FS-205BD Rev. 7/96 @& NATIONAL OILWELL FC-2200 TRIPLEX MUD PUMP OPERATION & MAINTENANCE Any references to Continental Emsco shall be deemed to mean National-Oilwell.PREFACE This manual is provided for guidance of those who wish to install, repair, maintain, or adjust the National-Oilwell Products equipment covered herein. This information has been prepared with a basic viewpoint to give accurate and concise data needed to perform minor adjustments as well as major overhauls, This information is not elementary, as it is intended for operators and servicemen who are familiar with drilling equipment in general. It is not intended, nor would it be possible in such limited space, to cover every possible condition which may be encountered. Always use good, sound mechanical practices and safety precautions All specifications are in accordance with Engineering designs and should be adhered to in all repairs. Operation and maintenance information on equipment other than National-Oilwell Products is taken in part from the various manufacturers’ manuals. If the equipment manufacturers issue later instructions, or in the event of conflict, the manufacturer's information will take precedence over that shown in this manual, unless specifically stated otherwise. The manual sections follow logical divisions in major components, and cover all standard production unless otherwise specified. Specifications and components covered are for standard equipment current at the time this manual was approved for printing, National-Oilwell Products reserves the right to discontinue models at any time, or change specifications or design of any model without notice and without incurring any obligationSAFETY IN ORDER TO PREVENT PERSONAL INJURY during performance of any] maintenance or inspection procedures, this equipment must be shut down and not loperating. Each motor and generator is equipped with a motor cutout switch. This switch should be IN, and the safety bar in place, when any maintenance or inspection procedures are performed. Employ good mechanical practices when making maintenance repairs, adjustments, inspections, etc. COMES [When operating all mechanical and electrical equipment, all safety devices must be| engaged, properly adjusted, and in good operating condition, including overtravel] devices for traveling blocks, warning or shutdown devices for engines, ete. FIRSTFS-2058D FC-2200 PUMP OPERATION AND MAINTENANCE MANUAL INDEX Section 1 General Information Section 2 Installation Section 3 Commissioning Section 4 Operation Section 5 Maintenance Section 6 Fluid End Section 7 Lubrication Section 8 Fault Finding & Corrections Section 9 Does Not Apply Section 10 Parts Lists and Drawings Section 11 Recommended spare Parts List Section 12 Miscellaneous Vendor DataA\..Continental Emsco Company GENERAL INFORMATION DESCRIPTI General Dimensions Specifications. Performance Data. Description of Components [NAWPSVsiush-mudiPC-2200.co\FS.205-01,doe SECTION 1 INDEX FS-205 1.0 PAGE NO.FS-205 Ll GENERAL INFORMATION GENERAL DIMENSIONS INCHES | MILLIMETERS INCHES | MILLIMETERS A_| 239.0 6071 H 86.00 2184 B | 8375 | 2127 J 14,25 362 c | 27.50 699 kK 67.50 1745 D | 66.50 | 1689 L 56.13 1426 E | 2413 613 mM | 59.25 1505, F | 42.50 | 1080 N 10.00 254 G | 14.00 356 aa 875) Keyway | Continuous HP Rating Stroke Length Max. Liner Rated Speed Valve Pot Size Approximate Weight SPECIFICATIONS 2200 1641 KW foe 381mm 8" 203 mm 100 SPM Max. API #8 79,600 Ibs. 36,100 Kg. [NAWPS\slush-mud\EC-2200 001 FS-205-01 doeFS-205 12 PERFORMANCE DATA: FC-2200 TRIPLEX PUMP (8"X15") PERFORMANCE DATA 7500 PSI MAXIMUM DISCHARGE PRESSURE LINER/PLUNGER SIZE AND RATING LINERS PLUNGERS Inch |—@.00 ] 7-50 ]7.00 | 6.50 6.00. [5.50 [5.05 |5,00 wm) | (203) | aor | azar | aes) | casa) | (ao) | (33) | 27) PST aes [3843 [4527 [5250 | 6161 | 7332 | 7500 | 7500 car) | (239) | (272) | (312) | (62) | (a2s)_| (505)_| (sa7)_| (517) SEM EE VOLUME — GALLONS PER MINOTE (ea) (VOLUME LITTERS PER MINUTE) Too [2200 o75 Ber 750 646 SL 463 422 382 (2642) | (3706) | (3258) | (2e38) | (2447) | (2085) | (1752) | (as97) | (2446) 30 1380 Bar 775 675 38 296 a7 380 344 (2477)_| (3336) | (2932) | (2554) | (2202) | (2876) | (1577) | (2438) | (2301) 80 1760 Tas a8 600 3i7 rrr 370 338 306 (2313) | (2965) | (2606) | (2270) | (1958) | (2668) | (2402) | (2279) | (2157) 70 1540 a5 602 525 452 386 324 295 287 (214s) | (2595) | (2280) | (2987 | (2713) | (2459) | (226) _| (2227) | (2012) 60 7320 587 316 450 388 330 278 253 223 (985) | (2224) | (2955) | (2702) | (2468) | (1252) | (2051) | (958) | (868) GAL_PER_REV. ses [peso tee |e 50m |e = 46S 52 tac osed|areeazme|eeo earl ure.per Rev. | (37.1) | (32.6) | (28.3) | (24.4) | (20.9) | (27-5) | as.0) | (24-5) Based on 100% volumetric efficiency and 90% mechanical efficiency. 7500 PSI (517 Bar) maximum fluid end pressure rating, [NAWESIsushmud\FC-2200.c01FS-208-01 doeFS-205 13 SHAFT ROTATION RESTON OF PORE J ( ¢ PiNwow aie ~ centeror (9) Ul GRAVITY Figure 1.1 NAWPSI\shashemdiPC-2200 co FS-205-01 docFS-205 14 3 sous 11 a ‘4. ny oO ret —} i — B) le H TTS | mp — i , ; ; ; Orem {2 a) fig. 12 Refer to Figs. 1.1 and 1.2 for items listed below 1. Power End Converts rotary to reciprocating motion for powering the pistons 2. Fluid End Consists of three L-shaped modules which house the suction and di liners, pistons, and fluid passages. 3. Electric Drive Motors Variable speed DC traction-type motors, Speed is controlled at driller’s console, [NAWPSI\shah-mu F-22000 F8-205-01 doe6. LA %. 10. FS-205 15 V-Belt Drive (Both sides) The belt guards provide enclosure for the 8-V kevlar cord belt drives. An opening at the centerline of pinion shaft provides access for the operator to insert a 1" drive socket extension bar to reach Item 20, the manual rotating device. The guards are constructed such that the DC motors can be moved horizontally to obtain proper belt tension on the drive belts, Gear Case Cover Remove for access to the main bearing cap hold-down bolts and to inspect and service the internal power end assembly. Inspection Door - Gear Case Cover Remove the inspection door for access to th ermal oil pump and suction screen. Inspection Door - Crosshead Compartment Remove door for access to the crossheads, guides, and crosshead bearings of the power end. Liner Wash Pump The electric motor powered centrifugal pump circulates the cooling/wash fluid from the reservoir tank (10) to the circulating system for each of the liner/piston assemblies. The fluid then drains back to the reservoir for recirculation, The recommended fluid for this system is fresh water. The use of salt water is not recommended as it is detrimental to the structural parts of the pump and also because some of the water will invariably find its way into the power end of the pump and the salt water has a very corrosive effect on the bearings. It is essential that the cooling/wash fluid be clean and free of abrasive contamination to obtain optimum service life from the pistons and liners Liner Wash Reservoir The reservoir tank provides an enclosed system for the liner wash fluid. The tank is divided into two sections - the settling chamber and the suction reservoi Contaminated fluid returns to the settling chamber where the heavy solids will settle out. It then passes through a screen into the suction reservoir. [NAWPSI\suth-mudFC-2200oo1F8-205-01.4001. 12, 13. 14. 15, 16. 