Magnum IOM - (Rev H)

Magnum I Pumps
Installation, Operation,
and Maintenance
Instructions
Bulletin No.
M203-3C –
660999988
Rev. H
Sales / Technical Information
USA Tollfree: 1-800-800-4110

Phone: 1 (281) 943-5801
Email: mission@nov.com
Internet: http://www.nov.com
ISSUE: September 27, 2000

REVISED: August 14, 2015
REVISED: March 14, 2016
REVISED: April 19, 2017
501 N. George Nigh Expressway McAlester, Oklahoma 74501 REVISED: August 21, 2019
REVISION HISTORY
Revision Date (mm/dd/yyyy) Reason For Issue Prepared Checked Approved
E 08/14/2015 Update logo; add warning C. Hale M. Herandy T. Burns

F 03/14/2016 Update figure 4; remove reference T. Burns M. Herandy T. Burns
G 04/19/2017 Add additional ATEX warnings M. Herandy C. Hale T. Burns
H 08/21/2019 Updated per engineering requests A. Donovan C. Hale T. Burns
CHANGE DESCRIPTION
Revision Change description

Update to current division logo;
E
Added Warning about running dry to the end of the Operation section (page 17).
Updated Figure 4 on page 16 to show current design and grease procedure. Removed
F
reference to grease relief port.
Added paragraphs 13 and 14 to ATEX Warning Statements; renumbered previous paragraph
G
13 to 15.
H Reformatted the manual and added several sections per the engineering redlines
Installation, Operation, and
Maintenance Instructions
Foreword…
This manual contains instructions for the installation, operation, maintenance, and troubleshooting of the Magnum I
Pump. As pump service conditions and specifications vary considerably in pump installations, this manual cannot
possibly cover every situation, but the information included will serve as a guide.
Reference: Should questions arise, or start-up problems occur, contact the local pump distributor or salesman.
The Magnum I pump generation is an improved version of the older S&W pump line. The Magnum I pump is
designed to give longer service life through heavier fluid end parts, heavier shaft bearings, and reduced
hydraulic loads.
There are many principles of proper pump installation and application as well as special considerations for the
Magnum I design, which, if followed, will further enhance the performance of the purchased Magnum I Pump.
This manual will deal with both general and specific recommendations for the improved Magnum I Pump
performance in both oilfield and industrial applications.
GENERAL INSTRUCTIONS
Adhere to the following general guidelines:
• Operate the pump only in the performance range for which the pump was designed.
• When operating in drilling mud, prevent packing drippage from clogging the drip pan and hardening around the
slinger and front seal area.
• Adjust the packing, so that a small amount of leakage remains for lubrication and cooling.
Reference: For the mechanical seal installation procedures, refer to the MECHANICAL SEAL section on page 30.
! WARNING ! WARNING ! WARNING !

EXERCISE SAFETY IN ALL PERFORMANCES. DO NOT IGNORE ANY WARNINGS. USE ONLY APPROVED
METHODS, MATERIALS, AND TOOLS. DO NOT PERMIT ANY FUNCTION OF QUESTIONABLE SAFETY.
ACCIDENTS ARE CAUSED BY UNSAFE ACTS AND UNSAFE CONDITIONS. SAFETY IS THE OPERATOR’S
BUSINESS AND THE OPERATOR SHOULD ALWAYS BE INVOLVED.

BEFORE PERFORMING ANY SERVICE FUNCTION, BE CERTAIN THAT THE UNIT IS SEPARATED FROM THE
POWER SOURCES AND THAT THE POWER SOURCES ARE LOCKED-OUT TO PREVENT ANY FORM OF
ENERGY FROM ENTERING THE EQUIPMENT. THE POWER SOURCES INCLUDE ELECTRICAL OR
MECHANICAL ENERGY INTO OR FROM THE PRIME MOVER(S), PNEUMATIC ENERGY FROM THE
COMPRESSOR/AIR SYSTEM, OR OTHER COMPONENTS.
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FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS MANUAL CAN RESULT IN
PROPERTY DAMAGE, SERIOUS BODILY INJURY, OR DEATH.
! ATTENTION - NOTICE - IMPORTANT !

THESE TERMS ARE USED TO DRAW ATTENTION TO ACTIONS THAT WILL CAUSE DAMAGE TO THE PUMP,
COMPONENTS, OR ATTACHMENTS.

BEFORE SERVICING THE PUMPS, COMPLETE THE FOLLOWING STEPS:
1. SHUT DOWN OR DISENGAGE THE PUMP POWER SOURCES.
2. SHUT DOWN ALL PUMP ACCESSORY EQUIPMENT.
3. RELIEVE OR “BLEED OFF" ALL PRESSURE FROM THE LINES PRIOR TO REMOVING PIPING.
FAILURE TO SHUT DOWN POWER AND RELIEVE PRESSURE FROM THE PUMP BEFORE SERVICING CAN
RESULT IN SERIOUS PERSONNEL INJURY AND PROPERTY DAMAGE.
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ATEX Warning Statements – Pumps and Pump Units

Adhere to the following warning statements for the pump:
1. When a pump or pump unit is to be installed in a potentially explosive atmosphere, ensure that the information
has been specified at the time of purchase and that the equipment has been supplied accordingly. Also, ensure
the equipment displays an ATEX nameplate or is supplied with a declaration of conformity. If there is any doubt
as to the suitability of the equipment, please contact NOV before commencing with the installation
and commissioning.
2. All process liquids or fluids must be kept within the specified temperature limits. Otherwise, the surface of the
pump or system components may become an ignition source due to temperature rises. When the process liquid
temperature is less than 194 ºF (90 ºC), the maximum surface temperature will not exceed 194 ºF (90 ºC),
provided the pump is installed, operated, and maintained in accordance with this manual.
3. Electrical installation and maintenance work must only be carried out by suitably qualified and competent
persons, in accordance with relevant electrical regulations.
4. All electrical equipment, including the control and safety devices, must be suitably rated for the environment into
which the equipment is installed.
5. When there may be a risk of an accumulation of explosive gases or dust, non-sparking tools must be used for
installation and maintenance.
6. To minimize the risk of sparking or temperature rises due to mechanical or electrical overload, the following
control and safety devices must be fitted:
• A control system that will shut the pump down if the motor current or temperature exceeds specified limits.
• An isolator switch that will disconnect all electrical supply to the motor and auxiliary electrical equipment and
be capable of being locked in the off position.
• All control and safety devices must be fitted, operated, and maintained in accordance with the
manufacturer’s instructions.
• All valves on the system must be open when the pump is started, otherwise serious mechanical overload
and failure may result.
7. Ensure that the pump rotates in the direction indicated on the nameplate. The pump rotation direction must be
checked on during installation, commissioning, and after any maintenance has been carried out. Failure to
observe this may lead to dry running, mechanical overload, or electrical overload.
8. Ensure the fitting drives, couplings, belts, pulleys, and guards to a pump or pump unit are correctly fitted,
aligned, and adjusted in accordance with the manufacturer’s instructions. Failure to do so may result in sparking
due to unintended mechanical contact or temperature rises due to mechanical or electrical overload or slipping
of the drive belts. Regular inspection of the parts must be carried out to ensure good condition, and the
replacement of any suspect part must be carried out immediately.
9. The mechanical seals must be suitably rated for the environment. The seal and any associated equipment, such
as a flushing system, must be installed, operated, and maintained in accordance with the manufacturer’s
instructions.
10. Ensure the packed gland seal (when applicable) is correctly fitted and adjusted. This type of seal relies on the
process liquid to cool the shaft and packing rings, so a constant drip of liquid from the gland section is required.
An alternative seal type must be fitted when the packed glad seal cannot be used.
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ATEX Warning Statements – Pumps and Pump Units…

