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Operation and Maintenance


WF-400 Triplex Mud pump

Document Number

TSC-WF400-07048

Rev A

Serial Number
WF400-07048
Reference Description
This document contain proprietary and
confidential information ......

INDEX
PREFACE .................................................................................................................................................................5
INTRODUCTION .................................................................................................................................................5
GENERAL SAFETY NOTICE ............................................................................................................................6
NOTICE, CAUTION AND WARNING ...............................................................................................................6
INSTALLATION GUIDELINE .................................................................................................................................9
REFERENCE DOCUMENT ...............................................................................................................................9
INSTALLATION SAFETY NOTICE ...................................................................................................................9
NECESSARY INSTALLATION EQUIPMENT AND TOOLS ...................................................................... 10
PREPARATION ................................................................................................................................................ 10
MECHANICAL INSTALLATION ..................................................................................................................... 11
INSTALLATION................................................................................................................................................. 11
BOLT CONNECTION....................................................................................................................................... 13
PIPING INTERCONNECTION........................................................................................................................ 13
SUCTION PIPING ........................................................................................................................................ 13
DISCHARGE PIPING ................................................................................................................................... 13
LIFTING PROCEDURE ....................................................................................................................................... 17
LIFTING SAFETY NOTICE ............................................................................................................................. 17
EQUIPMENTS TO BE LIFTED ....................................................................................................................... 18
PREPARATION ................................................................................................................................................ 18
LIFTING PROCEDURES ................................................................................................................................ 18
POST-PROCEDURE TASKS ......................................................................................................................... 19
START UP ............................................................................................................................................................. 22
GENERAL MAINTENANCE ................................................................................................................................ 25
LUBRICATION SYSTEM ..................................................................................................................................... 30
LINER WASH SYSTEM ....................................................................................................................................... 33
GENERAL ASSEMBLY ....................................................................................................................................... 36

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CRANKSHAFT ASSEMBLY ........................................................................................................................... 37


GEARBOX ASSEMBLY ................................................................................................................................... 38
CROSSHEAD ASSEMBLY ............................................................................................................................. 39
INDIVIDUAL ALIGNMENT .................................................................................................................................. 40
FLUID END ASSEMBLY ................................................................................................................................. 42
LINER AND PISTON ASSEMBLY ................................................................................................................. 43
DECOMMISSIONING: ......................................................................................................................................... 46
TROUBLE SHOOTING ........................................................................................................................................ 49
STORAGE, PRESERVATION AND TRANSPORTATUION OF THE HP MUD PUMP ............................. 52
GENERAL .......................................................................................................................................................... 52
SAFETY ............................................................................................................................................................. 52
TOOLS AND EQUIPMENT ............................................................................................................................. 53
CONSUMABLE MATERIALS ......................................................................................................................... 53
PREPARATION ................................................................................................................................................ 53
STORAGE AND PRESERVATION OF THE HP MUD PUMP .................................................................. 54
TRANSPORTATION OF THE HP MUD PUMP ........................................................................................... 57
RETURN TO SERVICE ................................................................................................................................... 58
POST-PROCEDURE TASKS ......................................................................................................................... 58
RECORD OF PRESERVATION ..................................................................................................................... 59
PUNCH LIST ..................................................................................................................................................... 60
TECHNICAL SPECIFICATIONS ........................................................................................................................ 63
MRB AND FAT ...................................................................................................................................................... 67
APPENDIX ........................................................................................................................................................... 109
SUPER BOLT TECHNICAL REFERENCE ................................................................................................ 109
COMPONENT DATASHEET ........................................................................................................................ 113
TYPICAL PARTS LIST AND TORQUE TABLE ......................................................................................... 129

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Document Number
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Title

WF400 MUD PUMP

Document Name

GENERAL INFORMATION

Document Number

TSC-WF400-07048

TSC-WF400-07048
A

Revision A

Reference Number

REVISION HISTORY

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PREFACE
The Work Force series of positive displacement triplex pumps are designed and precision built to address the
dynamic needs and challenges presented in 21st century well service, vertical, and directional shale oil/gas drilling
campaigns worldwide. For over 2 decades, TSC has proudly employed an elite team of tenured and talented
specialists whom have converged their efforts from designing an exclusive response to the market demand, to
carefully selecting the finest raw materials, to diligently assembling each unit to a precise protocol, to an in depth
testing/inspection regiment, to finally delivering each work of art with pride and a collective brand promise in mind.
In addition, our worldwide team proudly continues to work around the clock, year-round, to strengthen channel
partner relations, manufacturing capacity, documentation control, R&D for product improvement, and response time
in an ongoing campaign to bringing you, our esteemed buyer, an ownership experience and a brand you can trust.
The following pages provide an organized collection of instructions and data that you will find useful in the proper
operation and safe application of your new Work Force mud pump. On behalf of the TSC management team and
the talent that has made the WorkForce possible, we extend our gratitude for your business and welcome you to
the TSC family.
TSC Management

INTRODUCTION
This publication, issued by TSC Group Holdings Limited for the Mud Pump equipment installed in the cabin, and is
a part of the integral Mud Pump equipment. Therefore, this publication must accompany every transfer of property.
This publication contains the necessary information to correctly install the equipment in accordance with the
manufacturers recommendations.
This publication must only be used by trained and qualified personnel that are familiar with the equipment included
in this publication.
All procedures and instructions in this publication must be followed as they are given. Failure to do so can cause
loss of life, injury to persons or damage to the equipment, its assemblies, components or parts.
You must read, understand and obey all WARNINGS and CAUTIONS used in this publication.
All operations and work on this equipment must be performed in accordance with the local health and safety
regulations and environmental regulations and the safe working practices of the applicable site, installation or
operational environment (rig/drilling platform, etc.).
There are numerous variations in procedures, techniques and tools to install the equipment, as well as in the skill
of the personnel performing the work. This publication cannot anticipate all such variations and provide advice or
cautions as to each. If a tool, procedure, work method or part that is not specifically recommended by TSC is used,
you must be assured that it is safe for yourself and for others. You should also ensure that the equipment will not
be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that are intended
to be used.
TSC cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this
publication and on the equipment are, therefore, not all inclusive.
For any installation problem is not covered by this publication, please consult TSC.

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GENERAL SAFETY NOTICE


The following list contains some general guidelines to follow when working on the equipment:

Always wear appropriate personal protective equipment for the task being performed.

Keep yourself and your clothing away from moving parts.

To prevent serious burns, avoid contact with hot metal parts such as the prime mover, exhaust components,
oil cooler and hydraulic system components.

Do not smoke while working on the equipment.

To avoid injury, always remove rings, watches, loose hanging jewelry and loose clothing prior to beginning
work on a crane.

NOTICE, CAUTION AND WARNING


Through this publication, NOTICE, CAUTION and WARNING are used to emphasize instructions or information
considered to be unusual or critical. Each one has specific purpose.
NOTICE
Notice offers you added information that will help you to complete a particular task.

CAUTION
CAUTION OFFERS INFORMATION TO PREVENT YOU FROM MAKING AN ERROR THAT COULD DAMAGE
THE EQUIPMENT.

WARNING
WARNING OFFERS INFORMATION TO BE ESPECIALLY CAREFUL IN THOSE AREAS WHERE IMPROPER
OPERATION CAN CAUSE EQUIPMENT DAMAGE, PERSONAL INJURY, OR POSSIBLE LOSS OF LIFE.

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Revision

Title

WF400 MUD PUMP

Document Name

INSTALLATION GUIDELINE

Document Number

TE02030101-KA-0301

TSC-WF400-07048
A

Revision A

Reference Number

REVISION HISTORY

2014-7-30

First issue

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Date

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INSTALLATION GUIDELINE
REFERENCE DOCUMENT
ITEM

DOCUMENT NO.

TE02030101-KA-0201

DOCUMENT NAME
WF400, LIFTING PROCEDURE

INSTALLATION SAFETY NOTICE


For safety reasons, all instructions listed in this document shall be read, understand and adhered to.

Involved personnel shall be familiar with the contents of this procedure. This can be managed in a review
meetings.

Only qualified workers shall perform installation work.

Only certified lifting gear, rated for the actual load, shall be used.

A WARNING sign, DO NOT OPERATE, should be placed on the control console of the equipment before
installation.

If contact is made with a person when lifting heavy equipment, it can cause an injury or possible loss of life.
When working with heavy equipment, you must wear the applicable safety clothing and equipment. When lifting
heavy equipment, ensure that you and other persons are clear of and not go below the suspended load. If you
or other persons are injured, stop the work and seek medical help immediately.