17. FS-205, 16 Liner Wash FI Regulator Valve This valve is to regulate the flow of water to the liner wash circulating system. Regulate valve to provide the maximum flow possible without splashing onto the crosshead extension rods Suction Manifold Suction and supercharging system can be connected to the center flange or on either end. Discharge Manifold The discharge manifold is bolted to each fluid end section and provides a common fluid passage from the discharge ports on each fluid end section. Accessory Manifold The accessory manifold attaches to one end of the discharge manifold and provides mounting provisions for the pulsation dampener, pressure relief valve, and the discharge pressure gauge. Pulsation Dampener Service per Manufacturers instruction. Discharge Strainer Housing AA strainer screen is installed in the discharge housing for the purpose of preventing large chunks of debris from being pumped into the drill string and plugging bit jets. Routinely remove discharge strainer cover and clean the screen. Clean Out Plugs - Power End Remove caps on either or both sides of the pump to drain and flush power end oil reservoir. Clean Out Plugs - Crosshead Compartment Remove cap on both sides of the pump to drain off any contamination that has settled into the sump located under the lower crosshead guide. See maintenance section for schedule Excess quantities of water or mud emulsion could indicate worn or bad diaphragm stuffing box seals or wiper seals. [NAWPStsash-mudFC-2200.c01FS-205-01.d0019. 20, 2. 22. 23, FS-205 7 Reset Relief Valve (Not Shown) The reset relief valve is installed on the discharge side of the fluid end, generally on the accessory manifold, and is for the purpose of protecting the pump from excessive high-pressure overloads, The relief valve must be installed so that it is directly exposed to the discharge fluids and must not have any type of shut-off valve between it and the fluid end. The discharge port of the relief valve is to be piped directly into the mud tanks with as few turns as possible and securely anchored in place. DO NOT pipe into the suction manifold, Use pipe and fittings with the same rating as maximum fluid end rating, Set relief valve at approximately 10% above the pressure rating for the liner size being used. Manual Pump Rotating Device Insert 1" (25.4mm) drive socket extension through the hole in the guard (one side only) into recessed square in the rotating spider mounted on pinion shaft. Use ratchet to rotate pump manually. Power End Oil Level Dip Stick (Both Sides) Oil level may be checked from either side of pump. Check oil level with pump shut down, Check each tour. Suction Desurger The suction desurger is mounted internally in the suction manifold. Charge bladder with compressed air as instructed in manual. Service Crane To prevent injury, use crane for handling heavy objects such as liners, valve pot covers, etc., when working on pump. [NAWPSIIslashema C2200 co FS-205-01 doeFS-205, 2.0 AX. Continental Emsco Company SECTION 2 INSTALLATI EX DESCRIPTIO! PAG! Mounting Pump on Substructure 20 Suction System . = Boa SD-8 Suction Desurger....... cae 2S Discharge Housing with Strainer. 12.5 Accessory Manifold 25 Pulsation Dampener. 25 Liner Wash System 26 Water Supply. . . 26 Fluid End Expendables, 2.6 [NaWPS1'sushadFC-2200 0 1.205-02 doeINSTALLATION | aa \ {| | YA ! iY t: i DIRECTON OF en cen oop || ¢ Pro Z fF 1 IN 61.50 \ Ee 5 FS (562), : e ott, —— 104.75 L 5 1 Yr (2661) CENTER PF : GRAVIT' 6a 64 64 a (1626) 1 626) (1626) 3.75 . - (2127) 7 239 (6071) Fig. 2.1 Mounting Pump on Structure FS-205, 21 5A 10} & PUNE. Figure 2.1 shows the minimum points of support required on each of the two pump skids, Adequate supports are the responsibility of the purchaser. At installation, DO NOT deflect flanges on pump skid beams when clamping the skids to the support. Where necessary, shim any gap present to prevent twist or distortion. The shims should extend the full width of the flanges on both the pump skids and the support beams. [AWPS'eush-mud FC-2200<01S-205.02 doe‘oD i a! 6 oak a Figure 2.2 [N:WPST slush mu FC-2200 o\FS-205.02 doeFS-205 23 MOUNTING PUMP ON SUBSTRUCTURE Cont'd; ‘Anchor pump skids to support beams as illustrated in fig. 2.3 shown below. Install shear blocks at each anchor bolt and stops at the end of each skid to position the pump. 1,25" - TUNC Gr.5 (M30X3.5 class 8.8) bolts are recommended. 8 required, RECOMMENDED. 1=1/4°=7 UNC GRS - 1.38[35] DIA HOLES 14 X 82" ‘SKIQ BEAM 758811827] CIR 10 CIR | SKID BEAM suIMS_AS £1 Reouied = 1 t . 4 K 2.78 [70} 7 a 6.06(129] 4] +] 6,00[152] ™] 10.3{257]4 MIN . { ian 12,0051] Fig. 23 For installation on floating vessels with maximum acceleration forces of 0.5g horizontal and 1.5g vertical, use the bolt pattern shown in Fig, 2.4 1.00-8 UNC Ge, 8 BOLTS ARE RECOMMENDED. 16 REQUIRED RECOMENDED xe (2 EAGH/16 BOLTS TOTAL) SKID SEAM Se Tatas 75.88 [1927] WOR HUES ag | KD BEAM SHS AS ECOMMENDED ) | Reaves SUPPORT PONT PER ARRANGEMENT i 7 WG. (8 PLACES) ——-—+ soos! | 5.06 [129]. 1200 [305] 1 1013 [257} yi NIN Fig. 2.4 [NAWPS Push mud FC-2200. 000 /.00aT 700 /.10T Gear to Flange z ooxt/.00st 031/.137 Brg. Carrier to Frane P 000 /.00aT 200 /.08T Outer Race to Bore ¢ 0004n/.00247 06n/. 0127 Inner Race to Pin # ooz2t/.00asT 5 [NaWESI'SLUSH-MUDIEC-2200,CO¥FS20SBD05 DOCFS-205BD 58 CRANKSHAFT ASSEMBLY The crankshaft assembly consists of the crankshaft, the ring gear, eccentric strap with bearings, and the main bearing, The running clearances of the bearings are predetermined by their precision fit to the shaft and their respective bores. When performing any maintenance or overhaul, make sure the fits shown in Chart II are obtained. Assembly the crankshaft in the following manner: Reference fig. 5.2 a. Mount gear on flange, Refer to Chart II Position E Thoroughly clean mating faces of ring gear and flange and bolt ring gear into position. Tighten ring gear bolts (2) to 1550 ft. Lbs. (2101 NM) of torque. Set crankshaft on a set of rollers (at main bearing position) and check runout on face of gear with a dial indicator. If total indicator runout exceeds .006" (.15mm), remove gear and determine cause of misalignment NOTE: If runout on face of gear is checked while crankshaft is mounted in the pump frame, the running clearance in main bearings will require that a simultaneous set of dial indicator readings be taken at the end of the shaft and the face of the gear; the actual face runout at any point being the difference between these readings. b. Install the outer races of the eccentric bearings (13) and the outer race retainer ring (3) in the three eccentric straps, Outer race retainer ring must be positioned so that oil scoop is at the bottom when pump is at mid-stroke. Tighten retainer bolts (4) to 73-75 ft. Lbs, (99.101NM) of torque; safety wire bolt heads. NOTE: The inner and outer races of the eccentric bearings are matched and must not be intermixed, Install the outer races of the crosshead bearings (19) in the three eccentric straps. It is, preferred that the outer race assembly be “pressed” into position or frozen in “dry ice” or a deep freeze until it can be inserted into the bore. Under emergency circumstances, the outer race assembly can be installed by using a large torch and heating the eye of the eccentric strap, DO NOT EXCEED 300°F (149°C) (Use Tempil-Stik) and DO NOT USE WATER to cool the strap. NOTE: The inner and outer races of the crosshead bearings are matched and should not be intermixed, NAWPS1\SLUSHE-MUDIFC-2200,COS20SBD08.D0CFS-205BD 5.9 Remove all nicks and burrs from the crosshead pins. Install the inner races of the crosshead bearings on the pins and mark according to their respective eccentric strap positions. After the pins and eccentric straps are cooled to ambient temperature, Make a trial fit to assure the pins will slide freely