage to pump components. Factors that can contribute to cavitation, such as fluid velocity and pressure, can sometimes be attributed to an inadequate mud system design and/or the diminishing performance of the mud pump’s feed system.

Although cavitation is avoidable, without proper inspection of the feed system, it can accelerate the wear of fluid end parts. Over time, cavitation can also lead to expensive maintenance issues and a potentially catastrophic failure.

When a mud pump has entered full cavitation, rig crews and field service technicians will see the equipment shaking and hear the pump “knocking,” which typically sounds like marbles and stones being thrown around inside the equipment. However, the process of cavitation starts long before audible signs reveal themselves – hence the name “the silent killer.”

Mild cavitation begins to occur when the mud pump is starved for fluid. While the pump itself may not be making noise, damage is still being done to the internal components of the fluid end. In the early stages, cavitation can damage a pump’s module, piston and valve assembly.

The imperceptible but intense shock waves generated by cavitation travel directly from the fluid end to the pump’s power end, causing premature vibrational damage to the crosshead slides. The vibrations are then passed onto the shaft, bull gear and into the main bearings.

If not corrected, the vibrations caused by cavitation will work their way directly to critical power end components, which will result in the premature failure of the mud pump. A busted mud pump means expensive downtime and repair costs.

Washouts are one of the leading causes of module failure and take place when the high-pressure fluid cuts through the module’s surface and damages a sealing surface. These unexpected failures are expensive and can lead to a minimum of eight hours of rig downtime for module replacement.

To stop cavitation before it starts, install and tune high-speed pressure sensors on the mud suction line set to sound an alarm if the pressure falls below 30 psi.

Although the pump may not be knocking loudly when cavitation first presents, regular inspections by a properly trained field technician may be able to detect moderate vibrations and slight knocking sounds.

Gardner Denver offers Pump University, a mobile classroom that travels to facilities and/or drilling rigs and trains rig crews on best practices for pumping equipment maintenance.

Program participants have found that, by improving their maintenance skills, they have extended the life of fluid end expendables on their sites. They have also reported decreases in both production and repair costs, as well as reductions in workplace hazards.

Severe cavitation will drastically decrease module life and will eventually lead to catastrophic pump failure. Along with downtime and repair costs, the failure of the drilling pump can also cause damage to the suction and discharge piping.

When a mud pump has entered full cavitation, rig crews and field service technicians will see the equipment shaking and hear the pump ‘knocking’… However, the process of cavitation starts long before audible signs reveal themselves – hence the name ‘the silent killer.’In 2017, a leading North American drilling contractor was encountering chronic mud system issues on multiple rigs. The contractor engaged in more than 25 premature module washes in one year and suffered a major power-end failure.

Gardner Denver’s engineering team spent time on the contractor’s rigs, observing the pumps during operation and surveying the mud system’s design and configuration.

The engineering team discovered that the suction systems were undersized, feed lines were too small and there was no dampening on the suction side of the pump.

There were also issues with feed line maintenance – lines weren’t cleaned out on a regular basis, resulting in solids from the fluid forming a thick cake on the bottom of the pipe, which further reduced its diameter.

Following the implementation of these recommendations, the contractor saw significant performance improvements from the drilling pumps. Consumables life was extended significantly, and module washes were reduced by nearly 85%.

Although pump age does not affect its susceptibility to cavitation, the age of the rig can. An older rig’s mud systems may not be equipped for the way pumps are run today – at maximum horsepower.

I’ve run into several instances of insufficient suction stabilization on rigs where a “standpipe” is installed off the suction manifold. The thought behind this design was to create a gas-over-fluid column for the reciprocating pump and eliminate cavitation.

When the standpipe is installed on the suction manifold’s deadhead side, there’s little opportunity to get fluid into all the cylinders to prevent cavitation. Also, the reciprocating pump and charge pump are not isolated.

The gas over fluid internal systems has limitations too. The standpipe loses compression due to gas being consumed by the drilling fluid. In the absence of gas, the standpipe becomes virtually defunct because gravity (14.7 psi) is the only force driving the cylinders’ fluid. Also, gas is rarely replenished or charged in the standpipe.

Installing a suction stabilizer from the suction manifold port supports the manifold’s capacity to pull adequate fluid and eliminates the chance of manifold fluid deficiency, which ultimately prevents cavitation.