11. Failure to operate or maintain the pump and auxiliary equipment in line with the manufacturer’s instructions may
lead to a premature and potentially dangerous failure of components. Regular inspection and, where necessary,
replacement of bearings and lubrication is essential.
12. The pump and pump components have been designed to ensure safe operation within the guidelines covered by
legislation. Accordingly, NOV has declared the machine safe to use for the duty specified as defined by the
Declaration of Conformity on page 6 that is issued with the manual.
13. Pump units must be installed and operated in accordance with the manufacturer’s instructions.
14. If the pump unit is driven with a frequency converter, the motor manufacturer’s instructions for use with a
converter must be followed.
15. Figure 1 is an example of a nameplate.
Figure 1 – Sample nameplate
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ATEX Declaration of Conformity
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Table of Contents…
INSTALLATION ....................................................................................... 10
I. PUMP PACKAGE ................................................................................................................................................... 10
II. INTERCHANGABILITY .......................................................................................................................................... 10
III. LOCATION ............................................................................................................................................................. 10
IV. FOUNDATION ........................................................................................................................................................ 11
V. COUPLING ALIGNMENT ....................................................................................................................................... 13
VI. PIPING
A. GENERAL ......................................................................................................................................................... 14
B. SUCTION .......................................................................................................................................................... 14
C. DISCHARGE .................................................................................................................................................... 14
PRE-COMMISSIONING PROCEDURES ............................................. 15

I. INITIAL LUBRICATION (GREASE LUBRICATED PUMP) .................................................................................... 15
II. INITIAL LUBRICATION (OPTIONAL OIL LUBRICATED PUMP) .......................................................................... 15
III. MECHANICAL SEALS ........................................................................................................................................... 15
IV. START-UP.............................................................................................................................................................. 16
COMMISSIONING PROCEDURES ...................................................... 17

I. GENERAL INSTRUCTIONS .................................................................................................................................. 17
II. PRIMING ................................................................................................................................................................ 17
III. MAXIMUM OPERATING CONDITIONS ................................................................................................................ 18
IV. PUMP RECORDS .................................................................................................................................................. 19
OPERATION ............................................................................................ 20
I. GENERAL INSTRUCTIONS .................................................................................................................................. 20
II. OPERATING THE PUMP
A. CHECKING THE PUMP ROTATION ................................................................................................................ 20
B. PRIMING THE PUMP ....................................................................................................................................... 21
C. PACKED PUMPS ............................................................................................................................................. 21
D. MECHANICAL SEAL PUMPS .......................................................................................................................... 21
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MAINTENANCE ...................................................................................... 22
I. GENERAL .............................................................................................................................................................. 22
II. LUBRICATION
A. BEARINGS...................................................................................................................................................... 22
1. GREASE ........................................................................................................................................... 22
2. OIL .................................................................................................................................................... 22
B. STUFFING BOX ....................................................................................................................................... 23
C. LIP SEALS ............................................................................................................................................... 23
III. DISASSEMBLY ...................................................................................................................................................... 24
IV. INSPECTION
A. IMPELLER ....................................................................................................................................................... 26
B. SHAFT ............................................................................................................................................................. 26
C. SHAFT SLEEVE .............................................................................................................................................. 26
D. MECHANICAL SEAL ....................................................................................................................................... 26
E. BALL BEARINGS............................................................................................................................................. 26
F. SEALS ............................................................................................................................................................. 26
G. GENERAL ........................................................................................................................................................ 26
V. ASSEMBLY
A. GENERAL ........................................................................................................................................................ 27
B. SHAFT AND BEARING SUBASSEMBLY ....................................................................................................... 27
C. POWER FRAME SUBASSEMBLY .................................................................................................................. 28
D. FLUID END TO POWER FRAME .................................................................................................................... 29
E. PACKING THE PUMP ..................................................................................................................................... 30
F. MECHANICAL SEAL ....................................................................................................................................... 30
G. ASSEMBLY FIGURES 6 THRU 10 ................................................................................................................. 33
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TROUBLESHOOTING PROCEDURES ................................................. 38

I. EXCESSIVE PACKING LEAKAGE, RAPID PACKING WEAROUT, AND SHAFT SLEEVE
COATING WORN ................................................................................................................................................... 38
II. PACKING BURNED ............................................................................................................................................... 38
III. EXCESSIVE STUFFING BOX PRESSURE .......................................................................................................... 38
IV. TROUBLESHOOTING GUIDE ............................................................................................................................... 39
MOUNTING DIMENSIONS .................................................................. 40