Consumable materials can cause an injury to your skin, eyes and respiratory system. Before using consumable
materials, you must read, understand and obey the manufacturers applicable health and safety instructions.
When using consumable materials, you must wear the applicable safety clothing and equipment. If you have
contact with consumable materials on your skin, eyes or mouth, flush immediately with clean cold water and
seek medical help immediately.

Be careful when working at heights. If you fall, it can cause injury or possibly possible loss of life. Ensure that
you use the correct access and safety equipment. Ensure all the access and safety equipment is checked and
certified. Before using the access and safety equipment, you must read understand, and obey the
manufacturers applicable health and safety instructions. If you or other persons are injured, stop the work and
seek medical help immediately.

Be careful when working at heights. If you drop tools or equipment, it can cause injury or possible loss of life.
Ensure the area below is clear of all personnel. Ensure that applicable barriers are erected around the work
area so that persons cannot enter. If you or other persons are injured, stop the work and seek medical help

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immediately.

Be careful when lifting or lowering the equipment. If heavy equipment contacts the rig structure or other
equipment, or falls, it can cause damage to the structure and other equipment.

NECESSARY INSTALLATION EQUIPMENT AND TOOLS


Lifting equipment shall be prepared according to lifting procedures.
Necessary equipment and tools to be prepared prior to installation are as follows:
ITEM
1

TYPE/SIZE

DESCRIPTION
Torque wrench

QTY.
1 SET

PREPARATION
Before installing the equipment, verify that the following preparations have been accomplished:
1.

Ensure the lifting equipment is safe to use and is certified.

2.

Ensure the access equipment is safe to use and is certified.

3.

Read, understand and obey all the manufacturers applicable safety and operating instructions.

4.

Ensure all involved persons have the applicable Permit to Work.

5.

Read, and obey the Safety information.

6.

Ensure there is a WARNING sign DO NOT OPERATE, on the control console.

7.

Ensure there is sufficient access to the work area.

8.

Ensure that all persons have the applicable and serviceable communications equipment.

9.

Ensure that all necessary persons wear the applicable safety clothing and equipment.

10. Ensure the work area is clean and clear of unwanted equipment and materials.

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MECHANICAL INSTALLATION
WARNING
TO AVOID ANY DAMAGE TO EQUIPMENT IT IS RECOMMENDED TO HAVE A TSC SUPERVISOR PRESENT
DURING INSTALLATION. FAILURE TO DO SO MAY CAUSE INJURY OR POSSIBLY LOSS OF LIFE.

INSTALLATION
Unless otherwise instructed, the lubrication is drained from the power end of the pump.

Preparation
Proper pump installation requires some pre-planning before delivery to the location and the rig-up is performed. It
is difficult and expensive to correct errors in piping, pulsation dampener mounting, and tie down after they have
been fabricated and welded in place. The following outline is intended as a guide when planning your installation
and can help avoid unnecessary and expensive corrections. Refer to the illustrations for suggested piping
arrangements.

Foundation
Setting Pump
Set the pump level. This is necessary for proper distribution of the lubricating oil in the power end when the pump
is running.
Temporary Support
Plank or beam foundation matting should support the pump evenly throughout its length.
Permanent Support
Permanent installations must be levelled when the pump is set. The foundation should support the pump evenly
throughout its length. Do not lock the pump down unevenly, this will place an unnecessary stain on the frame.

Adjust-Balance
On permanent installations such as ground, platform, structural base, concrete slab, or where pump skids are bolted
down, it is essential that the skids be properly shimmed to prevent the possibility of twisting or distorting the power
frame. The pump skids must be positioned solid on all shim points with bolts loose.
Install shims at points shown in figs. 1 and 2 and observe and use caution of proper shimming to prevent twist or
distortion. The shims on all installations should extend the full width of the skid beam flanges and have a minimum
length of 12" (305 mm).

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Figure 1

Figure 2

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BOLT CONNECTION
Bolt connection is very important to the safety of the equipment. Care should be taken on the following issues:

It is important to install bolts in all holes of the connection and bring and toughen them to a snug tight condition
to compact the joint.

Tightening should begin at the most rigidly fixed, or stiffest point, and progress toward the free edges that will
minimize relaxation on previously tightened fasteners.

In some cases, proper tensioning of the bolts may require more than a single cycle of systematic tightening.

WARNING
PROPER BOLT TORQUE OR TURNS SHALL BE APPLIED TO FASTENERS.

PIPING INTERCONNECTION
SUCTION PIPING
Suction Piping Arrangement
TSC triplex mud pumps will operate satisfactorily with "natural" suction in many drilling situations. However, there
are circumstances that will require a "charged" suction. The piping design for a "dual" arrangement permits both
"natural" as well as "charged" suction operation. The line used for "natural" suction must be as short as possible
and preferably without bends. It must also be at least as large as the inlet of the pump and should be larger if length
exceeds six feet. The line leading to the charging pump discharge may make any bends that are necessary.
Suction Line Valves
Always use full opening valves such as gate or butterfly valves. Never use a restricting valve such as a plug valve
as this type will restrict the flow and reduce the pump efficiency.

DISCHARGE PIPING
Discharge Cross
The discharge piping can be simplified by using the forged discharge cross available from TSC. This would be at
the customer's option. The forged cross provides a mounting for the discharge pulsation dampener on top of the
cross and two end outlets for the mud lines. The cross also incorporates a side connector for mounting a pressure
gauge and easy access for cleaning the strainer. The complete assembly may be flanged directly to either side of
the pump and is designed with an integral support mounted between the cross and the pump frame.
Cross Strainer
The optional TSC discharge cross strainer incorporates a strainer pipe which should be checked and cleaned at
least once a month.
Pulsation Dampener

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A discharge pulsation dampener, mounted in the discharge line of each pump, will prevent harmonic vibration from
damaging the discharge piping. For instructions on the safe operation of the high pressure discharge dampener,
refer to the documentation supplied by the manufacturer.

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Document Number
Revision

Title

WF400 MUD PUMP

Document Name

LIFTING PROCEDURE

Document Number

TE02030101-KA-0201

TSC-WF400-07048
A

Revision A

Reference Number

REVISION HISTORY

07/30/2014

Original issue

XQ

LGM

WSL

Revision

Date

Revision for issue

Prepared

Checked

Approved

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Revision

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LIFTING PROCEDURE
LIFTING SAFETY NOTICE
For safety reasons, all instructions listed in this document shall be read, understand and adhered to.

Only persons that are correctly trained to handle this equipment shall perform this procedure.

Only persons that are correctly trained to use lifting equipment shall perform this procedure. All other personnel
shall be kept at a safe distance. If verbal warnings are not sufficient, the area should be cordoned off with
barriers and signage.

If contact is made with a person when lifting heavy equipment, it can cause an injury or possible loss of life.
When working with heavy equipment, you must wear the applicable safety clothing and equipment. When you
lift heavy equipment, ensure that you and other persons are clear of the suspended load and not go below. If
you or other persons are injured, stop the work and seek medical help immediately.

Consumable materials can cause an injury to your skin, eyes and respiratory system. Before using consumable
materials, you must read, understand and obey the manufacturers applicable health and safety instructions.
When using consumable materials, you must wear the applicable safety clothing and equipment. If consumable
materials contact your skin, eyes or mouth, flush immediately with clean cold water and seek medical help
immediately.

Never use sharp tools to remove the packing materials.

Be careful when lifting or lowering the equipment. If heavy equipment contacts the rig structure or other
equipment, or falls, it can cause damage to the structure and other equipment.

Never leave a suspended load unattended.

Make sure all the lifting equipment is certified.

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EQUIPMENTS TO BE LIFTED
The main parts that regu?re lifting are as below:

WF400 Mud Pump

PREPARATION
Before lifting the equipment, verify that the following preparations have been accomplished:
1.

Ensure all the lifting equipment has the correct SWL capacity.

2.

Ensure the lifting equipment is certified.

3.

Ensure all involved persons have the applicable Permit to Work.

4.

Ensure sufficient access areas for all aspects of lifting.

5.

Move all obstacles from the area.

6.

Before you use the lifting equipment, you must read, understand and obey the manufactures applicable safety
and operating instructions.

7.

Protect surface painting from scuffing of slings, etc., by using padding.

LIFTING PROCEDURES
WARNING
IF THE ASSEMBLY FALLS, IT CAN CAUSE INJURY OR POSSIBLE LOSS OF LIFE. BEFORE LIFTING THE
ASSEMBLY, ENSURE ALL THE LIFTING EQUIPMENT HAS THE CORRECT SWL CAPACITY. MAKE SURE
ALL THE LIFTING EQUIPMENT IS CERTIFIED. BEFORE YOU USE THE LIFTING EQUIPMENT, YOU MUST
READ, UNDERSTAND AND OBEY THE MANUFACTURES APPLICABLE SAFETY AND OPERATING
INSTRUCTIONS.

