Mud Pump Gardner Denver Maintenance Doc - Schlumberger
Drilling Services SDS PMS Equipment: Mud Pump Manufacturer: Gardner Denver Model: PZ-8/9 PSS Code: GA-327-32 Item Level
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Drilling Services SDS PMS Equipment: Mud Pump Manufacturer: Gardner Denver Model: PZ-8/9 PSS Code: GA-327-32 Item Level Inspect
Department: Frequency: Issued: Completed: Description
Mechanical Annually
Safety Considerations 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.
Resources: A
Task Items: Mud Pump Condition Evaluation
1. [M3] [
] Complete a complete condition evaluation of the mud pump.
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
File: Document1
Last Revised: November 14, 2017
Page 1 of 9
Drilling Services SDS PMS Equipment: Mud Pump Manufacturer: Gardner Denver Model: PZ-8/9 PSS Code: GA-327-32 Item Level Inspect 1. [M3] [
Department: Frequency: Issued: Completed: Description
Mechanical Annually
] Inspect condition of lube oil. If in good condition take a representitive sample and send for laboratory analysis.
Note: Contamination of the oil might indicate that the cross head extension rod diaphragm assemblies needs replacement. 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.
5. [M3] [
6. [M3] [
File: Document1
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 retightening 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. ] 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. ] Renew lip oil seal and "O" rings, clean and replace plate and stuffing box. Torque bolts to 12 18 ft/lbs.
Last Revised: November 14, 2017
Page 2 of 9
Drilling Services SDS PMS Equipment: Mud Pump Manufacturer: Gardner Denver Model: PZ-8/9 PSS Code: GA-327-32 Item Level Inspect 7. [M3] [
Department: Frequency: Issued: Completed: Description
Mechanical Annually
] 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" 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.
File: Document1
Last Revised: November 14, 2017
Worn out chain =
Page 3 of 9
Drilling Services SDS PMS Equipment: Mud Pump Manufacturer: Gardner Denver Model: PZ-8/9 PSS Code: GA-327-32 Item Level Inspect 14. [M3] [
Department: Frequency: Issued: Completed: Description
Mechanical Annually
] 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.
Caution: The pony rod clamps MUST remain in pairs, they are machined as a pair and odd halves will cause misalignment. 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:
20. [M3] [
Record pressure_________ psi. Min 30 psi, max 40 psi. ] 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] [
File: Document1
] Enter details of completion on PMS history card. and file a copy of the completed Condition Evaulation form in the maintenance file.
Last Revised: November 14, 2017
Page 4 of 9
Drilling Services SDS PMS Equipment: Mud Pump Manufacturer: Gardner Denver Model: PZ-8/9 PSS Code: GA-327-32 Item Level Inspect
Department: Frequency: Issued: Completed: Description
Mechanical Annually
Condition Evaluation Recording Table
Front #1 Crosshead Maximum alloable bearing clearance
.007" (.125mm)
#2 Crosshead Maximum alloable bearing clearance
#3 Crosshead
.007" (.125mm)
Bearing Clearance General Condition
Bearing Clearance General Condition Guide Clearance Min .037" (.940mm) Cold
Maximum alloable bearing clearance
.007" (.125mm)
Bearing Clearance General Condition
Guide Clearance Min .037" (.940mm) Cold
Guide Clearance Min .037" (.940mm) Cold
Rear
Rear
Rear
Front
Front
Front
Right Chain
Left Chain
Max Elongation 3 % Measured Lenth General Condition
Max Elongation 3 % Measured Lenth General Condition
Sprockets
Sprockets Bull
Bull
Pinion
Pinion
Left Jackshaft Bearing Maximum alloable bearing clearance
.004" (.102mm)
Right Jackshaft Bearing Maximum alloable bearing clearance
Bearing Clearance General Condition
Bearing Clearance General Condition
Left Main Bearing Maximum alloable bearing clearance
.008" (.203mm)
Right Main Bearing Maximum alloable bearing clearance
Bearing Clearance General Condition
% Worn
Bearing Clearance General Condition
.008" (.203mm)
Condition
#2 Excentric Bearing Maximum alloable bearing clearance
Bearing Clearance General Condition
#3 Excentric Bearing
Bull Gear
.008" (.203mm)
Maximum alloable bearing clearance
% Worn Condition Backlash Maximum alloable bearing clearance
.020" (.508mm)
Bearing Clearance General Condition
Rear
File: Document1
Last Revised: November 14, 2017
.008" (.203mm)
Bearing Clearance General Condition
Pinion Gear
#1 Excentric Bearing Maximum alloable bearing clearance
.004" (.102mm)
Page 5 of 9
.008" (.203mm)
Drilling Services SDS PMS Equipment: Mud Pump Manufacturer: Gardner Denver Model: PZ-8/9 PSS Code: GA-327-32 Item Level Inspect
Department: Frequency: Issued: Completed: Description
Mechanical Annually
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.
File: Document1
Last Revised: November 14, 2017
Page 6 of 9
Drilling Services SDS PMS Equipment: Mud Pump Manufacturer: Gardner Denver Model: PZ-8/9 PSS Code: GA-327-32 Item Level Inspect
Department: Frequency: Issued: Completed: Description
Mechanical Annually
Table 1. Maximum Chain Elongation Limits Up to 67
Chain Number
68-73
Measuring Length
74-81
82-90
91-103
104-118
119-140
141-173
Number of Teeth in the Largest Sprocket
ANSI
Pitch Inches
Number Of Pitches
Nominal Length Inches
Length of Chain (inches) When Replacement is Required
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.
Guidelines for Installing a Replacement Chain Before installing a new chain, carefully check sprocket teeth. If teeth are worn to a hooked shape, the sprockets should be replaced to assure full-capacity performance and satisfactory life from the new chain. Proper tension is essential when installing new chain. Tight chain causes an additional load which increases wear on chain joints, sprocket teeth, and shaft bearings. Slack chain produces vibration which may result in excessive chain wear, noise, or shock loading.
Visually inspect the chain checking for broken or cracked side bars, missing pins. If chain appears worn, pull 1 link and inspect the two pins. If they are cut or worn through the case hardening, then the complete chain should be replaced.
File: Document1
Last Revised: November 14, 2017
Page 7 of 9
Drilling Services SDS PMS Equipment: Mud Pump Manufacturer: Gardner Denver Model: PZ-8/9 PSS Code: GA-327-32 Item Level Inspect
Department: Frequency: Issued: Completed: Description
Mechanical Annually
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
File: Document1
Sprocket Centers, Inches
Sag in Inches
20
.50
30
.63
40
.88
60
1.25
80
1.63
100
2.00
125
2.50
Last Revised: November 14, 2017
Page 8 of 9
Drilling Services SDS PMS Equipment: Mud Pump Manufacturer: Gardner Denver Model: PZ-8/9 PSS Code: GA-327-32 Item Level Inspect
Department: Frequency: Issued: Completed: Description
Mechanical Annually
Comments ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
File: Document1
Last Revised: November 14, 2017
Page 9 of 9