I. PUMP DIMENSIONS ............................................................................................................................................. 40
II. PUMP AND FABRICATED BASE .......................................................................................................................... 41
III. PUMP AND CHANNEL BASE................................................................................................................................ 42
IV. PUMP AND SKID BASE ........................................................................................................................................ 43
V. MAGNUM PUMP FLANGE LOCATIONS AND UNIT WEIGHTS .......................................................................... 44
ENGINEERING DATA ............................................................................ 45
APPENDIX A ........................................................................................... 51
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Installation…
I. PUMP PACKAGE PRESERVATION
The pump packages must be stored indoors in a clean, dry, and protected environment. Prior to storage, the
following steps must be taken to preserve the package:
1. The pump fluid end internal parts must be sprayed with a light oil to prevent corrosion of the exposed
cast iron.
2. The end caps must be fitted to the suction and discharge flanges to prevent water and other contaminants
from entering the pump fluid end.
3. All exposed shafts on the motor and pump should be coated in a heavy grease to prevent corrosion.
4. If not crated, the unit should be covered with a plastic sheet or tarp to prevent moisture from contacting
the package.
5. The package must be raised above ground level by placing the unit on a pallet or wood strakes.
6. The storage area should be free from any vibration and temperature extremes.
7. The motor and pump shafts must be rotated manually every two months. A record of the rotation must
be made.
8. When the unit is removed from storage, purge the grease in the motor and pump bearings.
9. Replace with an ample supply of fresh grease in each grease cavity.
10. The motor windings must be meggered at the time the equipment is placed in storage. At the time of
removal from storage, the resistance reading must not have dropped more than 50% from the initial reading.
NOTE: Any drop more than 50% indicates electrical or mechanical drying of the motor windings. Condensation
from hot days and cool nights can fill the motor half full of water. This is a greater potential problem in
damp areas.
11. If the pumps are to be stored outdoors, the pump suction and discharge openings must be sealed to prevent
any water from entering the pump housing, which will prevent rust and corrosion.
12. As stated on the preservation tag, replace corrosion protection inside the junction box (J-box), and treat all
unprotected surfaces outside of the J-box to prevent corrosion.
II. INTERCHANGEABILITY
Interchangeability between the Magnum I Pump Horizontal Centrifugal Pumps and older W pumps will permit
pumps of the same nominal size to be interchanged using the existing piping and bases.
III. LOCATION
The pump should be located near the liquid source, so that the suction line may be short and direct. The pump
must be located below the level of the liquid to eliminate the necessity of priming.
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Installation…
IV. FOUNDATION
The foundation must be sufficiently rigid and substantial to absorb any vibration. The foundation must also
permanently support the base plate at all bolting points. The top of the base, where the pump skid package will
be mounted, needs to be within 0.05 in. (1.3 mm) flatness across the top surface to prevent twisting or distorting
of the base upon installation.
NOTE: For vibration analysis purposes, the “rigid structure” means that the pump has the first fundamental
natural frequency of 15% or more above the operating rotating frequency of the motor.
A concrete foundation, poured on a solid footing of adequate thickness to support the pumping unit, provides the
best option for the foundation. The base plate must be installed in a level position. Figure 2 displays a typical
arrangement for bolting channel bases.
The rugged design of the frame and fluid end makes the Magnum I Pump more tolerant of improper foundations
than other pumps. The vibration must be under 4.2 mils peak-to-peak at 1,800 rpm (30 hz), according to the
Hydraulic Institute Standards, HI ANSI/HI 1.3.
The foundation must be checked with a straightedge across the length and width. Each foundation must be
checked to ensure the flatness is within 0.05 in. (1.3 mm) prior to installation of the pump package. Once the
foundation flatness is within the NOV recommendations, the pump package must be placed on the mounting
pads with the bolts.
NOTE: The bolts are used only for the alignment of the mounting holes in the base to the mounting holes in
the foundation.
A feeler gauge must be used at each mounting pad to determine the gap between the foundation and pump
base. The shims need to be installed at each location. The shim thickness needs to equal the gap measured by
the feeler gauge, which will ensure the full contact of the base to the shims and foundation before the mounting
bolts are tightened.
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Installation…
IV. FOUNDATION (continued)…
Once all the shims are installed and a feeler gauge cannot be inserted at any of the mounting locations, the
mounting bolts can be torqued down.
NOTE: NOV recommends using spring or lock washers when bolting the pump base to the foundation.
Channel base
Grout
Concrete
foundation
Figure 2 – Typical bolting channel bases arrangement
NOTE: A detailed description of proper procedures for grouting the base plates may be found in
the Hydraulic Institute Standards, HI ANSI/HI, 1.3.
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Installation…
V. COUPLING ALIGNMENT
Long service life of the pump and driver depends upon proper alignment through the flexible coupling. If the
electric motor was mounted at the factory, the pump and motor were in alignment when shipped.
CAUTION: The alignment between the driver and pump must be inspected after installation to ensure
that transportation or other handling has not caused misalignment of the unit. Poor
alignment may cause failure of the coupling, pump, motor bearings, or of either shaft.
Alignment must not be attempted until the base is in position and the mounting and flange
bolts have been tightened. Failure to follow this caution could result in equipment damage
and/or unplanned rig downtime.
The recommended procedure for the coupling adjustment includes using the dial indicator (figure 3 and figure 4).
The dial indicator is attached to one coupling half with the indicator button resting on the outer diameter (OD) of
the other coupling half to measure the offset misalignment.
To measure angular misalignment, the indicator is positioned so that the button rests on the face, near the OD,
of the other coupling half. Rotate the shaft and dial indicator one full revolution while the other shaft remains
stationary and note the total indicator reading (TIR). Unless otherwise specified by the coupling manufacturer,
the offset misalignment must be limited to 0.01-in. (0.25-mm) TIR. The angular misalignment must be limited to
0.005-in. (0.127-mm) TIR. Adjust the misalignment by loosening the driver or pump mounting bolts, and then re-
tightening or shimming as required.
Figure 3 – Measuring offset alignment (1 of 2) Figure 4 – Measuring angular alignment (1 of 2)
NOTE: In areas where a dial indicator arrangement is not available, an adequate job of alignment can be done
with a straightedge. This method is especially useful if the coupling used contains an all rubber drive
element.
To check the offset misalignment, lay the straightedge in line with the shafts on the OD of the coupling halves.
There must be no gaps under the straight edge. Check at two locations, 90º apart. Angular misalignment can be
checked by measuring the gap between the coupling half faces. There must be no more than a 1/64-in.
(0.4-mm) gap under the straightedge or 1/64-in. (0.4-mm) variation in the gap between the coupling halves
(figure 3A and figure 4A).
Figure 3A – Measuring offset alignment (2 of 2) Figure 4A - Measuring angular alignment (2 of 2)
Reference: For additional information on the coupling alignment, refer to the Hydraulic Institute
Standards, HI ANSI/HI, 1.1-1.5.
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Installation…
VI. PIPING
A. GENERAL
CAUTION: The piping must not be connected to the pump until the grout has hardened and
foundation bolts and pump hold-down bolts have been tightened. Failure to follow this
caution could result in equipment damage and/or unplanned rig downtime.
The piping must be anchored independently of the pump and as close to the pump as possible. The pipe
companion flanges must line up naturally with pump flanges.
CAUTION: Do not draw the pipe to the pump with flange bolts. Failure to follow this caution could
result in equipment damage and/or unplanned rig downtime.
B. SUCTION
Proper selection and installation of the suction piping is extremely important to eliminate vibration and
cavitation in the pump. Vibration can cause packing problems, mechanical seal damage, or undue bearing
loads. The suction line must be equal to or larger than the pump suction.
CAUTION: The flow rate and capacity of a centrifugal pump must never be adjusted by throttling
the suction line. Failure to follow this caution could result in equipment damage and/or
unplanned rig downtime.
A positive shut-off valve that causes minimum turbulence must be installed in the suction line to permit the
closing of the line and removal of the pump for inspection and maintenance. The suction line must be
designed to eliminate any air pockets. The piping must gradually slope downwards to the source of supply to
eliminate air pockets. The suction line must have a straight section into the pump of a length equivalent to at
least two times the diameter; i.e., 4-in. (101-mm) suction and 8-in. (203-m) straight run.
For a temporary hook-up, where the flexible hose is used, a non-collapsing hose is essential since the
suction line pressure is often below the atmospheric pressure. A collapsing suction line will result in below
average or complete loss of flow.
Reference: For additional information on the suction line, refer to the ENGINEERING DATA section on
page 45.
C. DISCHARGE
A positive shut-off valve must be located in the discharge piping to permit the closing of the line for removal
of the pump for inspection and maintenance. All piping must be independently supported and
accurately aligned.
CAUTION: The pump must not support the weight of the pipe or compensate for misalignment.
Failure to follow this caution could result in equipment damage and/or unplanned
rig downtime.
If operating conditions are not known with sufficient accuracy, provide a throttle valve in the discharge line to
ensure the pump operates at the design point. If the pump is connected to a pressurized system, install a
check valve between the pump discharge and throttling valve. The check valve will prevent back flow
through the pump. The back flow may cause the impeller to become loose on the shaft that may result in
damage to the pump and/or leakage past the seals. A loose impeller will likely result in mechanical damage
and fluid leakage beneath the shaft sleeve.
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Pre-Commissioning Procedures…
I. INITIAL LUBRICATION (GREASE-LUBRICATED PUMP)
The standard pumps are shipped pre-lubricated with grease. No lubrication is required until after the first year
of operation.
The air vent should be kept clean to prevent pressure build-up due to heating that occurs in normal operation.
When lubrication is required, there are plugs in the front and rear bearing caps that can be removed and
replaced with grease fittings.
NOTE: Oil lubrication is also available as an option if requested.
II. INITIAL LUBRICATION (OPTIONAL OIL-LUBRICATED PUMP)
The oilers are set at the factory to the lowest position. This setting will place the oil level just below the center of
the bottom ball of the bearing when the housing is level. Any higher oil levels may cause churning and
overheating of the bearings. Any lower oil levels may provide insufficient lubrication and promote rapid wear. The
correct oil level will be visible at the center of the sight oil gauge.
The air vent should be kept clean to prevent pressure buildup because of normal heating that occurs during
operation. An oiler with a 4 oz (118.3 ml) capacity bottle is used. The correct bottle must be used with the
corresponding oiler body.
The standard pumps may be shipped with the oiler loose and with empty oil reservoirs. Oil must be added before
operating the pump. To add the oil, complete the following steps:
1. Attach the oiler to the bearing housing, fill the bottle with oil, and place into position.
2. Refill the bottle until the bottle remains full of oil.
NOTE: The oil should not be added to the reservoir except through the oiler bottle. A good grade of SAE 10W
30 oil, or equivalent, may be used.
III. MECHANICAL SEALS

NEVER OPERATE A PUMP “DRY” WITH MECHANICAL SEALS. MECHANICAL SEAL FAILURE WILL OCCUR.
FAILURE TO FOLLOW SAFE WORK PROCEDURES COULD RESULT IN SERIOUS OR FATAL INJURY TO
PERSONNEL, SIGNIFICANT EQUIPMENT DAMAGE, AND/OR UNPLANNED RIG DOWNTIME.
When the mechanical seals are furnished, the seals are installed and adjusted at the factory. The mechanical
seals normally used in drilling cuttings slurry service environments do not require external flushing. To prepare
special or industrial mechanical seals for operation, various cooling and flushing flows may have to be connected,
and liquid from an outside source may be required. If outside flushing is required, complete the following steps:
1. Connect the necessary cooling or flushing lines to the seal.
2. Ensure the lines and seals are ready for operation before starting the pump.
Reference: If special seals are used, refer to the seal drawings and instructions in the vendor documentation.
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Pre-Commissioning Procedures…
IV. START-UP