1.

Connect the shackles and steel rope to the pump (reference Figure 1).

2.

Lift the whole pump via the shackles and steel rope gradually with a crane.

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Figure 1

POST-PROCEDURE TASKS
1.

Ensure the work area is clean and clear of all unwanted tools and materials.

2.

Discard all unwanted materials in accordance with the local health and safety regulations and local
environmental regulations.

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Title

WF400 MUD PUMP

Document Name

START UP

Document Number

GLF-423-002

Revision 0

Reference Number

REVISION HISTORY

08/01/2012

Original issue

Revision

Date

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Prepared

Checked

Approved

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Change Description

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START UP
Confirm the following prior to start-up:

The pump has been inspected for any damage or loose components.

The charge pump is connected and is providing the correct flow rate and pressure.

The lubrication and liner wash pumps are operational.

The drive components are installed and aligned properly.

All guards and safety devices are installed.

All controls have been functionally checked.

Once the charge, lubrication and liner wash pumps are on-line, slowly bring up the prime mover to approximately
ten percent of maximum rated pinion speed (RPM) and hold for ten to fifteen minutes. Verify that there are no leaks
or unusual noises, especially any metal to metal sounds.
At ten percent speed, slowly increase the pressure on the pump until the maximum pressure is achieved, or the
prime mover power is at maximum. Back off the pressure to approximately fifty percent of the maximum rating and
slowly increase the pinion speed until it reaches the maximum. Again, verify that there are no leaks or unusual
noises or sounds. As the speed starts to approach maximum, check the temperature of the pinion and main bearing
areas. The bearing temperature rise should not exceed 70F (39C). Therefore, the pinion and main bearing areas
should not exceed 70F (39C) above the ambient temperature. Ensure the appropriate lubricant is used for the
ambient temperatures experienced during equipment operation. Section 5 Lubrication System for further
information.
At maximum speed, slowly increase the pressure on the pump until the maximum rated pressure is achieved or
power is at maximum level. Again, verify that there are no leaks or unusual noises or sounds. As the pressure starts
to approach maximum, check the temperature of the pinion and main bearing areas. The bearing temperature rise
should not exceed 70F (39C). Therefore, the pinion and main bearing areas should not exceed 70F (39C)
above the ambient temperature. Continue to run the pump, at the last achieved speed and pressure, for a couple
of hours to make sure the start up procedure has stabilized. Record operating temperatures and pressures for future
reference.
After the test, remove the lubrication suction strainer and clean. Replace the discharge filter on the lubrication
system. Verify the lubrication and liner wash tank levels are correct.
After completing the procedure above, the pump is ready to be placed in service.
CAUTION:
Never engage the prime mover at a high speed. This could induce a high shock load to critical
components and ultimately shorten expected life of the pump.

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Revision

Title

WF400 MUD PUMP

Document Name

GENERAL MAINTENANCE

Document Number

GLF-423-002

TSC-WF400-07048
A

Revision 0

Reference Number

REVISION HISTORY

08/01/2012

Original issue

Revision

Date

Revision for issue

Prepared

Checked

Approved

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GENERAL MAINTENANCE
Shift Change

Verify that the fluids levels are correct.

Verify that the lubrication and liner wash pumps are operating correctly.

Verify the liner wash by opening the three inspection covers on the top of the pump and visually inspect
that each liner is being sprayed by the system.

Verify the lubrication system by opening the access cover above the bull gear and visually checking for
oil flow. Ensure that the discharge pressure is approximately 20 PSI or greater. A higher pressure, 60
to 80 PSI, on start-up is normal until the oil temperature increases and the lubricant thins out.

Verify that the drive system is operating with-in normal parameters.

Visually inspect the pump for any damage or leaks. Repair as required.

Check the condition of the liner for signs of scoring or excessive wear. Replace as required.

Indication of mud on the piston rod is normal. However, excessive amounts of mud indicate a piston

Daily

that is worn out and requires replacement.

Check the liner compartments for excessive mud build up. Clean as required.

Inspect the weep holes on the modules for signs of seal leakage. If seepage is noted, schedule the
modules for rebuild as soon as possible. Always rebuild all the modules together.

Weekly

Remove the suction strainer element and clean.

Remove the piston rod clamps and inspect the mating surfaces for excessive or uneven wear. Rotate
the piston rod 90 before reassembling to ensure even wear.

Bi Weekly

Replace lubrication discharge filter. Clean liner wash tank of excess debris. Check module bolts for
correct torque using a click wrench. Use the reference drawings and torque tables provided in the pump
documentation to determine the correct torque.

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Remove and clean the valves and seats. Check the pony rod packing for signs of oil seepage. Look for
signs of scoring or other damage on the pony rod. Replace as required.

Monthly

Remove the side covers and inspect the clearance on the cross heads and crosshead alignment.

Check the slides for uneven or excessive wear.

Check for signs of scoring.

Check the clearance between the wrist pin and the crosshead. Compare against the original amount.
If this increases, tighten the bolts to specified torque and re-measure the gap. Note the new gap value
on the side of the cross head with a paint pen or similar writing device. A decrease of a couple of
thousandths is acceptable. If it decreases more than a couple of thousandths, the wrist pin is
experiencing excessive movement and these components need to be replaced.

Every 500 hours of operation:

Remove the pistons and inspect the rod and retaining nut for damage.

Replace the pony rod packing.

Inspect the mating surfaces of the pony and piston rods.

Re-torque the module fasteners.

Every 1000 hours operation:

Drain the lubrication sump and clean.

Inspect the fasteners on the connecting rods and the bull gear.

Check the torque on the super nuts.

Check the clearances on all the bearings.

Check the backlash on the gear set.

Inspect the inside of the pump for any damage or debris.

Repair and clean as necessary.

Clean the liner wash tank.

Inspect all rotating seals for any signs of seepage.

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The recommendations above are general guidelines for maintenance on your pump. Actual operating conditions
will play a large part in the frequency and level of maintenance required for your specific application.
If in doubt, perform the planned maintenance more frequently.

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Title

WF400 MUD PUMP

Document Name

LUBRICATION SYSTEM

Document Number

GLF-423-002

Revision 0

Reference Number

REVISION HISTORY

08/01/2012

Original issue

Revision

Date

Revision for issue

Prepared

Checked

Approved

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Revision

Change Description

Original issue

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LUBRICATION SYSTEM
The lubrication system uses an electric motor, coupled to a positive displacement pump, as the primary system with
the conventional splash system as a backup. With this arrangement, the minimum operating speed of the pump is
approximately 10% of the maximum number of strokes per minute.
Note:
When a mechanically driven lubrication / liner wash system is supplied, the minimum strokes per minute
will be about 50% of the maximum strokes per minute. The minimum can be decreased so long as the oil
pressure remains above 15 PSI. If lower minimum strokes per minute are required, contact TSC for
assistance in determine the best way to achieve that requirement.
The lubrication system uses a combination of orifices and spray nozzles to ensure that the system is balanced and
that all components receive the correct amount of lubrication. DO NOT change the size or location of any of the
components. It will adversely affect the balance of the system and could ultimately shorten the life of critical
components.
Reference the Parts List in the Appendix to determine the specific system for your pump.
The selection of lubricating fluid is critical to the trouble free operation of the pump. Too light of viscosity and the
bearings/gearing will not be adequately lubricated. Too high of viscosity, the lube pump will draw to much current
and trip the overload heaters in the motor starter.
If the pump is to be used across a broad temperature range without changing the viscosity of the lube oil, it is
suggested that a heater be placed in the sump of the pump to keep the viscosity low enough so that it will not cause
overload problems with the pump.
The suggested lubrication grades based on temperature variation is as follows;
Use an EP rated, non-corrosive, anti-foaming gear lubricant

TEMP: +50F to +155F AGMA #7 EP

TEMP: +20F to +100F AGMA #6 EP

TEMP: -20F to +60F AGMA #2 EP

The above is a general recommendation and the actual lubrication selected will be based on the actual operating
conditions and field experience with this type of equipment.
Although the bypass pressure is typically set at 30 PSI at the factory, the actual minimum required pressure can be
significantly lower and still maintain adequate lubrication. Consult the factory if high start-up viscosity is creating
problems with the lube pump.