Another benefit of installing a suction stabilizer is eliminating the negative energies in fluids caused by the water hammer effect from valves quickly closing and opening.

The suction stabilizer’s compressible feature is designed to absorb the negative energies and promote smooth fluid flow. As a result, pump isolation is achieved between the charge pump and the reciprocating pump.

The isolation eliminates pump chatter, and because the reciprocating pump’s negative energies never reach the charge pump, the pump’s expendable life is extended.

Investing in suction stabilizers will ensure your pumps operate consistently and efficiently. They can also prevent most challenges related to pressure surges or pulsations in the most difficult piping environments.

Created specifically for drilling equipment inspectors and others in the oil and gas industry, the Oil Rig Mud Pump Inspection app allows you to easily document the status and safety of your oil rigs using just a mobile device. Quickly resolve any damage or needed maintenance with photos and GPS locations and sync to the cloud for easy access. The app is completely customizable to fit your inspection needs and works even without an internet signal.Try Template

Fulcrum lets employees on the floor who actually are building the product take ownership. Everyone’s got a smartphone. So now they see an issue and report it so it can be fixed, instead of just ignoring it because that’s the way it’s always been done.

One of the big things you can’t really measure is buy-in from employees in the field. People that didn’t want to go away from pen and paper and the old way of doing things now come to us and have ideas for apps.

Easy to custom make data collection forms specific to my needs. Very flexible and I can add or adjust data collection information when I need it. The inclusion of metadata saves a lot of time.

If you run a mud rig, you have probably figured out that the mud pump is the heart of the rig. Without it, drilling stops. Keeping your pump in good shape is key to productivity. There are some tricks I have learned over the years to keeping a pump running well.

First, you need a baseline to know how well your pump is doing. When it’s freshly rebuilt, it will be at the top efficiency. An easy way to establish this efficiency is to pump through an orifice at a known rate with a known fluid. When I rig up, I hook my water truck to my pump and pump through my mixing hopper at idle. My hopper has a ½-inch nozzle in it, so at idle I see about 80 psi on the pump when it’s fresh. Since I’m pumping clear water at a known rate, I do this on every job.

As time goes on and I drill more hole, and the pump wears, I start seeing a decrease in my initial pressure — 75, then 70, then 65, etc. This tells me I better order parts. Funny thing is, I don’t usually notice it when drilling. After all, I am running it a lot faster, and it’s hard to tell the difference in a few gallons a minute until it really goes south. This method has saved me quite a bit on parts over the years. When the swabs wear they start to leak. This bypass pushes mud around the swab, against the liners, greatly accelerating wear. By changing the swab at the first sign of bypass, I am able to get at least three sets of swabs before I have to change liners. This saves money.

Before I figured this out, I would sometimes have to run swabs to complete failure. (I was just a hand then, so it wasn’t my rig.) When I tore the pump down to put in swabs, lo-and-behold, the liners were cut so badly that they had to be changed too. That is false economy. Clean mud helps too. A desander will pay for itself in pump parts quicker than you think, and make a better hole to boot. Pump rods and packing last longer if they are washed and lubricated. In the oilfield, we use a petroleum-based lube, but that it not a good idea in the water well business. I generally use water and dish soap. Sometimes it tends to foam too much, so I add a few tablets of an over the counter, anti-gas product, like Di-Gel or Gas-Ex, to cut the foaming.

Maintenance on the gear end of your pump is important, too. Maintenance is WAY cheaper than repair. The first, and most important, thing is clean oil. On a duplex pump, there is a packing gland called an oil-stop on the gear end of the rod. This is often overlooked because the pump pumps just as well with a bad oil-stop. But as soon as the fluid end packing starts leaking, it pumps mud and abrasive sand into the gear end. This is a recipe for disaster. Eventually, all gear ends start knocking. The driller should notice this, and start planning. A lot of times, a driller will change the oil and go to a higher viscosity oil, thinking this will help cushion the knock. Wrong. Most smaller duplex pumps are splash lubricated. Thicker oil does not splash as well, and actually starves the bearings of lubrication and accelerates wear. I use 85W90 in my pumps. A thicker 90W140 weight wears them out a lot quicker. You can improve the “climbing” ability of the oil with an additive, like Lucas, if you want. That seems to help.