THE ROTATION OF THE MOTOR MUST BE CHECKED BEFORE CONNECTING THE SHAFT COUPLING.
INCORRECT ROTATION OF THE PUMP FOR EVEN A SHORT TIME MAY DISLODGE THE IMPELLER AND
DAMAGE THE IMPELLER, SHAFT, OR BEARING HOUSING. THE PUMP SHAFT MUST TURN CLOCKWISE
WHEN VIEWED FROM THE MOTOR END. FAILURE TO FOLLOW SAFE WORK PROCEDURES COULD
RESULT IN SERIOUS OR FATAL INJURY TO PERSONNEL, SIGNIFICANT EQUIPMENT DAMAGE, AND/OR
UNPLANNED RIG DOWNTIME.
Check the following items before starting the pump:
• Pump rotates freely by hand
• Coupling aligned
• Oiler full and oil level correct
• Suction valve fully open
• Pump and suction line full of fluid
• There is water found in stuffing box or gland flush
• Discharge valve slightly open
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Commissioning Procedures…
I. GENERAL INSTRUCTIONS
When commissioning the pump, adhere to the following guidelines:
• Operate the pump only in the performance range for which the pump was designed, according to the
MAXIMUM OPERATING CONDITIONS section on page 18.
• Verify the pump driver drives the pump CLOCKWISE when viewed from the coupling end, according to the
CHECK PUMP ROTATION section on page 21.
CAUTION: Reversing the rotation will damage the pump. Do not operate the pump with the suction
or discharge valves closed, which causes the pump to run dry. Failure to follow this
• Do not operate the pump with the suction or discharge valves closed.
• Adjust the packing so that a small amount of leakage remains for lubrication and cooling.
• When operating with drilling mud, prevent packing drippage from clogging the drip area and hardening
around the slinger and front seal.
Reference: For mechanical seal installation, refer to the MECHANICAL SEALS section on page 15.
II. PRIMING
To prime the pump, complete the following steps:
CAUTION: If the pump is operated without fluid, the mechanical seal or packing can be destroyed in
one minute. Failure to follow this caution could result in equipment damage and/or
1. Ensure the pump has fluid in the casing before running.
2. Vent air from the suction line and fill with liquid.
CAUTION: Do not run the pump with the suction and discharge valves closed. Failure to follow this
3. Start the pump with the discharge valve cracked open.
CAUTION: Thermal shock may crack the ceramic stationary seat if the temperature rises from room
temperature to 250 ºF (121 ºC) in less than 30 seconds. Failure to follow this caution
could result in equipment damage and/or unplanned rig downtime.
4. After the discharge pressure stabilizes, gradually open the discharge valve to the required position. If the
flow is lost, close the discharge valve and wait a few seconds for the discharge pressure to build.
NOTE: Continued flow restriction indicates an improper position selection or installation. Running the pump
too long with improper prime may destroy the sealing faces of the mechanical seal due to
mechanical damage from pulsation and interference between rotating and stationary components.
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III. MAXIMUM OPERATING CONDITIONS
NOTE: The maximum operating conditions apply to pumps without external insulation which are exposed to
room temperatures.
.
The following are the maximum operating conditions and guidelines for the pump:
• For cast iron pumps, the maximum working pressure is 175 psig at 150 ºF (66 ºC) to 150 psig at 250 ºF
(121 ºC). Modification is required for pressures between 150 ºF (66 ºC) and 250 ºF (121 ºC) maximum.
NOTE: The 3X2X13 and 4X3X13 pumps may operate at a higher pressure than listed. For additional
clarification, contact an NOV Service Center.
• For steel pumps, the maximum working pressure and test pressure are in accordance with Tables 2.1
through 2.23 and Table 3 in the ANSI B 16.5-1973 Standard.
Reference: For the H-30 and High Chrome alloy pumps, contact the NOV Distributor.
• Running cooling water through the lantern ring is required when the fluid being pumped is between 150 ºF
(66 ºC) and 250 ºF (121 ºC). Personnel may need to run water over the exposed shaft to prevent excessive
heat at the lip seals and bearings.
NOTE: The maximum hydraulic performance is in accordance with the published performance curves for
individual pump sizes.
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IV. PUMP RECORDS
Maintain data cards or pump records whenever possible, which will provide ready access to information
for ordering spare parts and for evaluating pump and mechanical seal performance.
The following information must be included in the records:
• Pump size and serial number
• Pump model number, impeller diameter, and material of construction
• Mechanical seal type
• Motor horsepower and speed of operation
• Service conditions
• Frequency of operation
• Record of maintenance, including parts usage and general condition of the pump
• Nomenclature and part number of replacement items
V. PUMP SPEED LIMITATIONS
Pump speed limitations

Bearing lubricant Max. rpm allowable
Grease 2,400 (40 Hz)
Oil bath 3,600 (60 Hz)
With the large shaft and bearings used in the pump, the above limitations must be observed to control the bearing
operating temperature.
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Operation…
I. GENERAL INSTRUCTIONS
When operating the pump, adhere to the following guidelines:
CAUTION: Reversing the rotation will damage the pump. Failure to follow this caution could result in
equipment damage and/or unplanned rig downtime.
CAUTION: Do not operate the pump with the suction or discharge valves closed. The pump must never
be started dry. If run dry, the seal faces will gall in one minute. Failure to follow this
• Operate the pump only in the performance range for which the pump was designed, according to the
MAXIMUM OPERATING CONDITIONS section on page 18.
• Verify the pump driver drives the pump CLOCKWISE when viewed from the coupling end, according to the
CHECK PUMP ROTATION section on page 21.
• Adjust the packing so that a small amount of leakage remains for lubrication and cooling.
• When operating with drilling mud, prevent packing drippage from clogging the drip area and hardening
around the slinger and front seal.
Reference: For mechanical seal installation, refer to the MECHANICAL SEALS section on page 15.
II. OPERATING THE PUMP
Verify the following procedures have been completed before operation:
• INITIAL LUBRICATION (GREASE LUBRICATED PUMP) section on page 15
• INITIAL LUBRICATION (OPTIONAL OIL LUBRICATED PUMP) section on page 15
• MECHANICAL SEALS section on page 15
A. CHECKING THE PUMP ROTATION
The pump rotation must be determined before starting the pump. If the Magnum I pump is turned backwards, the
impeller may unscrew.
NOTE: This will not happen in keyed models, but the packing or mechanical seal can run dry and be destroyed.
NOTE: Most manufactured pumps have clockwise rotation when viewed from the coupling end. The correct
rotation can be found by an arrow on the casing. The optimal way to check the rotation is to disconnect the
coupling. However, the rotation can be checked without disconnecting the coupling.
To check the pump rotation, one personnel member should be at the pump watching the shaft, while a second
person starts, and then immediately stops, the pump, so the shaft barely turns over.
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Operation…
II. OPERATING THE PUMP (continued)…
B. PRIMING THE PUMP
To prime the pump, complete the following steps:
CAUTION: If the pump is operated without fluid, the mechanical seal or packing can be destroyed in one
minute. Failure to follow this caution could result in equipment damage and/or unplanned
rig downtime.
1. Ensure the pump has fluid in the casing before running.
2. Complete the steps in the PRIMING section on page 17.
NOTE: Run the pump with the discharge valves closed only for short periods of time. The energy going into
the pump heats the fluid in the casing. The suction line should never be closed during operation.
3. If pump testing needs to be completed, run the pump with the discharge line closed for a maximum of two
minutes to measure the maximum pressure produced.
4. If the pump needs to operate shut in (running the pump with the discharge closed) for a period of time during
operations, install a small line [1/4- or 1/2-in. (6.4- or 12.7-mm)] back to the suction tank between the
discharge valve and pump for cooling.
C. PACKED PUMPS
Loosen the packing on startup.
NOTE: The gland bolt nut should only be finger-tight.
New packing will expand faster with heat than older packing. Therefore, new packing must be adjusted more
slowly than old packing. If the packing is too tight, the packing will not leak. With no cooling, the packing will burn
and be detrimental to sealing. The Magnum I pumps with mechanical seals have backup packing. The backup
packing should be very loose and not tightened until seal failure occurs.
D. MECHANICAL SEAL PUMPS
CAUTION: Do not operate the pump with the suction or discharge valves closed. The pump must never
be started dry. If run dry, the seal faces will gall in one minute. Failure to follow this
CAUTION: If shipped loose, do not install the packing until the seal starts to fail. The packing can then
be installed, and the pump can be run normally until the mechanical seal is repaired. Failure
to follow this caution could result in equipment damage and/or unplanned rig downtime.
The pump must never be started dry. If run dry, the seal faces will gall in one minute. The backup packing can
be installed at the factory or shipped loose.
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Maintenance
I. GENERAL
Reference: For the maintenance materials and component locations, refer to figure 5, figure 6, figure 7, and
figure 10.
II. LUBRICATION
A. BEARINGS
The bearings (figure 5) are pre-lubricated from the factory. The grease-lubricated and oil-lubricated centrifugal
pumps should be included in the customer’s lubrication maintenance program.
Figure 5 – Front view with cutaway of inboard bearing cover
Inboard Bearing Cover