through the outer roller assembly. If not the bore in the eccentric strap may have shrunk or gone out of round. If this has happened the bearing must be pressed out and the bore reworked. This can usually be accomplished with a large cylinder hone powered with an electric drill. Refer to bearing fit Position H, Chart Il Install inner race of center eccentric bearing on the shaft. Refer to Chart Il, Position C. Allow race to cool to room temperature and slide eccentric strap into position. Install eccentric bearing thrust ring (13) and inner race retainer (5) and tighten retainer bolts (5A) to 107-110 ft. Lbs, (143-149NM) torque. Safety wire retainer bolts. Install eccentric bearing retainer (7) in groove and tighten retainer bolts 97A) to 107-110 ft. Lbs. (143-149NM) torque. Install inner race of the eccentric bearing on the shaft. Refer to Chart Il, Position C. Allow race to cool to room temperature and slide the eccentric strap into position. Install the eccentric bearing thrust ring (13A) and inner races retainer ring (6). Tighten inner race retainer ring bolts (6A) to 73-75 ft. Lbs. (99-101NM) torque and safety wire. Install the inner race of the eccentric bearing on the remaining journal. After race has cooled to room temperature, slide the eccentric strap into position. Install inner race thrust ring (13A) and inner race retainer ring (8). ‘Tighten inner race retainer ring bolts (8A) to 73-7 ft. Lbs. (99-101NM) torque and safety wire. Place main bearings (9) in the main bearing carriers (10 RH and 11 LH) and install outer race retainer (12) and retainer bolts (15). Tighten bolts to 73-75 ft. Lbs. (99-101NM) torque and safety wire Shrink main bearings (9) on each end of the shaft. Install inner race retainers (17) and retainer bolts (18). Tighten retainer bolts to 73-75 ft. Lbs. (99-101NM) torque and safety wire. [NAWPSN\SLUSH-MUDIFC-2200,CO1ES20SBD08 DOCFS-205BD 5.10 INSTALLING CRANKSHAFT ASSEMBLY IN FRAME In order to obtain a more precise fit between the main bearing housing and the frame bore ‘on FC-2200 pumps, the installation procedures outlined below are to be followed: 1. Place piece of wood between eye of eccentric strap and crosshead guide as shown in fig. 5.3 to protect guide from scoring or gouging as the straps are sliding into position. fig. 5.3 2. Rotate the main bearing carrier so that the two flat spots (180° apart) are parallel with the main bearing bolt holes, and slowly lower the crankshaft into position. (The fiat spot provides clearance for the main bearing bolts.) Check main bearing carrier on both ends of the crankshaft to assure the OD of the carriers are seating properly in the frame. NOTE: The main bearing on the RH side is the floating bearing Ifnecessary, bump the carrier to one side or the other to allow carrier to set properly. 3. After placing crankshaft in the frame, and before installing the main bearing caps, rotate the crankshaft manually two complete revolutions to allow the floating outer race to seek its center. Check the rollers in the main bearings to assure that each row of rollers in each bearing is equally loaded, Equal loading is obtained by positioning the floating bearing outer race so that the same number of inner and outer rollers supporting the weight of the crankshaft in each bearing are tight. Because of tolerances, etc., the total number of tight rollers could vary slightly between individual bearings. NAWPSI\SLUSH MUDAFC-2200.COWS20SED05:DOC4, FS-205BD 5.11 Install and shim main bearing caps to obtain .004" (.101mm) clamp or preload on the main bearing carrier. This preload is obtained by placing the correct amount of shims under the main bearing cap. The required amount of shims is determined as follows: fig. 5.4 a. Install .020" (.51mm) shims under both ends of the main bearing cap. b. Place a piece of lead wire (approximately 1/32" diameter) (79mm) or Plastigage between OD of bearing carrier and ID of bearing cap, as near center of bearing cap as can be determined, and tension bearing cap studs is instructed in Step 5. c. Remove main bearing cap and determine clearance between bore of cap and OD of bearing carrier by either measuring thickness of lead wire with a micrometer or measuring compressed dimension of Plastigage. -MUDIFC-2200,COFS20SBD05 DOCFS-205BD 5.12 d. Using this dimension, calculate the required thickness of shims as follows: Subtract thickness of compressed lead or Plastigage from the original .020" (.51mm) shim thickness, Then subtract .004" (1016mm) for preload. The result is the correct shim thickness required. Example: 020" Original Shims 508mm Less .006" Lead Thickness Less .152mm 04 355mm Less .004" Clamp Fit Less .1016mm 010" Correct Shim Thickness 254mm NOTE: Machining tolerances make it necessary to determine individual shim requirements for each (right hand and left hand) main bearing cap. e. Install main bearing caps with the correct amount of shims as determined above, and tension main bearing cap studs as instructed in Step 5. Again check inner and outer row of rollers on each bearing as previously outlined to. assure equal loading is stil present on each bearing. Stud Tensioning Instructions The FC-2200 pump uses studs and nuts in place of bolts to retain the split main bearing cap. This allows a hydraulic stud tensioner unit to be used to tighten the nuts. Special Equipment AHTF 10 stud tensioner unit or equal, and a 10,000-12,000 PSI (689.5-827.4 Bar) hydraulic power unit with appropriate high pressure hoses is required for this procedure. NAWPSI\SLUSH-MUDIEC-2200,CO1S20SBD05 DOCFS-205BD 5.13 Procedure: a. Install (verify) 6323-0072-00 studs at 18" (457mm) stand-off. b. Install cap with shims (per Step 4) and 3-%-8 (82.5mm) Hvy. Hex nuts. Tighten nuts (run down good and snug with hand wrench). c. Install stud tensioner unit on lower stud and pressure to 5000 psi (344.7 Bar), Tighten nut using socket and bar. d. Install stud tensioner unit on upper stud and pressure to 9500 PSI (655.0 Bar). Tighten nut using socket and bar. e. Install stud tensioner unit on lower stud and pressure to 9500 PSI (655.0 Bar). Tighten nut using socket and bar. f. Repeat procedure on second cap. g. To remove caps, install stud tensioner and pressure to 10,000 PSI (689.5 Bar) and loosen nuts two or more tums. NOTE: _ If two HTF 10 stud tensioner units are available with parallel piping, Step C can be omitted and Steps D & E combined Check rollers on top of bearing. No more than four rollers (each row) should be tight. There will be tight rollers on each row at the bottom of the bearing due to the weight of the crankshaft assembly. Safety wire nuts to studs and studs to main bearing cap handle. Tools required to remove or install the crankshaft assembly: 2-5 ton chain blocks 4-1 ton chain block 4-3 ton chain block 4. - HTF 10 Stud Tensioner winut rotating socket to fit 3%’ (82.5mm) hvy. hex nut. Unit to fit 3%"-8N-3A thread. 