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Title

WF400 MUD PUMP

Document Name

LINER WASH SYSTEM

Document Number

GLF-423-002

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LINER WASH SYSTEM


The liner wash system uses an electric motor coupled to a centrifugal pump. The pump is typically located between
the primary skid rails, below the liquid level of the liner wash tank, to ensure flooded suction at the inlet of the pump.
With this arrangement, the minimum strokes per minute is approximately 10% of the maximum strokes per minute.
Note:
When a mechanically driven lubrication / liner wash system is supplied, the minimum strokes per minute
will be about 50% of the maximum strokes per minute. The minimum can be decreased so long as the flow
is adequate to pull the heat out of the liners. If the liners heat up, or lower minimum strokes per minute are
required, contact TSC for assistance to determine the best way to achieve that requirement.
There is no filtration on the system other than the typical sediment retention baffle in the liner wash tank. The tank
should be cleaned on a regular basis to ensure that a limited amount of debris is pulled into the pump intake.
The system is a simple design and will use spray nozzles to supply cooling water to the liners.
For the specific type of system installed on your pump, reference the drawing and parts list for liner wash system.
It is recommended that a rust inhibitor be added to the liner wash system to help keep the system clean. In higher
ambient temperatures, an anti-fungal additive may also be required.

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Title

WF400 MUD PUMP

Document Name

GENERAL ASSEMBLY

Document Number

GLF-423-002

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GENERAL ASSEMBLY
The general assembly includes assemblies and auxiliary components, which are added as part of your pump
configuration. The pump is categorized into basic sub-assemblies as follows:

Lubrication and liner wash systems (described previously).

Crankshaft assembly.

Gearbox Assembly.

Cross head assembly.

Fluid end assembly.

Frame.

Skid.

The frame and skid are generally not considered field replaceable items and will not be discussed. If there are
questions concerning ether of these items, please contact the factory with your concerns.
All bearings are shrink fit with the exception of the floating crank bearing. The bearing fits are designed so that
temperatures above 250F are not required to install or remove the bearings. Use a temp stick to ensure that the
bearing temperature DOES NOT exceed 250F during installation or removal. The preferred method of installation
is to use heated oil to bring the bearing to the required temperature. When the bearing is installed, it is necessary
to hold the bearing in position until it has cooled sufficiently to hold position.
NOTE: NEVER ATTEMPT TO SPEED UP THE BEARING COOLING PROCESS WATER OR SIMILAR LIQUID.
Always use grade eight, drilled head fasteners, when replacing any fastener on the pump. Install the fastener using
a good anti-seize grease, and follow the recommended torque specifications on the individual assembly drawings.
Use an accurate torque wrench to verify all achieved torques.
Always use flat washers, preferably hardened. If using a lock washer, use a star type. Do not use a conventional
spiral lock washer. They are unreliable under high load and vibration.
The auxiliary items such as suction dampener, pulsation dampener, strainer cross, etc., are unique to each pump
delivered. The technical data for each of the items is found in the appendix.

CAUTION:
Always lock out the prime mover prior to any repair or adjustment.

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CRANKSHAFT ASSEMBLY
The crankshaft is a conventional forged core with welded eccentrics.
The crankshaft assembly is secured with bearing caps that are secured by Super Nuts.
Although these nuts deliver a very high holding force with relative ease, they require particular attention with regards
to how they are installed or removed. The nuts use a series of jack screws, arranged in a circular pattern, to be
able to achieve the high holding force. These jack screws need to be tightened and loosened in a progressive
manner, similar to the process of tightening or loosening the head bolts on an engine.
NOTE: THE BEARING CAPS ARE MACHINED AS AN ASSEMBLY AND DO NOT REQUIRE ANY ADDITIONAL
SHIMMING. THESE CAPS ARE MARKED AS SUCH AND SHOULD NOT BE SWAPPED SIDE TO SIDE OR
INTERCHANGED WITH OTHER PUMP BEARING CAPS.
The final torque should be achieved starting at approximately 25% of the required torque. Cross torque the jack
bolts until all are at specified torque. Then, repeat this process in 10% to 15% increments until the required torque
is achieved.
Additional information on the Super Nuts is available in the appendix.
The bull gear is a shrink fit on the gear journal and is held in place with grade eight fastener and self-locking nuts.
Achieve the required torque in steps, and tighten in a crossing pattern, similar to how head bolts on an engine would
be tightened.
NOTE: IN NO CASE SHOULD THESE FASTENERS BE CHANGED OUT FOR ANYTHING OTHER THAN
ORIGINAL EQUIPMENT.
The outer race of the eccentric bearing is a shrink fit into the conn rod and is additionally secured with the keepers.
The inner race is a shrink fit on the crankshaft and is additionally secured with the keepers. Install the keeper bolts
with a good anti-seize grease and torque to specified value and safety wire. Shim under the keeper to maintain the
bolt mating surface orientation parallel to the side of the conn rod.
The main bearings are a shrink fit on the crankshaft journals. The bearing should fit solidly against the journal
shoulder.
Before proceeding with the installation or removal of bearings, reference the section on bearings in the general
assembly section.
NOTE: DO NOT EXCEED 250F AT ANYTIME.

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GEARBOX ASSEMBLY
The gearbox assembly is a designed gear reduction from the prime mover to the HP mud pump crankshaft assembly.
The gearbox assembly has a symmetrical design, allowing it to be mounted on either side of the HP mud pump.
The symmetrical design allows for viewport access and lubrication oil fill and discharge access regardless of which
side the pump the gearbox is mounted.
This is a high load area. Ensure all threads are in good condition. If in doubt, replace with TSC approved fasteners.
After the gearbox assembly has been installed on the required side of the HP mud pump and the fasteners have
been torqued to spec, then rotate the gearbox pinion to ensure that it rolls freely without any tight spots.
All fasteners should be installed with good anti-seize grease and torqued to the required specification with an
accurate torque wrench and safety wired.

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CROSSHEAD ASSEMBLY
The cross head guides and crossheads are cast for long life. The cross head guides are interchangeable.
Prior to installation, all parts should be inspected for any signs of damage or burrs in the slide area.
The outer race of the wrist pin bearings are shrink fit in the conn rods, and the inner race bearings are shrink fit on
the wrist pin. The wrist pin is a taper on taper fit to the cross head.
Install the upper and lower cross head guides and tighten the fasteners to hold position. The cross head guides will
be shimmed later to achieve correct alignment and running clearance.
The cross head can be installed from the oil sump area or from the pony rod area, depending on whether or not the
crank assembly is in place.
It is recommended that the center crosshead be installed first. This will allow the most clearance to work on the
crosshead assembly.
INDIVIDUAL ASSEMBLY

Rotate the crankshaft assembly until the eye of the conn rod is approximately in the center of the
stroke.

Block the bottom of the conn rod to keep the eye approximately in the center of the cross head.

Insert the wrist pin into the crosshead assembly, ensuring the wrist pin and mating face are clean and
dry at all contact points. Lightly tap the end of the wrist pin to seat it.

Install the fasteners with a good grade of anti-seize grease, tighten to the 50% of the specified torque
in a crossing pattern, using a torque wrench. Tighten to the final torque in a crossing pattern and safety
wire.

Install the pony or extension rod, stuffing rod, glands, etc. following the recommended torques and
safety wire.

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INDIVIDUAL ALIGNMENT
With the crosshead at one end of the stroke or the other:

Set up a dial indicator to read of the top of the pony or extension rod. Set the travel of the indicator at
approximately its mid-range to protect the dial indicator. Record the reading on the indicator.

Slowly move the cross head to the other end of the stroke. Record the reading on the dial indicator.

The difference between the first reading and the last reading indicate how parallel the cross head is
running with respect to the theoretical centerline of the fluid end. If this value exceeds .004, the lower cross
head guide needs to be shimmed to bring the run out to within specifications. The lower the variation, the
less wear and tear on the glands.

Once the parallelism is confirmed, verify that the head is running true to the centerline of the piston.

Using a long feeler gauge, check the clearance between the top of the cross head and the upper cross
head guide in a number of places. This should be checked at the extremes of the stroke also.

The goal is to have about .012 to .013 clearance between the cross head and the upper cross head guide.
Shim the upper cross head guide to meet this requirement.
o

Repeat the above process with the two outer cross head assemblies.

See the sketch below for measurement points.

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FLUID END ASSEMBLY


The supplied fluid end assembly is a PAH style fluid end.
Before starting any assembly, make sure all parts are clean and free of any physical damage. Perform repairs
necessary before starting the assembly work.
This is a high load, high pressure area. Make sure that all threads are in good shape. If in doubt, replace with TSC
approved fasteners.
Individual Fluid End Assembly

Refer to the drawing in the appendix for the specific fluid end that is used on your pump.

All parts should be thoroughly cleaned and inspected for any damage. Repair or replace the damaged
parts as required.

Assemble all metal to metal fits with good anti-seize grease. This will help in both assembly and disassembly.