Outside the pump, but still an important part of the system, is the pop-off, or pressure relief valve. When you plug the bit, or your brother-in-law closes the discharge valve on a running pump, something has to give. Without a good, tested pop-off, the part that fails will be hard to fix, expensive and probably hurt somebody. Pop-off valve are easily overlooked. If you pump cement through your rig pump, it should be a standard part of the cleanup procedure. Remove the shear pin and wash through the valve. In the old days, these valves were made to use a common nail as the shear pin, but now nails come in so many grades that they are no longer a reliable tool. Rated shear pins are available for this. In no case should you ever run an Allen wrench! They are hardened steel and will hurt somebody or destroy your pump.

One last thing that helps pump maintenance is a good pulsation dampener. It should be close to the pump discharge, properly sized and drained after every job. Bet you never thought of that one. If your pump discharge goes straight to the standpipe, when you finish the job your standpipe is still full of fluid. Eventually the pulsation dampener will water-log and become useless. This is hard on the gear end of the pump. Open a valve that drains it at the end of every job. It’ll make your pump run smoother and longer.

Instead of using paper checklists when out in the field, drilling contractors and rig inspection services can generate a new inspection form from anywhere and the results are saved electronically.

Specifically designed for drilling companies and others in the oil and gas industry, the easy to use drilling rig inspections app makes it easy to log information about the drill rigs, including details about the drill rigs operators, miles logged and well numbers. The inspection form app covers everything from the mud pump areas and mud mixing area to the mud tanks and pits, making it easy to identify areas where preventative maintenance is needed. The drilling rig equipment checklist also covers health and safety issues, including the availability of PPE equipment, emergency response and preparedness processes, and other critical elements of the drilling process and drill press equipment.

A comprehensive range of mud pumping, mixing, and processing equipment is designed to streamline many essential but time-consuming operational and maintenance procedures, improve operator safety and productivity, and reduce costly system downtime.

The 2,200-hp mud pump for offshore applications is a single-acting reciprocating triplex mud pump designed for high fluid flow rates, even at low operating speeds, and with a long stroke design. These features reduce the number of load reversals in critical components and increase the life of fluid end parts.

The pump’s critical components are strategically placed to make maintenance and inspection far easier and safer. The two-piece, quick-release piston rod lets you remove the piston without disturbing the liner, minimizing downtime when you’re replacing fluid parts.

Completed Maintenance DatabaseOnce the repair is competed the item is moved to the Completed Maintenance Database is the complete history of repairs carried out on the rig and this is the one that the client will want to see to verify the rig maintenance is up to date.

To edit or add additional checks to any of the checklists n Rig Maintenance, editing is done in the edit section and linked to the checklist. You can add to or edit any checklist in the editor.

If you have installed the PM Schedule all the rig equipment listed details will be linked in the Schedule which can be edited to reference any equipment due for scheduled checks as Daily, Weekly, Monthly Due or Completed maintenance

Set up the recommended service hours in the editor. Add the recommended service hours for each piece of equipment This section is linked to the monthly hours and the service hours. A visual warning shows if any equipment has exceeded the recommended hours At the end of the month the month hours are transferred to the monthly service hours which lists the total running hours for the month any equipment over service hours is indicated in RED Click on the cell to indicate the service has been carried out to zero the hours and start a new month’s running hours.

SDS PMS Equipment: Mud Pump Department: Mechanical Manufacturer: Gardner Denver Frequency: Annually Model: PZ-8/9 Issued: PSS Code: GA-327-32 Completed:Item Level Inspect Description

1. [M3] [ ] Insure proper work permits are obtained before performing maintenance on this equipment. 2. [M3] [ ] Insure personnel performing this maintenance is familiar with the equipment and manufacturer"s operation and maintenance manual before beginning. 3. [M2] [ ] Make arrangements with the Rig Superintendent before performing this task and insure that it will not affect the drilling operations. 4. [E2] [ ] Isolate and tag out the electric power to the mud pump. 5. [M3] [ ] Close and tag out the pump suction and discharge valves.

