JET Module 2

Triplex Pumps

Provisory
 TABLE OF CONTENTS TOC
1 Introduction pg 04

2 Introduction to triplex pumps pg 05

3 Triplex pump main components pg 06

3.1 Pump types pg 08

3.1.1 Cementing/completion services pg 08

3.1.2 Mixed cement/frac- services pg 12

3.1.3 Fracturing services pg 15

3.3.4 Coiled tubing services pg 18

4 Pump rate calculations pg 20

5 Specifications & ratings PG Series triplex pump pg 21

5.1 Chain case pg 21

5.2 Power end pg 22

5.3 Fluid end pg 23

5.3.1 Specifications pg 24

6 Routine maintenance pg 26

6.1 Pump cavitation pg 27

6.2 Power end pg 29

6.2.1 Temperature pg 29

6.2.2 Noises pg 29

6.2.3 Pony rod seals pg 30

6.2.4 Sludge and cement pg 30

6.2.5 Chemical and salt water corrosion pg 31

6.2.6 Power end lubrication system pg 31

6.2.7 hydraulic pump types pg 33

6.3 Fluid End pg 34

6.3.1 Fluid end lubrication system pg 34

6.3.2 Plungers and packing assembly pg 38

6.3.3 Fluid end cover retainers pg 39

6.3.4 O-ring and backup ring pg 40

6.3.5 Valves (MacClatchie valves) pg 42

6.3.6 Valve Seats (MacClatchie valve seats) pg 44

JET 2 - Triplex Pumps v1.0 (Provisory) 2

 TABLE OF CONTENTS TOC
6.3.7 Packing pg 46
6.3.7.1 Fluid end repacking procedure pg 47
6.3.7.2 Valve seat removal and installation pg 54
6.3.7.3 Header ring packing installation pg 59
6.3.7.4 Repacking the header ring pg 62
6.4 Chain case lubrication system pg 65
7 Servicing pg 66
7.1 STEM 1 and operation of the triplex pump pg 66
7.1.1 Triplex pump STEM 1 pg 66
7.2 Triplex pump STEM 2 pg 69
7.2.1 Chain case pg 69
7.2.2 Power end pg 70
7.2.3 Fluid end pg 71
7.2.4 Packing oilers (Alemite) pg72
7.2.5 Triplex pump annual inspection - every 12 months pg 72
8 Troubleshooting pg 73
9 Appendix 1 - prime-up procedures pg 75
9.1 Priming triplex pumps using gravity feed pg 76
9.2 Priming triplex pumps using a pressurizer pump pg 77
10 Appendix 2 - hydraulic horsepower test (HHP) pg 78
11 References pg 79
12 Check your understanding pg 80

JET 2 - Triplex Pumps v1.0 (Provisory)

3

The purpose of any pump is to convert mechan-
ical energy provided by motors, engines, tur-
bines, and other prime movers into fluid energy
as efficiently as possible. The pump should be
light, compact, simple, and easy to operate and
maintain while providing the efficiency and the
power required.
Schlumberger Well Services uses low-pressure
and high-pressure pumps (also called positive
displacement pumps). High-pressure pumps
use plungers to displace fluid.
This training introduces you to one of the most
common high-pressure pumps in the oilfield
industry, the triplex pump.
Learning objectives:
Upon completion of this training, you should be
able to:
· explain the function of a triplex pump
· identify the various components of the
triplex pump
· describe how the triplex pump operates
· identify different pump models
· identify the sizes and ratings on the
triplex pump
· maintain the triplex pump
· troubleshoot common pump problems
· maintain the triplex pump
· service the triplex pump.
Safety warning:
Proper supervision is required during hands-on
training. Request assistance from your supervi-
sor if you are unfamiliar or uncomfortable with
the operation.
Ensure that all safety devices are in place and
operational before using a triplex pump. This
includes overpressure shutdowns and rupture
disc valves.
JET 2 - Triplex Pumps v1.0 (Provisory)
INTRODUCTION 1.0.0
When working on the pump, follow the proce-
dures in Well Services Safety Standard 4 -
Facilities and Workshops.
When conducting function testing on the pump,
follow the procedures in Well Services Safety
Standard 5 – Location Safety.
Terms used in this training
Reciprocating pump
A mechanical device consisting of single acting
positive displacement elements, such as pis-
tons or plungers and is used to impart a pulsat-
ing flow to a liquid. The reciprocating pumps
used by Well Services are single acting triplex
(three plungers) and quintuplex (five plungers)
units.
Single acting
A pump in which the liquid in each plunger is
discharged only during forward stroke for one-
half of the crank revolution.
Positive displacement pump
A pump utilizing a plunger or cylinder to dis-
place fluids, usually under pressure. Closing a
valve on the discharge side results in overpres-
sure.
4
 INTRODUCTION TO TRIPLEX PUMPS 2.0.0
Triplex pump is the general name given to any type of pump assembly consisting of three
plungers.

The reciprocating plunger pump is the most efficient pump for pumping abrasive fluids at high
pressure (1,000 psi and above) and requires the least amount of maintenance.

JET 2 - Triplex Pumps v1.0 (Provisory) 5

 TRIPLEX PUMP MAIN COMPONENTS 3.0.0
Most types of pump assemblies have three
main components:
Chain case, also called a speed reducer:
Reduces the input shaft rpm. Well Services
uses chain cases on PG series pumps and
gear reducers on most other pumps.
Chain case
The chain case has two important functions:
a) Provides flexibility when mounting the
pump assembly in different locations
with respect to the prime mover output
shaft center-line. You can mount the
chain case on either side of the power
end.
JET 2 - Triplex Pumps v1.0 (Provisory)
b) Converts a low-torque, high-rpm engine
output to a high-torque, low-rpm output
more suited to the power end require-
ments. The prime mover drives the chain
over the upper and lower sprockets that
are mounted on the pump pinion shaft.
When the prime mover rotates the lower
shaft, the chain transmits the power to the
upper shaft and rotates as well. This shaft
then transfers the rotation to the power
end pinion shaft. The different diameters
of the two sprockets in the chain case
reduce the prime mover output speed
increasing the torque input to the pump.
A typical twin P.G. pump layout
To prevent the chain case from moving when
power is applied, secure the chain to the chas-
sis or skid using a pair of torque rods.
6
 Power end: Converts rotational power into
reciprocating power. The power end functions
the same way as a crankshaft in a motorcar
engine. The pinion shaft drives the crankshaft
using bull gears. The eccentrics of the crank-
shaft change the rotation of the mainshaft into
a reciprocating action. The reciprocating force
is then transferred to the connecting rods and
crossheads, moving the plungers in the fluid
end.
JET 2 - Triplex Pumps v1.0 (Provisory)
Fluid end: Receives the power from the power
end. This part of the triplex pump receives fluid
at low pressure, applies horsepower to the
fluid, and discharges fluid at a high pressure.
The mechanical pumping action is similar to a
conventional piston-type internal combustion
engine or a reciprocating piston-type air com-
pressor.
As the plunger is drawn toward the power end
during the suction stroke, it reduces the pres-
sure inside the chamber between the suction
and discharge valves. This causes the suction
valve to lift and allow the fluid to flow into the
suction manifold through the suction port,
around the suction valves, and into the cham-
ber.
When the plunger moves in the opposite direc-
tion toward the fluid end, also called discharge
stroke, the fluid inside the chamber is forced
out. The suction valve closes immediately and
the fluid lifts the discharge valve from its seat
and flows into the discharge chamber.
Flow through fluid end
7
 PUMP TYPES 3.1.0
Triplex pumps are used in cementing services, mixed cement/frac services, fracturing services,
and coiled tubing services.

3.1.1 Cementing/completion services

3.1.1.1 Pump types

5-in Stroke PG series

The PG series pump was the main pump for all cementing services equipment until recently.
This pump was available in a magnesium frame (truck mounted) and steel frame (offshore).
Power end gear reduction is internal using a bull gear and pinion shaft. The pump is usually cou-
pled to a chain case to
provide additional
reduction and driveline
offset.

8
JET 2 - Triplex Pumps v1.0 (Provisory)
JET 2 - Triplex Pumps v1.0 (Provisory) 9
 6-in Stroke SPM TWS600S
This pump uses stuffing box construction in the fluid end. The plunger size can be varied over
a limited range. This can be done by only changing the stuffing box.

This pump is used as a replace-

ment for the PG series pump on
new completion/cementing equip-
ment designs. It features a crank-
shaft style power end with a bolt-on
gear reducer.

This pump is a much more compact

design and is rated at 600 hp input
as compared to 250 hp rating for
the PG series pump. This is also
advantageous for the new higher
horsepower cementers being devel-
oped and more suitable for continu-
ous pumping operations associated
with coiled tubing services.

JET 2 - Triplex Pumps v1.0 (Provisory) 10

 3.1.1.2 Components

Valves and seats

There are no special valves and seats for
cementing/completions services. Several
vendors can supply these components.

Some locations use valves with stretch-on rub-

ber inserts for better results during pressure
testing since they tend to hold pressure better.

Rupture disc suction valves of the correct rat-

ing are required for all completions/cementing
pumping applications.

Packing
Using a universal header ring packing is rec-
ommended for completions services.

Suction stabilizers
Suction stabilizers are not used in completions
services.

JET 2 - Triplex Pumps v1.0 (Provisory) 11

 3.1.2 Mixed cement/frac services

GD1250
The GD1250 is a lightweight
design offering high horse-
power per pump weight. It
was originally used on the
Pumper Pod, which is a frac
pump and blender combina-
tion. It is also used on high-
horsepower offshore skids as
a replacement for MD1000.

Three series of fluid ends are

available. Two of these fluid
ends can be fitted with multi-
ple plungers and have inter-
changeable stuffing boxes.