All fasteners are to be installed with a good anti-seize grease and torque setting to final torque in steps
using a crossing pattern with an accurate torque wrench. The fasteners should be torqued to about 1/3
of the required torque in a crossing pattern, then to about 2/3 the required torque in a crossing pattern,
and then to final torque in a crossing pattern. Final torque should be verified with an accurate torque
wrench.

NOTE: AFTER THE FLUID END HAS BEEN PRESSURIZED, GO BACK AND RE-CHECK THE TORQUE
ON ALL FASTENERS AND THE VALVE COVERS.
Individual Fluid End Assembly to the Frame

Lightly coat the studs with good anti-seize grease before placing the fluid end on the frame.

Run all the nuts up snug against the frame. Make sure that the fluid end is seating evenly across the
face plate of the frame.

Proceed to tighten the nuts to the specified torque in steps using a crossing pattern. Tighten the nuts
to about 1/3 of the final torque using a crossing pattern, then tighten to about 2/3 of the final torque
using a crossing pattern, and then go to final torque using a crossing pattern. Use an accurate torque
wrench to verify the final torque.

Repeat the above procedure for the other two fluid end modules.

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LINER AND PISTON ASSEMBLY

Select the correct size liner that correlates to the intended piston.

Lightly coat the mating surfaces of the liner with 30 weight oil. Install the gasket and slide the liner into the
fluid end.

Slide the retaining ring over the liner and run the nuts until snug against the retaining ring.

Tighten the nuts to about 10% of the required torque to ensure that the retaining ring is square to the mating
surface on the liner.

Tighten the nuts to about 50% of the required torque in a crossing pattern, similar to how an engine head
bolts are tightened.

Tighten the nuts to 75% of the required torque using the same procedure as above.

Complete the final torque of the nuts using the same procedure as above.

Repeat the above procedure for the other two liners.

Place the baffle on the pony rod.

Install the piston/rod assemblies.

Install the rod clamps and tighten to the specified torque.

Install the liner wash components.

Visually inspect the area to ensure that no tools or debris is left behind.

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Title

WF400 MUD PUMP

Document Name

DECOMMISSIONNING

Document Number

GLF-423-002

Revision 0

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DECOMMISSIONING:
If the pump is to be out of service for more than a couple of days, the following steps are recommended:

Thoroughly clean the exterior and the liner areas with fresh water to remove all drilling mud, etc.

Drain and clean the lube sump and liner wash system.

Run a gallon or two of biodegradable antifreeze through the liner wash system to lubricate and prevent rust.

Place desiccant in the oil sump to absorb any moisture.

Remove the valves from the fluid ends and thoroughly clean the fluid end with fresh water.

Coat the valves and other parts with light grease and re-assemble the fluid end.

Remove the piston assemblies and lightly coat the liners with grease.

To re-commission the pump, follow the installation and start-up procedures previously described in the manual.

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Title

WF400 MUD PUMP

Document Name

TROUBLE SHOOTING

Document Number

GLF-423-002

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TROUBLE SHOOTING
General Application Problems:

Pump performance is based on two variables: torque and speed. Torque provides pressure and speed provides
flow.

Check the following if the pump is not getting the anticipated performance:
o

Is the piston size correct for the required flow and pressure?

First, determine if the correct piston diameter is used for the desired flow rate at the current
operating speed. This can be determined by entering in various numbers into the following
formula and solving for the theoretical flow rate (GPM) output.
GPM = 0.01 x ID2 x L x SPM
GPM = flow rate
L = stroke length (inches)
ID = inner diameter (inches)
SPM = strokes per minute

If the GPM is correct, determine how much torque is required to achieve the required pressure.
This can be achieved by identifying the approximate torque at the pinion to achieve the required
pressure by entering in various numbers into the following formula and solving for the
theoretical torque required @ 85% efficiency.
Tor = (3.61 x PSI x GPM) / RPM
Tor = Torque (foot-pounds)
PSI = pounds per square inch (fluid pressure)
GPM = gallons per minute (volume flow)
RPM = revolutions per minute (pump pinion speed)

The next step is to determine the theoretical horsepower required at the pinion to achieve the
required flow rate and pressure by entering in various numbers into the following formula and
solving for the theoretical power (HP) required.
HP = (RPM x Tor) / 5252
HP = horsepower (power input at the pinion)
Tor = Torque (foot-pounds)
RPM = revolutions per minute (pump pinion speed)

The final step is to determine if your prime mover is delivering the required horsepower to the
pinion. You will have to refer to the engine or motor performance charts to determine the actual
horsepower available from the prime mover to achieve the required speed and power at the
pinion of the pump. Do not forget to include drive inefficiencies.

Are the valves in the fluid ends opening and closing properly?

Is suction being supplied at adequate flow with pressure at no more than 40 PSI?

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Title

WF400 MUD PUMP

Document Name

STORAGE, PRESERVATION AND TRANSPORTATUION OF THE HP MUD PUMP

Document Number

GLF-423-002

Revision 0

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STORAGE, PRESERVATION AND TRANSPORTATUION OF THE HP MUD PUMP

GENERAL
This section provides the correct procedure for the storage, preservation and transportation of the HP mud pump.
The storage section also includes proper preservation of the equipment.
The record of preservation must be completed for the duration while the equipment is in storage.

SAFETY
Only persons that are properly trained to handle this equipment can perform this procedure.
Only persons that are properly trained to use lifting equipment can perform this procedure.

WARNINGS AND CAUTIONS:


Before performing this procedure, you must read, understand and obey all the WARNINGS and CAUTIONS below:

WARNING
If contact is made with a person when using heavy equipment, it can result in injury or loss of life. When
working with heavy equipment, you must wear the appropriate personal protective equipment. When you
lift heavy equipment, ensure that you and other persons are clear of the suspended load and must not go
below. If injury results, stop work immediately and get medical attention.

WARNING
Consumable materials can cause injury to your skin, eyes and respiratory system. Before you using
consumable materials, you must read, understand and obey the manufacturers applicable health and
safety instructions. When using consumable materials, you must wear the appropriate personal protective
equipment. If consumable materials contact with your skin, eyes or mouth, flush immediately with clean
cold water and get medical help immediately.

CAUTION
Sharp tools can damage the surface of the equipment or the crate material. Do not use sharp tools to remove the
packing materials.

CAUTION
Be careful when lifting or lowering the equipment. If heavy equipment falls or strikes the rig structure or other
equipment, damage to the structure and other equipment may result. Do not leave a suspended load unattended.
Make sure all the lifting equipment is calibrated and certified. You must read, understand and obey the
manufacturers' applicable safety and operating instructions.

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TOOLS AND EQUIPMENT


Part No.

Description

Local supply

Access equipment, certified

Local supply

Wooden chocks / stocking material

CONSUMABLE MATERIALS
Specification

Description

Qty

Veto 342

Corrosion preventative, unpainted metal

AR

Rocol Industrial Cleaner

Solvent

AR

Local supply

Desiccant, silica gel

AR

Local supply

Cloths, lint free

AR

NOTE: AR As Required
NOTE: stated equipment weight is inclusive of standard accessories - as shown in GA drawing TE030101-GAREVA1

PREPARATION
Preparation for Storage, Preservation and Transportation
(1) The consignee is responsible for the care and cleanliness of the equipment during storage, preservation
and transportation.
(2) The consignee must ensure the standard of care complies with the requirements given in this
procedure.
(3) Only persons that are properly trained and qualified to handle heavy equipment can perform this
procedure.
(4) Ensure that all necessary persons read, understand and obey the local lifting regulations and local
health and safety regulations.
(5) Ensure that all necessary persons have the applicable Permit to Work.
(6) Ensure that all necessary persons have the applicable and serviceable communications equipment.
(7) Ensure that all necessary persons wear the appropriate clothing and personal protective equipment.
(8) Ensure there is sufficient access around the equipment.
(9) Ensure the correct access equipment is available:
a) Ensure the access equipment is safe to use and is certified.
b) Ensure there is no damage, wear or corrosion to the access equipment.

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c) Ensure the operator(s) read, understand and obey all the manufacturers applicable safety and
operating instructions.
(10) Ensure there is a barrier around the work area.
(11) Ensure only the persons necessary to perform the work enter the work area.
(12) Ensure the work area is clean and clear of unnecessary equipment and materials.