Condition Evaluation Particulars Equipment Description: Manufacturer Model: Serial Number PSS Code & Tag Number: Maximum Input Power Driven By: Rig Name District Date of Condition Evaluation: Cummulative Hours on Pump: Hours/Date of Last Condition Evaluation Person in Charge of Condition Evaluation

SDS PMS Equipment: Mud Pump Department: Mechanical Manufacturer: Gardner Denver Frequency: Annually Model: PZ-8/9 Issued: PSS Code: GA-327-32 Completed:Item Level Inspect Description

1. [M3] [ ] Inspect condition of lube oil. If in good condition take a representitive sample and send for laboratory analysis.

2. [M3] [ ] If lube oil is contaminated, drain and flush the crankcase. Clean out the settling chamber in the forward part of the power end floor. Thoroughly clean the oil troughs and the compartment in top of the crosshead guide. Clean the element in the breather cap and clean the suction screen. Refill using Shell Omala 220.or equivalent oil; 130 US gallons. 3. [M3] [ ] Drain and flush clean the chain drive case. Clean the breather element. Refill using Shell Vitrea 150 or equivalent oil 4. [M3] [ ] Remove the all bearing and crankcase covers for inspection of the following components. Insure nothing drops inside. 1. Check the safety retaining wires on all bolts including the main bearing hold down bolts, eccentric bearing retainer bolts and gear retainer bolts. Replace any broken wires after re- tightening the bolts. Refer to crankshaft assembly section for torque values. 2. Visually inspect all bearings for damage or wear while rotating pump slowly. With a feeler gauge check and record all bearing diametrical clearances. Record the condition and clearances on the Checking Form below. 3. Inspect the ring wear and oil seal condition on the left and right side main bearings. 4. Inspect all main and eccentric bearings for cracked inner & outer bearing races. Inspect the bronze bearing cages for damage or cracks. 5. Make a complete visual inspection of all components checking for looseness, wear or damage. 6. Check the main and pinion gears for condition and wear. Measure and record the backlash. 7. Check each connecting rod retaining bolts for tightness and retaining wires for proper installation. 8. Run lube oil pump and insure all nozzles are free and clear and have a good spray pattern. 5. [M3] [ ] Remove the diaphragm stuffing box and plate. Check the safety retaining wires of the extension rods insuring none broken or missing. Where wire is broken or missing inspect all bolts for crack and thread damage. Retorque to 350 - 370 ft/lbs. Re-install all safety retaining wires. 6. [M3] [ ] Renew lip oil seal and "O" rings, clean and replace plate and stuffing box. Torque bolts to 12 - 18 ft/lbs.

SDS PMS Equipment: Mud Pump Department: Mechanical Manufacturer: Gardner Denver Frequency: Annually Model: PZ-8/9 Issued: PSS Code: GA-327-32 Completed:Item Level Inspect Description

7. [M3] [ ] Remove the ispection covers for the crossheads and carry out the following ispections: 1. Check crosshead pin retainer bolt tightness using torque wrench. Torque value 210 ft/lbs. Insure all locking wire is properly installed 2. Measure the play of the bearing, roller and crosshead pin. Record the readings on the checking form below. 3. Check crosshead clearance, use a feeler gauge between crosshead and upper crosshead guide. Do not operate pump with less than 0.010" clearance. Record the clearances on the Checking Sheet below. They should be .010 - .020. 4. Inspect crosshead and guides for condition and uniform wear. Insure there are no scratches or abnormal wear on the upper or lower slide guides. 5. Check the crosshead slide to frame bolts for tightness. 6. Check the pony rod (extension rod) surface condition for damage or scratches. A deterirated surface will cause premature failures of seals. 7. Check the pony rod to crosshead bolts for correct tighness.

8. [M3] [ ] Check for proper crosshead alignment. Refer to manufacturer"s manual for correct method to use. Record below: Top Front Top Back #1 Cylinder #2 Cylinder #3 Cylinder Note: If the centreline of the extension rod exceeds 0.015" low, re-shimming of guides is necessary

Misalignment can be detected by uneven wear on the pony (extension) rods. Premature liner wear will also be a result. Refer to the mud pump fluid end log book for signs of premature liner wear.