2-Medium size rosebud heating torches 1 - Tempil Stick 30°F 4 - Set feeler gauges 12” (304mm) long NaWPSI'SLUSHE-MUDIFC-2200,COFS20SBD0s DOCFS-205BD 5.14 INSTALLATION OF CROSSHEAD GUIDES When installing crosshead guides, observe the following procedures and precautions: 1. Thoroughly clean all dirt or contamination and remove all burrs or rough edges from both sides of the guides and the frame bore where the guides fit. 2. If old guides are to be reused, inspect the wearing surfaces for wear and scoring streaks. Upper and lower crosshead guides are NOT interchangeable. The guides are machined so that the lower guide places the crosshead on frame centerline, and upper guides are machined to afford proper crosshead to guide clearance. The guides are marked “UPPER” and “LOWER. They can also be identified by their respective part number, 3. __ Install upper and lower guides. Torque guide screws to 194-200 ft. Lbs. (263-271 NM) torque. Do not install the lock pins at this time. 4, Check between OD of guides (top and bottom) and frame bore with a ,002" (.05 mm) feeler gauge to assure guides are seating properly. No gap should exist. NOTE: FC-2200 Pumps serial numbers 1 through 32 were manufacured with crosshead guide retainer screwswhich had slotted heads and drilled holes in the crosshead guides for a 1/8” locking pin. Effective with serial number 33 the retainer screws were replaced with regular socket head capscrews with a nylon locking device. The lock pin and the drilled holes in the guides were eliminated. This is a time saving feature and allows precise torquing of the screws. Figure 5.5 illustrated the difference between the two designs, ot 86, ne ~e) 8 CANS ees A Old style assembly with Old style slotted head capscrew. New style retainer capscrew. lock pin. Figure 5.5 [Na WESI\SL.USH-MUDIFC-2200,CO¥S205BD05,D0CFS-205BD 5.15 INSTALLATION OF CROSSHEADS: If old crossheads are to be reused, inspect the sliding surfaces for wear or scoring. If necessary, the crossheads may be switched to the opposite sides of the pump and rotated 180° to provide a smooth surface for the bottom of the crosshead. The center crosshead can be rotated 180° and the crosshead pin installed from the opposite side of the pump. It is OK to have grooves in the top surface of the crosshead but ridges and high spots should be smoothed down with a disc grinder. i. To passace [B> 983 POSION[E> Is TION|E> Fig. 5.6 The crossheads are installed from the front of the power end frame by removing the diaphragm stuffing box plate. When installing the crossheads, observe the following precautions: 1. Thoroughly clean all dirt or contamination and remove all burrs or rough edges from OD of the crosshead, crosshead pin bores, and inner bore of crosshead guide. Dry crosshead pin bore so that taper bore connection will make up metal to metal. _NAWPSISLUSHL-MUD\FC-2200.COFS20SBD05 DOCFS-205BD 5.16 2. Starting with the center crosshead, position the crosshead at the front of the guide check the running clearance by sliding long feeler gauges between top of crosshead and upper guide. Check clearance over entire surface of crosshead. Move crosshead to rear of guide and repeat the above check. Clearance should be .020" - 030" (.6 -.76 mm). If clearance is more than .030" (.76 mm) see "CHECKING CROSSHEAD ALIGNMENT" in this section 3. After proper clearance and alignment are established. Install the lock pins for the crosshead guide screws. See fig. 5.5, The slots in the top of the screws must be aligned with the two drilled holes in the crosshead guide counterbore. Be extremely careful as the guides can be easily broken by excessive torque on the screws. 4. Bend the lock pins in the middle until the ends will fit into the counterbore. Align the ‘ends of lock pin with drilled holes in counterbore and straighten pin by driving with a punch and hammer, guiding the ends into the holes and slots in the guide screw. 5. Complete the assembly of center crosshead, pin and extension rod before installing the outside parts. 6. Position eye of the eccentric strap at the opening in the side of the pump frame Block the end of the eccentric strap so that crosshead will clear the eye of the strap as it is sliding into position to where the crosshead pin holes are in alignment. See fig. 5.6 7. Make sure the tapered bores in the crosshead and the tapered surfaces on the crosshead pin (1) are clean, dry, and free of nicks or burrs, and install the crosshead pin LOOSELY into the crosshead bore. NOTE: Position the crosshead pin so that the oil passage A is located at the top of the pin. 8. _ Position the oil through opening at the top and bolt the crosshead pin retainer (2) to the crosshead pin (1). Tighten retainer bolts (3) snug at this point. [NAWPSI\SLUSH-MUDIFC-2200,CO\FS20SBD05 DOC10. FS-205BD 5.17 Rotate the crosshead pin retainer plate (2) to where the four bolts holes are in alignment and install the four retainer bolts (4) as follows: a. Clean threads with Loctite solvent #577 b. Apply Loctite #242 to the threads and screw into place. c. In acriss-cross pattem, tighten the retainer bolts to 165-175 ft. Lbs. (210-237 NM) torque. Install safety wire. d. Clean and apply Loctite to retainer bolt (3) and tighten per above. Install safety wire. NOTE: To prevent distortion of the crosshead, DO NOT EXCEED THE MAKE-UP TORQUE VALUES. Use torque wrench. e. Recheck crosshead clearance. Less running clearance at center of crosshead can be caused by swelling from over tightening the crosshead pin retainer bolts (4). If present, loosen pin and re-tighten into place by using the make-up torques shown. Follow the same procedures for installing the two outside crosshead assemblies. NOTE: To pull the crosshead pin, remove the four crosshead retainer to crosshead bolts (4) and screw two of the bolts into the “jack screw” holes (5). Tighten the two jack screw bolts unti the pin breaks loose. Complete removal of the crosshead pin retainer plate (2) and slide pin out of bore. ‘NAWPS1\SLUSHMUDIEC-2200,CO1FS20SED05 DOCFS-205BD 5.18 CHECKING CROSSHEAD ALIGNMENT In order for the pistons to run true in the liners, the crosshead must travel in a straight line along the horizontal centerline of the frame bore. To check and adjust crosshead alignment, proceed follows: 1. Remove diaphragm stuffing box from the diaphragm plate. Do not remove the plate, 2. Position crosshead at mid stroke, Make sure crosshead is setting flat on bottom. If necessary, insert wedge between top of crosshead and upper guide. With inside calipers or telescoping gauges, accurately measure the distance from the diaphragm plate bore to the crosshead extension rod at the top and bottom. Compare the two measurements to determine the position of the rod relative to the centerline of the bore. 3. If the centerline of the extension rod is more than .015" (381mm) low in the diaphragm plate bore, shims should be inserted under the lower guide at position "B" (4 places) to bring the extension rod back to center, provided there is ample clearance between the top of crosshead and upper crosshead guide. Cut shims from steel shim stock long enough to reach completely across the guides. Avoid use of several thin shims. Always use thick, single shim where possible. 4, Check clearance over top of crosshead with long feeler gauge. Shim top guide to .020" - 030" ( .5 -.76 mm) if necessary. [NWPSIISLUSH.MUD\FC-2200.CO\FS20SBD05.DOCFS-205BD 5.19 INSTALLATION OF CROSSHEAD EXTENSION ROD AND DIAPHRAGM STUFFING BOX SEALS. fig. 5.7 1. Installation of crosshead extension rod. a. Remove diaphragm stuffing box plate (1) from front of crosshead compartment. These plates are line bored with pump frame and MUST NOT be interchanged. b. Rotate pump to where crosshead is at the front of the stroke. Thoroughly clean the face and counterbore on front of the crosshead. Remove any burrs or rough spots. Clean the face and boss of crosshead extension rod and remove any burrs or rough spots. [NAWPSISLUSH-MUDIEC-2200,COWFS20SBD05:DOCFS-205BD 5.20 c. __ Insert alignment boss on crosshead extension rod into crosshead counterbore and tighten the retainer bolts (2) to 660-680 ft. Lbs. (895- 922 NM) torque. Install safety wire and recheck extension rod flange to assure it is mad up metal to metal to the face of the crosshead. d. Reinstall diaphragm stuffing box plate (1) and gasket (1A). Install retainer bolts and lock washers (3) and tighten to 73-75 ft. Lbs. (99- 102 NM) torque. NOTE: Apply Permatex to the bottom three bolts on each diaphragm stuffing box plate to prevent seepage through the bolt threads. 