STORAGE AND PRESERVATION OF THE HP MUD PUMP


Recommended Preservation - General
(1) Secure all loose hoses, pipes, cables or components with appropriate cable-ties or tape.
(2) Install steel caps/plugs on open connections of hydraulic piping and hoses.
(3) Install steel caps/plugs on open connections of electrical cables.
(4) Check the tightness of steel caps/plugs.
Recommended Preservation - HP Mud Pump
(1) Storage after Test.
a) Drain all oil and thoroughly clean the inside of the frame.
b) Coat pinion shaft oil seals with grease.
c) Remove breathers, keep with mud pump.
d) Seal the breather hole with greased solid plugs.
e) Remove extension (intermediate) rods and oil seal stop head, keep with mud pump.
f)

Protect extension rods and oil seal stop head with corrosion inhibiting paper.

g) Seal the stop head openings with wooden covers.


h) Apply applicable corrosion preventative (Veto 342) to the mating surfaces of covers and oil seals.
i)

Remove valves and valve springs.

j)

Clean valves and valve springs, and wrap in corrosion resistant paper.

k) Remove liners and pistons.


l)

Clean liners and pistons and wrap in corrosion resistant paper; keep pistons upright.

m) Clean and dry fluid end bores.


n) Apply applicable corrosion preventative (Veto 342) to internal surfaces of fluid end bores.
o) Apply grease to the threads of valve cover, thread ring, liner clamps and liner pilot bushings, and
install them in fluid end.
p) Protect all external machine surfaces with applicable corrosion preventative (Veto 342).
q) Drain liner water tank, and flush with clean water and drain.
r)

Examine complete pump and record all details on the protection and storage log.

s) Cover Mud Pump with plastic sheeting.

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(2) Six Week Storage Maintenance


a) Remove plastic sheeting.
b) Rotate gearbox pinion 5 revolutions.
c) Examine external protection (i.e. rust inhibitor and paint) and apply more inhibitor as necessary.
d) Cover mud pump with plastic sheeting.
e) Record inspection and note any changes in the record of preservation.
(3) Six Month Storage Maintenance
a) Remove the plastic sheeting.
b) Rotate pinion shaft 5 revolutions.
c) Examine external protection (i.e. rust inhibitor and paint) and apply more inhibitor as necessary.
d) Examine for internal corrosion. If corrosion is found, record and report to responsible person.
e) Replace side covers and top cover of mud pump.
f)

Cover mud pump with plastic sheeting.

g) Record inspection and note any changes in the record of preservation.


Preservation Records
(1) Record the details of all preservation on the Record of Preservation sheets (located at the end of this
section)
(2) Put the preservation documents in an applicable container and attach the container to the mud pump.
Recommended Storage Requirements - General
(1) For special or sensitive equipment:
a) Make sure the store room is heated, vented, clean and dry.
b) Make sure the storage environment complies with the suppliers requirements.
(2) Storage of mechanical and hydraulic equipment:
a) Only store equipment outside if it is correctly prepared by the supplier. On the packing list, record
if the equipment is stored outside or inside.
b) If equipment that does not have a wooden pallet is stored outside, make sure the equipment is
supported clear of the ground with applicable wooden chocks.
c) To protect the equipment from the environmental conditions, cover it with weatherproof sheeting.
(3) Storage of electrical/instrument equipment:
a) For all electrical equipment, the packing list shall reflect the requirements for inside storage. Only
use desiccant in sealed bags; do not let the desiccant touch stainless steel.
b) Junction box openings shall be plugged and door gaskets checked to make sure they are intact
and tight. Put sufficient desiccant in the junction box to last 1 month. If necessary, replace the
desiccant every month.
c) All non-terminated cable ends shall be covered with shrinking shrouds.

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d) Gaskets and O-rings on instrument equipment shall be lubricated with applicable grease (Rocol
Precision Silicone Spray).
Recommended Storage Requirements - HP Mud Pump
(1) Store the mud pump in accordance with local health and safety regulations and environmental regulations.
(2) Make sure the storage area:
a) Is sheltered from extreme environmental conditions.
b) Is free of equipment that produces extreme temperatures.
c) Has an ambient temperature between 0 C and + 50 C.
d) Has a maximum humidity of 70%.

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TRANSPORTATION OF THE HP MUD PUMP


WARNING
The HP Mud Pump assembly is very heavy. If the assembly falls, it can cause extensive injury or possible
loss of life. Before you lift the assembly, ensure all the lifting equipment has the correct SWL capacity.
Ensure all the lifting equipment is calibrated and certified. Before you using the lifting equipment, you must
read, understand and obey the manufacturers applicable safety and operating instructions.
Safety
(1) Before you perform the procedures that follow, you must read, understand and obey the WARNINGS and
CAUTIONS used in the safety section.
Packing the HP Mud Pump
(1) Check the mud pump against the packing list:
a) Make sure all parts are included.
b) Record any missing parts on the Punch List (located at the end of this section).
(2) Examine the mud pump for damage:
a) Record any damage on the Punch List (located at the end of this section).
(3) Make sure to disconnect and drain all hydraulic pipes and hoses.
(4) Ensure steel blanking caps/plugs are installed on the open connections of all pipes, hoses or cables.
(5) Install the applicable packing and protection materials on the mud pump.
Load the HP Mud Pump onto the Transportation Vehicle or Vessel
(1) Attach applicable lifting equipment to the mud pump skid.
(2) Slowly and carefully lift and move the mud pump above the vehicle or vessel:
a) Ensure the slings do not directly contact any sharp edges on the mud pump.
b) Ensure the mud pump remains level.
(3) Slowly and carefully lower the mud pump onto the vehicle or vessel.
(4) Secure the mud pump to the vehicle or vessel.

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RETURN TO SERVICE
Return the HP Mud Pump to Operational Condition
(1) Remove mud pump plastic sheeting.
(2) Use applicable solvent to remove the grease from the pinion shaft oil seals.
(3) Remove solid plugs from the breather hole.
(4) Install breathers.
(5) Remove corrosion resistant paper from extension rods and oil seal stop head.
(6) Remove wooden covers from stop head openings.
(7) Install extension (intermediate) rods and oil seal stop head.
(8) Use applicable solvent to remove corrosion preventative from the mating surfaces of covers and oil seal.
(9) Remove corrosion inhibiting paper from valves and valve springs.
(10)Install valves and valve springs.
(11)Remove corrosion resistant paper from liners and pistons.
(12)Install liners and pistons.
(13)Use applicable solvent to remove corrosion preventative from internal surfaces of fluid end bores.
(14)Use applicable solvent to remove corrosion preventative from all external machine surfaces.
(15)Examine complete pump and record all details on the protection and storage log.
(16)Ensure there is no damage to the mud pump.
(17)If necessary, repair the paint finish to the original condition.
(18)Ensure the mud pump has the necessary documentation.

POST-PROCEDURE TASKS
Complete the Task
(1) Make sure the work area is clean and clear of all unnecessary tools, equipment and materials.
(2) Discard all unneeded consumable materials in accordance with the local health and safety regulations and
environmental regulations.
(3) If applicable, complete and return the Permit to Work.
(4) If applicable, complete and return the Punch List (located at the end of this section) to TSC.

TASK COMPLETE

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Name

Signature

RECORD OF PRESERVATION
HP Mud Pump
Details of Preservation

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PUNCH LIST
The table that follows gives a list of missing items, items necessary to replace defective items, non-finished items
and details of any repair work required for the applicable assembly. Copy more sheets if necessary. Send the
applicable Punch List to TSC within seven (7) working days.
HP Mud Pump

No.

Description of Work to be Carried Out

Close
Date

Out

Client
Initial

TSC Initial

Title

Name

Signature

Date

Checker/Inspector:

_______________________

____________

_______

The Checker/Inspector to retain a copy and the original is to be returned to TSC Engineering Ltd, Document
Control.
Close Out:

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_______________________

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____________

_______

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WF400 MUD PUMP

Document Name

TECHNICAL SPECIFICATIONS

Document Number

GLF-423-002

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TECHNICAL SPECIFICATIONS
Performance Criteria

Nominal Input Horsepower:


Maximum Strokes per Minute: 155
Stroke: 8-1/2 inches (215.9 mm)
Maximum Piston Diameter & Pressure:
Minimum Piston Diameter & Pressure:
Suction Manifold:
Discharge Manifold:
Estimated Dry Weight:
Oil Capacity:
Gear Ratio:
API standard expendables

400 (298 kW)

5 inches (127 mm) @ 1837 PSI


3 inches (76.2 mm) @ 3118 PSI **
6 inches (152.4 mm) with 150# flanges
3 inches (76.2 mm) with 5000 PSI RJ flanges
10,100 pounds (4600 kg) ^^
55 gallons (208 liters)
5.7 : 1

** Pressure rating limited to fluid end and discharge flange ratings


^^ Stated weight is for bare pump and skid, less standard accessories

Standard Features:

Small foot print with high horsepower to weight ratio


Bearings and gearing designed for a minimum L10 life of 30,000 hours at rated load
Rigid, fabricated oilfield style frame and skid providing stable operating platform
Fabricated crank shaft with forged core to minimize vibration and ensure longevity
Cast cross heads and guides to maximize longevity
3118 psi valve-over-valve Fluid Ends (PAH style)

Standard Accessories:

5 gallon pulsation dampener (Accumulator Style)


Discharge strainer cross assembly
Lubrication system
Liner wash system
Pressure relief valve
Discharge pressure gauge

Available Options:

Custom unitization package on oilfield skid base


Charge pump
Motor starter(s) in explosion proof enclosure
Valve seat puller assembly

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WF-400 Typical Arrangement Drawing

NOTE: Dimensions are approximate and subject to change; Shown with standard accessories.