JET 2 - Triplex Pumps v1.0 (Provisory) 12

 MD1000
The MD1000 type triplex pump gets its
name from its developer, Michel Drevet
and its maximum hydraulic horsepower
(hhp) output, which is 1000 hhp. Unlike the
other two types of triplex pumps, the
MD1000 type of pump uses a single
swashplate rather than separate wheels to
operate the three plungers.

The MD1000 pump consists of three, 120-

degree thrust rods connected to an oscil-
lating plate. Each thrust rod is, in turn,
attached to a crosshead, which operates a
plunger. As power turns the gears of the
power end, one thrust rod is at the
Maximum Forward Position (MFP),
while a second is in forward motion, and a
third in backward motion.
Advantages of the MD1000 pump
These models have many advantages over
traditional triplex pumps, but are commonly
used only in offshore applications. These
advantages include:
· Global efficiency: While a traditional,
crankshaft-type pump typically has a
maximum efficiency of 80%, the
MD1000 type of pump has an efficiency
of 93%. This means that there is more
hydraulic horsepower delivered to the
fluid being pumped, that intermittent
horsepower is closer to continuous
horsepower, and that less horsepower
is dissipated in heat. This last point is
especially important, because it means
that the cooler operation requires a
smaller oil cooler, which saves in both
weight and size.
· Weight/horse power ratio: The weight
of the MD1000 type of pump with its
input horsepower has a ratio of 6.68.
The same ratio for a crankshaft pump
varies from 8.33 to 19.82. This
means that the MD1000 pump provides
more hydraulic horsepower for the
same pump weight. In fact, pump
weight can be reduced by up to one-
third that of the crankshaft pump and
still delivers the same horsepower. This
means that more hydraulic horsepower
and less dead weight can be transport
ed. For offshore operations where
transportation costs are significant, this
is a great advantage.
· Plunger size: If the plungers on an
MD1000 pump and a crankshaft pump
are the same, the MD1000 pump will
have a higher working pressure and
flow rate.

JET 2 - Triplex Pumps v1.0 (Provisory) 13

 · Horsepower/volume ratio: The input
horsepower of the MD1000 pump with
its overall volume has a ratio of 13.52.
The same ratio for the crankshaft pump
is between 3.5 and 10. This means that
if the two pumps have the same vol-
ume, the MD1000 pump will deliver
more hydraulic horsepower. Or if the
horsepower is the same, the MD1000
pump will require less overall volume.
So, for any given application, the
MD1000 pump will be a smaller, more
compact unit than the crankshaft alter
native and will be easier to transport.
JET 2 - Triplex Pumps v1.0 (Provisory)
· Balance: The swashplate design allows
the mainshaft assembly to be perfectly
balanced. This reduces vibrations in the
system and leads to longer bearing life
and reduced noise. Related to this, the
main center line of the MD1000 pump is
aligned with the center line of the prime
mover (motor or engine). This allows for
a better equipment layout design and
reduction in space required.
14
 3.1.3 Fracturing services
3.1.3.1 Pump types

8-in stroke HD2250

HD2250 is the standard pump for
fracturing services. Currently, it is
placed behind a 2250 brake horse-
power prime movers. Older units
may have an earlier version called
the 1800 AWS pump. This pump
uses internal gear reduction. Each
plunger size uses a different fluid
end.

JET 2 - Triplex Pumps v1.0 (Provisory) 15

 SD2000 Crossbore pump

The 11-in stroke pump was originally developed to replace the in-line fluid ends. This pump has a
weight disadvantage for trailer units since it weighs approximately 4000 lbs more than the
HD2250.

3.1.3.2 Components

Valves and seats

Bonded insert valves are used in fracturing service. The proppant-laden fluids will get under the
snap on inserts and lead to valve failure.

Rupture disc suction valves of the correct rating are required for all pumping applications. Valves
and seats are available from several vendors.

Packing
Header ring packing is standard for all services. For more detailed refer to Section 6.3.7 -
Packing.

JET 2 - Triplex Pumps v1.0 (Provisory) 16

 3.1.3.3 Special CO2 considerations
Commonly, CO2 is used with fracturing jobs. Special equipment specifications, such as CO2
rated suction manifold that are capable of handling high suction pressure, is required.

When pumping CO2, the suction stabilizer MUST be disconnected by blanking off the suction
header.

For CO2, you can use up to 5000 psi standard header ring packing and plunger lube. Pressure
above 5000 psi requires the use of special header rings.

At higher pressures, CO2 gas is entrained in the header ring during pumping and released after
the job. This causes the packing to fail when a conventional job is performed after a CO2 job.

JET 2 - Triplex Pumps v1.0 (Provisory) 17

 3.1.4 Coiled tubing services
With coiled tubing services, different pump parameters are required. Due to the high friction pres-
sure through the coiled tubing, fluid can only be pumped at a limited maximum pump rates. Use
the dedicated coiled tubing triplex pumps for this type of application.

3.1.4.1 Pump types

6-in stroke OPI600

JET 2 - Triplex Pumps v1.0 (Provisory) 18

 PG/Butterworth
To convert a standard PG pump for high-pres-
sure coiled tubing services, use a stainless steel
Duralife fluid end.

While the PG pump is not designed for continu-

ous pumping coiled tubing operations, the
Duralife fluid end performs better than a stan-
dard triplex in this application. The 2.5 plunger
size is well suited for low rate pumping, and this
pump offers replaceable fluid cylinders. The
stainless steel construction makes this pump
well suited for pumping sea water or brines.

JET 2 - Triplex Pumps v1.0 (Provisory) 19

 PUMP RATE CALCULATIONS 4.0.0

EXAMPLE:

SPF 343
Allison 9800 series transmission - 4th gear
(1.77 : 1 ratio)
Engine rpm = 1900
HD2250 power end 6.353:1 ratio
IOPI fluid end (5 ½ plungers)

JET 2 - Triplex Pumps v1.0 (Provisory) 20

 SPECS & RATINGS FOR PG SERIES TRIPLEX PUMP 5.0.0
CHAIN CASE 5.1.0
Most twin pump cement units, such as CPS and CPT, use a standard 23.15-in center-to-center
chain case for the downhole pump using a 90-in pitches long chain.

Mixing pumps use an extended chain case (6-in extension section to increases the chain case
length to 29.15-in center-to-center. They also use a 95 pitches long chain. To extend the chain
case, add a spacer and increase the chain length. Both chains are known as Quad 80 chain,
which means 80 pitch (length from pin to pin) and 4 links wide.

Chain case

Torque arms are designed to stabilize and control the reaction of the torque being applied
through the chain case. To adjust the torque arms, complete the following steps:
1 Rotate the torque arms using the left-hand threads to change their length.
2 Set one of the torque arms to the desired position.
3 Ensure that the driveshaft is clear from any obstruction.
4 Adjust the other torque arm in any direction to tighten and lock the chain case
into position.
5 Tighten all locking nuts in position.

JET 2 - Triplex Pumps v1.0 (Provisory) 21

 POWER END 5.2.0
On PG pumps, you can configure the power end to be driven from the left or right-hand side.
These two configurations do not require different parts but is distinguished by the way the pinion
shaft is installed in the power end frame. When changing the position of the pinion shaft, retime
the timing gears.

NOTE: The district mechanic retimes the timing gears.

NOTE:
There are a few
instances where the
PG series power end
turns the opposite
direction. This is not
common, but you will
find it on units that
have two PG pumps
facing each other and
are driven by conven-
tional diesel engines.

Right-hand drive Left-hand drive

JET 2 - Triplex Pumps v1.0 (Provisory) 22

 FLUID END 5.3.0
There are five different fluid ends available for
the PG series power end. The most common
ones are the G, L, and H ends. Those are
machined from forged AISI 4340 steel or better.

The R and S fluid ends are used for special

applications requiring extremely high pres-
sures, such as stimulation jobs. They are usu-
ally autofrettaged to lengthen their life.
Autofretagging is similar to the process used in
making artillery gun barrels to improve metal
resistance to fatigue. The material is heat-treat-
ed and stress-relieved simultaneously at high
pressure.

JET 2 - Triplex Pumps v1.0 (Provisory) 23

 5.3.1 Specifications

*Calculate the maximum flow rate of a triplex pump based on 97% volumetric efficiency.

NOTE:
It is recommended to use both discharge ports for flow rates over 8.2 bpm to prevent the
erosion of the discharge port, bushing, and manifold. Maximum fluid end pressure limitations
are based on the power end maximum rod load rather than fluid end pressure limitations.

The assembly of the PG05 triplex pump weighs 5,250 lbs (2.4 tones). It is used on offshore skid
units, such as the CPS 362, where weight is not a critical factor. It is also used in corrosive envi-
ronments such as offshore areas where the PG03, which has a magnesium frame, is resistant to
severe corrosion. CPT 372, CPT 462, and CPS 310 Heli-units use PG03 because weight is an
important design factor.

JET 2 - Triplex Pumps v1.0 (Provisory) 24

JET 2 - Triplex Pumps v1.0 (Provisory) 25
 ROUTINE MAINTENANCE 6.0.0
Like any equipment, maintaining the triplex
pump ensures many years of trouble-free serv-
ice. This section provides guidelines for the
proper steps for care, maintenance, and repair
of triplex pumps.