9. [M3] [ ] Check all drive chain and sprockets for wear. New chain - 20 P. = 30" Worn out chain = 30.750" Record the measurements on the Checking Sheet below. 10. [M3] [ ] Inspect and test run the chain oil pump. Overhaul and align as necessary. 11. [M3] [ ] Inspect and test run the gear oil pump. Overhaul and align as necessary. 12. [M3] [ ] Renew the oil pump filter element. 13. [M3] [ ] Inspect and test run the flushing pump. Overhaul, repack and align as necessary.

SDS PMS Equipment: Mud Pump Department: Mechanical Manufacturer: Gardner Denver Frequency: Annually Model: PZ-8/9 Issued: PSS Code: GA-327-32 Completed:Item Level Inspect Description

14. [M3] [ ] Inspect the pony rod end and clamp for wear, damage and cracks. It is essential that a good face to face spigot connection of these rods is maintained. Improper tightening, dirt or debris on the faces when clamped up or the mixing of clamp halves, can lead to fatique cracking of the clamp area. Insure that drilling department is installing the clamps correctly. They must always be torqued evenly with equal gaps between clamp halves is maintained.

15. [M3] [ ] Clean breathers on chain case and gear box. 16. [M3] [ ] Restore power to unit and remove tag. 17. [M3] [ ] Check chain lube oil pressure and record ________ psi. 18. [M3] [ ] Check gear box lube oil pressure and record ________ psi. 19. [M3] [ ] Simulate electric driven gear lube oil pump failure: Record pressure_________ psi. Min 30 psi, max 40 psi. 20. [M3] [ ] Make a complete internal inspection to insure all tools and rags have been removed. Replace all covers and reconnect the pony rod clamp. Make a complete inspection around unit insuring pump condition is ready for operation.

CAUTION: Use extreme caution whenever using RTV for sealing the gaskets faces. Do not use RTV if possible. In many cases pumps have been totally ruined, when too much RTV is applied; the excess gets squeezed into the pump mixing in the oil and eventually plugging oil passages resulting in failures.

Maximum Allowable Bearing Wear The following are figures found to be pactical and acceptable in determining the condition of the bearings. These figures apply provided that the bearings have passed a visual inspection. The highest values are extreme outer limits and in some cases the bearing may begin to spall which will result in damage to other components. Bearing wear and spalling will first be detected in a lube oil analysis.

0.008 - 0.010 Okay to run untill the next annual inspection 0.011 - 0.013 Replace at the next scheduled maintenance. 0.014 - 0.016 Replace at first opportunity. 0.017 and greater Stop Pump and replace immediately.

21. [M3] [ ] Enter details of completion on PMS history card. and file a copy of the completed Condition Evaulation form in the maintenance file.

SDS PMS Equipment: Mud Pump Department: Mechanical Manufacturer: Gardner Denver Frequency: Annually Model: PZ-8/9 Issued: PSS Code: GA-327-32 Completed:Item Level Inspect Description

File: Document1 Last Revised: November 14, 2017 Page 5 of 9 Drilling Services

SDS PMS Equipment: Mud Pump Department: Mechanical Manufacturer: Gardner Denver Frequency: Annually Model: PZ-8/9 Issued: PSS Code: GA-327-32 Completed:Item Level Inspect Description

Guidelines for Replacing a Roller Chain Roller chain is recognized as an exceptionally dependable means for the positive transmission of power. To assure optimum performance and maximum efficiency, it is desirable to anticipate the occasional need for chain replacement, thereby avoiding unexpected interruption or delays in operation. Joint wear, certain overload conditions, metal fatigue, or pitch elongation will limit the useful life of any chain; therefore, the following information will aid in determining when chain replacement is advisable. Effects of Chain Wear During operation, chain pins and bushings slide against each other as the chain engages, wraps, and disengages from its sprockets. Even when the parts are well-lubricated, some metal-to-metal contact does occur, and these parts eventually will wear. This progressive joint wear elongates chain pitch, causing the chain to lengthen and ride higher on the sprocket teeth. The number of teeth in the large sprocket determines the amount of joint wear that can be tolerated before the chain jumps or rides over the ends of the sprocket teeth. When this critical degree of elongation is reached, the chain must be replaced.