1. Lip seal inlet grease port
2. Bearing grease port
1. GREASE
NOV recommends that grease-lubricated pumps have five shots from a standard hand-operated grease gun
injected into the inboard and outboard bearing lubrication ports every three months. Figure 5 displays the
location of the bearing grease ports. The shaft should be rotated 1/4-turn between each shot of grease.
NLGI No. 2 is used during assembly at the factory. Ensure the same or a compatible NLGI No. 2 certified for
GC-LB high temperature grease is utilized. NOV recommends using grease available in sealed tubes. If grease
from other types of containers is used, ensure the grease is clean and free from water or other contamination.
2. OIL
The pumps are shipped without oil. The oil-lubricated pumps must be maintained and operated in a horizontal,
level position. The pump is equipped with a visual oil level indicator to allow personnel to check the oil level.
The oil-lubricated pumps should be inspected on a daily basis to ensure proper oil levels are maintained. The oil
should be changed on a quarterly basis or if contamination has occurred. The recommended oil is 10W30
non-detergent or an equivalent. Synthetic oils are not recommended due to the incompatibility with standard oils.
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Maintenance…
II. LUBRICATION (continued)…
B. STUFFING BOX
For packed pumps, the stuffing box must be relubricated daily and as often as necessary to prevent the packing
from overheating.
Grease should be pumped into the box while turning the shaft until the grease comes out around the packing
gland (approximately 20 shots).
NOTE: The mechanical seal stuffing box should not be greased.
If the packing leakage is excessive, a thick water-compatible pump grease should be used rather than the
general purpose grease. In most cases, the general purpose grease will be acceptable.
NOTE: Some pumps are shipped with a plug only at the bearing grease port and require a grease zerk when
the pump is commissioned.
C. LIP SEALS
The inboard bearing cover (figure 5) is supplied with a zerk fitting between the 10 and 11 o’clock position facing
the suction. The cover creates a grease barrier between the inboard lip seals. The cover should be greased prior
to washdown and at least once a week with five shots of general purpose or water pump grease.