JET 2 - Triplex Pumps v1.0 (Provisory) 26


Cavitation is the main damaging factor to a
triplex pump during operation, especially when
the pump pounds and the treating lines shake
and jerk violently. Another cavitation reason is
the premature rupture of burst disks (suction
valves) at much lower pressures than their
rated burst pressures. In either case, the result
is an operation failure.
Cavitation usually results from:
· using a worn or damaged pressurizing
pump that is not maintaining adequate
pressure on the pump suction manifold
· air leak in the suction manifold
· pumping too fast for the pressurizing
centrifugal pump to keep sufficient fluid
supply to the triplex pump.
Cavitation occurs when the chamber is not full
of liquid and the plunger changes direction
from suction to discharge. The plunger does
not push fluid out the discharge, but compress-
es vapor causing a momentary change in the
pump loading and the plunger's velocity. This
sudden change in velocity causes a tremen-
dous shock to the power and fluid ends, lead-
ing to a mechanical failure or fatigue.
Cavitation causes barrel counters and job
recorders to read incorrectly. These counters
measure the volume of fluid being pumped by
counting the number of revolutions on the pin-
ion shaft or engine output shaft. These coun-
ters continue to count as long as the pump is
turning even when nothing is being pumped.
PUMP CAVITATION 6.1.0
To prevent cavitation, perform the following
steps:
· Ensure that the triplex pump is properly
primed by bleeding all air from the
system.
NOTE:
Annually, inspect fluid ends for
cracks using the magnetic par-
ticle testing process. Contact
Gardner Denver for light serv-
ice. Check with your mainte-
nance supervisor for more
information.
· Ensure that the pulsation dampener is in
good operating condition and purged
of air while priming a pump on a
fracturing unit.
· When pumping high viscosity mud that
is stored in displacement tanks for a
long period of time, circulate the mud
back to the tanks before pumping it to
prevent the mud from becoming a gel or
restrict suction.

Cavitation is more likely to occur when pump-

ing oil, even after proper priming, than when
pumping water since water has a much lower
vapor pressure than oil.

JET 2 - Triplex Pumps v1.0 (Provisory) 27

 · Do not suck slurry at a slow speed. If
the slurry is foamy and the job must be
completed at a high rate, use an
antifoam product to minimize foaming.

· If pumping out of two or more tanks or

when changing displacement tanks,
open the second tank valve before
closing the first one to prevent air from
entering the system.

· Ensure that all suction hoses used do

not have air leaks at the connections or
around the nipples. It is possible to
conduct a pressure test on suction
hoses and connections by carefully
pressurizing them with a centrifugal
pump like the RA45.

· If there are indications of cavitation,

reduce the pump rate immediately and
correct the problem before increasing
the pump rate again.

· If cavitation occurs when using a pump

that does not have a pressurized
suction, check the O-ring seal on the
suction manifold of the fluid end to see if
the hoses and connections are tight.

JET 2 - Triplex Pumps v1.0 (Provisory) 28

 POWER END 6.2.0
To ensure that the power end is operating cor-
rectly, inspect and check the following: 6.2.2 Noises
Listen for unusual noises such as clicking or
6.2.1 Temperature knocking. Noises are caused by:
During any job, frequently check the power end 1. loose eccentrics or damaged
lubrication pressure gauge and the frame tem-
perature. The power end is considered over- NOTE:
heated when you are unable to touch the frame If keys and keyways are loose, you
for more than few seconds. Overheating occurs will hear a knocking sound during
during extended pumping at or near maximum pumping under pressure.
horsepower levels. Shutdown the pump if the
power end is overheating. keys/keyways
2. damaged bull or pinion gears
WARNING: 3. worn or damaged main bearings,
The power end can catch fire if heated crosshead, or connecting rod bushings
excessively. If the power end has a 4. damaged main crankshaft
magnesium frame, it is impossible to
extinguish the fire.

BEST PRACTICE:
If a fresh water hose is available, run a
stream of cool water over the frame to
cool it down during extended pumping.

5. cracked eccentric
6. Problems with the fluid end can also be
mistaken for power end noises. Inspect
the fluid end carefully to eliminate this as
a source of noise or knocking.

JET 2 - Triplex Pumps v1.0 (Provisory) 29

 6.2.3 Pony rod seals
The purpose of the pony rod seals is to keep
oil in and dirt out of the power end. If the
exposed end of the pony rod shows signs of
pitting or dullness, this is an indication that the
pony rod seals would wear out quickly.
6.2.4 Sludge and cement
During STEM 2 inspection, remove the rear
power end cover or inspection plate and feel
the bottom of the frame for cement or other
sludge. Sludge can quickly wear out the bear-
ings and brass bushings inside the power end.

IMPORTANT:
Ensure that lock-out tag-out proce-
dures are followed before reaching
inside the power end.

Slinger rings are installed on the pony rod to

help prevent dust or dirt from entering the
crosshead area and causing damage to the
pony rod seals. To work effectively, slinger
rings must fit firmly on the pony rod at all times.
Also, slinger rings prevent pressurized fluid
from being blown into the power end and past
the pony rod seal in the event of a plunger
packing failure.

JET 2 - Triplex Pumps v1.0 (Provisory) 30

 6.2.5 Chemical and salt water corrosion
Inspect the surface of the power end frame for
chemical and salt-water corrosion. Scrape or
wire brush any corrosion, then re-prime and
paint the power end.

IMPORTANT:
If you have a magnesium frame
power end offshore, take utmost
care to prevent corrosion (elec-
trolytic) from the salt environment.
It can quickly damage the power
end.

6.2.6 Power end lubrication system

Check each unit’s maintenance manual for the
proper lubricant.

When using a PG pump in high horsepower or

continuous pumping operations, an external oil
cooler may be required to keep the pump
below the maximum allowable operating tem-
perature.

Power ends in frac services have oil coolers

installed during manufacturing.

A pressure relief valve maintains the system

pressure from exceeding a set pressure.

There are two different styles of power end oil

filters and arrangements: internal bypass and
external bypass.

NOTE:
When checking oil level, always
remove the dipstick and allow air to
escape from the tube. Replace the
dipstick and check for the correct
oil level.
A mechanically or hydraulically-driven pump
pumps the lubricating oil out of the power end.
The oil then flows through a filter to the line’s
cross fitting, then to the mainshaft and
crossheads.
JET 2 - Triplex Pumps v1.0 (Provisory)
WARNING:
Since pressure in a hydraulic system is
a result of resistance and the flow rate
varies with engine rpms, the pump is
sized so that it maintains adequate oil
pressure at low engine speeds.
However, oil pressure becomes low
when components wear. This can cre-
ate catastrophic power end failures,
especially when the following condi-
tions exist at the same time:
31

· The power end is working at very
low rates and high discharge
pressures.
· Rpm is low to create enough oil
pressure to maintain a good film
of oil on the eccentric bearings.
· The rod load is high.
ALWAYS watch and maintain the
power end oil pressure. Proper sizing
of the fluid end prevents these types of
failure.
pressure on each pump.
To adjust a pressure relief valve, remove the
large cap. To increase pressure, turn the
adjustment screw clockwise. To reduce pres-
sure, turn the screw counterclockwise.
IMPORTANT:
There are oil seals inside the main
shaft-bearing cap of the power end.
When these seals wear, oil pres-
sure drops. You can check oil pres-
sure using the gauge attached to
the cap.

Remove and inspect the oil filter condition.

NOTE:
Clean and replace as necessary.
Always consult your supervisor
To check the oil’s color or clarity, compare a before tampering with any adjust-
sample from the power end with a new one. ments.
A bypass around the oil filter ensures continued
flow of oil in the event the filter becomes
clogged. A relief valve controls the bypass
process. On older styles, the valve is mounted
directly onto the filter and has a hose. The
valve directs any bypass flow to the down-
stream side of the filter.

On new styles, the bypass is internal of the fil-

ter housing and has a pre-determined differen-
tial setting. The new style filters have an indica-
tor that clearly indicates when and if the filter is
bypassing: green for good and red for bypass-
ing. This indicator works only when the oil is
flowing through the filter. During the job, check
and record the condition on a STEM I report.

A relief valve that is mounted directly to the

bottom of the power end frame controls oil
pressure. A pressure gauge mounted on the
control panel or directly on the power end lube
oil circuit allows the operator to monitor oil

IMPORTANT:
Keep oil clean at all times. A milky
color usually indicates water con-
tamination.

JET 2 - Triplex Pumps v1.0 (Provisory) 32

 6.2.7 Hydraulic pump types
There are two different styles of power end
lube pumps: gear type hydraulic pump and
vane type hydraulic pump. When the Gear type
is mounted to the Auxiliary drive shaft, which
rotates twice the engine rpm, an angle drive
adapter is used to reduce the rpms. The Vane
type hydraulic pump is directly mounted to the
gear train on the engine through a splined input
shaft. In both cases, the engine oil pressure
increases if the shaft seal leaks.

CAUTION:
Since a Tyrone pump uses a straight Power end lube pump
input shaft, take special care when
installing the tapered drive adapter.
The spacing of the drive gear is critical
to ensure that the gear is set correctly
in the center of the driving gear of the
angle drive. Failure to do so lowers the
power end oil pressure in critical situa-
tions.

IMPORTANT:
Webster Brand pump is obsolete
and must be replaced with a Tyrone
pump. Order a complete replace-
ment kit.

Power end lube pump

This pump is directly mounted to the gear train

o

JET 2 - Triplex Pumps v1.0 (Provisory) 33

 FLUID END 6.3.0
To ensure that the fluid end is operating cor-
rectly, inspect and check the following:

6.3.1 Fluid end lubrication system

The fluid end lubrication system uses an air-
driven pump to transfer packing oil to the
plungers. Check valves that are installed direct-

IMPORTANT:
For optimum packing life, it is
essential to properly lubricate the
plungers and packing. An improper-
ly lubricated packing leaks in few
seconds from pumping operation,
damaging the polished surface of
the plungers. It will also cause heat
generation and shorten the packing
life.
cycle. Plugging it in any hole stops the cycle
ly onto the fluid end prevent cement from and shuts down the lubrication system. If it
migrating into oil lines. A divider block is used becomes necessary to abort lubrication to a
centrifugal pump for example, reroute the hose
NOTE: to the reservoir.
The Alemite pump used for the fluid
end lubrication system is a grease The air-operated Alemite pump delivers lubri-
pump that allows pumping high cating oil to a McCord divider block, which in
viscosity oils. turn delivers oil equally to each plunger. The

CAUTION:
Never reuse packing oil as dirt and
debris will contaminate the system,
damage the pump, and plug the
divider blocks.
NOTE:
The Alemite pump also provides
lubrication to the centrifugal pump
through a parallel discharge line or
divider block on older units.

in this system to distribute oil to the plungers.
The recommended oil to use is 15W40 clean
engine oil.
The Divider block uses two codes: Number 12
to indicate that the block will discharge out of
one side, and number 24 to indicate that the
block will discharge out of both sides.
These coded blocks cannot be used inter-
changeably. Each block must complete its
divider block outlet is connected through a
check valve to each fluid end-packing bore.
From there, oil flows into the fluid end and
enters the lantern gland for even distribution to
the packing.
The current Alemite pump used on the PG
series cementing pumps is Model 9668 with a
medium pressure pump (5:1 ratio). The pump
section works in conjunction with the
Pneumatic Logic Air Motor, Model 338066- A1.