Determination of Chain Wear An evaluation of a chain"s useful service life requires an analysis of pitch elongation. By placing a certain number of pitches under tension, elongation can be measured. When elongation equals or exceeds the limits in Table 1, chain should be replaced. The following procedure is suggested: 1. Remove chain from sprockets and lay on smooth, horizontal surface or suspend vertically. To remove slack from a chain measured in a horizontal position, refer to Table2 and apply the load indicated for the size chain involved. If chain must be measured while on sprockets, remove slack on a span of chain and apply sufficient tension to keep chain taut. See Figure below. 2. When chain is properly tensioned, consult Table 1 for the number of pitches which should be measured. This number is determined by chain size and number of teeth in largest sprocket. Pitches should be measured from center to center of pins as shown in Figure above. A steel tape will facilitate accurate measurement. If chain has offset links, do not include them in the measured segment. Select the appropriate column according to number of teeth in largest sprocket and compare published figure with measurement taken. If measurement equals or exceeds figure in Table 1, chain should be replaced.

SDS PMS Equipment: Mud Pump Department: Mechanical Manufacturer: Gardner Denver Frequency: Annually Model: PZ-8/9 Issued: PSS Code: GA-327-32 Completed:Item Level Inspect Description

Chain Measuring Length Number of Teeth in the Largest Sprocket Number ANSI Pitch Number Nominal Length of Chain (inches) When Replacement is Required Inches Of Length Pitches Inches 35 .375 32 12.00 12.38 12.34 12.31 12.28 12.25 12.22 12.19 12.16 40 .500 24 12.00 12.38 12.34 12.31 12.28 12.25 12.22 12.19 12.16 50 .625 20 12.50 12.88 12.59 12.81 12.78 12.75 12.72 12.69 12.66 60 .750 16 12.00 12.38 12.34 12.31 12.28 12.25 12.22 12.19 12.16 80 1.00 24 24.00 24.75 24.69 24.63 24.56 24.50 24.44 24.38 24.31 100 1.250 20 25.00 25.75 25.69 25.63 25.56 25.50 25.44 25.38 25.31 120 1.500 16 24.00 24.75 24.69 24.63 24.56 24.50 24.44 24.38 24.31 140 1.750 14 24.50 25.25 25.19 25.13 25.06 25.00 24.94 24.88 24.81 160 2.000 12 24.00 24.75 24.69 24.63 24.56 24.50 24.44 24.38 24.31 180 2.250 11 24.75 25.50 25.44 25.38 25.31 25.25 25.19 25.13 25.06 200 2.500 10 25.00 25.50 25.44 25.38 25.31 25.25 25.19 25.13 25.06 240 3.000 8 24.00 24.75 24.69 24.63 24.56 24.50 24.44 24.38 24.31

If a chain breaks or fails due to broken pins, sidebars, or rollers, emergency temporary repairs may be required in order to avoid a long shutdown. However, replacement of the entire chain is preferred for the following reasons: 1. If one section of a chain has broken because of fatigue, other sections probably have suffered fatigue damage as well and are subject to early failure. 2. If the chain has been broken by a single high overload, parts other than those at the point of failure are usually bent or severely weakened.

SDS PMS Equipment: Mud Pump Department: Mechanical Manufacturer: Gardner Denver Frequency: Annually Model: PZ-8/9 Issued: PSS Code: GA-327-32 Completed:Item Level Inspect Description

Proper chain tension is obtained by adjusting the sag (catenary) in the unloaded span. For most horizontal and inclined drives, chain should be installed with a depth of sag amounting to approximately 2% of the sprocket centers. See Table 3 for proper sag for various sprocket centers. To measure sag, pull the bottom span of the chain taut, allowing all of the excess chain to accumulate in the upper span. Then, place a straightedge on top of the sprockets and use a scale to measure sag. See figure below. For drives on vertical centers, or those subject to conditions such as shock loads, rotation reversals, or dynamic braking, install chain almost taut. It is essential to inspect such drives regularly for correct chain tension.

Table 3. Chain Sag Based On 2% of Sprocket Centers Sprocket Centers, Sag in Inches Inches 20 .50 30 .63 40 .88 60 1.25 80 1.63 100 2.00 125 2.50

SDS PMS Equipment: Mud Pump Department: Mechanical Manufacturer: Gardner Denver Frequency: Annually Model: PZ-8/9 Issued: PSS Code: GA-327-32 Completed:Item Level Inspect Description