F500mudpump.docx
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F500mudpump.docx
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F500mudpump
F-500MudPump
OperationandMaintenanceManual
NANTONGJIANGSUCHINA
NANTONGJOLLYENGINEERINGSERVICESINC.
1.InstallationofNewPump
F-500triplexsingleactionmudpump,suppliedbyNantongJollyEngineeringServicesInc,hasbeencompletelyassembledandtestoperatedunderpressurebeforeshippingtothefield.Unlessotherwiseinstructed,thelubricationisdrainedfromthepowerend.Beforeputtingthepumpintoservices,thefollowingprecautionsandoperationsmustbeperformedandchecked.
Inordertopreventpersonalinjuryduringtheperformanceofanymaintenanceorinspectionprocedures,thisequipmentMUSTBESHUTDOWNANDNOTOPERATINGandallsafetydevicesonprimemovers,drives,etc,MUSTBEINTHESAFEPOSITION.
1.1SettingthePump
Theskidunderthepumpissuitableformostanytypeofinstallation.Itshouldbenoted,however,thattheboxtypeconstructionofthepowerframehashighresistancetobendingbutrelativelylessresistanceagainsttwist.Therefore,thesupportunderthepumpmustbelevelandadequatetosupporttheweightandoperatingforcesexertedbythepump.
1.2LandInstallations
Inlandinstallations,amatof3”x12”boardslaidsidecrosswisetothepumpskidsfortheentirelength,atthepointsindicatedinFig.2,isusuallysufficient.Theboardsshouldbeafewfeetwiderthanthewidthofthepumpskidrunners.Wetormarshylocationsmayrequireamorestable
foundation.
1.3PermanentInstallation
Onpermanentinstallationssuchasbarge,platform,structuralbase,orconcreteslab,wherepumpskidsarebolteddown,itisessentialthattheskidsbeproperlyshimmedtopreventpossibilityoftwistingordistortingthepowerframe.Thepumpskidsmustsitsolidonallshimpointswithboltsloose.
Onbargeinstallation,thepumpskidsaregenerallybolteddowntoT-beamsrunningparallelandinlinewiththepumpskids.InstallshimsatpointsshowninFig.2and3andobservecautionofpropershimmingtopreventtwistordistortion.
Theshimsonallinstallationsshouldextendthefullwidthoftheskidbeamflangesandhaveaminimumlengthof12”(305mm).
Oninstallationswherethepowerunitorelectricmotorismountedintegrallywiththepumpskids,thepreferredinstallationwouldbetosetthepumppackageontheT-beamsskidsandprovideretentionblocksratherthanboltstoholditinplace.Thiswillallowthepumpto“float”andminimizethetransferofbargedeckorplatformdistortionintoframe.
1.4InstallationoftheDrive
Thedrivebetweenthemudpumpsandthepowersource,whetherV-beltsormulti-widthchains,shouldbeinstalledwiththegreatestcaretoassuremaximumoperatinglifewithminimumofunexpectedorundesirableshutdownsduetodrivefailures.
Wheninstallingthedrivesheaveofsprocket,makesureallgreaseorrustpreventiveisremovedfromtheshaftandtheboreofthedrive.Removeallburrsorroughspotsfromtheshaft,key,andkeyway.Fitkeytothekeywaysinboththeshaftanddriveandinstallkeyintoshaftkeyway.
Coatpinionshaftwithalightcoatingofanti-seizecompoundorlightoilandinstallthedrivesheaveorsprockethub.Tightenhubboltsasindicatedbelow:
Whenawrenchorlengthofpipeisusedtoincreaseleverageintighteningdraw-upbolts,itisimperativetoadheretothewrenchtorquevaluesgiveninthechartbelow.Thisadherenceisimportant,becauseinmountingthehub,thetighteningforceontheboltsismultipliedmanytimesbythewedgingactionofthetaperedsurface.Thisactioncompressesthehubforasnugfitontheshaft.Ifthebolttighteningforcesareextreme,burstingpressureiscreatedinthehubofthemountedpulley;thispressuremaycausethepulleytocrack.Thehubboltsshouldalwaysbetightenedalternatelyandprogressively.
ODHub
WrenchTorque
N.m
WrenchLength
mm
WrenchPull
N
F-500
N
406
760
534
1.4.1V-beltDrives
a.Checksheavegroovecondition.
Beforeinstallingthev-belts,checksheavegroovesforwear.WornorroundedgrooveswilldestroyV-beltsrapidly.Thesidewallsmustbestraight.Sheavegroovesmustbefreeofdirt,rustorotherextrusionsthatcoulddamagetheV-belts.
b.Checksheavealignment.
ThefinalalignmentoftheV-beltsheavesshouldbecheckedaftertheV-beltshavebeeninstalledandadjustedtotheiroperatingtension.Ifthesidesofthesheavesareofequaldistancefromthecenterlineofthegroove,checkalignmentbystretchingTWOstrings(fishlineorpianowirepreferred)alongonesideofthetwosheaves,oneaboveandonebelowthecenterline,andmovingoneofthesheavesuntilthestringstouchfourpointsonthesideofthesheaverims.Thiswilldeterminethatthecenterlineofthedrivesisparallelandthefacesofthesheavesaresquare.
c.AdjustV-beltforpropertension.