JET 2 - Triplex Pumps v1.0 (Provisory) 34

 To adjust the Alemite pump rate, set the air
pressure regulator between 110-120 psi.
Regulate the metering valve on the discharge
side of the pump to control the desired amount
of lubrication oil.
Current-generation pump units have a lube oil
filter installed downstream of the Alemite pump.
Unlike the old Alemite pumps, you cannot rely
on the air motor sound to determine the lubri-
cation rate. Install a pressure gauge in the dis-
charge side of the pump to determine air pres-
sure. Typical pressure is between 30 - 40psi.

IMPORTANT:
On Model 338066-A1 Pneumatic
Logic Air Motors, do not use an air
lubrication system. These motors
are packed with Teflon lubricant and
do not require any additional lubri-
cation except during service or
repair. However, it requires clean
dry air.

NOTE:
A blockage in any of the oil delivery
lines indicates failure of the entire
plunger lubrication system. The
McCord divider block does not
operate if any of its outlet ports is
blocked.

JET 2 - Triplex Pumps v1.0 (Provisory) 35

 6.3.1.1 Air-over-oil lubrication system · Reduces oil consumption.
The air-over-oil lubrication system is a highly- · Lessens the amount of wasted
reliable, low-maintenance lubrication system. It plunger lubricant.
replaces conventional Alemite systems in both · Does not affect packing life.
cementing and fracturing services. In 1999, this · Is compatible with all packing types.
system became the standard plunger lubrica-
· Simplifies operations in environmentally
tion system for new cementing and fracturing
sensitive areas, including offshore.
units. It can also be retrofitted on existing
pumping equipment in the field. · Uses air pressure to force lubricant to
the plunger packing and centrifugal
This new lubrication system uses an air-pres- pumps.
sured oil reservoir that forces oil through the · Has no moving parts to jam or fail.
delivery lines to each packing bore. Adjusting · Reduces maintenance costs.
the metering valves regulates oil flow. The · Provides annual operating savings that
metering valve is located between the oil reser- are estimated at $2,500 per unit.
voir and the packing bore check valve.
To convert existing units to the air-over-oil lubri-
This system is simple and easy to maintain due cation system, remove the entire existing
to the limited number of components. plunger lubrication system except for the waste
oil catch tank. Parts for the new system
CAUTION: include:
This system uses a pressure ves- · an ASME-coded, pressurized, oil tank
sel. Pay special attention to the and mounting bracket
operating and refilling procedures. · distribution manifold and hoses
All users must be familiar with the · new check valves at the fluid end
system’s pressure relief mecha-
nisms.
· wiper rings behind the lantern ring to
contain lubrication oil.
NOTE:
The lubrication system provides the following Follow Schlumberger guidelines as
advantages when properly installed: described in Maintenance Bulletin
No. 625E and Well Services Safety
Standards, including Safety
Standard 26 – Air Tanks and
Receivers and Safety Standard 27 -
Inspection and Testing of Pressure
Relief Valves and Gauges.

JET 2 - Triplex Pumps v1.0 (Provisory) 36

 Major Components 3. Distribution Manifold and Hoses
The distribution manifold simplifies hose rout-
1. Tank ing. All the hose connections are push-loc to
enable you to make field installations without
The tank must have the following characteris-
special tools or hose crimping.
tics:
· ASME-coded
4. Chain case
· certified to 200 psi/13.79 bar
The Chain Case requires minor maintenance if
· maximum capacity of 16.4 checked regularly. Check for the following:
US gallons/62 liters
· contaminated oil
· fill point at top sight plug of · torque rods with loose ends, which are
13.2 U.S. gallons/50 liters worn, improperly adjusted, or corroded
The tank has the following safety features:
NOTE:
· two-piece fill cap
Grease the torque rods when per-
· brass, three-way, pressure/bleed ball forming a STEM 2.
valve
· 150 psi pressure-relief valve
· 0-100 psi liquid-filled, pressure gauge Unusual sounds such as slapping noises indi-
· three liquid-level, sight plugs – 1,750 cate the following:
psi/119 bar maximum working pressure · The chain is hitting the inside of
the case.
WARNING: · The companion flange splines are worn.
To insure safe and reliable operation, · The chain case bearings are faulty.
you must use the specified replace-
ment tank. Do not make substitutions
or use locally manufactured tanks. IMPORTANT:
Any unusual noises that cannot be
precisely traced require immediate
attention.
2. Fluid End Modifications
Fluid end parts that must be modified are:
· three Haskel SS, 15,000 psi
check valves
· three wiper seals to be installed in the
packing nuts on fracturing units

IMPORTANT:
Packing nuts can be modified local-
ly or purchased. Cementing units
using the PG pump must have a
seal groove in the packing ring
between the packing nut and the
lantern ring.

JET 2 - Triplex Pumps v1.0 (Provisory) 37

 6.3.2 Plungers and packing assembly
The fluid end is rugged and requires little atten-
tion. Detailed repacking procedure will be
described in Section 6.3.7.1.
Complete the following before each job:
6. Carefully check the rubber diaphragms
to ensure that they have not been perfo-
rated. Perforated diaphragms could
cause cement to flow into the lines
leading to the overpressure shutdowns
(OPSD) and console gauges.

1. Tighten the plungers and check the

packing.

2. If the packing is double stack or header

ring, verify that the packing gland nuts
did not back off.
3. On conventional Alemite systems, adjust
the oil flow from the Alemite pump to the
packings. Check for leaks along the air
and lubrication lines.
4. In air-over-oil systems, ensure that the
three-way pressure valve is on and the
lube level in the tank is correct.
5. Inspect the Martin Decker gauge
protectors to ensure that they are
pumped up and working properly.

CAUTION:
Do not over tighten the packings.
Never re-tighten the header ring
packing.

JET 2 - Triplex Pumps v1.0 (Provisory) 38

 7. Check the OPSD at this point to protect · Electronic engines: electrical
the equipment and most importantly the power to the engine electronic
operators on: control modules throttle connection is
· CPS-361 units with air throttles: cut off to set the engine to the idle posit-
OPSD cuts off air supply for the tion.
throttle and transmission to set
the engine to idle position and to 6.3.3 Fluid end cover retainers
return the transmission shift cylin- Use a pipe wrench to remove or reinstall retain-
der to the neutral position. ers, then top them with a heavy hammer to
ensure proper seating.
There are two ranges available
for OPSD: 0-10,000 psi and
0-15,000 psi. Calibrate the OPSD
when performing a pressure test
on the triplex pump using an
accurate pressure gauge or other
instrument as follows:

1. Adjust the OPSD to

1000 psi.
2. Bring the pressure up to
the OPSD trips, which
should be 1000 psi
+/- 500 psi.
3. Check OPSD accuracy.
4. Adjust the calibration plate
to coincide with the OPSD
trip pressure.
5. Perform steps 1 through 4
at different pressure rates Tightening the cover retainer with a pipe
to ensure the OPSD wrench is only to prevent the nuts from being
accuracy on the unit. backed-out due to vibration. The actual seal
NOTE: efficiency will not improve by over-tightening
the nuts.
Do not exceed the
maximum allowable
working pressure of
the fluid end.

· Units with standard transmission:

cutting off air disconnects the
clutch to disable the transmission
and set the engine to the idle position.

JET 2 - Triplex Pumps v1.0 (Provisory) 39

 6.3.4 O-ring and backup ring
After removing the suction or discharge covers, remove the O-rings and back-up rings to inspect
and clean the groove from cement or other debris. After the O-rings and backup rings are rein-
stalled in the groove, sparingly grease the cover and retainer threads. Excessive greasing caus-
es a grease lock, which prevents properly tightening the cover or extrudes the O-rings and back-
up rings from the groove. Extruded O-rings are easily cut or nicked. If this happens, remove the
cover and replace the damaged seals.

NOTE:
Grease lock occurs when grease acts like an incompressible hydraulic fluid in a jack.
Grease caught between threads and an O-ring prevents tightening the threads. When
pressure is applied on the cover retainer, the O-ring may give way. Generally, this
happens with the suction and discharge covers as the O-ring seal is entering the
sealing bore of the fluid end. When pushing excess grease ahead of the threads on
the retainer, grease gets trapped as the O-ring begins to seal. Excess grease does
not squeeze past the O-ring and prevents tightening the cover

Suction cover Discharge cover

JET 2 - Triplex Pumps v1.0 (Provisory) 40

 COMMON PRACTICE:
When installing the port-end bushing, insert the bushing with the short shoulder
towards the fluid end first for effective sealing when the fluid end seal area is in good
sealing condition. When the seal effectiveness is reduced with use, reverse the direc-
tion of the bushing, placing the longer shoulder in first. This offsets repositioning the
O-ring to an effective sealing area. This procedure can improve the sealing efficiency.

JET 2 - Triplex Pumps v1.0 (Provisory) 41

 6.3.5 Valves (MacClatchie valves)
Valves are manufactured in the following forms:

Discharge Valves Suction valves (burst disk)

Burst disk valves (Frangible suction valves)

were designed for two reasons:

1. To protect the treating equipment and

power end from damage due to
accidental and violent over
pressuring of the fluid end.