2. Installation of diaphragm stuffing box and packing, a Install the diaphragm stuffing box (4) and gasket (4A) in the bore of the diaphragm stuffing box plate (1). Note “Bottom” stenciled on face of flange and position box to where this is located at the bottom. b The diaphragm stuffing box packing assembly consists of a single lip inner seal (5), @ spacer (6), @ double lip outer seal (7), and a rod wiper 98), Install packing assembly as follows: 1) Remove the spring from the single lip oil seal (5) and slide it on the crosshead extension rod (lip pointing toward power end). 2) Insert spacer (6) over rod and slide it into stuffing box bore. 3) Remove spring from double lip oil seal (7) and place seal in the outer position on the crosshead extension rod with main lip toward power end. Replace the spring in the seal lip and slide the seal into position in the stuffing box. SEE NOTE BELOW. 4) Install rod wiper (8) so that the molded letters “TOP” are located at the top. Install rod wiper retainer plate (9) and tighten capscrews with lock washers (9A) to 14-15 ft. Lbs. (19-20 NM) torque [WAWPS1\SLUSH-MUDIFC-2200,CO1FS20SBD05 DOCFS-205 5.21 APPROXIMATE WEIGHTS OF MAJOR PUMP ASSEMBLIES CAUTION: Before lifting any of the following parts the hoisting equipment should be carefully analyzed to insure it is adequate to handle the load. Pounds Kgs. Crankshaft Assembly Bio. 095 9,570 crankshaft (bare) ......+.. 0s esses eee = 9,648 4,376 Crosshead... 2... cece e cece eee e ene eens 785 356 Crosshead Extension............++e+eee+ 205 93 Crocehead S00 268 122 Crosshead Guide.........--0-.ee eee eee 191 87 Eccentric Strap......-..-eee eee eee eee ee 1,621 735 Gear Case Cover......-.2-.e eee eee eee 694 315 Pinion Shaft............seeeeeee eee eres 3,715 1,685 Ring Gear...... 66. cee e eee e cence cee er eee 2,685 1,118 Fluid End Module (discharge).........- eee 1,666 Fluid End Module (suction)...........- 1,150 522 Discharge Manifold.............--.--+++ 1,248 566 suction Mani folder ee ee 611 277 Thread Ring.... 2-1 se eee ee eee eee eee eee 161 73 Wear Plate..... 6... cece eect ener eee eee 301 137 [NAWPSI\SLUSH.-MUDIFC-2200,COHS20SBD05 DOCFS-20580 522 ‘SERVICE CLEARANCE DIMENSIONS -- 275 (24). FoR Pusan raed fig. 59 CRANKSHAFT ASSEMBLY NaWP51\SLUSH-MUDEEC-2200,CO1FS20SBD05 DOCFS-205BD 5.23 fig. 5.10 PINION SHAFT, SUCTION DESURGER & DISCHARGE STRAINER ‘NAWPSI\SLUSHEMUDIFC-7200 CO}S205BD05.D0CFS-205BD, 6.0 SECTION 6 FLUID END INDEX DESCRIPTION _PAGE NO. Fluid End Maintenance. 64 Fluid End Modules Assembly... 62 ‘Two-Piece Piston Rod. — 64 Welding Procedures. ae 66 Piston and Liner Wash System....... 67 Operation and Maintenance... 69FS-205BD 64 FLUID END MAINTENANCE The high operating pressures of the present day drilling requirements have imposed higher stresses on the fluid end which, when combined with the corrosive characteristics of the driling fluids, have resulted in the demand that more and better maintenance be given to the fluid end parts and pieces if a reasonable operating life is to be obtained. A few of the obvious points are as follows: a. Make sure all valves on the discharge side of pump are opened before pump is put into operation. Kicking pump in against a closed value can often be the start of a fatigue crack. An open crack may not necessarily occur at the precise moment, however, a small crack could occur and start the process of ‘corrosion fatigue failure” b. Do not engage pump when prime mover is running at a high rate of speed. To do so can cause undesirable shock loads against both power end and fluid end, c. Properly maintain pressure relief valve to assure it is set for the pressure rating on the liner size being used. d. Do not operate the pump for an extended period of time if a severe fluid knock is present. The additional stress cycle, although of a lesser magnitude than normal operating loads, must be added to the total number of cycles when considering the fatigue life of the equipment. e. Properly prepare fluid end for storage. When pump is to be shut down or not operated for a period of two weeks or more, it is recommended that the fluid end parts such as liners, pistons, rods, etc., be removed from the pump and the fluid end flushed out completely with fresh water. After a thorough flushing, apply grease or a rust preventative to all of the machined surfaces such as valve pot cover threads, valve pot cover gasket surfaces, valve seats, liner bores, etc. The parts removed from the pump including liners, piston rods, etc., should of course be protected from the elements. This will not only extend the life of the fluid end through resistance to corrosion, but will also protect the usable life still left in the expendable parts and maintain them in good condition for installation in the pump at the next start-up period.FS-205BD 62 ‘The FC-2200 pump features fully interchangeable L-shaped forged steel modules which have separate suction and discharge sections. The two sections can be replaced independent of each other should damage beyond repair occur to either section. Assembly of L-Shaped Modules: DISCHARGE MANIFOLD DISCHARGE ‘MANIFOLD SLOT DOWN 1 — LEAK HOLE DOWN fe) INSTALL WITH fig. 6.1 FC-2200 FLUID END ASSEMBLYFS-205BD 63 Each fluid end module bolts metal to metal to the face of the power end frame through the retainer studs (2). Alignment to the power frame bore is made through wear ring (1). To assure accurate make-up and alignment, all nicks or burrs must be removed from each mating piece and all dirt or foreign matter removed from the metal to metal contact areas. The fit between OD of wear ring (1) and frame bore (Position A) is .002" - 007" (.05- 177mm) loose. a. Lightly oil and install liner seal (3) in counterbore and install wear ring (1) and liner thread ring (4) to where they make up metal to metal to the face of the module and to each other. Tighten retainer nuts (5) to 675-725 ft. Lbs. (915-1917 B NM) torque (lubricated). NOTE: Make sure the drain slot in the wear ring (1) and the leak hole in the liner thread ring (4) are located at the bottom. b. Lightly oil and install module seal (6) in counterbore and slide the suction module to where it aligns with the counterbore and seats metal to metal against the discharge module. Tighten retainer nuts (7) snug, oF sufficient to hold the suction module in place. c. After setting suction manifold into the pump skid, install the three L-shaped modules into their respective bores. Tighten retainer nuts (8) snug or to where they will hold modules in place. Lightly oil O-ring (9) and install in the groove. Slide discharge manifold into position to where it makes up metal to metal against face of discharge module. Tighten retainer nuts (10) snug or to where it will hold the discharge manifold into place. e. Lightly oil O-ring (11) and install in the suction manifold flanges. Position the suction manifold flanges against the bottom face of the suction modules and after aligning and starting all of the suction manifold screws (12), tighten the screws to 220-250 ft, Lbs, (298-338 NM) torque (lubricated).FS-205BD 64 Finally tighten the retainer nuts in a criss-cross manner to the torque values shown below: Retainer Nut Torque ( Lubricated) Ft.Lb. NM 5 675-725 915-970 7 2980-3000 4000-4067 8 2950-3000 4000-4067 10 1575-1625 2135-2201 14 950-1000 1288-1355 g. Install threaded rings (13) on the suction and discharge modules and tighten retainer nuts (14) to 950-1000 ft. Lbs. (1288-1355 NM) torque —_(|ubricated). TWO PIECE PISTON ROD As illustrated in the fig. 6.2, a two-piece piston rod is used in the FC-2200 triplex pump to allow the operator the option replacing wom pistons by removing the piston rod and liner as one unit, or by separating the two-piece piston rod and removing the worn piston while liner remains in place. fig. 6.2 PISTON REPLACEMENT: To replace the piston by separating the rods proceed as follows;FS-205bd 65 1. Remove the liner end cover, the %" Liner Wash Nipple and disconnect the hose from the piston rod clamp. 