WF-400 Typical Performance Characteristics


WF-400
Performance
Characteristics
Piston Dia. Pressure
inches
psi

3
3.5
4
4.5
5

3118
3118
2870
2267
1837

Pinion HP
Pinion lb-ft
Pinion RPM

80
2378
171

133

187

240

293

247

400

285

399

513

627

741

884

Strokes / min

30

50

70

90

110

130

155

GPM

23
32
42
53
65

39
53
69
88
108

55
74
97
123
152

70
96
125
158
195

86
117
153
193
238

101
138
180
228
282

121
165
215
272
336

Notes:

All data is subject to change without notice


All data is based on 100% or continuous duty cycle
Data is based on 90% mechanical and 100% volumetric efficiency
Achievable pressure will be limited by the horsepower available or the pressure limitations of the module used.

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MRB and FAT

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MRB AND FAT

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Qingdao TSC Offshore Equipment Co., LTD

WF400 Mud Pump Archive

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Qingdao

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TSC Offshore Equipment Co., LTD

WF400 Mud Pump Gearbox Dimension Inspection

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TSC Offshore Equipment Co., LTD

Gearbox Dimension Inspection

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WF400 MUD PUMP

Document Name

APPENDIX

Document Number

TSC-WF400-07048

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APPENDIX
SUPER BOLT TECHNICAL REFERENCE

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WF400 MUD PUMP

Document Name

COMPONENT DATASHEET

Document Number

TE02030101-DS-0101

TSC-WF400-07048
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Revision 1

Reference Number

REVISION HISTORY

2014-9-5

CHANGE GEAR PUMP

XQ

LGM

WSL

2014-7-30

INITIAL RELEASE

XQ

LGM

WSL

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COMPONENT DATASHEET
GENERAL
The purpose of this publication is to list all of the necessary datasheet, operating manual or other user document
of buyout components of this equipment.
The datasheet, operating manual or other user document listed in this publication contain useful information
regarding interface, installation, operation and maintenance, and are necessary to use the machine.

DATASHEET LIST
The datasheet of buyout components are listed in table below:
DATASHEET NO.

DESCRIPTION

PART NO.

PAGES

DS-01

SPRAY PUMP

59000282

DS-02

ROTARY GEAR PUMP

GP1-047-031-01

COMPONENT DATASHEET ATTACHED

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GEAR PUMP TYPE YCB


OPERATION & MAINTENANCE MANUAL

HEBEl HENGSHENG PUMPS CO., LTD.

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GENERAL
YCB series of circular arc gear pump is a new type external gear pump and of the latest construction, jointly
developed by the Hydraulic Research Office of Mechanical Engineering Department, Shanghai Jiaotong Universitv,
and Botou Gear Pump General Plant. The gears of pump have the teeth figure of the advanced arcs compounded
with other curves thus making it have good-working quality. Compared with the traditional Gear Pump 2CY with
involutes teeth, this pump has the characteristics of little pressure wave, low noise, high efficiency and long service
life. It is a new type of energy-saving pump.
The circular arc gear pump is suitable for petrochemicals, ship-building industries and other industries to pump in
different mediums, such as petroleum, heavy oil and industrial light oil, at a temperature below 80 and with a
viscosity 5-1500cSt.But it is not suitable for pumping in oil with hard particles and the other fibred particles, nor is
fit for high volatile but low flash point oil, such as gasoline, benzene medium liquid .If change the pump material ,it
can pump the mediums that temperature below 300C,corrosive and low flash point.
Safety valve is supplied with standard pump unless otherwise stated.
The pump is driven by the motor through the claw coupling, and they are fixed on a cast base plate or a welded
from profile steel.
The circular arc gear pump can be installed horizontally or vertically or in other directions as required to meet
different conditions.

MODEL AND STANDARD TECHNICAL DATA OF PUMP


Model and standard technical data of pump

Motor power is chosen according to the shaft power, when the viscosity of oil is at 30cSt.
The motor power should be raised along with the increase of the viscosity, the exhaust pressure or the
exhaust pressure with safety valve.
Selection of the motor speed: Four-phase motor is for viscosity below 500cSt; six-phase motor is for
viscosity above 500cSt.
The standard scope of viscosity: 5-1500cSt.
Temperature below 300 .
The direction of rotation is clockwise viewed from coupling end (the pump-in entrance is on the left And
exhaust exit on the right). If the end users require to change the rotation, please indicate when ordering.

Model explanation
For example:

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Working principle of gear pump


Fig.1 shows that a pair of gears that are engaged are installed inside the casing with two ends sealed by the front
and back covers. Gears divide the inside of the casing into cavity A and cavity 8 which are not interlinking. When
gears revolves as Fig. 1 indicates, cavity A's volume is enlarged gradually because of the disconnection of the teeth,
resulting in part vacuum, and oil in the tank flows through oil tubes into cavity A under the external atmosphere
pressure. So cavity A is called as absorption cavity. The absorbed oil in the cavity A flows into cavity 8 in sealed
space along the inside wall of casing when gears revolve. Oil between gear teeth are extruded out when they are
engaged and therefore the volume of this cavity reduced. This is called as press oil cavity. When gears revolve
constantly cavities A and 8 always pump in and exhaust oil, which is the working principle of the gear pump.

Fig.1 Working principle of gear oil pump

Fig.2 Construction of gear pump


1. back cover
2. gasket
3. bush
4. bearing stand

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5. driven shaft
6. gear
7. driving shaft
8. front cover

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9. soft graphite
10. press cover
11. pump body
12. safety valve

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PUMP CONSTRUCTION AND FUNCTION

This pump series is characterized as simple construction and compactness. Pump body and safety valve
are separated. So it's easy to use and maintain. Quality of the product is guaranteed, for the main parts are
made of top-quality steel and precisely processed.

Oil pump has the self-absorption function. So it is unnecessary to add oil before working.

Lubrication of pump is achieved automatically through the transmission of oil. So no lubrication oil is
necessary while working.

Pump body: Two holes on the parallel surfaces of pump body are fixed with a pair of gears and four bearing
stands. Safety valves are put on the top. Front cover and back cover are in the front and back respectively.
Flanges on both side are for connection. Flange connector dimensions are up to the ISO and DIN standards
and that of the china state ship-building corporation's CBM.

Gear and shaft: All gears are of spiral gears, the gear and shaft compose of the shaft gear.

Bearing stand and bush: The revolving of the shaft gear is backed up by bearing stand and bush that have
already been put together as a whole.

Gasket: Gasket are inserted into the press surfaces between the pump body and the front and the back
covers in order to achieve the better results of the sealing.

Shaft seal: There are two kind of axle-end seals, mechanical seal and packing seal. The seal rings are
made of soft graphite which are elastic, high and-low-temperature-resisting, and of chemical stability and
self-lubrication.

Safety valve
o

The safety valve of this series of pumps is assembled on the pump body as a whole. If safety valve
is not required, special cover fixed on the safety valve position can be provided.

Fig.3 For pumps with safety valve and without safety valve

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20. valve body


21. spacer
22. protective cap
23. washer

24. Nut
28. safety valve push pitch
25. washer
29. cover
26. adjusting screw
27. safety valve spring

The working principle of the safety valve is to use spring to control the working of the safety valve. The
function of the safety valve is to avoid incidents that might result from too much high exhaust pressure.
the breakage of the exhaust pipes or the close of the exhaust oil pipes' valves. When such incidents
occur, safety valve opens immediately and the liquid part or even all, will flow back to the pumping in
cavity. Safety valve is not used to adjust the capacity of the pump for long.

PUMP INSTALLATION

Before assembling, it is required to check up whether the motor is affected by damp or there is damage to
the dust-proof covers of pump's inlet or outlet, which might lead the dirt things into the cavity.

Oil pump and motor are fixed on the base plate. Hooks must hang on the base plate rings .In lifting single
pump head, hooks must hang on the inlet or exit flange tubes.