2. To avoid injury or death of personnel

due to a rupture of treating equipment
resulting from over pressurizing the
triplex pump.
WARNING:
Never use Burst disk valves in
the discharge
Suction side(burst
Valves of thedisk)
fluid
end, or discharge valves in the
suction side.
Burst disk valves are designed to last at least
500,000 pressure cycles. This is equal to
approximately 8,300 barrels pumped per
plunger in a TG (3-3/4-in) fluid end to 14,700
barrels per plunger in a TH (5-in) pump. Given
the cross-section of the jobs we perform, the
valves or packing would be worn out long
before this volume is reached.
NOTE:
A pressure cycle is defined as 1
plunger stroke at the maximum
pressure rating of the fluid end.
There were instances of premature failure of
burst disk valves, and in almost all cases, the
causes have been attributed to:
· Circulation at excessively high rates
during the priming of pumps while using
gravity feed: This causes pressure
peaks that are not visible on pressure
gauge and exceeds the pressure ratings
of burst disk valves. To prime a pump,
use a rate no more than 50% of the
rated volume output of the pump
being primed.
· High Pressure testing of lines: When the
pump is not properly primed, it
causes the plunger to accelerate and
jerk creating water-hammer effect. If
possible, pump at a low rpm using a
larger pump to build some pressure in
the system, then change to the smaller
pump as required.

JET 2 - Triplex Pumps v1.0 (Provisory) 42

 · Cavitation during pumping: Maintain a minimum of 20-30 psi suction at all times on the
suction side of the triplex pump. If cavitation becomes imminent, immediately slow down
the pump. The larger the fluid end, the more vulnerable it becomes to suction problems,
especially at high rates.

NOTE:
Old style high-strike valve body is obsolete and no longer manufactured. High
strike is the amount of metal contact between the valve body and seat when the
valve is closed.

Three types of valve inserts are available depending on the service requirements:

1. Rubber inserts (black color) are used for basic cementing and acid jobs. However, they
have poor resistance to abrasives, such as sand, and hydrocarbons.

2. Urethane inserts (yellow color) is used for sand fracture stimulation. They have poor
resistance to acids. They last approximately one year in hot/humid conditions.

3. Urethane Bonded inserts (yellow color) are supplied as one integral piece of urethane
insert bonded to a steel valve body. This type is used in high pressure fracturing jobs
using proppants. The insert prevents abrasives from working their way between the valve
body and the insert. If the insert becomes damaged, remove it using a low-heat cutting
torch. Once removed, install either a standard rubber or urethane inserts. You can use the
valve for cementing or general pumping only.

NOTE:
If using a cement pumping unit in sand control service, the bonded insert valve
must be used.

Urethane inserts deteriorate with time while being stored. Their shelf life is approximately one
year when not stored properly. Ideal storage area is a cool, dark place with low humidity. The
insert turns yellow along the edges when it starts to deteriorate. Later, the whole insert begins to
change to yellow and starts to crumble like old bread.
JET 2 - Triplex Pumps v1.0 (Provisory) 43
 To install an insert, soak it in hot water for few minutes and then force the insert over the indenta-
tion.

NOTE:
When stocking inserts, take into account factors such as average con-
sumption.

6.3.6 Valve Seats (MacClatchie valve seats)

Two valve seat types were previously available: tapered and straight-hole. The straight-hole type
is obsolete and no longer available. Only the tapered type is currently used.

When pumping at a high pressure or when a plunger makes a complete pressure cycle, the clos-
ing valves hammers the seat. Constant hammering effect presses the valve seats tightly into the
fluid end.

Use a valve seat gauge to determine the degree of wear on the seat. Replace the seat when
the indicator becomes flush with the top of the gauge or when you see signs of pitting, corrosion,
and wash-outs.
Straight-hole and tapered valve seat

Check the valve seat for pitting, erosion, wash-outs, and cracks
when the fluid end is opened.

JET 2 - Triplex Pumps v1.0 (Provisory) 44

 To install new valve seats, complete the following steps:

Clean the bore and remove any Set the seat in the bore, ensuring
STEP 01 rust, scales, and cement. STEP 02 that the O-ring is seated correctly
Inadequate removal of these scales causes the in its groove
O-ring to hang up and get cut or bruised on the
valve seat bore.

Place the seat squarely in the

STEP 03 bore.

IMPORTANT:
Do not use any lubricant on the
seat or in the valve seat bore.

Drive the seat into the bore.

Place an old valve, without an

STEP 04 insert, on the seat.

Strike the center of the valve with

STEP 05 a steel bar to drive the seat into
the bore.

JET 2 - Triplex Pumps v1.0 (Provisory) 45

 Complete repacking of the pump
STEP 06 Remove the old valve. STEP 07 and pressure test the fluid end to
the rated pressure.

6.3.7 Packing
Field testing conducted has demonstrated the
superior life of the header ring packing system
over conventional single stack (hard and soft
ring assembly) and elastoplast packing in
cementing service, and over the double stack
packing in fracturing services. This new system
also provides superior results in drilling (Mud)
systems.

Single-stack (rubber/fiber or hard/soft assem-

bly) and double-stack (Elastoplast) packing
assemblies are now replaced with the header
ring packing for cementing, fracturing, and
coiled tubing services. Refer to Maintenance
Bulletin 1103, InTouch content ID 2023279, for
details on ordering and installing new header
ring packing assemblies.

JET 2 - Triplex Pumps v1.0 (Provisory) 46

 6.3.7.1 Fluid end repacking procedure
TOOLS
· a piece of hardwood
(not the handle of the hammer)
· a short piece of broomstick or
old hammer handle
· plunger puller tool
· a 4 lb (2 kg) hammer
· C wrench for the gland nuts
· an 18-24 in pipe wrench
· on older fluid ends, a hex nut and steel
bar may be required
· rags or other clean-up material
NOTE:
Use the packing tool kit (P/N
570376000). It is recommended to
use this kit if available in the
location.
STEP 01 Tap the ears of the fluid end cover
with a hammer until the cover
starts to loosen up.
JET 2 - Triplex Pumps v1.0 (Provisory)
SPARES
· O-rings
· backup rings
· valve inserts
· springs
WARNING:
Wear safety equipment. Turn off air or
electric supply to the pump. Ensure
that the pump cannot be started.
Display warning signs prominently on
the controls, following the Lock Out-
Tag Out procedure in Well Services
Safety Standard 15.
NOTE:
Whenever working above ground
level, use a purpose-built platform.
A proper platform provides enough
space for laying out pump parts in a
logical order if troubleshooting is
required.
47
 Use a pipe wrench to unscrew Extract the suction valve retainer
STEP 02 the cover from the fluid end body. STEP 03 and place the cover and retainer
The suction valve retainer is in a logical order on the platform
removed with the cover. or pallet.

Remove the suction valve. Remove the discharge cover. If a

STEP 04 Inspect its condition then place STEP 05 Martin Decker Sensor is
it with the other parts from the same cham- attached, remove it first. Place all parts togeth-
ber. er with those from the same chamber.

JET 2 - Triplex Pumps v1.0 (Provisory) 48

 Using a wrench and hammer, Unscrew the plungers completely
STEP 06 break the plungers from the STEP 07 from the pony rods using the pipe
pony rods. wrench. Do not damage the
threads on the pony rods.
NOTE:
Do not put a wrench on the pony
rod. Use the tapered end on the
plunger for screwing or unscrewing
the plunger as required.

If a plunger is covering the suction valve, rotate the drive shaft to the chain case
STEP 08 using a pry bar in the u-joint to retract the plunger.

The correct way The wrong way

WARNING:
Using a pipe wrench can cause drive shaft tube damage. Any pipe wrench marks on the drive
shaft creates a crack and causes a catastrophic failure or twist-off during a job.

JET 2 - Triplex Pumps v1.0 (Provisory) 49

 Use the C spanner to unscrew Install the plunger remover by
STEP 09 the packing gland nut and STEP 10 carefully screwing it with a turning
release the packing compaction. motion. Slowly remove the
plunger from the chamber.

Completely unscrew the pack-

STEP 11 ing gland nut and place it with
the other parts.

NOTE:
If the pony rods are not fully with-
drawn as close to the power end as
possible, it may be difficult to with-
draw the packing gland nuts.

CAUTION:
While removing the plunger, ensure
that it does not fall out and cause
an injury. Do not drop or nick the
plunger on the chromed surface.

JET 2 - Triplex Pumps v1.0 (Provisory) 50

 Using a piece of hardwood, gen-
STEP 12 tly and evenly tap the brass on
the opposing sides. The brass is close to the
packing bore. Any slight misalignment makes
the brass difficult to remove.
b. Clean and inspect the O-ring
grooves for foreign particles.
Inspect the coarse ACME threads
for damage or cracks.
Use a file to fix small thread
bruises.
Clean and inspect O-ring grooves
JET 2 - Triplex Pumps v1.0 (Provisory)
Carefully remove the male pack-
STEP 13 ing adapter. Cement might be
stuck around it making it difficult
to remove.
IMPORTANT:
Do not use excessive force.
Repeat the previous steps for
STEP 14 all chambers.
STEP 15 Inspect the parts as follows:
a. Wipe the O-rings and backup rings to
inspect them for stretching, bruises,
or cuts.
IMPORTANT:
Do not use diesel or solvent on rub-
ber parts. O-rings may swell on con-
tact with diesel or solvents.
c. Inspect the valve bodies for washouts,
pits, and corrosion. Check the valve
inserts for abrasion damage or cracks.
Replace as necessary. Check the burst
disk to ensure that it is intact.
Replace the springs if they are distorted
or corroded.
Inspect the valve bodies
51
 d. Inspect and change the plungers if
they are dull or show score marks.
Using dull or scored plungers
severely reduces the packing life.