2. Remove the piston rod clamp and fit one of the 3" open end wrenches over the hex on one of the rods. Rotate the rod assembly until the wrench handle is firmly against the pump frame. Fit the other 3" wrench over the hex on the other rod in a convenient position to strike it with a hammer to break the connection loose. 3. Screw the rear rod section (1) off and lay it aside. 4. If the piston is badly worn it may be possible to pull the piston out of the liner by hand, if not, screw the installation tool into the front rod section and rotate the pump by hand until the crosshead extension rod mates with the installation tool. Fit the clamp loosely over the tapered rod flanges and rotate the pump backwards to pull the piston out of the liner. 5. Clamp the front piston rod section in a large vise and remove the piston rod lock nut. The piston will then slide freely off the rod. 6. Clean the end of the piston rod and the piston bore throughly. Fit the "O" ring seal in the piston counterbore and slide over the rod end. Install the elastic lock nut and tighten to 2000 ft. Ibs torque. (2710 N-m) NOTE: The Elastic Lock Nut should not be reused more than three times as the locking element will loose its ability to grip the rod, Replace the nut after three installations. 7. Install the assembly by holding the installation tool against the end of the extension rod and install the piston rod clamp to hold the assembly in a horizontal position. 8. Apply a liberal coat of grease to the piston OD. Rotate the pump by hand to move the piston forward and push it into the liner. 9. Remove the piston rod clamp and installation tool. 40.Rotate pump far enough to install rear section of piston rod (1). Clean threads, remove any burrs that might be present, apply a light coat of oil to threads and screw into front section. 14.Rotate pump to bring ends of extension and piston rods together, install clamp loosely over flanges and tighten the threaded connection by bumping the wrench handle with a sledge hammer.FS-205BD 66 NOTE: — When handling the separate pieces, care must be taken to prevent damage to the ends of the rods, as burrs or high spots on the rod ends can cause misaligned makeup and/or early failure. fig.6.2.4 WELDING PROCEDURES 1. All areas to be repair-welded shall be ground or machined down to defect free metal. 2. Inspect interior of fluid end with dye check or magnetic particle inspection to confirm that defects have been completely removed. 3. Prior to welding, the surface prepared for welding shall be cleaned of all oil, grease, dust and scale. 4, Preheat in the area of the repair to 350°F (162°C) and maintain temperature while welding 5. Weld up the repair area using AWS E-100018D-2 Low Hydrogen Welding Rod. 6. Apply sufficient weld metal to the repair area to provide an extra overlay of weld metal which will ultimately be machined away. The final weld pass is necessary to refine the structure and improve the properties of previously deposited weld. 7. Immediately after welding, cover the fluid end with an insulating blanket and allow it to cool slowly to ambient temperature. 8. After welding, the fluid end should be magnetic particle inspected to confirm that no cracks are present in the repair welded surfaces.FS-205BD 67 PISTON AND LINER WASH SYSTEM Close attention must be paid at all times to the piston and liner wash system to assure that adequate cooling fluid is being applied to each piston and liner assembly. Stoppage of the cooling fluid will result in almost instant failure of the piston rubbers and possibly extensive damage to the liner bores. RETUN DRAIN TO TANK 7O DISSCARGE |FS-205BD 68 As illustrated in fig.6.3, the piston/liner wash system consists of an electric motor powered centrifugal pump (1), a fluid reservoir tank (2), and a fluid regulator valve (3), plus necessary suction and discharge lines to provide cooling fluid to the liner spray system. Briefly, the electric motor driven centrifugal pump circulates fluid from the reservoir tank (2) to the discharge manifold (4) shown in fig. 6.4. fig. 6.4 Flexible hoses (5) connect the water supply to the piston rod clamp for distribution to the liner and piston through the 14" NPT pipe nipple screwed into the clamp, as illustrated in fig. 6.4.F-205BD 69 Cooling fluid is applied directly onto the back of the piston through the %4" pipe and sprays the liner ID at that point as the piston moves through is stroke. This system has been proven superior to stationary spray systems, Do not attempt to modify the system just because a hose has broken. The advantages far outweigh a few broken hoses. After circulating through the liners, the cooling fluid then drains from the pump cradle back into the reservoir tank. The reservoir is divided into two sections. The return cooling fluid is dumped into the “settling” side of the tank. The partition has a screened section near the top to filter out the larger pieces of debris. Check condition of the cooling fluid at frequent intervals. Clean and flush reservoir when fluid become contaminated with drilling mud or sand or if it becomes extremely hot. Contaminated fluid can cause premature liner and piston wear from abrasion or blockage of the fiuid passage. Adjusting Flow of Cooling Fluid Regulate the amount of fluid being supplied to the liner wash system by adjusting the fluid regulator valve (3) fig. 6.3.It is desirable to have a as much flow as possible. Adjust flow of fluid to maximum volume possible without splashing onto crosshead extension rods. to cool the pistons and liners but if water splashes onto the extension rods it will work back into the power end. This can be very detrimental to the bearings, especially salt water. FLUID FOR LINER WASH SYSTEM ‘The recommended fluid for the liner wash system is cool, clear, fresh water. Lubricating oils are not desirable because they leave an insulating film on the liner bore that inhibits the transfer of heat to the fluid. Salt water is destructive to the pump frame structure and can be disastrous if it gets into the power end. Fresh water is much cheaper in the long run. Liner End Cover and Fluid Baffle Disc The liner end cover (6) and the fluid baffle disc (7) are provided for the purpose of deflecting the cooling fluid as it is being flushed from the liner bores. DO NOT operate pump unless these items are in place as excessive amount of fluid splashing around the extension rod compartment can possible enter into the power end and contaminate the lubricating oilFS-205 74 SECTION7 LUBRICATION INDEX DESCRIPTION PAGE NO. Maintenance and Inspection. wT Lubrications Specifications. wT Extemal Electric Motor Driven Oil Pump........