THE PUMP IS NOT TO BE RUN DRY OR TO OPERATE AGAINST A CLOSED VALVE. FAILURE TO FOLLOW
SAFE WORK PROCEDURES COULD RESULT IN SERIOUS OR FATAL INJURY TO PERSONNEL,
SIGNIFICANT EQUIPMENT DAMAGE, AND/OR UNPLANNED RIG DOWNTIME.
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Maintenance…
III. DISASSEMBLY
Reference: For the following procedure, refer to figure 6 for numbered component references, unless
otherwise noted.
To disassemble the pump, complete the following steps:
1. Loosen the packing gland nuts (6B) and swing the gland bolts to the side. Remove the packing
gland halves (4).
2. Remove the casing bolt nuts (1B).
3. Remove the casing (1).
4. Restrain the shaft (7) at the coupling end to prevent rotation while removing the impeller using the Impeller
Removal Wrench (P/N 20952).
NOTE: If the Impeller Removal Wrench (P/N 20952) is used, the wrench can be impacted against a solid
surface using the impeller’s own weight to jar it loose.
5. Place a wooden block or pipe (or similar component) against the web between the impeller vanes. Hit the
wooden block or pipe with a sledge hammer to turn the impeller counter-clockwise as viewed from the
suction end.
6. Remove the stuffing box cover bolt (3A).
CAUTION: If the disassembly being performed does not require the replacement of the mechanical
seal, the stationary seat (1 in figure 10) must not be removed from the stuffing box.
Failure to follow this caution could result in equipment damage and/or unplanned
rig downtime.
7. Remove the stuffing box cover (3) from the frame by hammering on the back side in the area where the box
fits into the frame (9).
8. Pull the packing (5) from the stuffing box bore.
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Maintenance…
III. DISASSEMBLY (continued)…
CAUTION: If the pump has a mechanical seal that does not need to be replaced, care must be taken
to avoid damaging or dropping the rotary seal ring (4A in figure 10) when removing the
shaft sleeve. Failure to follow this caution could result in equipment damage and/or
9. Remove the shaft sleeve (7A).
NOTE: A wedge may be driven between the end of the sleeve and shoulder on the shaft to free the sleeve.
If the disassembly is being performed to replace or install a mechanical seal and/or shaft sleeve
only, no further disassembly is required.
Reference: For the seal assembly instructions, refer to the mechanical seal installation instructions in the
MECHANICAL SEAL section on page 31.
10. Remove the deflector (8).
11. Remove the plug (10A) from the inboard bearing cover (10).
12. Remove the two through bolts (12B) on the outboard bearing housing (12).
NOTE: The through bolts (12B) are the bolts threaded into the frame (9).
13. Pull the complete shaft and bearing subassembly from the frame.
14. Remove the outboard bearing cover (13).
15. Bend the tab on the lockwasher (14A) back.
16. Remove the locknut (14B) and lockwasher.
17. Remove the bearing housing (12) and bearings (14) from the shaft.
NOTE: Impacting the entire shaft assembly against a board on the ground will remove the outboard
bearing assembly.
18. Press the inboard bearing (11) off the shaft.
NOTE: NOV recommends using a piece of 3-in. (76-mm) standard wall pipe slipped over the shaft and
impacted against the inner race of the bearing.
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Maintenance…
IV. INSPECTION
A. IMPELLER
If the impeller shows excessive erosion (especially on pump-out vanes on the back side of the impeller),
corrosion, extreme wear, or vane breakage, replace the impeller.
B. SHAFT
To inspect the shaft, complete the following steps:
1. Check for runout to ensure that the shaft has not been bent. If the runout exceeds 0.002 in. (0.051 mm),
replace the shaft.
2. The bearing seats and oil seal area must be smooth and free of scratches or grooves.
3. Verify the shaft threads are in good condition.
4. Replace the shaft, if necessary.
NOTE: If the pump has run hot enough to discolor the shaft, the pump must be replaced.
C. SHAFT SLEEVE
The sleeve surface in the stuffing box must be smooth and free of grooves. If the surface is grooved, replace
the components.
D. MECHANICAL SEAL
Excessive leakage may result if the seal faces, gaskets, and shaft sealing members are not in good condition.
Replace worn or damaged parts, if necessary.
E. BALL BEARINGS
Replace the ball bearings if the bearings are worn, loose, rough, or noisy when rotated.
NOTE: The new bearings should not be unwrapped until ready for use. The replacement bearings must be the
proper size and type as supplied with the original equipment.
F. SEALS
NOV recommends that all O-rings and gasket seals removed during disassembly be replaced. In the event that
new seals are not available, the old seals can be reused, if the seals are not torn or otherwise damaged.
G. GENERAL
All parts should be cleaned before assembly, especially the retaining ring, O-ring grooves, threads, gasket
surfaces, bearings, and bearing lubricated areas. Any burrs should be removed with a crocus cloth.
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Maintenance…
V. ASSEMBLY
A. GENERAL
Reference: For the following procedures, refer to figure 6 for the numbered component references, unless
otherwise noted.
B. SHAFT AND BEARING SUBASSEMBLY
To assemble the shaft and bearing subassembly, complete the following steps:
NOTE: Installation of the bearings with a press is an acceptable substitute for the following method. When
pressing the bearings onto the shaft, apply the load to the inner race only.
CAUTION: Use caution when handling the hot bearings. Failure to follow this caution
1. Heat the bearings to 300 ºF (149 ºC).
NOTE: NOV recommends heating the bearings for a half-hour in an oven at 300 ºF (149 ºC).
2. Slip the large, inboard bearing (11) onto the shaft (7).
CAUTION: The bearings must shoulder against the shaft. Failure to follow this caution could result
in equipment damage and/or unplanned rig downtime.
3. With the bearing housing seal (12A) in place, slide the bearing housing (12) onto the shaft (7) from the
coupling end. The large outside diameter (OD) of the bearing housing must face the coupling end.
4. Slip the outboard bearings (14) onto the shaft (7), and allow the bearings to cool.
NOTE: The bearings must be mounted back-to-back, which is when the sides of the bearings with the
manufacturer’s name and the bearing number are placed together.
5. With the lockwasher (14A) in place, tighten the locknut (14B) with the bevel positioned against the bearings.
6. Tighten the locknut to 250 ft-lb (339 Nm) torque, and bend the tab of the lockwasher into the nut.
7. Pack the bearings (14 and 11) full using the recommended grease in the Recommended Lubricants
Guide (D811000719-PRO).
8. Lightly grease or oil the outboard bearing (14) OD. Pull the bearing housing over the outboard bearing and
into place.
NOTE: The outer races can be assembled pushing by hand or with light tapping (applied only to the
outer race).
9. Install the lip seal (13C) in the outboard bearing cover (13) with the lip aimed inward toward the bearings.
Generously lubricate the rubber lip and shaft in the sealing area.
10. Fill the space behind the lip on the seal and half the bearing cover with grease.
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Maintenance…
V. ASSEMBLY (continued)…
B. SHAFT AND BEARING SUBASSEMBLY (continued)…
CAUTION: Be cautious not to cut the oil seal on the edge of the shaft keyway. Failure to follow this
11. Put the cover seal O-ring (13B) in place and slide the outboard bearing cover (13) over the shaft.
12. Secure the cover with two bolts (13D) [3/8 X 1-1/4 in. (9.5 X 31.8 mm)] and washers (13E) tightened evenly
to approximately 20 ft-lb (27 Nm) torque.
C. POWER FRAME SUBASSEMBLY
To assemble the power frame subassembly, complete the following steps:
1. Install the inboard bearing cover seal (10C) into the inboard bearing cover assembly (10A) flush with the
backside of the cover. Install the exclusion seal (10F) flush with the outside of the cover.
NOTE: The sealing lips on both seals should be pointed away from the bearings for grease lubrication. The
lip of the inboard bearing cover (10C) points inward for oil lubrication.
2. Pack the area between the lip seals full with grease. Using the grease to hold the inboard bearing cover
gasket (10B) in place, put the gasket on the cover.
3. Insert the shaft (7) and bearing subassembly into the frame (9) until the threaded end of the shaft extends
approximately halfway into the drip pan area.
4. Slip the inboard bearing cover assembly (10A) over the end of the shaft (7). Continue installing the shaft (7) and
bearing assembly in the frame until the gap between the frame and bearing housing flange is 1/4 in. (6.4 mm).
5. Install two through bolts (12B) [1/2 x 1-1/2 in. (12.7 x 38.1 mm)] with the jam nuts (12C) in the threaded holes in the
bearing housing.
6. Install the remaining two through bolts (12B) through the unthreaded holes in the bearing housing, and
thread the bolts into the frame. Do not tighten any bolts at this point.
7. Bolt the inboard cover to the frame with the bolts (10D) [3/8 x 2 in. (9.5 X 50.8 mm)] and nuts (10E).
8. Lubricate the deflector O-ring (8A) and install the deflector (8). Slip the deflector assembly on the shaft (7)
with the ribbed side facing away from the bearing cover.
9. Slip the shaft sleeve seal (7C) onto the shaft and push the seal to the shoulder where the sleeve will seat.
Reference: For pumps with a mechanical seal, refer to the mechanical seal installation instructions in the
MECHANICAL SEAL section on page 30.
CAUTION: The sleeved area of the shaft must be lightly coated with an anti-seize compound before
installing the sleeve. Failure to follow this caution could result in equipment damage
10. Install the sleeve (7A) with a twisting motion to spread the anti-seize compound. The gap between the
sleeve and shaft shoulder should be approximately 1/32 in. (0.8 mm)
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Maintenance…
D. FLUID END TO POWER FRAME
To assemble the fluid end to the power frame, complete the following steps:
1. Lubricate the inside of the frame where the stuffing box cover slips in with an anti-seize compound.
2. Install the stuffing box cover (3) and secure with the bolt (3A).
3. Lubricate the shaft threads and face of the shaft sleeve with an anti-seize compound.
4. Wash off the O-ring with clean shop solvent and pat dry with a clean cloth.
CAUTION: Do not use any lubricants in the following step. Failure to follow this caution could result
in equipment damage and/or unplanned rig downtime.
5. Install the O-ring into the impeller, and thread the impeller (2) with the impeller seal O-ring (2A) onto the
shaft. Tighten to approximately 160 ft-lb (217 Nm) torque.
6. Loosen the two through bolts (12B).
7. Pull the bearing housing rearward with the jam bolts, while rotating the impeller. Stop when the impeller
touches the stuffing box cover.
8. Bring the through bolts (12B) up and finger-tighten.
9. Loosen the jam bolts.
10. Tighten the through bolts (12B) until a clearance of 0.020 in. (0.500 mm) exists between the impeller back
vanes (2) and stuffing box cover (3).
NOTE: A hacksaw blade is about 0.020-in. (0.500-mm) thick and can be used as a gauge when no other
tooling is available.
11. Advance both jam bolts until the bolts touch the frame and finger-tighten the bolts.
12. Tighten the jam nuts (12C).
13. Tighten the through bolts (12B) down evenly, and rotate the shaft.
CAUTION: The impeller should turn freely without rubbing. Failure to follow this caution could
result in equipment damage and/or unplanned rig downtime.
14. Install the casing gasket (1A) and hold in place with grease, if necessary.
15. Apply a light coat of anti-seize compound on the stuffing box cover.
16. Install the casing (1) on the frame using studs (1C) and nuts (1B).
17. Place a small quantity of anti-seize lubricant on the threads on the nut end of the studs. Tighten the nuts to
140 ft-lb (190 Nm) torque using a crisscross tightening pattern.
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Maintenance…
E. PACKING THE PUMP
To pack the pump, complete the following steps:
1. Grease all five shaft packing rings (5).
2. Insert three packing rings (5), alternating the splits in the rings from top to bottom, starting with the split on
the first ring at the bottom.
NOTE: If the King type packing is being used, the rings should be installed with lips toward the impeller.
3. Install the lantern ring with the split in the vertical position. The two halves of the packing gland (4) may be
used to push the packing and lantern ring together and to the bottom of the box.
4. Insert the final two packing rings (5).
5. If the King type packing is being used, insert the final ring with the lip toward the outside and split the ring on
top (making a cut on top of the ring). Finish the assembly with the single ring of square packing.
CAUTION: In the following step, only finger-tighten the gland against the packing. If the packing is
over-tightened, the packing may be burned when the pump is started. Failure to follow
this caution could result in equipment damage and/or unplanned rig downtime.
6. With the packing gland (4) in position, swing the gland bolts into place. Tighten the gland lightly against the
packing using the gland bolt nuts.
F. MECHANICAL SEAL
To assemble the mechanical seal, complete the following steps:
NOTE: The following are the temperature ratings for the seals:
• Tungsten/tungsten: 250 °F (121 °C) max