CAUTION:
Do not reuse the packing.

e. Inspect the fluid end

body by ensuring that
the valve seats are not
washed out or pitted.
Check the ACME
threads and packing
bores.
Thoroughly clean out
cement, sand, rust, or
dirt using a wire brush,
emery cloth, or steam
cleaner.

f. Clean and inspect the brass for any sign

of discoloration, distortion, nicks, or
bruises. Install the brass over the
plunger to check for its eccentricity
(ovaling). Place the brass on a flat piece
of glass to check for distortion. Rub the
brass with fine emery cloth to remove
minor scratches and nicks.

JET 2 - Triplex Pumps v1.0 (Provisory) 52

 g. Check the oiling system (Alemite or air-
pressure type) to ensure that a positive
flow of oil is coming through the oiling
hole at the top of the packing bores.
Start the unit and turn on the lube
system.
JET 2 - Triplex Pumps v1.0 (Provisory)
WARNING:
Turn off the power or air supply after
checking the oil system and hang
warning signs.
NOTE:
Perform repacking according to
Maintenance Bulletin 1103. Always
verify the packing assembly order
before repacking.
IMPORTANT:
If the packing is not the header ring
packing, remove older packing and
install a conversion kit. Obtain and
install the correct conversion kit
according to Maintenance Bulletin
1103.
53
 6.3.7.2 Valve seat removal and installation
Valve seat puller types:
Valve seat puller assembly
TYPE 01 P/N 428024000:
This type is designed for use on conventional
triplex pump fluid ends, especially stimulation
pumper fluid ends that do not have suction
caps and require the lug to swivel. By rotating
the assembly to the vertical position, it passes
through the valve seat from above and subse-
quently rotates freely into the engaged position
below the valve seat.
JET 2 - Triplex Pumps v1.0 (Provisory)
Valve seat puller assembly
TYPE 02 P/N 902857000:
This type is designed for MD1000 fluid end and
can be used in conventional fluid ends that
have suction caps. This puller allows the inser-
tion of a split washer onto the tie rod once it
passes through the valve seat from above.
54
 Clamshell-type puller assembly
TYPE 03 P/N 902857000:

You can machine this type approximately 0.040-in at each

pulling shoulder for a total of 0.080-in for an 0.080-in
reduction in circumference. This is necessary when pulling
suction seats in the small bore SPM fluid ends, to fit the
puller through the seat.

NOTE:
The following steps provide a
guideline for pulling a valve seat,
but not necessarily the only method
used in the field.
IMPORTANT:
Pulling a valve seat requires two
people. If you have questionable
valve seats, pull them before failure
occurs.

JET 2 - Triplex Pumps v1.0 (Provisory) 55

 Open the fluid end as described
TOOLS STEP 01 in the Fluid end repacking proce-
· valve seat puller dure section. After removing the suction and
· hammer discharge covers, check and replace, if neces-
· 24-in pipe wrench sary, the valve seat by feeling the seating area.
· chisel or old screwdriver Use the proper seat wear gauge for your fluid
· bucket and cleaning solvent end as defined in the Treating Equipment
· rags Manual.
· grease
· other spares like O-rings
or backup rings

Using puller assembly P/N Insert the collar and threaded rod
STEP 02 428024000, install the collar onto STEP 03 through the pressure plate.
the threaded rod. Adjust the placement of the
collar by estimating the length of threaded rod
required to reach the valve seat.

JET 2 - Triplex Pumps v1.0 (Provisory) 56

 Thread the nut under the pres- Attach and hand-tighten the head
STEP 04 sure plate from the bottom of the STEP 05 to the threaded rod without the
threaded rod to secure the collar lug and pin components.
and pressure plate.

Lift and insert the complete Install the lug and pin compo-
STEP 06 assembly into the top of the fluid STEP 07 nents onto the head.
end. Ensure that it is centered so that the head
passes readily through the valve seat. The
head should now be visible below the valve
seat that will be pulled
NOTE:
Follow the correct safety proce-
dures when lifting heavy objects.

JET 2 - Triplex Pumps v1.0 57

 STEP 07 Continued from previous page.

IMPORTANT:
Do not attempt to make replacement lugs or pins at a local machine shop. These
parts are made of high strength steel. Using the wrong material will result in lug or pin
failure when pulling seats.

Making sure that the lug is horizontal, rotate the connecting rod until the lug
STEP 08 makes contact with the lower side of the valve seat.

Continue to rotate the connection rod, slowly continuing to pull the valve, until
STEP 09 completely extracted.

JET 2 - Triplex Pumps v1.0 58

 6.3.7.3 Header ring packing installation

Complete the following steps to install the header ring packing:

Use a disc or puller to remove Clean and lubricate the packing

STEP 01 the old packing and brass. The STEP 02 nut threads.
steel junk ring has a stepped
bore.

Clean any cement and proppant

STEP 03 from the bore and Inspect it for
damage.

STEP 04 Install the junk ring. STEP 05 Install the header ring.

JET 2 - Triplex Pumps v1.0 59

 Install the female adapter - brass
STEP 06 Install the pressure ring. STEP 07 and PEEK

STEP 08 Install the lantern ring. STEP 09 Install the packing nut.

a. Tighten packing nut to seat the packing.

b. Loosen the packing nut a ½ turn.
c. Hand-tighten until it touches the packing.
d. Tighten a ¼ turn and paint the alignment
marks on the packing nut and fluid end.
e. Loosen the packing 1 turn.

JET 2 - Triplex Pumps v1.0 60

 Lubricate the packing and
STEP 10 plunger.
Drive the plunger through the
STEP 11 packing with a slide hammer or
using a large piece of wood, tap
the end of the plunger to ensure
that the plunger and the pony rod
are conected.
Start the pump and check the
STEP 13 installation. Note that the packing
does not require further adjustment.
JET 2 - Triplex Pumps v1.0
Coat the pony rod pin with Never-
STEP 12 Seize thread compound and then
tighten the plunger onto it. Snap
tight with a sharo blow using a
hammer and a pipe wrench.
IMPORTANT:
Change the plungers when they
become dull or show score marks.
Using dull or scored plungers
severely reduces the packing life.
61
 6.3.7.4 Repacking the header ring
To repack the header ring, complete the following steps:
Since one of the fluid end
STEP 01 chambers is repacked, install
the valve springs and cover retainer assem-
blies. Clean, inspect, and replace these
parts if necessary.
JET 2 - Triplex Pumps v1.0 (Provisory)
Install the O-rings and backup
STEP 02 rings. Using excess grease cre-
ates a grease lock during the installation of
retainers and covers.
CAUTION:
Do not soak the O-ring in solvents.
62
 Coat the retainer with a thin layer Once the suction spring is under
STEP 03 of grease and install the suction STEP 04 the cover, tighten the assembly
valve. Screw in the suction valve cover/retainer by hand or with a pipe wrench. Tighten the
assembly until it touch the springs. Use a retainer with a few hammer strikes.
piece of wood to compress and engage the
spring under the cover, while simultaneously CAUTION:
screwing the retainer in. Ensure that the suction cover is
properly installed with the flat side
holding the valve spring com-
CAUTION: pressed. Covers are sometimes
Do not tie the springs with rope installed 90-180° out of the proper
or wire. position. It is crucial that the flat
portion of the wedge that com-
presses the suction spring be
exactly perpendicular to the valve.
To check the position, ensure that
the two screw holes in the suction
cap are perpendicular to the wedge
surface.

Ensure that the O-ring and backup ring are in good condition and clean the groove.
STEP 05 Lightly grease the groove. Excessive grease prevents the rings from properly seat-
ing.
Carefully install the discharge
STEP 06 cover and retainer. Ensure that
the discharge valve spring is properly centered
so that it engages the spring retainer stub on
the bottom of the discharge cover.

CAUTION:
You must never put a burst disc valve
in the pump discharge.

JET 2 - Triplex Pumps v1.0 (Provisory)

63
 Hand-tighten the discharge cover
STEP 07 then hammer it to properly seat
the cover.
Engage the pump in low gear and
STEP 09 tighten all the packing nuts with
the C spanner
CAUTION:
Any moving piece of equipment
could become a hand trap.
JET 2 - Triplex Pumps v1.0 (Provisory)
Perform a STEM I, then check
STEP 08 that you have installed all the
parts. Start the unit and observe for correct
operation of the Alemite lubricator.
After tightening the packing
STEP 10 assembly, circulate water for 15-
20 minutes at different rates to verify that the
packing and lubrication systems are performing
properly.
CAUTION:
Do not use an extension handle on
a packing gland nut wrench. It will
damage or over tighten the packing
nut and assembly. Remove any nut
that becomes hard to tighten.
Check the packing nut and fluid
end threads for damage or hard-
ened cement.
64
 CHAIN CASE LUBRICATION SYSTEM 6.4.0

Each chain case is equipped with either a sight

glass or a dipstick to indicate the oil level in the
case. The oil level indicator should be center-
lined with the bottom of the input shaft.

NOTE:
When checking oil level, always
remove the dipstick and allow the
oil level to settle. Reinsert and
remove the dipstick to check the
correct oil level.