-.7-6 sevens CE-58E. General Lubrication Bulletin.FS-205BD 7A LUBRICATION SYSTEM MAINTENANCE AND INSPECTION Proper lubrication of the moving parts in any piece of machinery is the most important single factor affecting its ultimate life. To obtain maximum trouble-free service life from the power end of the pump it is necessary to perform routine maintenance care and inspections to insure the proper amount of CLEAN lubricant is being provided. ‘The FC-2200 pumps utilize the controlled flow oil bath splash and pressure system to lubricate the entire power end. The splash system is the primary source of lubrication, because it will operate over a wider range of temperatures and will began to lubricate on the first revolution of the pump. It does have a minimum speed where it becomes ineffective. See “OPERATION” section for minimum speed. The purpose of the pressure system is to assist the splash system at slow speeds. The pressure system consists of a gear type positive displacement oil pump, internally mounted inside the power end and driven by a small gear which is meshed with the eccentric ring gear. For this reason, proper rotation as shown in fig. 7.1 is essential. The oil pump and suction screen can be accessed through the large bolted inspection plate on the rear of the gear case cover. Fig. 7.1 When installing a new oil pump, position it so that the back face of the drive gear is flush and parallel with the edge of the eccentric ring gear and shim undemeath to. provide .015-.035" (.38-.89mm) backlash. This can be measured by inserting a feeler gauge between the gear teeth.FS-205BD 7.2 In the controlled flow splash system, the main gear picks up oil from the reservoir. When the gear teeth mesh with the pinion, the oil is displaced into various troughs and compartments in the frame. The oil is then directed to the various lubrication points throughout the power end. This system is supplemented by the pressure lubrication. ‘A schematic diagram of the pressure lubrication system is shown in fig. 7.2. wa BRC. ‘wn prcrasasan nny srare 20 ‘wn caossiead, —SRagsneap fig. 7.2 As illustrated, oil pump (P) picks up oil through the suction filter screen STRN and discharges it into the manifold block MAN located on the inner back wall of the power end case, The oil is then distributed to the main bearings, pinion bearings, and to the second manifold block MAN located in the frame above the crosshead compartment. The second manifold block distributes oil to the crossheads, wrist pins, and the extension rods. A pressure gauge is mounted on the outside wall of the power end case and registers the oil pressure being provided to the pressure system.FS-2058D 73 This gauge should be observed frequently when pump is in operation to assure 10-40 PSI (.7-2.75 Bar) oil pressure is being provided. A pressure relief valve D1 set at 40 PSI (2.75 Bar) is mounted on the rear manifold block to protect the oil pump from excess pressure, Should low oil pressure occur, check for: - Clogged suction screen - Broken oil lines - Defective relief valve - Damaged or worn oil pump fig. 7.3,FS-205BD 74 As illustrated in fig. 7.4, a settling chamber is located on each side of the pump frame, underneath the crosshead area. Alll lubricant pumped or splashed into the crosshead area flows through this chamber on its return to the main oil reservoir. Since this is a non-turbulent area, much of the oil contamination from condensation, mud intrusion, dirt or water can settle out of the oil before oil is returned to the main reservoir. ONCE EACH WEEK remove the pipe plug from the clean out covers on each side of the pump and check for the accumulation of contamination. If the amount of accumulation appears to be substantial, remove both clean out covers and drain the entire chamber. Clean and flush the settling chamber of all residue and check pump for cause and/or where contamination is entering the reservoir. The most likely place would be worn diaphragm stuffing box seals. NOTE: Replace the volume of oil removed from the settling chambers to the main oil reservoir. Power End Lubrication The lubricant recommendations shown below and on the name plate on the side of the pump are the result of extensive field tests. Substitutions should be made only in extreme emergencies. Lubricant Specifications Use extreme pressure, non-corrosive, anti-foaming gear lubricant as follows: 0° to 155°F (-18 to 68°C) AGMA #6 EP -20° to +40°F (-29 to +4°C) AGMA #4 EP FC-2200 oil reservoir capacity: 120 US Gal. (454 liters) If loss of pressure occurs, check for: - Clogged suction screen - Low oil level ~ Broken or loose connections - Damaged or worn oil pump - Defective relief valveFS-205BD 75 For an abnormal increase in oil pressure, check for: - Plugged oil lines - Contamination causing oil to be viscous - Relief valve inoperative - Defective gauge - Other conditionsFS-205 76 EXTERNAL ELECTRIC MOTOR With the addition of an optional Electric Motor Driven Oil Pump the minimum speed for the Triplex Pump is eliminated so that the Triplex Pump can be operated as slow as desired. The External pump is connected in parallel with the internal pump with check valves to isolate one pump in case it is not functioning. At normal operating speeds and temperature the triplex power end lubrication system can not take the full output of both pumps so it is normal is have oil bypassing at the relief valves. The internal relief vaive on the external pump is factory set to relieve at 50 PSI (3.45 Bar). This adjustment is very critical because the electric motor will not handle the load of pumping cold oil without bypassing some of the oil at the pump. This also has the positive effect of warming the oil as it bypasses. If the pump is replaced or repaired, a tee and pressure gauge should be installed in the line directly at the pump output port and the relief valve adjusted to 50 PSI (3.45 Bar) with the oil at normal operating temperature. The electric motor can be operated simultaneously with the triplex pump if desired but its only function is to supplement the internal system at speeds below 20 SPM or below 40 SPM in event of failure of the internal lube pump. Above these speeds the power end is adequately lubricated by the splash system. CAUTION: Although both the intemal and external lube pumps are #2 Brown & Sharp they are not interchangeable. The intemal pump is a #2S without a relief valve, rated for 1800 RPM while the extemal pump is a plain #2 with relief valve, rated for 900 RPM. Do Not interchange these two pumps.FrODSip | oaertomeagy, |) aut] ad Sta] Se Lal ett ora a 0022-34 O-6r01L-109 ‘8N TaN samt gt Sais ee v id W @/t x zen 8/S “N13 ONIaML | 98-0¢47-1094 1 [sz veiz 3YNOIS ‘LAN JWWWIS Z/b “BATVA YORHO | Of -O167-ZO9L t 4dN Z/t ‘Sal ddld | ¥O-O19%-1092 1 wv LAN 2/1 ‘3dld “Fiddin 35010 | 1-£8SZ-1094 z (Of) LIN 1 "Fal Said | 90-0197-1092 L v (118) 00% X LAN .t ‘did “Tddin | 9%-O8SZ-109¢ z ¥ ‘91 009! X Wid B/S ‘ONIGM Y3dd09 | 91-OOrs-1092 L y NNOO 14N 1 ‘OOL-OLL # “3dGAL dWNS GFONOB ‘WHT | 9S-1401~-ZO9L ‘ vL ¥ wt “LAN 38ML GUYIANI | pr-OLe7—-109L 2 {a 97 00'%Z X “VIO .t ‘ONIGNL H3dd09 | ¥Z-Of"E-109L L L ¥ id W 2/1 X 36ML 8/S ‘HOLOZNNOD ONIBML | 00-ZSZ7~1092 L o (O18) 00'9 X LN yt “did "Fiddin | Z5-vBGz~109L fe v (78) dN b “MOET3 Idld | ¢¢-0257-109¢ y {9 v (18) 00'S X LAN yl “Bdid ‘FiddIN | _4Z-0BS7-1094 gis ¥ Ong) LAN 2/1 X yb CONIHSNE 3dld | O1-0FS2-109¢. ziiy v (M8) 00°% XK LAN 2/1 ‘3did “FddiN | #10852 -1092 z fe v 8/S ‘LAN 3ANL GaLNaANI | SE-O427~109L z izon uv 4s) 06~6211-1169 12) oaa_| ¢ ani vada aco 288 al Ls yesCE-538E Rev. 11/96 GENERAL LUBRICATION BULLETIN FOR CE DRILLING EQUIPMENTCES38E GENERAL LUBRICATION INSTRUCTIONS FOR CONTINENTAL EMSCO PRODUCTS DRILLING EQUIPMENT Using the right kind of oil or grease on a regular basis extends the service life of machinery. Where and how to lubricate is described in each Maintenance Manual for