• Tungsten/silicon: 275 °F (135 °C) max
1. Tighten the two through bolts (12B) until the gap between the frame (9) and outboard bearing housing (12) is
approximately 1/16 in. (1.6 mm).
2. Ensure that the inside of the stuffing box (3) is clean and that the 30º bevel on the 3-3/8-in. (85.7-mm) inner
diameter (ID) is free of burrs and sharp edges.
3. Coat the ID of the stuffing box stationary seat pocket with oil. Place the stuffing box on a table, or other flat
surface, with the impeller side facing up.
4. If a sticker is attached, remove the sticker from the stationary seat (1 in figure 10).
NOTE: The sticker or slotted side must be installed away from the impeller or down when the stuffing box is
positioned as described in step 3.
5. Coat the OD of the stationary seat and O-ring (1 and 1A in figure 10) with a thin film of oil.
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Maintenance…
F. MECHANICAL SEAL (continued)…
CAUTION: Ensure the groove of the stationary seat fits properly over the drive pin (1 and 15 in
figure 10). Ensure that the stationary seats sits evenly against the stuffing box shoulder
(figure 6). Failure to follow this caution could result in equipment damage and/or
6. Carefully install the stationary seat (1 in figure 10) into the stuffing box.
NOTE: Wrap the end of a wooden hammer handle with a rag and press firmly on the face of the stationary
seat. Do not strike, but gently push on a side, alternating from side-to-side until the stationary seat is
all the way down.
CAUTION: Caution should be taken to prevent bumping the stationary seat (1 in figure 10) on the
shaft end. Failure to follow this caution could result in equipment damage and/or
7. Coat the stationary seat (1 in figure 10) face with light oil and wipe off the majority of the oil with a clean
cloth, leaving only a light film.
8. Lubricate the inside of the frame (9), where the stuffing box (3) slips in, with an anti-seize compound. Install
the stuffing box and secure with the bolt (3A).
9. If the ring is not glued in position, remove the rotating seal ring (4A in figure 10), and store in a safe place.
NOTE: Whether or not the ring is glued can be determined by gently pulling on the ring.
10. Coat the OD of the shaft sleeve (7A) and ID of the bellows (4B in figure 10) with a thin coat of oil.
11. Place the shaft sleeve (7A) with the impeller end (the end with the smallest ID) up on a table.
12. With the sealing face of the rotary unit facing down and the rubber end up, gently ease the rubber bellows
over the sleeve and push the bellows to the bottom half of the sleeve.
NOTE: Personnel do not need to push the bellows all the way to the bottom of the sleeve.
13. If the rotating seal ring (4A) has been removed, lightly coat the face of the bellows (4B in figure 10) with
grease to hold the rotating seal ring in place during assembly. Reinstall the rotating seal ring into the cage
assembly (4C in figure 10).
14. Ensure no foreign material is on the seal faces and the shaft (7) is free of nicks and burns. Clean
and dry as necessary.
15. Lightly coat the sleeve area of the shaft, shaft threads, and shaft face with an anti-seize compound before
installing the sleeve (7A).
16. Install the sleeve (7A) with a twisting motion. As the seal faces make contact, continue to push the sleeve
through the ID of the rotary seal element until the gap between the sleeve and shaft shoulder is
approximately 1/32 in. (0.8 mm).
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Maintenance…
F. MECHANICAL SEAL (continued)…
17. Install the spring retainer (9 in figure 10) and impeller O-ring (2A) in the groove and coat with an anti-seize
compound. Place the mechanical seal spring (6 in figure 10) over the rotary unit of the seal, which is inside
the back cover.
CAUTION: Do not move the impeller (2) toward the stuffing box and then back out. This will cause
improper compression of the seal bellows. If the impeller is moved out by mistake, the
entire seal rotary unit must be removed and reinstalled on the sleeve. Failure to follow
this caution could result in equipment damage and/or unplanned rig downtime.
18. Thread the impeller (2) onto the shaft (7).
19. Ensure that the spring engages in the retainer on the impeller and tighten to approximately 160 ft-lb
(217 Nm) torque.
20. Back the through bolts (12B) out approximately 1/4 in. (6.4 mm). Tighten the jam bolts until a clearance of
0.015–0.020 in. (0.381–0.508 mm) between the back of the impeller (2) and stuffing box (3)
is obtained.
21. Alternately tighten the through bolts (12B) and jam bolts ensuring that the clearance set above is
maintained. Tighten the jam nuts and recheck the clearance.
22. Install the casing gasket (1A) and hold in place with grease if necessary.
23. Apply a light coat of anti-seize compound on the 14-1/8-in. (35.9 cm) diameter of the stuffing box cover.
Install the casing (1) on the frame using studs (1C) and nuts (1B).
24. Put a small quantity of anti-seize lubricant on the threads on the nut end of the studs. Tighten the nuts to
140 ft-lb (190 Nm) torque using a crisscross tightening pattern.
25. Grease all three shaft packing rings (5). Insert all the packing rings (5), alternating the splits from top to
bottom, starting with the split on the first ring at the bottom.
26. Attach the gland bolts (6) to the pump with the nuts (6A) and position the gland bolt nuts.
CAUTION: In the following step, finger-tighten the gland against the packing. Packing will only
be used if the seal fails. Failure to follow this caution could result in equipment damage
27. With the packing gland (4) in position, swing the gland bolts into place. Tighten the gland bolt nuts lightly
against the packing.
NOTE: The flushing arrangement for seals is shipped with the pump, along with the instructions.
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Maintenance…
G. ASSEMBLY FIGURES 6 THRU 10
Reference: For the pump assembly component locations, refer to figure 6.
Figure 6 – Pump assembly components
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Maintenance…
G. ASSEMBLY FIGURES 6 THRU 10 (continued)…
Figure 7 – Pump assembly parts list
Reference: For additional information on the spare parts, refer to the Magnum I Two Year Recommended
Spares (17751353-SPL).
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Maintenance…
Figure 8 – Braided packing
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Maintenance…
Figure 9 – King type packing
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Maintenance…
Figure 9
Figure 10 – 2-1/2-in. mechanical seal/packing
Item Qty. Part Name Arrangement for Magnum I