Ensure that you have only the required amount

of oil to prevent the chain case from overheat-
ing. When a chain case is overheated, the
bearing grease seals become damaged. If
overheating continues, oil breaks down chemi-
cally, losing its viscosity, lubricating, and cool-
ing properties, which will severely damage the
bearing and chain case.
JET 2 - Triplex Pumps v1.0 (Provisory) 65

STEM 1 AND OPERATION OF THE TRIPLEX PUMP 7.1.0
Before starting up, properly STEM the unit using the following:
Tightly screw the plungers to the
STEP 01 pony rods (crossheads) with a
pipe wrench. Do not overtighten.
With pressure on the power end
STEP 03 lube circuit, verify that the AlemiteSTEP 04
pump is functioning. Adjust the oil flow as
described in Maintenance Bulletin 982.
NOTE:
Refer to Maintenance Bulletin 1085
(InTouch ID: 2023265) for air-over-
oil lubrication system.
Put the pump back in neutral
STEP 05 gear and ensure that the packing
gland nuts are snug. If the header ring packing
is installed, regular tightening in not required.
Verify that the gland nuts have not backed off.
JET 2 - Triplex Pumps v1.0 (Provisory)
SERVICING 7.0.0
Ensure that the oil level in the
STEP 02 chain cases, power ends, and
packing lubricant reservoir is correct and that
the specified lubricants are used.
For the Alemite pump to operate and deliver
lubricant to the plunger's packing, open the air
supply valve.
Ensure that the power end oil
pressure is correct while the
pump is running. At 1000-rpm pinion speed
(2/3 of the maximum pumping rate), oil pres-
sure should be approximately 50 psi for cold oil
and 40 psi for warm oil (above 100 deg F).
For single stack (cementing),
STEP 06 tighten the packing gland nuts
before each job.
66
 For elastoplast (cementing), tight- For double stack (fracturing), per-
STEP 07 en the packing gland nuts before STEP 08 form periodic adjustment per
each job. Maintenance Bulletin 1103
(InTouch ID: 2023279).

For header ring packing with a
STEP 09 teflon back-up ring, verify that the
nuts did not back off. Once adjusted, the head-
er ring packing does not require additional
adjustment.
NOTE:
Do not overtighten the header ring
packing.
Refer to Maintenance Bulletin 1103 for part
replacement information.
Ensure that the pump is ready for
STEP 10 priming and operations.
After completion of any pumping
STEP 11 operation, pump clean water
through the discharge piping until you see
clean water flowing from the pump, then stop
pumping.
CAUTION:
Never loosen the fluid end packing
gland nut during this operation.

Remove the suction manifold Check under the pony rods

STEP 12 caps and flush the manifold out
with water. If the weather is cold and there is a
chance of freezing, drain all water from the
pump by fanning the pump and prying up the
suction valves.
STEP 13 (behind the fluid end) to ensure
that the drip pan drain is not blocked. Flush out
the drip pan with water.

JET 2 - Triplex Pumps v1.0 (Provisory) 67

 Check and replace the pony rod
STEP 14 seals on the power end if there is
an oil leak. Ensure that the slinger rings are not
loose. These rings prevent any high pressure
fluid that leaked past the packing from damag-
ing the pony rod seal and entering the power
the power end.
JET 2 - Triplex Pumps v1.0 (Provisory)
Before starting a job, per-
SUMMARY form STEM 1 (pre-job
inspection):
· Check plunger tightness.
· Check condition and lubricant level of
the chain case.
· Check condition and lubricant level of
the power end.
· Check the condition and lubricant level
of the packing oil (Alemite) reservoir.
· Check the operation of the packing
oiler (Alemite).
· Check the power end lube oil pressure:
50 psi for cold oil
40 psi for hot oil
· Check that the gland nuts are tight.
· Proceed to prime the pumps.
· Clean the pump and manifold by pump-
ing clean water through it.
· Flush out the suction manifold.
· Drain the pump if there is cold weather.
· Check the crosshead seals.
· Check that the slinger rings are
not loose.
68

EVERY 6 MONTHS OR 300 HOURS 7.2.0
It is the responsibility of the equipment operator
to perform STEM 2 with assistance from the
mechanic.
7.2.1 Chain case
· Check the condition of the torque-rod
end bushings and lock nuts. Replace
worn bushings.
· Grease the torque-rod ends and adjust
the length as necessary.
· Inspect the retaining pin.
NOTE:
End bushings are no longer avail-
able as separate items. You must
change the torque-rod assembly
when replacing the bushings.
Check the Equipment Parts Manual
(InTouch ID 3015447).
· Grease the chain case bearings. Check
the condition of the oil filler cap/breather.
If necessary, wash the filler cap/breather
in solvent and blow dry.
· On older units remove the oil and rein-
stall the barrel counter drive cable.
JET 2 - Triplex Pumps v1.0 (Provisory)
TRIPLEX PUMP STEM 2
· Carefully grease the barrel counter right
angle drive if a grease zerk is installed.
Most barrel counters use a proximity
switch to determine pump rate. No
lubrication is required.
NOTE:
Size the ratio of the right angle
drive specifically for the fluid end on
that pump.
Grease Zerk
EXAMPLE:
TRO uses a 0.249 ratio,
TGO - .385, TLO - 0.466 and
THO - 0.555 gear ratio. When using
incorrect ratio, the mechanical bar-
rel counter will not be accurate.
This ratio coincides with the bbl/per
revolution for each fluid end
(InTouch ID 3015637)
· Switch the end caps to reverse the right
angle drive and to change the rotation of
the cable.
69
 7.2.2 Power end
· Inspect the power end mounting for
loose, worn, or broken bolts.
· Inspect the frame for cracks or
broken sections.
IMPORTANT:
The power end frame and mount-
ings are exposed to extreme load-
ing and vibration during pumping
operations. Fix damaged mountings
or loose bolts immediately to avoid
expensive repairs. Bolts should be
torqued 600lb-ft (+ 10%).
NOTE:
Never weld a magnesium power
end.
· Check for oil leaks, and take oil samples
to inspect for metal particles or water
contamination and determine the cause.
Ensure that the slinger rings fit snugly
on the pony rods. Replace broken or
missing slinger rings.
JET 2 - Triplex Pumps v1.0 (Provisory)
Ensure that slinger rings fit snugly on the pony rods.
· Inspect the power end lubrication oil
suction hoses. If a suction hose is col-
lapsing, it indicates that the oil is
severely contaminated and the lube
pump does not have enough oil. To
clean the lubrication system:
1. Drain the oil.
2. Analyze a sample in a lab.
3. Remove the power end back
cover.
4. Clean and flush inside the power
end with a solvent.
5. Flush and clean the hoses.
6. Clean the lubrication system, oil
pump, and filter.
70
 7. Install the fluid end’s back cover
and fill with new oil to the speci-
fied level.
NOTE:
Oil volume for the power end is 17
gallons in addition to the oil
required for hoses, pump, and filter.
The maximum pressure differen-
tial across the filter is 75 psi. If
pressure becomes higher, a relief
valve in the system opens and
the oil bypasses the filter and
continues to supply the
power end.
NOTE:
Prime new or reassembled lubricat-
ing pumps before operating the unit
by opening the lines and filling the
pump with oil. Reconnect the hoses
then crank the engine for 30 sec-
onds with the engine Stop button
pressed down.
7.2.3 Fluid end
· Inspect the packings, packing glands,
and plungers for any wear,
leaks, or looseness.
CAUTION:
It is unnecessary to remove the
packings for inspection unless there
are indications that the packing
assembly is leaking or failing.
Packings are usually damaged dur-
ing removal from the fluid end bore.
Do not over tighten the packing
gland nut. Refer to Maintenance
Bulletin 1085 for more information.
· Open the fluid end and inspect the
valves, valve seats, inserts, and springs
for cracks, wear, or damage. Compare
them to new components if in doubt.
Replace as necessary.

· Listen for any unusual noises and per

form a Hydraulic Horsepower (HHP) test
to reveal any potential mechanical
problems. Record the test results for
future reference and place a copy with
the STEM 2 report. Refer to Appendix 2
in this training for the HHP test
procedure.

JET 2 - Triplex Pumps v1.0 (Provisory) 71

 · Replace any damaged backup rings and
O-rings on the discharge and suction
covers. Remove all hardened cement
from the O-ring groove.
· Inspect the ACME threads of the fluid
end and cover retainers for cracks.
Ground off the first or last thread if
cracked no more than 1/2 of a thread. If
more than 1/2 of a thread is cracked,
replace the fluid end. Notify your
maintenance department before
repairing threads.
· If the packing is failing prematurely,
tighten or replace the plungers and
packing gland nuts as necessary. Check
for proper lubrication from the
Alemite pump.
NOTE:
Signs of wear on the bottom of a
failing packing indicate excessive
crosshead wear on the power end.
7.2.4 Packing oilers (Alemite)
Check that the lube tank is clean. Drain, flush,
and refill as necessary.
NOTE:
Water can easily enter the tank
where the Alemite pump is mount-
ed and become mixed with the
lubrication oil giving a false indica-
tion that the packing is leaking.
7.2.5 Triplex pump annual inspection -
every 12 months
The mechanic performs annual Inspection;
however, it is essential for the operator to
understand the requirements as well as the
importance of the mechanic's responsibilities.
(Procedure for annual inspection is covered in
the fluid end section of the Treating Equipment
Manual)

· Check tightness of the tie rod nuts

(900 ft-lbs). Tighten as required.
NOTE:
Loose tied rod nuts can cause the
fluid end to crack due to uneven
stress.

JET 2 - Triplex Pumps v1.0 (Provisory)

72
 TROUBLESHOOTING 8.0.0

JET 2 - Triplex Pumps v1.0 (Provisory) 73

JET 2 - Triplex Pumps v1.0 (Provisory) 74
 APPENDIX 1 – PRIME-UP PROCEDURES 9.0.0
Refer to Safety Standards for Well Services
Operations for recommended procedures
(InTouch content ID 3038426).

JET 2 - Triplex Pumps v1.0 (Provisory) 75

 PRIMING TRIPLEX PUMPS USING GRAVITY FEED 9.1.0

To prime the triplex pumps using gravity feed, complete the following steps:

Place the first pump in high gear Increase the triplex pump rate to
STEP 01 at idle speed. Make sure there
STEP 02 3 bpm (0.5 m3/min.). Continue
are fluid returns in the displace- pumping until you have a steady
ment tank. continuous return of the fluids.

Return the pump to neutral gear

STEP 03 and run the engine at idle speed. STEP 04 Repeat Step 1 through Step 3 for
the second pump.

Close the gravity feed lines. Open the pressure feed lines to
STEP 05 STEP 06 the pumps.