the particular piece of equipment. The following information lists the recommended type of lubricant to use, and the chart identifies individual manufacturers products. Companies not listed can use the chart to recommend their equivalent brands. CROWN AND TRAVELING BLOCKS Use a multipurpose lithium base grease. Ambient temperatures; O°F to 125°F (-18°C to 52°C) NLGI #2 -20°F to 40°F (-29°C to 4°C) NLGI #0 SWIVELS Main reservoir: Use an extreme pressure, non-corrosive, anti-foaming gear lubricant. Ambient temperatures; 0°F to 155°F (-18°C to 68°C) AGMA #6EP -20°F to 40°F (-29°C to 4°C) AGMA #4EP Wash pipe packing, oil seals and bail pins; Use a multipurpose lithium base grease. ‘Ambient temperature, _O°F to 125°F (-18°C to 52°C) NLGI #2 -20°F to 40°F (-29°C to 4°C) NLGI #0 ROTARY MACHINES and UNITIZED ROTARY CHAIN COUPLING; Main reservoir; Use an extreme pressure, non-corrosive, anti-foaming gear lubricant. Ambient temperatures; O°F to 155°F (-18°C to 52°C) AGMA #6EP_ -20°F to 40°F (-29°C to 4°C) AGMA #4EP_ Pinion Cartridge; Use a multipurpose lithium base grease. Ambient temperatures; —0°F to 125°F (-18°C to 52°C) NLGI #2 -20°F to 40°F (-29°C to 4°C) NLGI #0 Page 1 CES38E 2:vupdocsmanuasenisc 5386GENERAL LUBRICATION INSTRUCTIONS Contd. DRAWWORKS, COMPOUND TRANSMISSIONS, _UNITIZED _ROTARY TRANSMI INS, ECR UNITS & PUMP DRIVES. Grease lubricated bearings, drum brake centralized lubrication system, gear couplings and all miscellaneous grease fittings; Use a multipurpose lithium base grease. Ambient temperatures: —_0°F to 125°F (-18°C to 52°C) NLGI #2 -20°F to 40°F (-29°C to 4°C) NLGI #0 il lubricated bearings and roller chains; Use a non-detergent machine oil as follows: Ambient temperatures: 80°F to 125°F (27°C to 52°C ) SAE 40 32°F to 100°F (0°C to 38°C) SAE 30 O°F to 40°F (-18°C to 4°C) SAE 20 ELECTROHOIST GEAR BOX Use an extreme pressure, non-corrosive, anti-foaming gear lubricant as follows; Ambient temperatures: 0°F to 155°F (-18°C to 68°C) AGMA #6EP -20°F to 40°F (-29°C to 4°C) AGMA #4EP. AIRLINE LUBRICATORS Use SAE 10 Wt. Motor oil. GB & GBH CATHEAD: Use a multipurpose lithium base grease. Ambient temperatures: O°F to 125°F (-18°C to 52°C) NLGI #2 -20°F to 40°F (-29°C to 4°C) NLGI #0 DUPLEX & TRIPLEX MUD & SLURRY PUMPS Use an extreme pressure, non-corrosive, anti-foaming gear lubricant. Ambient temperatures: _0°F to 155°F (-18°C to 52°C) AGMA #6EP -20°F to 40°F (-29°C to 4°C) AGMA #4EP OVERRUNNING CLUTCH Use SAE 50 Wt. Non-detergent machine oil Equipment not manufactured by Continental Emsco Company should be lubricated as specified by the manufacturer. CAUTION: Do not mix greases with different bases. Always clean reservoirs thoroughly when changing to a grease with a different base Page 2RECOMMENDED LUBRICATION PRODUCT CHART Revised 6/92 Retyped 11/96 NLGI #2 NLGI#0 MANUFACTURER AGMA #4EP AGMA #6 MULTIPURPOSE MUI OSE AMOCO AMOGEAR AMOGEAR EP Lubricant #150 EP Lubricant #320 Rykon Grease #2 Rykon Grease #0 ARCO. Pennant NL150 Pennant NL320 —Litholine HEP 2 _Litholine HEP 00 BP Energol GR-XP 150 Energol GR-XP 320 Grease NLGI #2 Grease NLGI #0 CHEVRON OIL Chevron NLGear Chevron NLGear Chevron Polyurea Chevron Polyurea ‘Compound 150 Coumpound 320 EPGrease #2 EP Grease #0 crrco EP Compound 150 EP Coumpound 320 Citgo AP Citgo AP conoco Gear Oil 150 fear Oil 320 EP Conolith #2 EP Conolith #0 EXXON Spartan EP 150 Spartan EP320 Unirex #2 Lidok EP #0 LUBRIPLATE APG 90 APG 140 Lubriplate 1200-2 Lubriplate MAG 1 MOBIL OIL CORP Mobilgear 629 Mobil 632 Mobilgrease 77 Mobilux EPO PENZOILCO. — Maxol EP Gear Maxol Gear Lube MP 705, MP 170 Lube #64 Lube # 152 PHILLIPS PETRO. Philube SMP Gear Philube SMP Gear Philube L-2 Philube L-0 Oil SAE 90 Oil SAE 140 QUAKER STATE Super Quadrolube Lithium EP Lithium EP SAE 90 NLGI #2 NLGI #0 SHELL OIL CO, —Omala Oil 150, AlvaniaEP2 ——Allvania EPRO STATOIL Loadway 150 Loadway 320 TEXACOINC. — Meropa Lubricant Meropa Lubricant MultifakEP2 Multifak EPO 150 320 UNION OILCO. ExtraHeavyNL —-ExtraHeavyNL— Unoba EP #2 Unoba EP #0 OFCALIFORNIA Gear Lube 4 EP Gear Lube 6 EP Page 3 ZAWPDOCSMANUALSIMISCHSS38ERECOMMENDED LUBRICATION PRODUCT CHART MANUFACTURER AMOCO. ARCO BP CHEVRON OIL, crtco coNnoco EXXON LUBRIPLATE, Revised 6/92 Retyped 11/96 NON-DETERGENT NON-DETERGENT NON-DETERGENT MACHINE OIL, MACHINE OIL MACHINE OIL, SAE 20 WT. SAE30 WT, SAE40 WT. HYDRAULIC OIL Industrial Oil #68 Industrial Oil #100 Industrial Oil #220 Rubilene 68 Bartran HV 68 AW Machine Pacemaker 68 Redlind 68, Teresstic 33 3V Motor Oil MOBILOIL — DTE Heavy Med. PENZOIL CO. PHILLIPS PETRO. QUAKER STATE, ‘SHELL O1LCO. TEXACO INC. UNION OIL. CO. OF CALIFORNIA Rubilene 100 Rubitene 220 Bartran HV 100 Bartran 220 Bartran HV 22 100 AW Machine Oil 150AW Machine 1220 Pacemaker 100 Pacemaker 150 Redlind 100 Rediind 150 ‘Teresstic 100 Teresstic 150 #3MotorOil #4 Motor Oil DTE Extra Heavy DTEExtraHeavy ATF 220 or DTE 24 AW Hydraulic # 68 AW Hydraulic # 100 AW Hydraulic # 150 Condor O11 68 (Grade 315) Condor Oi 100 Magus Oi1 150 (Grade 465) (Grade 700) SAE 20 Motor Oil SAE 30 Motor Oil SAE 40 Motor Oil Tellus O11 68 Tellus O11 100 —TellusOi1150 Tellus 01132 Regal Oi RKO 68 Regal ORO 100 Regal Oi RKO 150 Rando Oil HA 32 Unax 68 ZAWPDOCSMANUALSIMISCIPSS38E ‘Unax 100 Unax 150 Page 4GENERAL LUBRICATION BULLETIN Rev. 11/96 QIL_ CAPACITIES FOR CONTINENTAL EMSCO EQUIPMENT DRAWWORKS C-1 Type! C-t Type Ill C-2 Type Il C-2 Type Ill C-3 Type! C-3 Type Il C-3 Type Ill DA D2 D3 TYPE “U” CATWORKS WIRight Angle Drive COMPOUNDS CTS cCT7 cT-9 D-221 W/Separate Lube System D-232 W/Separate Lube System E-SERIES TRIPLEX PUMP F-350 F-500 F650 F-750 F-800 F-41000 F, FA, FB & FC-1300 F, FA, FB & FC-1600 FC-2200 UNITIZED PUMP DRIVE FOR ELECTRIC MOTOR, PER GUARD 105 U.S. Gal. 105 U.S. Gal. 110 U.S. Gal. 110 U.S. Gal. 60 U.S. Gal. 60 U.S. Gal 60 U.S. Gal 78 U.S. Gal. 115 U.S. Gal. 85 U.S. Gal 45 U.S. Gal, 50 U.S. Gal. 130 U.S. Gal. 130 U.S. Gal. 148 U.S. Gal. 80 U.S. Gal. 80 U.S. Gal. 148 U.S. Gal, 65 U.S. Gal 55 U:! 55 U.S. Gal. 65 U.S. Gal. 75 U. 100 U.S. Gal. 100 U.S. Gal. 120 U.S. Gal. 20 U.S. Gal . Gal. S. Gal. 400 Liters 400 Liters 420 Liters 420 Liters 230 Liters 230 Liters 230 Liters 296 Liters 436 Liters 332 Liters 170 Liters 190 Liters 493 Liters 493 Liters 560 Liters 303 Liters 303 Liters 152 Liters 246 Liters 208 Liters 208 Liters 246 Liters 284 Liters 380 Liters 380 Liters 454 Liters 76 Liters PAGE 5GENERAL LUBRICATION BULLETIN TYPE “F" UNITIZED PUMP CHAIN DRIVE F-350 F-500 F650 F800 F100 DUPLEX PUMPS D-225, D-375, DB-550 DC-700 DC-1350 DC-1650 ROTARIES T-1750 (S/N 181 only) T-1750 (S/N 182-253) T-1750 (S/N 254-268) T-1750 (S/N 269 & UP} T-2050 (S/N 31 only) T-2050 (S/N 32-110) ‘T-2050 S/N 111 & UP) 17-2750 (S/N 89-94) 17-2750 (S/N 95-228) 17-2750 (S/N 229 & UP) ‘7-3750 7-4950 ROTARY TRANSMISSIONS RT-3A VERTICAL RT-3A HORIZONTAL CHAIN COUPLING SWIYELS LB-140 LA, LB-200 LA, LB-300 LA, LB-400 LB-500 L&LB-650 15 U.S. Gal. 30 U.S. Gal. 30 U.S. Gal. 30 U.S. Gal. 30 U.S. Gal. 25 U.S. Gal. 53. U.S. Gal 58 U.S. Gal. 65 USS. Gal. 100 U.S. Gal. 100 U.S. Gal. 6 U.S. Gal. 12 US. Gal. 8 U.S. Gal. 10 U.S. Gal. 5 U.S. Gal. 13 U.S. Gal. 6 U.S. Gal. 9U.S. Gal. 13 U.S. Gal. 10 U.S. Gal. 15 U.S. Gal. 15U.S.Gal. 21 U.S. Gal 28 U.S. Gal. 1U.S. Gal. 3-3/4 US. Gal. 4-3/4 U.S. Gal. 6-3/4 U.S. Gal. 10 U.S. Gal. 12 U.S. Gal. 19-1/2U.S. Gal. Rev. 11/96 57 Liters 115 Liters 115 Liters 115 Liters 115 Liters 95 Liters 201 Liters 220 Liters. 246 Liters 379 Liters 379 Liters 23 46 31 38 19 50 23 34 50 38 3s7 3S7 Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters 80 Liters 106 Liters 4 Liters 14 18 26 38 46 74 Liters Liters Liters Liters Liters Liters Page 6