Select a dry and bright place so that management people can watch when pump is working. A certain
space should leave out if it is close to wall, for it is easy to maintain. Don't put it at a place where is humid
and wet, being exposed to sun and rain. Oil pump should be installed in place above the water level so
that it cannot be flooded.

The foundation of pump should be stable so that pipes will not be released or vibrated. In order to avoid
the deformation of the base plate, bolts should be fixed firmly. If only the pump head is installed on the
machinery, the least vibrated place must be chosen.

Washing the inside wall of pipes by kerosene before installation in order that no dirt things especially no
rubbing matters are allowed to remain in the pipe, because they might cause the damage to the gears.
The dimensions of the absorption and exhaustion pipes are by no means smaller than the nominal size of
pump. Absorption pipe should be bigger and the shorter the better. Elbow should have bigger radius.
Throttle valve should be used on the pipe valves to reduce the resistance.

No foot valve is needed for oil pump. But it is suggested to fix a filter gauze at the entrance of the intake
pipe to prevent dirt things from entering in pump body .The effective area of the filter gauze should not be
two times smaller than that of the dimensions of the tubes. The mouth of the intake tube should be cut to
an angle of 45.

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Pump shaft and motor shaft should be installed concentrically. If it is not properly fixed, it might cut off the
claw of the shaft couplings when revolving.

PUMP OPERATION
Start-up

Before the oil pump to be used, it is required to check up whether all tubes are fixed properly, and open
valves of intake oil pipes.

Revolve the couplings by hand to see if there is an abnormal phenomenon.

Press the button on shortly before oil pump starts and make it sure the revolving direction is right and
everything is perfect

If oil pump is in operation, close the control valve of the outlet oil pipes gradually so as to adjust the
pressure required.

But the adjusted pressure should not be higher than the rated pressure. When oil pump is in constant
operation, shaft seal and vibration should be carefully observed.

Adjustment of the safety valve

In normal circumstance, the working pressure of the safety valve is 1.5 times as against the rated
pressure. In case lower pressure is needed, adjust it according to Fig.3

Release the protective cap and unscrew the adjusting nut.

Make the adjusting screw revolving clockwise and then close gradually the control valve on the outlet
tubes to determine whether the returned pressure is that needed. f the requirement cannot be fulfilled
through one time of adjustment, you should proceed with several times.

After the adjustment, screw the adjusting nut and protective cap.

Stop working

Cut of motor power and close control valve on the outlet tubes.

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PUMP DISASSEMBLY AND REASSEMBLY


Following orders should be followed to disassemble to oil pump.

Disassemble the couplings on the oil pump shaft end .If it is too tight, use a copper stick to hit it gently
and let it out.

Disassemble the press cover first and then the soft graphite ring or mechanical seal ring.

Disassemble the front and back covers and take the gasket out.

Disassemble bearing stand and then take out driving-and driven-shaft gears.

Disassemble nut and spring washes of the driving and driven-shaft and then take out the left and-right
gears

Disassembly of safety valve

First disassembly the protective cap, gasket and nut, then unscrew the adjusting screws, springs and safety
valve push pitch and lastly the valve body and gasket.
Oil pump check-out
Check out every part. Worn part must be repaired or replaced.
Oil pump reassembly

The procedure for assembling is nearly the reversal of that for disassembling, i.e., last disassembled first
assemble .But the following points should be noted.

AII the parts must be checked before assembling.

All the parts that are going to be assembled must be washed with kerosene and lubricated. No dirt things
are allowed to enter the inside while assembling

While assembling the upper and lower bearing stands and the driving and driven gears, the thickness
difference of every pair of bearing stand and gear should be less than 0.005mm.

The gap on both gear sides should be adjusted by paper gaskets. Bigger gap will easily cause the
leakage and reduce the efficiency, but if the gap is too small, the pump will get a higher temperature
quickly or can't run freely.

Assembling the soft graphite ring or mechanical seal0-ring by special sleeve. Soft graphite ring must be
handled with care and be put in order, and shown in Fig.4

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After assembling, use hand to revolve the driving gear, to make sure that it revolves evenly.

USUAL TROUBLE AND WAYS OF REMEDY


Troubles
Productive
Reason
Ways of
remedy

Troubles Productive Reason Ways of remedy

Troubles Productive Reason Ways of remedy

No
discharging
oil or
discharging
little oil

1. Revolving direction reversed


2. Valve closed
3. Oil absorption tube has not been soaked
into the oil
4. The high of absorption exceeds the rated
5. The filtering area of the filter at absorption
end is too small
6. Air leakage in absorption tube
7. Safety valve blocked or doesn't work well
8. Lower temperature of oil results in viscosity
increasing

1. Change into right direction


2. Open valve
3. Check out oil absorption tube and soak it in
the liquid
4. Measure absorption pressure and raise the
oil level
5. Change filter and extend the filtering area
6. Check every joint and seal them with
sealing materials
7. Disassemble and wash safety valve and
polish with abrasive grease
8. Heat liquid or reduce exhausting pressure
or the volume of oil exhaustion

No
pressure or
pressure
not rising

Oil leakage
in
mechanical
seal

Noise and
vibration

Safely
valve

1. The button of the pressure meter is still in


OFF position
2. The pressure of the safety valve is too low
3. Side tube valve is on
4. High temperature, low viscostiy of oil and
small resistance of the tube
5. Air leakage in the tube
1. Shaft seal has not been adjusted property
2. O-ring wear
3. The defects caused by wearing of
stationary and rotating rings of mechanical
seal
4. Spring flabby
1. Improper assembling
2. The in concentricity of pump shaft and
motor shaft
3. Absorption tube or filter stopped up
4. Absorption tube dimension is too small and
long. It could not pump in, for resistance is too
big
5. Oil exhaustion tube's resistance i s too big
6. Air leakage
7. Fastener is relaxed
8. Gears and bearings stand sides show
serious wear and tear or gripped
1. Wrong position
2. Pressure too high

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1. Press the button ON of the pressure meter


2. Readjust the safety valve pressure
3. Close the side tube valve
4. Reduce oil temperature
5. Check out absorption tube
1. Adjust it
2. Change 0-seal
3. Change stationary and rotating rings or
polish them again
4. Change spring
1. Check out and maintain
2. Readjust it
3. Clear dirt things in the absorption tube or
filter
4. Readjust it
5. Check up whether exhaustion tube or valve
are stopped up
6. Check up and maintain
7. Check up and tighten it
8. Disassemble and maintain or change them
semble and maintain or change
1 .Reassembling it
2. Lower the pressure

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unworkable

No
pressure or
pressure
not rising

3. Safety valve chip gripped


1. Exhaustion pressure too high
2.Low temperature results in increase of oil
viscosity
3.Improper assembling
4. Revolving shaft curved
5. Somewhere in the exhaustion tube stopped
6. Gears and bearing stand sides show
serious wear and
tear or gripped

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3. Disassembling, wash and readjust


1. Lower pressure
2.Heat liquid or reduce exhaustion pressure or
volume of
exhaustion oil
3. Reassembling
4.Straighten or change it
5. Check up and maintain it
6.Disassemble and maintain or change them

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POINTS FOR ATTENTION IN OPERATION AND WAYS OF MAINTENANCE


Points for attention
Apart from the above-mentioned points, following points should be noted.

Check up whether nuts and bolts, couplings and motor are tight.

Clear away the unnecessary dirt things and tools near the oil pump.

0perator is required to be at a distance from oil pump in operation to avoid being spattered with gushing oil.

Ways of maintenance

Pay attention to the pressure and vacuum meters, figures of which should be in accordance with those stipulated in
the technical data.

Pay attention to the packing seal. If too much oil leakage, screw the press cover as required. If too tight, it will result
the packing seal becoming excessive hot

When abnormal noise and excessive rise of temperature occur, turn off oil pump immediately to check up.

Check up timely and frequently and clear any stoppage. Be sure oil pump works properly.

SPARE PARTS, ACCESSORIES AND TECHNICAL DOCUMENTS

Spare parts,accessories and technical documents


o

Oil seals (soft graphite)

4 set

Eiastomer (for coupling)

1 set

0peration and maintenance manual 1 set

Product certificate

1 set

Product packing list

1 set

The pump don't together with above spare part when need the parts should indicated in the order and need additional
cost.

The shaft seal are easy-out part, the warranty are within 6 months.

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TYPICAL PARTS LIST AND TORQUE TABLE

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TSC, Casper, WY

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TSC FINAL DOCUMENTATION


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TSC MANUFACTURING AND SUPPLY LLC


13788 West Road Suite 100,
Houston, Texas 77041 U.S.A.
Tel: 832.456.3900
Toll Free: 1.866.8300.TSC
Fax: 832.456.3998
sales@t-s-c.com