JET 2 - Triplex Pumps v1.0 (Provisory) 76

 PRIMING TRIPLEX PUMPS USING
A PRESSURIZER PUMP 9.2.0

To prime the triplex pumps using the pressurizer pump, complete the following steps:

Start the prime up procedure Place the pump in high gear at

STEP 01 using the engine pressuring and-
STEP 02 idle speed.
make up centrifugal pumps.

Make sure there are fluid returns Increase the pump rate to 3 bpm
STEP 03 in the displacement tank.
STEP 04 (0.5 cubic m/min.), and run the
engine at a fast enough speed to operate the
hydraulic system. Continue pumping until you
have a smooth return of fluids.

Return the pump to neutral gear Repeat step 2 through step 5 for
STEP 05 and maintain engine speed at the
STEP 06 the second pump.
same rpm.

Prime each pump through the

STEP 07 mixing equipment.

JET 2 - Triplex Pumps v1.0 (Provisory) 77

 Appendix 2 – hydraulic horsepower test (HHP) 10.0.0
Follow all applicable Well Services Safety Standards for rig-up, priming, and pumping.

Hydraulic horsepower tests are generally conducted at the district to verify unit performance.

To perform a hydraulic horsepower test, complete the following steps:

Obtain the performance curve for Rig up following Well Services

STEP 01 your unit to get the actual
hydraulic performance for the unit.
STEP 02 Safety Standards 5 – Location
Safety. You will need a water supply, charge
pump (if the unit does not have a pick-up
pump), and a discharge choke.

IMPORTANT:
This procedure assumes that you
have a remote-actuated choke. If
not, you must shutdown while mak-
ing adjustments to the choke. Rig
up the choke to allow isolation and
bypass.

Pressure test the discharge pip-

STEP 03 Conduct a STEM 1 of the unit. STEP 04 ing and verify that the unit over-
pressure shutdowns are functioning using Well
Services Safety Standards 5.

Referring to the unit performance Open the choke, select the

STEP 05 curve, select a gear in the mid-
range that results in pumping pressure of 5,000
psi or lower and rates of 8 bpm or lower
(assuming full engine rpm) for units rated under
1000 HHP. For large frac units, select a gear
that results in a maximum pumping pressure of
10,000 psi or lower, and rates of 8 BPM or
lower.
STEP 06 appropriate gear, and establish
the desired rate at full engine rpm. If using a
remote choke, slowly close the choke until the
engine droops the correct amount. If the
engine’s full-load droop is not known, droop the
engine 25-50 rpm.

If you are using a manual choke, Note the rate and pressure and
STEP 07 shutdown the unit and adjust the
STEP 08 calculate the hydraulic
choke in small increments until the correct horsepower.
droop is obtained.

JET 2 - Triplex Pumps v1.0 (Provisory) 78

 References 11.0.0
Treating Equipment Manual (InTouch ID 3013931)

Safety Standards for Well Services Operations (ID# 3038426)

Well Services Safety Standard 4 - Facilities and Workshops

Well Services Safety Standard 5 – Location Safety

Well Services Safety Standard 15 – Lock Out-Tag

Well Services Safety Standard 26 – Air Tanks and Receivers

Well Services Safety Standard 27 - Inspection and Testing of Pressure Relief Valves and Gauges

Maintenance Bulletin 625E

Maintenance Bulletin 1103, InTouch ID 2023279

Maintenance Bulletin 982

Maintenance Bulletin 1085, InTouch ID 2023265

Header ring packing ordering information:

Gardner Denver Tulsa

Customer Service
Phone: 800 637 8099
Fax: 918 664 6225
email: customerservice@gardnerdenvertulsa.com

CDI
Customer Service contacts:
Beatriz Trevino
email: btrevino@cdiseals.com
Scarlett Roberts
email: sroberts@cdiseals.com
Phone: 281 446 6662
Fax: 281 446 7034

UTEX
Weimar Molded Products
605 UTEX Dr.
Weimar, TX 78962
Phone: 979 725 8529 or 877 469 2829
Fax: 800 924 8277
JET 2 - Triplex Pumps v1.0 (Provisory) 79
 CHECK YOUR UNDERSTANDING 12.0.0
Q 01 The power end converts energy from: Q 06 For coiled tubing operations, use
Hydraulic energy to mechanical energy (Select all that apply)
Reciprocal power to rotational energy MD1000
Rotational power to reciprocal power 8-in stroke HD2250 pump
Mechanical energy to pressure energy 6-in stroke OPI600 pump
PG/Butterworth pump

Q 02 The main components of a triplex pump

are: (Select all that apply) Q 07 The correct level for oil in the power end is
Engine ½ full
Shaft ok as long as oil is visible in the
Chain case bottom of the power end
Power end ½-in below the bottom of the main
Fluid end bearings caps
½-in above the top of the main
bearings caps
Q 03 Chain cases important functions are
(Select all that apply)
Lubricate and cool the chains. Q 08 The maximum flow rate of a triplex pump
Secure the power end from flexing during is calculated on
pumping 88 % volumetric efficiency \
Provides flexibility in mounting 92 % volumetric efficiency
Converts rpm to torque 97 % volumetric efficiency
Provides storage of power end lubrication 100 % volumetric efficiency
Does not depend on volumetric efficiency

Q 04 A triplex pump is
Low-pressure positive displacement Q 09 Low-pressure in the power end is caused by:
pump
High-pressure pump using gear principle high discharge pressure
High-pressure positive displacement Engine rpm is low
pump consisting of three plungers Rod load is low
Worn components
All of the above
Q 05 The maximum fluid end pressure limita-
tions is based on Q 10 Crosshead seals are used for:
Metal used in the construction of the fluid (Select all that apply)
end Preventing leakage of oil from the power
Power end maximum rod load end via the pony rods.
AJSI steel grades Keep oil in and dirt out of the power end
Autfretaging processes Supporting the crossheads (pony rods)
Backing up the O-rings in the power end

JET 2 - Triplex Pumps v1.0 (Provisory) 80

 Q 11 It is recommended to reuse packing oil Q 17 During STEM 1, it is essential to:
(Select all that apply)
True Tighten the packing before pumping
False operations.
Drain all water in cold (typo) weather after
washing the pump
Q 12 The divider block functions to: Check for oil leaks in the crosshead seals
Divide equally oil to each plunger Check oil level in the chain cases, power
Boost the oil pressure to the lantern ends, and packing lubricant reservoir
glands All of the above
Prevent the lubrication system from failing
when one of the discharge ports are
blocked Q 18 Unusual noises in the power end could
Control the discharge rate from the indicate: (Select all that apply)
Alemite pump Damaged bull or pinion gears
Worn or damaged main bearings,
crosshead, or connecting rod bushings
Q 13 A block divider that is coded 24 has Damaged crankshaft.
One outlet Must discharge from one end Cracked eccentric
Two outlets Must discharge from both All of the above
ends
Cannot be used with a divider block
coded 12 Q 19 Cavitation is more likely to occur when
pumping oil than water.
True
Q 14 A discharge stroke is when the plunger is False
drawn toward the power end.
True
False Q 20 Burst disk valves are designed to last at
least 500,000 pressure cycles.
True
One of the most damaging factor for a False
Q 15 pump fluid end is:
Pump cavitation
Excessive pressure Q 21 Using dull or scored plungers does not
Pumping inhibited acids reduce the packing life.
Excessive rates True
False

Q 16 Cavitation can be the result of:

Q 22 Urethane inserts shelf life is
(Select all that apply)
Keeping the pump chambers full of sand 1 year
Worn or damaged pressurizing pump not 6 months
maintaining adequate pump suction mani- 2 years
fold pressure. 1 month
Pumping too fast for the pressurizing
pump to keep up
Not keeping the fluid end chambers full of
fluid

JET 2 - Triplex Pumps v1.0 (Provisory) 81

 Q 23 5-in stroke PG series pump
is primarily used for
Frac services
Coiled tubing services
Cementing/completion services
Mixed cement/frac services

Q 24 A Hydraulic Horsepower Test (HHP) is

performed to confirm the units perform-
ance level, and reveal potential mechani-
cal problems
True
False

Q 25 The power end can catch fire due to

excessive heat.
True
False

Q 26 Excessive greasing of the suction and

discharge cover and retainer threads can
cause a grease or hydraulic lock
True
False

Q 27 Triplex pump annual inspection is per-

formed by:
Unit operator
Field specialist
Mechanic
Field engineer

JET 2 - Triplex Pumps v1.0 (Provisory) 82

 CHECK YOUR UNDERSTANDING: ANSWERS 12.0.1

A 01 Rotational power to reciprocal power A 16 Worn or damaged pressurizing pump

not maintaining adequate pump
A 02 Chain case suction manifold pressure.
Power end Pumping too fast for the
Fluid end pressurizing pump to keep up
Not keeping the fluid end chambers full
A 03 Provides flexibility in mounting of fluid
Converts rpm to torque
A 17 Drain all water in clod (typo) weather
A 04 High-pressure positive displacement after washing the pump
pump consisting of three plungers Check for oil leaks in the crosshead
seals
A 05 Power end maximum rod load Check oil level in the chain cases, power
ends, and packing lubricant reservoir
A 06 6-in stroke OPI600 pump
PG/Butterworth pump A 18 All of the above

A 07 ½-in below the bottom of the main A 19 True

bearings caps
A 20 True
A 08 97 % volumetric efficiency
A 21 False
A 09 Power end is working at a low rate
and high discharge pressure A 22 1 year
Engine rpm is low
Worn components A 23 Cementing/completion services

A 10 Preventing leakage of oil from the A 24 True

power end via the pony rods.
Keep oil in and dirt out of A 25 True
the power end
A 26 True
A 11 False
A 27 Mechanic
A 12 Divide equally oil to each plunger

A 13 Two outlets Must discharge

from both ends

A 14 False

A 15 Pump cavitation

JET 2 - Triplex Pumps v1.0 (Provisory)

ANSWERS
83