Adjustthebelttensionbymovingthesheavesapartuntilallofthesaghasjustbeeneliminatedfromthetightsideofthebeltandsomeofthebeltsontheslackside.Thenincreasethecentersapproximately13mm(1/2”)foreach2540mm(100”)centerdistance.Example:
On3180mm(150”)center,movepumpandadditional19.5mm(3/4”).
●NOTE:
DONOTOBTAINBELTTENSIONBYPICKINGUPENDOFPUMPANDALLOWINGBELTSTOTIGHTENUNDERWEIGHTOFPUMPASENDISBEINGLOWEREDTOTHEGROUND.
2.SuctionSystemRequirements
Individualinstallationconditionswilldictatethedesignofthesuctionsystem.ThesuctionoftheF-500pimpsmusthaveapositivehead(pressure)forsatisfactoryperformance.Theoptimumsuctionmanifoldpressureis20~30psi(0.14~0.21MPa)formaximumvolumetricefficiencyandexpendablepartslife.Thisheadpressureisbestsuppliedbya5x6centrifugalpumpwith40hp1150rpmelectricmotor.Thistypeofdriverequiresadevicetoautomaticallystartandstopthecentrifugalpumpmotorsimultaneouslywiththetriplexpump.OnDCelectricpoweredrigsasignalcanusuallybesuppliedfromtheDCcontrolpaneltoenergizeamagneticstarterwhenthemudpumpclutchairlinewillprovideasetofcontactsforenergizingthemagneticstarterwhenclutchisengaged.
Thechargingpumpcanalsobebeltdrivenfromthetriplexpinionshaftchargingtypeofdriveisnotasefficientatslowspeedswithviscousfluids.
UndersomeconditionstheF-500pumpmaybeoperatedwithoutachargingpump,providedthefluidlevelinmudpitsishigherthanthetopoftheliners,fluidbeingpamperedislowinviscosityandsuctionlinemustbeshort,straightandofatleastthesamediameterassuctionmanifoldinlet.
Thesuctionliensshouldbepipedwithvalvearrangementssothechargingpumpcanbeby-passedsooperationcanbecontinuedineventofchargingpumpfailureorformaintenance.Operationwithoutachargingpumpcanbeimprovedbyreplacingthesuctionvalvespringswithaweakerspring.
Suctiondesurgersareaveryeffectiveaidforfillingofthelinersanddampeningpulsationsinthesuctionline,whichresultsinasmootherflowinthedischargeline.
*CAUTION:
Donotpipethereturnlinefromtheshearreliefvalvebackintothesuctionsystemasareliefvalveoperationwillcauseasuddenpressureriseinthesystemvastlygreaterthanthesystempressureratings,resultingindamagetomanifold,suctiondesurgerandcentrifugalpump.
3.PreparationofPowerEnd
Yourpumphasbeencompletelyassembledandtestoperatedbeforebeingshippedtothefield.Unlessotherwiseinstructed,thelubricationisdrainedfromthepowerend,andtheexpendablesareremovedfromthefluidendforstorageprotection.Beforeoperatingthepump,thefollowingmustbeperformedorchecked.
3.1PowerEndLubrication
Beforeinstallinglubricant,openinspectiondoorincoverandcheckoilreservoirforpossibleaccumulationofcondensation,etc.,anddrainandflushbyremovingthepipeplugsoneachsideofthepump.ReferItem2.Fig7.
Addthepropertypeandquantityoflubricationinthepowerend.Refertolubricationplateonpumpframefortypeandquantityrequired.
Recheckoillevelafterpumphasoperatedforaperiodof15minutes.Shutpumpdownandallowapproximatelyfiveminutesfortheoilleveltoequalize.Checkatoillevelgauge,Item1,Fig.7.Itisusuallynecessaryforafewmoregallonsofoiltobeaddedduetoacertainamountbeingretainedinthecrossheadareaandframecavities.
3.2InstallationofCrossheadExtensionRodsandDiaphragmStuffingBoxSealsforF-500
WithreferencetoFig4A,removethediaphragmstuffingboxandplate
(1)androtatepumpsothatcrossheadisatthefrontofthestroke.Thoroughlycleanthefrontofthecrossheadandthefaceofthecrossheadextensionrod.Insertalignmentbossoncrossheadextensionrodintothecrossheadboreandtightentheretainerbolts
(2)tothefollowingtorque:
67.5-81N.m(50-60ft.lbs)Safetywireboltheads.
Thoroughlycleanfaceofcrossheadguide(3)anddiaphragmstuffingbox
(1).InstallO-ringseal(4).Fitconnection(5)ondiaphragmstuffingbox
(1).Installdiaphragmstuffingboxandtightencapscrewstothefollowingtorque:
16-19N.M(12-4ft.lbs).
Fitoilpipe(6).
Thediaphragmstuffingboxpackingassemblyconsistsoftwodoublelipoilseal(7),anOilSealring(8),anO-ring(9),alockspring(10)andanO-ring(11).Installtheassemblyasfollows:
a.Removepressurespring(7a)fromdoublelipoilseal(7)andplacesealintheinner(powerend)positiononthecrossheadextensionrod,withliptowardpowerend.Replacethepressurespringintheseallipandslidethesealintopositioninthestuffingbox.
b.Inserttheoilsealring(8)andO-ring(11)overrodandslideintostuffingboxbore.
c.InstalltheO-ring(9)ingrooveinstuffingboxbore.
d.Installthelockspring(10).
NOTE:
*CAUTIONmustbeexercise
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