1 1 Stationary seat pumps in severe service
1A 1 Seat O-ring
4A 1 Rotating seal ring
. 4B 1 Bellows
4C 1 Cage assembly
5 3 Packing
6 1 Spring
7A 1 Sleeve**
9 1 Spring retainer
15 1 Spring pin
**Item is not included with the seal.
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Troubleshooting Procedures…
NOTE: For additional troubleshooting information, refer to the TROUBLESHOOTING GUIDE section
on page 39.
A. EXCESSIVE PACKING LEAKAGE, RAPID PACKING WEAROUT, AND SHAFT SLEEVE COATING WORN
To troubleshoot the components, complete the following steps:
1. Remove the packing.
2. With a short section of the tip bent 90º, slip a wire into the stuffing box.
CAUTION: Excessive tightening of the packing will cause rapid sleeve failure. Failure to follow this
3. Run the stylus tip of the wire along the shaft sleeve. If deep grooves are present, the sleeve must
be replaced.
B. PACKING BURNED
CAUTION: Initial overtightening and attempting to run the packing without leakage will cause the
packing to burn. Once the packing is burned, the packing becomes hard and will not
squeeze down on the shaft, resulting in uncontrollable leakage. Failure to follow this caution
If the packing is burned, replace the packing.
C. EXCESSIVE STUFFING BOX PRESSURE
Excessive stuffing box pressure is most commonly caused by too much clearance between the impeller back
vanes, stuffing box cover, and/or worn impeller back vanes. To fix the pressure, readjust the impeller clearance.
Reference: For additional information on the proper impeller clearance, refer to the ASSEMBLY OF FLUID END
TO POWER FRAME section on page 28.
NOTE: Troubleshooting of the mechanical seals is covered by the seal manufacturer. If the problems persist,
contact the seal manufacturer.
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Troubleshooting Procedures…
D. TROUBLESHOOTING GUIDE
Excessive Short
Noise/ No Insufficient Insufficient Intermittent
Causes power bearing
vibration flow flow pressure flow
required life
Pump not primed X X
Speed too low X X
Excessive discharge head X X
Insufficient NPSH X X X X
available
Impeller clogged X X X
Wrong direction of rotation X X
Plugged suction or X X X
discharge line
Foot valve or suction line X X X
not immersed deeply
enough
Impeller damaged X X X
Shaft packing or seal X X
defective
Impeller diameter too X X
small
Impeller diameter too large X
Excessive amount of air or X X X
gas in liquid
Speed too high X X
Total head lower than X
design
Specific gravity or X X X
viscosity too high
Bent shaft X X X
Improper electric motor X
wiring or voltage
Rotating elements bind X X X
Leaky suction line or shaft X X X
seal
Misalignment X X X
Bearings worn X X
Impeller out of balance X X
Suction or discharge X
piping not anchored
Improper foundation X
Insufficient discharge X X X X X
head (excessive flow)
Improper lubricant or level X
Impeller clearance too X X X
large
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Mounting Dimensions…
I. PUMP DIMENSIONS
NOTE: All dimensions are in inches and should not be used for construction.
Figure 11 – Pump dimension specifications
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II. PUMP AND FABRICATED BASE
NOTE: All dimensions are in inches (millimeters in brackets) and should not be used for construction.
Figure 12 – Pump and fabricated base specifications
41
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III. PUMP AND CHANNEL BASE
Figure 13 – Pump and channel base specifications
42
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IV. PUMP AND SKID BASE
Figure 14 – Pump and skid base specifications
43
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Pump Flange Locations and Unit Weights…

V. MAGNUM PUMP FLANGE LOCATIONS AND UNIT WEIGHTS
NOTE: All dimensions in inches and pounds (millimeters and kilograms in brackets) and should not be used
for construction.
Figure 15 – Magnum pump flange specifications
44
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Engineering Data…
Reference: For additional information on the suction piping, refer to the PIPING section on page 14.
Figure 16 – Suction piping arrangements
45
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Engineering Data…
Figure 17 – Suction piping submergence
46
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Engineering Data…
Figure 18 – Suction piping configuration
47
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Engineering Data…
Figure 19 – Suction piping suction
48
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Engineering Data…
Figure 20 – Suction piping specifications
49
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Engineering Data…
Figure 21 – Theoretical discharge of nozzles (U.S. gpm)
50
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Appendix A…
TORQUE VALUES FOR BOLTS
Description Bolt size Torque (ft-lb) Torque (Nm) Additional information

Case bolts 3/4-in.-10 80 108.5 Tighten in star pattern
Stuffing box bolts 1/2-in.-13 32 43.4 None – used for assembly only
Bearing cap 3/8-in.-16 13 17.6 None
Anti-rotation bolt 1/2-in.-13 30 40.7 Left-hand thread
51
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With over 120 locations worldwide, National Oilwell Varco is located near you. To find
the nearest Distribution Service Center, machinery center or repair facility, please give
us a call at our main office listed below.
Or you can access our website at the URL listed below, where you may search by
location or country.
http://www.nov.com/
National Oilwell Varco is a leading © Copyright 1999 by National Oilwell, L.P. All Rights
Sales/Technical Information: Reserved. NATIONAL OILWELL, NATIONAL, and
manufacturer OILWELL are registered trademarks of NATIONAL
USA Tollfree: 1 (800)800-4110 of reciprocating plunger pumps, OILWELL, L.P. Houston, Texas, USA. All other
centrifugal pumps, and fluid trademarks used are registered to their respective
Phone: 1 (281) 943-5801 end replacement parts. We also offer a
companies. The information and data in this
brochure, including but not limited to pictures,
Internet: complete set of solutions to fluid photographs, charts, diagrams, drawings, lists,
http://www.nov.com transfer challenges. For more Information, written comments, and specifications, are accurate to
the best of our knowledge and belief, but are
contact National Oilwell Varco directly at intended for general information only. Applications
the Headquarters in Houston, Texas. All suggested for the materials and other information are
National Oilwell Varco products are described only to help readers make their own
evaluations and decisions, and are neither
available throughout the U.S. and around guarantees nor are they to be construed as express
the world from service centers, authorized or implied warranties of suitability for these or other
distributors, and representatives. applications. National Oilwell makes no warranty,
either express or implied, beyond that stipulated in
National Oilwell’s Standard Terms and Conditions of
Sale which are available upon request.

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Magnum I Pumps

Sales / Technical Information

USA Tollfree: 1-800-800-4110

ISSUE: September 27, 2000

Revision Date (mm/dd/yyyy) Reason For Issue Prepared Checked Approved

E 08/14/2015 Update logo; add warning C. Hale M. Herandy T. Burns

Revision Change description

Adhere to the following general guidelines:

! WARNING ! WARNING ! WARNING !

! WARNING ! WARNING ! WARNING !

! WARNING ! WARNING ! WARNING !

! ATTENTION - NOTICE - IMPORTANT !

! WARNING ! WARNING ! WARNING !

1. SHUT DOWN OR DISENGAGE THE PUMP POWER SOURCES.

2. SHUT DOWN ALL PUMP ACCESSORY EQUIPMENT.

ATEX Warning Statements – Pumps and Pump Units

ATEX Warning Statements – Pumps and Pump Units…

15. Figure 1 is an example of a nameplate.

Figure 1 – Sample nameplate

ATEX Declaration of Conformity

PRE-COMMISSIONING PROCEDURES ............................................. 15

COMMISSIONING PROCEDURES ...................................................... 17

TROUBLESHOOTING PROCEDURES ................................................. 38

MOUNTING DIMENSIONS .................................................................. 40

ENGINEERING DATA ............................................................................ 45

9. Replace with an ample supply of fresh grease in each grease cavity.

Figure 2 – Typical bolting channel bases arrangement

Figure 3 – Measuring offset alignment (1 of 2) Figure 4 – Measuring angular alignment (1 of 2)

Figure 3A – Measuring offset alignment (2 of 2) Figure 4A - Measuring angular alignment (2 of 2)

NOTE: Oil lubrication is also available as an option if requested.

II. INITIAL LUBRICATION (OPTIONAL OIL-LUBRICATED PUMP)

2. Refill the bottle until the bottle remains full of oil.

III. MECHANICAL SEALS

! WARNING ! WARNING ! WARNING !

1. Connect the necessary cooling or flushing lines to the seal.

! WARNING ! WARNING ! WARNING !

Check the following items before starting the pump:

• Pump rotates freely by hand

• Oiler full and oil level correct

• Suction valve fully open

• Pump and suction line full of fluid

• There is water found in stuffing box or gland flush

• Discharge valve slightly open

When commissioning the pump, adhere to the following guidelines:

To prime the pump, complete the following steps:

1. Ensure the pump has fluid in the casing before running.

3. Start the pump with the discharge valve cracked open.

The following information must be included in the records:

• Pump size and serial number

• Pump model number, impeller diameter, and material of construction

• Mechanical seal type

• Motor horsepower and speed of operation

• Nomenclature and part number of replacement items

V. PUMP SPEED LIMITATIONS

Pump speed limitations

When operating the pump, adhere to the following guidelines:

II. OPERATING THE PUMP

Verify the following procedures have been completed before operation:

• INITIAL LUBRICATION (GREASE LUBRICATED PUMP) section on page 15

• INITIAL LUBRICATION (OPTIONAL OIL LUBRICATED PUMP) section on page 15

• MECHANICAL SEALS section on page 15

A. CHECKING THE PUMP ROTATION

B. PRIMING THE PUMP

To prime the pump, complete the following steps: