9 NATIONAL OILWELL VARCO

9 NATIONAL OILWELL VARCO Reciprocating Plunger Pumps Installation, Care and Operation Manual 103Q-3 110Q-3 Covering the following pumps: 59T-3 103Q-3 110Q-3 Print Index i Sales r Technical Information USA Tol!free: I (800) 324 4706 Phone: 1 (918)447 4600 Fax: 1 (91 81 44 7 4677 Internet: M. Box 4638 Houston, Texas 77210-4638 REVISED: September 2, 2010 ISSUE: September 26, 2005 EFTA00795782 KW NATIONAL OILWELL VARCO SUPPLEMENT FOR ALL PUMP MANUALS A! WARNING !A PRESSURE RELIEF VALVES AI NOTICE I A Our technical publications relative to reciprocating pumps state that pressure relief valves must be installed in the discharge systems from these units. This supplement is issued to emphasize the importance of relieving the discharge system of all pressure which exceeds the rated working pressure applied by the manufacturer to the specific pistons and liners (or plungers and packing) in any particular unit. •Print4 Some I Index I Next I EFTA00795783 A! WARNING ! A For the protection of persons and property the discharge system from each Reciprocating Pump must be equipped with a device which relieves the system of all pressures which exceed the pressure rating applied by the manufacturer to each particular piston or plunger diameter. Allowances will be made for pressure surges which are inherent with the reciprocating action of piston and plunger pumps. The percentage of pressure allowance appears later in this publication and in the "Standards of the Hydraulic Institute" (131h edition). The relieving device must provide for instantaneous pressure relief, it may be a valve designed for automatic or manual resetting; however, if preferred, rupture discs or burst discs may be installed. FAILURE to comply with the procedures outlined in the Warning may result in damage to the pump and related equipment and more importantly may cause serious bodily injury or death! THE PRESSURE RELIEF VALVE: 1. This valve must be a full opening type. 2. It must have a working pressure rating, equal to or greater than, the maximum working pressure of the pump. 3. The through capacity of the valve, when fully opened, must be sufficient to relieve the full capacity of the pump without excessive overpressure. RUPTURE DISC OR BURST DISC: 1. These discs must have a diameter which is not less than the pipe size of the pressure relief flange. 2. These discs must have a rupture or burst pressure rating consistent with the specifications tabulated later in this publication. LOCATION OF THE RELIEF VALVE: 1. The relief valve must be placed in the discharge line as close as possible to the pump fluid end or it may be mounted on the pump discharge manifold. 2. The relief valve must be on the pump side of any discharge strainer. SUGGESTED SET PRESSURES PUMP TYPE: Double Acting - Duplex Double Acting - Triplex Double Acting - Quintuplex Single Acting — Triplex Single Acting — Simplex Single Acting — Duplex Single Acting — Triplex Single Acting — Quintuplex Single Acting — Septuplex Note: The above set pressures are to be observed when installing rupture discs or burst discs. 3. The relief valve must be between the pump fluid end and any valve in the discharge system. 4. There must be no restricting device(s) between the relief valve and the pump fluid end. THE RELIEF VALVE DISCHARGE LINE: 1. The relief valve discharge line should not terminate in the pump suction line. 2. The line should terminate in the supply tank, if possible. 3. The line must be securely anchored. 4. The line must be the same pipe size as, or may be larger than, the discharge connection on the relief valve. 5. If the line is of great length, this must be taken into consideration in sizing the relief valve. 6. There must be no restrictions or valves in the relief valve discharge line. NOTE: Follow the foregoing instructions if rupture discs or burst discs are installed. FOR THE PUMP RELIEF VALVES: OPERATING PUMP PRESSURE: Piston Pressure Rating - Plus 25% Piston Pressure Rating - Plus 10% Piston Pressure Rating - Plus 10% Piston Pressure Rating - Plus 10% Plunger Pressure Rating - Plus 25% Plunger Pressure Rating - Plus 20% Plunger Pressure Rating - Plus 10% Plunger Pressure Rating - Plus 10% Plunger Pressure Rating - Plus 10% Print Home Index Next I EFTA00795784 Installation, Care and Operation Manual Foreword... e NATIONAL OILWELL VARCO This manual is published as a guide for the normal operation of your NATIONAL OILWELL VARCO equipment. Because of the many factors, which contribute to the function or malfunction of this machinery, and not having complete knowledge of each factor or combination of factors, we cannot detail all facets of this subject. We must therefore confine the scope of this presentation and when situations encountered are not fully encompassed by complete, understandable instructions. these situations must be referred to the manufacturer. When other than routine servicing is necessary, it can be most efficiently performed if the unit is removed to an area of adequate space where an over-head crane, hydraulic lift, bearing pullers, impact tools, etc., are accessible. The dimension and tolerances specified in this publication are those desirable for the most efficient operations of the equipment. When components become worn or when new parts are introduced into a worn unit, it may not be possible or economically feasible to reestablish such strict alignment and correct all dimensional deviations. Improvements in design, engineering, materials, production methods, etc., may necessitate changes in these products and result in inconsistencies between the content of this publication and the physical equipment. We reserve the right to make these changes without incurring any liability or obligation beyond that which is stipulated in the purchase contract. The pictures. photographs, charts, diagrams, drawings. verbal contents and specifications are not to be construed as giving rise to any warranty on the part of NATIONAL OILWELL VARCO. National Oilwell Varco makes no warranty, either expressed or implied beyond that which is stipulated in the purchase contract. NATIONAL OILWELL VARCO pumps are manufactured by National Oilwell Varco at the Tulsa, Oklahoma plant. The serial number, assigned each pump is stamped on the power end. Please refer to this serial number when ordering parts for the pump. The right and left sides of the pump are determined by viewing the pump from the back of the power end, looking toward the fluid end. This position is also used to identify the plungers and their related parts as being number one, two and three, beginning at the left side of the pump. A! CAUTION! CAUTION! CAUTION!A 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 YOUR BUSINESS AND YOU ARE INVOLVED. A! WARNING! WARNING! WARNING! A BEFORE PERFORMING ANY SERVICE FUNCTION, BE CERTAIN THAT THE UNIT IS SEPARATED FROM ITS POWER SOURCE OR THAT THE POWER SOURCE IS LOCKED-OUT TO PREVENT ANY FORM OF ENERGY FROM ENTERING THE EQUIPMENT. THIS WOULD INCLUDE ELECTRICAL OR MECHANICAL ENERGY INTO OR FROM THE PRIME MOVER(S), PNEUMATIC ENERGY FROM THE COMPRESSOR/AIR SYSTEM. ETC. Print j Home 2 Index I Next e NATIONAL OILWELL VARCO EFTA00795785 NATIONAL OILWELL VARCO Installation, Care and Operation Manual A! WARNING ! WARNING ! WARNING !A FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS PUBLICATION CAN RESULT IN PROPERTY DAMAGE. SERIOUS BODILY INJURY. OR DEATH. A! ATTENTION - NOTICE - IMPORTANT !A THESE TERMS ARE USED TO DRAW ATTENTION TO ACTION THAT WILL CAUSE DAMAGE TO THE PUMP. COMPONENTS OR ATTACHMENTS. A! ATTENTION !A PUMP NOMENCLATURE: ALL PUMP SIZES WITHIN THIS MANUAL WILL BE DESCRIBED WITH THE NEW OR CURRENT NOMENCLATURE. THE OLD PUMP NOMENCLATURES DESCRIBED ON THE FRONT COVER, BUT NOT INCLUDED IN THIS MANUAL EXCEPT AS NEEDED, ARE TO BE UNDERSTOOD AS BEING INCLUDED WITH THE NEW NOMENCLATURES. A! WARNING ! WARNING ! WARNING !A BEFORE SERVICING PUMPS: 1. SHUT DOWN OR DISENGAGE THE PUMP POWER SOURCE. 2. SHUT DOWN ALL PUMP ACCESSORY EQUIPMENT. 3. RELIEVE OR "BLEED OFF" ALL PRESSURE FROM THE PUMP FLUID CYLINDER(S). FAILURE TO SHUT DOWN POWER AND RELIEVE PRESSURE FROM THE PUMP BEFORE SERVICING CAN RESULT IN SERIOUS PERSONAL INJURY AND PROPERTY DAMAGE. Print Home 3 Index Next it NATIONAL OILWELL VARCO EFTA00795786 Installation, Care and Operation Manual Plunger Pump Nomenclature Example.... 59 T-3 M F RATED INPUT HORSEPOWER T = TRIPLEX = QUINTUPLEX e NATIONAL OILWELL VARCO F - FLANGED L = LOW PRESSURE M = MEDIUM. H = HIGH STROKE LENGTH (IN.) *NOMENCLATURE MAY BE SHORTENED IN PARTS LISTS OR OTHER INSTANCES TO LEAVE OFF THE MATERIAL, VALVE TYPE, ETC. THIS FULL NOMENCLATURE DESCRIPTION IS GIVEN FOR INFORMATIONAL PURPOSES. Print I Home 4 Index I Next I e NATIONAL OILWELL VARCO EFTA00795787 NATIONAL OILWELL VARCO Table of Contents... INSTALLATION PAGE I. GENERAL A. Suction Line 8 B. Discharge Line 8-9 C. Power End 9 D. Fluid End 9 E. Plunger Packing 10 F. Plunger Packing Lubrication 10 G. Suction Pulsation Dampener 1. Low Pressure - Plastic Body 10 2. High Pressure - Aluminum Body 11 Installation, Care and Operation Manual LUBRICATION I. GENERAL A. Oil 12 OPERATION I. GENERAL A. Operation Check List 13 MAINTENANCE I. GENERAL A. Daily Maintenance 14 B. Monthly Maintenance 14 C. Storage 15 D. Start-Up After Storage 15 II. TROUBLE SHOOTING GUIDE 16-18 OVERHAUL AND REPAIR I. GENERAL A. Tools Required 19 B. Check Points and Adjustments 1. 59T-3 19 2. 103O-3 19 3. 59T-3, 103Q-3. 110O-3 19-20 Print 1 Home)5 Next e NATIONAL OILWELL VARCO EFTA00795788 Installation, Care and Operation Manual Table of Contents (continued)... DISASSEMBLY PAGE I. POWER END A. Plunger/Intermediate Rods and Oil Wiper Retainers 21 B. Crankshaft Assembly 59T-3 21-22 103O-3,110O-3 22 C. Crankshaft Bearings (All Pumps) 22-23 D. Lubrication Oil Pump (110Q-3) 24-25 E. Integral Gear Reducer 26 e NATIONAL OILWELL VARCO II. FLUID END A. Fluid Cylinder Removal All Pumps 26 B. Plunger Removal All Pumps 27 C. Stuffing Box Removal 27 D. Fluid End Valve Removal 27 ASSEMBLY I. POWER END A. Connecting Rod and Crosshead Assembly 59T-3, 103O-3 28 110O-3 29 B. Crankshaft Main Bearings and Center Support Bearings 59T-3 30-31 10343,1100-3 31-32 C. Connecting Rod to Crankshaft Assembly All Pumps 33 D. Intermediate Rods and Oil Seal Retainers All Pumps 33 II. FLUID END A. Stuffing Boxes and Plungers All Pumps 34 B. Power End/Fluid end Adapters All Pumps 35 C. Fluid Cylinders All Pumps 35 D. Fluid Valves—Tapered Seat All Pumps 35 E. Piping Installation All Pumps 35 F. Plunger Packing Installation 1. 838 Packing 36-37 2. Braided Packing 38-39 3. 1068-4 Spring Loaded Packing 40-41 rr Print Home I 6 Next I e NATIONAL OILWELL VARCO EFTA00795789 e NATIONAL OILWELL VARCO Table of Contents (Continued)... PLUNGER PUMP VALVES PAGE I. OPERATIONAL MAINTENANCE A. Suction and discharge 42 B. Valve Covers 42 C. Valve Cover Seals 42 D. Valve Springs 42 E. Valve and Seat 42 II. TAPERED SEAT VALVES A. Severe Duty Valve 1. Nomenclature 43 2. Valve Removal Procedure 44 3. Valve Inspection Procedure 45-46 4. Valve Installation Procedure 46-47 B. Disc Style Valve 1. Nomenclature 48 2. Valve Removal Procedure 49 3. Valve Inspection Procedure 50 4. Valve Installation Procedure 50-51 C. Spherical Valve 1. Nomenclature 52 2. Valve Removal Procedure 53 3. Valve Inspection Procedure 53 4. Valve Installation Procedure 54-55 D. Spherical Valve — Severe Duty 1. Nomenclature 56 2. Valve Removal Procedure 57 3. Valve Inspection Procedure 57-58 4. Valve Installation Procedure 58 P-55U LUBRICATOR I. PUMP OPERATING INSTRUCTIONS A. Operating Instructions 59 1. Box Suction Pumps 59 2. Flow Rate Adjustment 59 3. Sight Glass 59 4. Overfilling of Sight Glass 59 5. Reservoir Oil Level 59 6. Pump Displacement 59 Installation, Care and Operation Manual Revisions effective September 2, 2010 - replaced the word multiplex with reciprocating. Print Home 7 Next e NATIONAL OILWELL VARCO EFTA00795790 Installation, Care and Operation Manual Installation... I. GENERAL e NATIONAL OILWELL VARCO Careful planning of the plant layout will save considerable time and expense, both initially when the installation is made and later during the operation of the plant. In selecting the location for the pump, consideration should be given to the fact that a positive suction head at the pump inlet contributes toward the pump efficiency. However, the layouts of the piping, the arrangement of the fittings, and restrictions in the suction and discharge lines have even more effect. For this reason, all fittings and valves should be full opening; all bends should be of long radius or should be eliminated where possible. Long radius 45° ells should be used, particularly if installed near the fluid cylinder. The following points outline the basic requirements for an installation that will contribute greatly toward good pump operation. A. SUCTION LINE 1. The suction line must not be smaller than the suction intake of the fluid cylinder and may be larger. The length of the suction line should be held to a minimum and should run straight from the supply tank to the pump. 2. When bends are required, they should be made with long radius 45° ells. Do not use a bend directly adjacent to the fluid cylinder. Avoid using any 90° bends if at all possible. 3. Provide a full opening gate valve in the suction line adjacent to the supply tank to permit the line to be drained when necessary. Do not use any type of restricting valve. 4. Do not use meters or other restrictions in the suction line. Eliminate any rise or summit in the suction line where air or vapor can collect. 5. Pulsation dampening devices are strongly recommended. 6. When necessary to manifold a number of pumps to a common suction, the diameter of the manifold and suction pipe leading from the supply tank must be such that it has a cross-sectional area equal to, or greater, than the area of the combined individual suction pipes. 7. When a charging or booster pump is used in the suction line, it must have a capacity equal to twice that of the pump output. This is necessary to provide a charging pump with an output great enough to meet the peak volume requirements of the plunger pump during the suction stroke and not act as a restriction in the line. 8. All piping, both suction and discharge must be solidly and independently supported. The first support must be as close to the pump as practical. This is necessary to prevent placing the pump in a strain and to keep any vibration in the system from acting directly on the pump. B. DISCHARGE LINE 1. Use a pulsation dampener or a desurger in the discharge line. It should be placed in the line as near the fluid cylinder as possible and ahead of any bend in the line. 2. Do not reduce the size of the discharge line below that of the pump outlet until the line has passed through the desurger, and is away from the pump approximately 20 feet (6m). 3. Any bend in the discharge line should be made with a long radius 45° ell. Do not use a bend directly adjacent to the fluid cylinder, particularly a 90° bend. Print Home I 8 Index I Next I de NATIONAL OILWELL VARCO EFTA00795791 S NATIONAL OILWELL VARCO Installation... I. GENERAL B. DISCHARGE LINE (Continued)... Installation, Care and Operation Manual 4. A pressure relief valve should be installed in the discharge line. The relief valve should be set to operate at a pressure no greater than 25% above the maximum rated pressure for the plunger size being used. It should be installed in the line ahead of any valve and be piped so that any flow is returned to the supply tank rather than the suction line. This will prevent possible damage to the suction line and suction dampener. 5. A by-pass line should be installed to permit the pump to be started without load. This allows oil to circulate and reach all parts in the power end before they are loaded. C. POWER END 1. The pump must be mounted level and should be grouted in and be free of strain. This applies to a skid-mounted pump or a pump mounted directly on a concrete base. 2. The sheave of a belt driven pump must be correctly aligned with the prime mover sheave. Care must be used to prevent over-tightening as this will shorten belt life, place the pump in a strain, and cause undue additional loads on the crankshaft and bearings. Sheave sizes should not be smaller than the minimum approved diameter. 3. When connecting a direct-driven pump, the shafts must be correctly aligned. Couplings should not be expected to compensate for avoidable misalignment. With Thomas Flexible Couplings, angular misalignment should not exceed one-half degree. Offset misalignment of the centerlines of the two shafts should not exceed .015" (.381 mm). Actually, misalignment should be as small as practical. 4. Provision should be made to stop the pump automatically in the event of supply fluid failure. A pump should not be run dry, as this causes wear on the packing. 5. Adequate plunger chamber drains have been provided in the pump and should not be plugged. Drain lines should never be reduced in size from the connection provided. 6. The pump has been drained of oil after testing at the factory and MUST be filled with the proper oil (see page 12) before starting. The rust inhibiting oil coating inside the power end need not be removed before filling; however, it is recommended that the power end be checked to make sure dirt or contamination has not entered during shipment. D. FLUID END 1. The fluid cylinder is shipped assembled to the pump complete with valves and cover plates. The stuffing boxes, plungers, and related items have also been assembled and tested with the pump (unless otherwise specified) and require no further assembly. Before the pump is started, these parts should be checked for tightness as well as for possible damage during shipment. 2. Thoroughly clean the suction line piping before starting the pump. Weld spatter, slag, mill scale, etc., will damage a pump in a short time. Print Home I 9 Index I Next I NATIONAL OILWELL VARCO EFTA00795792 Installation, Care and Operation Manual Installation... I. GENERAL (Continued)... E. PLUNGER PACKING e NATIONAL OILWELL VARCO The recommended style of packing has been installed and run at the plant. It does, however, require further "setting up" as the pump is started and brought up to pressure. Refer to pages 36 through 41 for correct procedure for packing used. F. PLUNGER PACKING LUBRICATION 1. Automatic packing lubricators are beneficial on all installations and are required on pumps operating at high pressure (1200 psi [85kg/cm 2] and up) to obtain good packing life. 2. When an automatic lubricator is used in water and power oil service, use Rock Drill (Air Drill) oil of proper viscosity. For butane-propane service, use NATURAL castor oil. Set lubricator to feed 5 to 7 drops per minute. G. SUCTION PULSATION DAMPENERS 1. Low Pressure - Plastic Body a. Some National Oilwell Varco plunger pumps are equipped with suction pulsation dampeners. These dampeners do an excellent job when properly charged and should be kept filled during operation. A! ATTENTION ! A At suction pressures over 10 psi (.7kg/cm2), the dampener should be deflated prior to bleeding off the suction pressure to prevent damage to the diaphragm. b. The plastic dampener body has an instruction decal attached, which lists the following installation and charging procedures. A! ATTENTION ! A HANDLE WITH CARE. This is a plastic part and can be broken. c. Tighten capscrews with 10 to 12ft-lbs. of torque. A! ATTENTION ! A Use thread-sealing compound on check valve and tighten until snug. OVERTIGHTENING WILL DAMAGE BODY. d. With pump operating - Charge dampener until bottom of diaphragm is visible through sight glass. Proper charge is when bottom of diaphragm is between center and top of sight glass. Print Home 10 Index I Next I e NATIONAL OILWELL VARCO EFTA00795793 S NATIONAL OILWELL VARCO Installation... I. GENERAL G. SUCTION PULSATION DAMPENERS (Continued)... 2. High Pressure - Aluminum Body Installation, Care and Operation Manual a. In pressures in excess of 20 psi (1.406 kg/cm?) and up to 70 psi (10.545 kg/cm2), it is necessary to use the National Oilwell Varco high-pressure suction dampener. b. The high-pressure dampener is charged in a similar manner to the low-pressure plastic dampener, using air or nitrogen to charge the diaphragm and maintain its position in relation to the sight glass. c. The following procedures should be used to service this dampener: (1) The dampener is fitted to an adapter that may be either welded into an existing line or be a part of a separate dampener housing. Place a gasket on each side of the diaphragm retaining plate and place on the adapter. (2) The dampener spacer is then placed on top of the retainer plate with the grooved side up and the flat side against the retainer gasket. (3) The diaphragm fits into the groove on the spacer with the curved portion of the diaphragm above the spacer. (4) Apply a continuous 1/8" diameter bead of silicone rubber on the outer edge of the diaphragm after it has been positioned into the spacer. This silicone rubber (GE Silicone Rubber or Dow-Corning Silastic) is readily available at most hardware stores. Assemble the body cover within ten minutes after applying the silicone rubber. (5) Fit the dampener cover over the diaphragm and assemble the capscrews. Tighten these capscrews evenly to approximate 80 ft-lbs. of torque. (6) Install the sight glasses, one in each side of the cover. Be sure to seat the sight glass packing carefully into the groove on the cover, as this must be an airtight connection. (7) The air check valve has a pipe thread and must be made up into the cover airtight. Use a good pipe thread sealant to promote sealing. Print I Home I 11 Index I Next I NATIONAL OILWELL VARCO EFTA00795794 Installation, Care and Operation Manual Lubrication... I. GENERAL • NATIONAL OILWELL VARCO NATIONAL OILWELL VARCO models 591-3 and 103O-3 reciprocating pumps are "splash" lubricated. The main bearings and crankshaft bearings are fed by splash. Crossheads and crosshead pin bushings are fed through holes in the crossheads and crosshead reservoir. Intermediate rods are lubricated from the splash they receive from the crosshead. NATIONAL OILWELL VARCO model 110Q-3 reciprocating pump is pressure lubricated via a small gear pump direct driven by the crankshaft. The gear pump provides oil to the crankshaft, connecting rod bearings and crosshead pin bushings. The main bearings and crossheads are splash lubricated from the main oil reservoir and crosshead oil reservoir. A. OIL Use "extreme pressure" gear oil. The chart below shows the recommended grades for various temperatures surrounding the pump. U.S. UNITS OF MEASURE Temperature +50°F to +155°F +20°F to +100°F -20°F to + 60°F AGMA Industrial EP Gear Oil AGMA No. 6 EP or ASTM/ISO Grade No. 320 (viscosity 1335 to 1632 SSU 100°F) AGMA No. 5 EP or ASTM/ISO Grade No. 220 (viscosity 918 to 1122 SSU 100°F) AGMA No. 2 EP or ASTM/ISO Grade No. 68 (viscosity 284 to 347 SSU 100°F) Crankcase Capacity - Quarts: 59T-3 - 10 103Q-3 - 20 110O-3 - 20 METRIC UNITS OF MEASURE Temperature i +10°C to +68°C AGMA Industrial Gear Oil AGMA No. 6 EP or ASTM/ISO Grade No. 320 (Viscosity 228-352 cSt at 37.8°C) AGMA No. 5 EP or ASTM/ISO Grade No. 220 (Viscosity 198-242 cSt at 37.8°C) -29°C to +16°C I AGMA No. 2 EP or ASTM/ISO Grade No. 68 (Viscosity 61-75 cSt at 37.8°C) Crankcase Capacity - Liters: 591-3 — 9.5 103Q-3 - 18.9 110Q-3 — 18.9 Oil must pour freely at minimum operating temperature. Change oil every six months or as frequently as operating conditions require maintaining a clean, sludge-free oil of proper viscosity. Print I Home I 12 Index I Next I • NATIONAL OILWELL VARCO -7°C to +38°C EFTA00795795 NATIONAL OILWELL VARCO Operation... I. GENERAL Installation, Care and Operation Manual A! ATTENTION !A THE FOLLOWING POINTS SHOULD BE CHECKED FOR THE PREVENTION OF TROUBLE OR TO CORRECT TROUBLE THAT MAY ARISE. A. OPERATION CHECKLIST 1. Pump must be a set level for proper lubrication. 2. Make sure pump is filled with clean oil of the proper viscosity (see page 12). 3. Do not over-speed the pump. 4. Do not use a smaller diameter sheave than is recommended for the pump. 5. Make sure all safety shutdown switches are operating properly. 6. Keep all suction and discharge line valves fully open. 7. If a bypass is used to regulate output, make sure it is set properly. 8. Make sure the pressure relief valve is set properly. 9. Do not exceed the pressure rating of the pump for the particular plunger size. 10. Make sure the suction line is tight, as air entering the suction line will cause severe hammering and knocking of the pump. 11. Make sure plunger and intermediate rod connections are tight and locked. 12. Check the plunger packing for correct adjustment (see pages 36 to 41). 13. Check the suction and discharge dampeners for proper charge, as this is very important for long life and good pump operation. 14. Make sure the hex nuts holding the cylinder in place are tight. Print Home I 13 Index I Next I NATIONAL OILWELL VARCO EFTA00795796 Installation, Care and Operation Manual • NATIONAL OILWELL VARCO Maintenance... I. GENERAL The following points are intended as a guide to be used in setting up a maintenance program. Good preventive maintenance will pay big dividends in the form of reliable service with a minimum of trouble. A. DAILY MAINTENANCE 1. Check power end oil level daily. Do not attempt to check the oil with the pump running. Inspect the oil for dirt or contamination and change if necessary. An increase in oil level indicates fluid end leakage into power end. Change oil immediately and check intermediate rod wipers and surface smoothness of rod. Check for plunger packing leakage. 2. Lubricate plunger packing frequently. Packing life can be greatly increased by greasing every four (4) hours with a small amount of grease. Grease is not recommended at pressures above 1200 psi. Use an alternate packing lubricator to drip the proper oil on the plunger for lubrication. (See page 10 for further details). 3. Check lubricator for proper level and operation. 4. Check plunger packing for excessive leakage. Replace packing as required. 5. Check stuffing box adjusting nuts for tightness. 6. Drain plunger leakage sump tanks if required. 7. Flush plunger chamber drain lines with kerosene on power oil pumps and fresh water on salt pumps. This may be done weekly unless salt and paraffin accumulation is severe. 8. Make sure suction and discharge line valves are fully open. 9. Check for leakage between the fluid cylinder and frame or stuffing box to fluid cylinder packing if required. 10. Check all seals for leakage. 11. Check belts or clutch for slippage. If either condition exists, correct immediately. B. MONTHLY MAINTENANCE 1. Drain and refill crankcase every six (6) months or as often as required to maintain a clean, sludge-free oil of the proper viscosity. 2. Clean crankcase air breather with a non-explosive solvent. 3. Check all studs, nuts and capscrews for tightness. Inspect gaskets for leaks; tighten or replace as required. 4. Clean pump. Good housekeeping is a prerequisite to good maintenance. Print Home 14 Index I Next I • NATIONAL OILWELL VARCO EFTA00795797 t NATIONAL OILWELL VARCO Maintenance... Installation, Care and Operation Manual I. GENERAL (Continued)... C. STORAGE If the pump is to be idle for longer than one (1) week, it should be prepared for storage as follows: 1. Drain and clean crankcase thoroughly. Leave drain open and install 90° elbow, pointing downward, to permit air circulation and prevent condensation build-up. 2. Coat all bearings, finished surfaces. and entire inside surface of crankcase with a rust inhibiting oil. 3. Remove plungers and packing, clean and coat with rust inhibiting oil. 4. Remove fluid cylinder valves allowing cylinder to be thoroughly cleaned and drained. 5. Coat entire cylinder, valves and parts, with a rust inhibiting oil. 6. Thoroughly inspect pump and rotate crankcase once each month. Re-coat with rust inhibiting oil where necessary. D. START-UP AFTER STORAGE Any pump that has been in storage, either after field use or as shipped from the plant, will need a thorough inspection to make sure it has not been damaged in any way and that all parts are properly in place. A! ATTENTION !A FAILURE TO OBSERVE THE FOLLOWING POINTS CAN RESULT IN SERIOUS DAMAGE. 1. Remove all covers on both power end and fluid end; thoroughly clean and inspect all parts and finished surfaces. 2. Check all bearings to make sure they are clean and in good condition. 3. Make sure valves, plungers and packing are properly installed and in good condition. 4. Carefully tighten all bolts, nuts, studs and working connections. 5. Fill power end to the proper level with clean oil of the proper viscosity. Make sure oil is poured into the crosshead reservoir and is worked into all bearings. 6. Fill packing lubricator and pump lines full. Check by breaking connection at stuffing box, working lubricator plunger until oil appears. Print Home I 15 Index I Next I S NATIONAL OILWELL VARCO EFTA00795798 Installation, Care and Operation Manual Maintenance (Continued)... II. TROUBLE SHOOTING GUIDE e NATIONAL OILWELL VARCO PROBLEM POSSIBLE CAUSE CORRECTION KNOCKING OR POUNDING IN FLUID END AND PIPING SUCTION LINE RESTRICTED BY: (1,2,3,4) 1. TRASH, SCALE BUILD UP, ETC. LOCATE AND REMOVE 2. PARTIALLY CLOSED VALVE IN SUCTION LINE LOCATE AND CORRECT 3. METERS, FILTERS, CHECK VALVES, NON-FULL-OPENING, CUT-OFF VALVE OR OTHER RESTRICTIONS. RE-WORK SUCTION LINE TO ELIMINATE 4. SHARP 90° BENDS OR 902 BLIND TEES. RE-WORK SUCTION LINE TO ELIMINATE. AIR ENTERING SUCTION LINE THROUGH CUT-OFF VALVE TIGHTEN OR REPACK VALVE STEM PACKING AIR ENTERING SUCTION LINE THROUGH LOOSE CONNECTION OR FAULTY PIPE LOCATE AND CORRECT AIR OR VAPOR TRAPPED IN SUCTION LINE LOCATE RISE OR TRAP AND CORRECT BY STRAIGHTENING LINE, PROVIDING ENOUGH SLOPE TO PERMIT ESCAPE AND PREVENT BUILD- UP LOW FLUID LEVEL INCREASE SUPPLY AND INSTALL AUTOMATIC LOW LEVEL SHUT-DOWN SWITCH SUCTION DAMPENER NOT OPERATING INSPECT AND REPAIR AS REQUIRED WORN VALVES INSPECT AND REPAIR AS REQUIRED ENTRAINED GAS IN FLUID PROVIDE GAS BOOT OR SCRUBBER FOR FLUID POOR INLET AND OUTLET ARRANGEMENT AT SUPPLY TANK INLET TO BE AT TOP OF TANK AND BAFFLED TO BREAKOUT GAS AND PREVENT CHANNELING. OUTLET TO BE 12" FROM BOTTOM OF TANK AND AS FAR FROM INLET AS POSSIBLE, NEVER CLOSER THAN 902. LOOSE PACKING ADJUSTING NUT TIGHTEN AND/OR REPLACE PACKING INADEQUATE SIZED SUCTION LINE REPLACE WITH INDIVIDUAL SUCTION LINE OF NEXT SIZE LARGER THAN INLET PUMP LEAKAGE PRESSURE RELIEF VALVE THAT HAS BEEN PIPED BACK INTO SUCTION LINE REPAIR VALVE AND RE-WORK PIPING TO RETURN TO SUPPLY TANK - NOT SUCTION LINE. BY-PASS PIPED BACK TO SUCTION REWORK TO RETURN BY-PASSED FLUID BACK TO SUPPLY TANK - NOT SUPPLY LINE BROKEN PLUNGER INSPECT WHEN ROTATING PUMP BY HAND AND REPLACE AS REQUIRED Print Home 16 Index I Next NATIONAL OILWELL VARCO EFTA00795799 t NATIONAL OILWELL VARCO Maintenance... II. TROUBLE SHOOTING GUIDE (Continued)...Installation, Care and Operation Manual PROBLEM POSSIBLE CAUSE CORRECTION VALVE WEAR OR DAMAGE CHECK FLUID END FOR BAD VALVES WORN MAIN BEARINGS REPLACE AS REQUIRED LOOSE PLUNGER - INTERMEDIATE ROD INSPECT FOR DAMAGE - REPLACE AS KNOCK IN POWER END CROSSHEAD CONNECTION REQUIRED AND TIGHTEN RAPID VALVE WEAR OR FAILURE SHORT PACKING LIFE PrintWORN CROSSHEAD PIN, OR CONNECTING ROD LOCATE AND REPLACE AS REQUIRED CORROSION TREAT FLUID AS REQUIRED ABRASIVES IN FLUID FILTER AS REQUIRED IMPROPER INSTALLATION INSPECT AND INSTALL PER INSTRUCTION SHEET IN PACKING BOX IMPROPER LUBRICATION (EITHER INSUFFICIENT OR EXCESSIVE OR INCORRECT TYPE) LUBRICATOR NOT OPERATING CHECK INSTRUCTIONS IN MANUAL AND CORRECT AS REQUIRED. INSPECT AND CORRECT AS REQUIRED ADJUSTING NUT LOOSE INSPECT AND REPACK PER INSTRUCTIONS SCALE OR BUILD UP ON PLUNGER TREAT FLUID AS REQUIRED WORN OR PITTED PLUNGERS AND/OR STUFFING BOX REPLACE AS REQUIRED ABRASIVES IN FLUID FILTER AS REQUIRED PUMP OPERATED WITHOUT FLUID CHECK SYSTEM FOR FAULTY LOW-LEVEL SHUTDOWN CONTROLS OR CLOSED VALVES AND CORRECT AS REQUIRED. ABNORMALLY HIGH FLUID TEMPERATURES CHECK WITH MANUFACTURER FOR RECOMMENDATIONS ON TYPE OF PACKING WRONG TYPE OF PACKING FOR PARTICULAR FLUID BEING HANDLED CHECK WITH MANUFACTURER FOR RECOMMENDATIONS ON TYPE OF PACKING CAVITATION (KNOCKING AND POUNDING IN FLUID CYLINDER AND PIPING) REFER TO CORRECTION OF "KNOCK IN POWER END" ABOVE Home I 17 Index I Next • NATIONAL OILWELL VARCO EFTA00795800 Installation, Care and Operation Manual Maintenance... II. TROUBLE SHOOTING GUIDE (Continued)... e NATIONAL OILWELL VARCO PROBLEM POSSIBLE CAUSE CORRECTION BROKEN OR PITTED FROM IMPLOSIONS CAUSED BY IN EXCESSIVE GAS OR AIR ENTRAINED FLUID. PLUNGER CRACKED AT INSTALLATION. INSTALL NEW PLUNGER USING CARE TO AVOID ANY SHARP BLOW OR FORCE ON PLUNGER. PLUNGER CRACKED FROM THERMAL SHOCK. CHECK SYSTEM TO ELIMINATE ANY SHARP OR SUDDEN TEMPERATURE DIFFERENCES. TEMPERATURE EXTREMES ON THE PLUNGER CAN OCCUR FROM PACKING AS DISCUSSED UNDER "SHORT PACKING LIFE" PROBLEM PR FROM TEMPERATURE CHANGES IN THE FLUID ITSELF. PLUNGER PITTED FROM IMPLOSIONS CAUSED BNY EXCESSIVE GAS OR AIR ENTRAINED IN FLUID. CHANGE SUCTION SYSTEM TO ELIMINATE OR CHECK WITH MANUF. REGARDING USE OF SPECIAL PACKING ARRANGEMENT. RAPID WEAR OF HARD-COATED PLUNGER PACKING FAILURE. CHECK AND CORRECT PER RECOMMENDATIONS UNDER "SHORT PACKING LIFE" PROBLEM. PLUNGER NOT SUITABLE FOR PARTICULAR SERVICE. CHECK WITH MANUF. FOR RECOMMENDATION. OIL SEAL LEAKS PLUNGER NOT SUITABLE FOR PARTICULAR SERVICE. CHECK AND CORRECT AS REQUIRED. PUMP NOT LEVEL. CHECK AND CORRECT AS REQUIRED. WORN, CORRODED, PITTED, OR OTHERWISE DAMAGED SEALING SURFACE. CHECK AND CORRECT AS REQUIRED. WORN OR DAMAGED SEALS. CHECK AND CORRECT AS REQUIRED. OIL LEVEL TOO HIGH. CHECK AND CORRECT AS REQUIRED. Print Home 18 Index I Next 4 NATIONAL OILWELL VARCO EFTA00795801 S NATIONAL OILWELL VARCO Overhaul and Repair... I. GENERAL Installation, Care and Operation Manual The bearings and other working parts in the power end have been designed for continuous duty, and if properly lubricated, will provide years of trouble-free service. However, after the pump has been in service for a long period of time, the bearings and other working parts will gradually loosen, and if not corrected, will lead to more serious trouble. The time to overhaul the pump will vary; depending on the operating conditions, and is therefore a matter that must be left to the good judgment of the operator. Complete disassembly and assembly procedures are discussed in their respective sections. A. TOOLS REQUIRED Most of the tools required to overhaul the pump will be found in an ordinary set of mechanics hand tools. The special tools and equipment required and not furnished with the pump include a torque wrench, bearing puller, and a valve servicing kit. Also, a hot oil bath capable of reaching a temperature of 300°F (149°C) will be needed. B. CHECK POINTS AND ADJUSTMENTS 1. 59T-3: The crankshaft main bearings are single row; shim adjusted, tapered roller bearings. They have been assembled and adjusted at the factory with proper clearance and will give long trouble-free service. The proper clearance is found by adjusting the amount of shims until the crankshaft has .003" to .005" endplay and will rotate freely. 2. 103O-3 and 110O-3: The 103O-3 and 110Q-3 have two single rows, shim adjusted, tapered roller end bearings. They have been assembled and adjusted at the factory with proper clearance and will give long trouble-free service. The proper end clearance is found by adjusting the amount of shims until the crankshaft has .004" to .006" endplay and will rotate freely. They also have two steel backed Babbitt center mains which are non adjustable. The center mains should have .008" to .014" (.203 mm to .356 mm) total diametrical clearance. This is non adjustable. 3. 59T-3. 103Q-3 and 110Q-3: a. The connecting rod shell bearings or inserts are precision made and adjustable by use of shims. Tolerances are listed on the following page. b. The normal clearance between the crosshead and crosshead bore is .00C (.102 mm) to .010" (.254 mm). The maximum allowable clearance, including wear, is .016" (.406 mm). c. The wrist pin bushings must be pressed into the connecting rods and reamed to size. The allowable clearance between the pin and bushing is listed on the following page. Print I Home I 19 Index I Next I NATIONAL OILWELL VARCO EFTA00795802 Installation, Care and Operation Manual Overhaul and Repair... I. GENERAL B. CHECK POINTS AND ADJUSTMENTS (Continued)... e NATIONAL OILWELL VARCO PUMP CRANKSHAFT PIN MAXIMUM CLEARANCE MINIMUM CLEARANCE In mm In mm In mm 59T-3 3.500 88.900 .005 .127 .003 .076 3.499 88.875 103Q-3 .005 3.500 88.900 .127 .003 .076 3.499 88.875 110Q-3 3500 88.900 .005 .127 .003 .076 3.499 88.875 CROSSHEAD PIN M. MAXIMUM CLEARANCE MINIMUM CLEARANCE PUMP In mm In mm In mm 59T-3 1.7505 44.463 .002 .051 .001 .025 1.7500 44.450 103O-3 1.7505 44.463 .002 .051 .001 .025 1.7500 44.450 110O-3 1.7505 44.463 .002 .051 .001 .025 1.7500 44.450 PUMP CRANKSHAFT CENTER MAIN In mm MAXIMUM CLEARANCE ON DIAMETER In mm MINIMUM CLEARANCE ON DIAMETER In mm 103O-3 7.247 I 1$±1„M 110O-3 7.246 I 184.048 .014 .356 .010 .254 Print Home_, Index 20 Next I e NATIONAL OILWELL VARCO EFTA00795803 NATIONAL OILWELL VARCO Disassembly... I. POWER END Installation, Care and Operation Manual It is not necessary to remove the fluid end when disassembling the power end. However, the plungers should be removed through the fluid end cylinder heads. The plungers and intermediate rods are one piece on 1-3/4" and larger plungers. 1-5/r and smaller plungers have separate intermediate rods. A! ATTENTION ! A POWER END DISASSEMBLY AND OVERHAUL IS BEST PERFORMED IN A WELL EQUIPPED SHOP ENVIROMENT. IF THE PUMP IS DISASSEMBLED AT LOCATION ENSURE THE PRESSURE HAS BEEN REMOVED FROM THE FLUID END AND THE PUMP BLOCKED OUT WITH APPROPRIATE BLOCK VALVES. ENSURE THE FLUID END IS DRAINED AND ANY POWER SOURCE OR DRIVER IS LOCKED OUT BEFORE PROCEEDING! A. PLUNGER/INTERMEDIATE RODS AND OIL WIPER RETAINERS (ALL PUMPS) 1. Remove the fluid end cylinder head. 2. Loosen the packing gland nuts. 3. If the pump has intermediate rods a back-up wrench is required. The plunger and intermediate rod separate at the knurl area interface. Using the back-up wrench break the plunger loose and unscrew from the intermediate rod. Remove the plunger through the fluid cylinder opening. 4. Using a pipe wrench on the knurled area of the intermediate rod, remove it from the crosshead and power end. 5. If the pump does not have an intermediate rod, use a pipe wrench on the knurled area of the plunger and break it loose from the crosshead. Unscrew and remove through the fluid cylinder opening. 6. Remove the two nuts holding the wiper box gland and remove the gland. 7. Slide the wiper box and seal assembly out of the power end. B. CRANKSHAFT ASSEMBLY • 591-3 1. Remove the rear power end crankcase cover. 2. Remove connecting rod bolts and cap. NOTE: Connecting rods and caps are match marked and must be kept together. Do not mix caps and rods. 3. Connecting rod and crosshead must be moved all the way forward to clear crankshaft. 4. Remove crankshaft bearing retainers, seals, and shims. These parts should be tied together and marked for reassembly at their original location. Thread bearing retainer capscrews into the two tapped holes of each bearing retainer and use them to push the bearing retainers out of their bores. Print I Home I 21 Index I Next I NATIONAL OILWELL VARCO EFTA00795804 Installation, Care and Operation Manual Disassembly... I. POWER END B. CRANKSHAFT ASSEMBLY (Continued)... • NATIONAL OILWELL VARCO ! ATTENTION ! COVER KEYWAYS TO PROTECT OIL SEALS DURING REMOVAL. 5. Carefully remove the crankshaft out either side of the power frame. If reusing the end bearings remember, the crankshaft end bearing cones and cups are matched sets. Do not mix cones and cups. 103O-3 & 1100-3 1. Remove the rear power end crankcase cover. 2. Remove connecting rod bolts and cap. NOTE: Connecting rods and caps are match marked and must be kept together. Do not mix caps and rods. 3. Connecting rod and crosshead must be moved all the way forward to clear crankshaft. 5. Remove crankshaft bearing retainers, seals, and shims. These parts should be tied together and marked for reassembly at their original location. Thread bearing retainer capscrews into the two tapped holes of each bearing retainer and use them to push the bearing retainers out of their bores. 6. While supporting the crankshaft carefully remove it out either side of the power frame. If reusing the end bearings remember, the crankshaft end bearing cones and cups are matched sets. Do not mix cones and cups. C. CRANKSHAFT BEARINGS • 59T-3, 103O-3 & 110O-3 The crankshaft main bearings may be inspected while on the crankshaft and should not be removed unless necessary. A puller is required when replacement is necessary. NOTE: Keep the component parts of the bearings together if they are to be re-installed. They are match marked and must be correctly assembled as a unit. 103O-3 & 1100-3 The center main bearings on the quintuplex model pumps normally have from .008 to .014 inches total diametrical clearance. When they require replacement a puller is necessary to remove them. Figure 1 shows a puller that can be made to remove old bearings and install new ones. Print I Home 22 Index I Next I e NATIONAL OILWELL VARCO EFTA00795805 NATIONAL OILWELL VARCO Disassembly... I. POWER END C. CRANKSHAFT BEARINGS • 103O-3 & 110O-3 (Continued)... BEARING PULLER SEE DETAIL FOR PULLER DIMENSINS 1"•8 UNC ALL THREAD STUD X 20- LONG 1-1/Y THICK STEEL PLATE X 6.112" LONG Print I 1.500 Installation, Care and Operation Manual REMOVAL OF CENTER MAINS - 6.000 - - - 0.250 07.125 TURN BEARING PULLER DETAIL Figure 1 Home I 23 CENTER MAIN BEARING POWER FRAME 01.125 THRU • 07.875 TURN Index I WRENCH Next S NATIONAL OILWELL VARCO EFTA00795806 Installation, Care and Operation Manual Disassembly... I. POWER END (Continued)... D. LUBRICATION OIL PUMP • 110O-3 • NATIONAL OILWELL VARCO The model 110O-3 has a lubrication pump that is an integral part of the power frame assembly. It is driven by a slotted shaft which is driven via the crankshaft. It has its own strainer/filter, oil pressure gauge, and relief valve. The pump draws oil through the strainer/filter located in the crankcase reservoir and discharges into the crankshaft, where it lubricates all connecting rod and wrist pin bearings. See Figure 2. rtANKSHAFT BEARING HOUSING 1 OIL PRESSUR: [RELIEF VALVE OIL PRESSUR _ GUAGE n SHIM GASKET(' f OIL PUMP r DRIVE PIN PRESSURE _ ADJUSTING SCREW OIL PUMP OIL PUMP BUSHING SUCTION SPRING -V±t'PRr; RELIEF VALVE Figure 2 CAI c WASHER — NUT The lube oil pump may be removed by removing the six capscrews retaining the bearing housing. After removing the capscrews, the complete unit may be slipped out. It is not necessary to disturb either the crankshaft or bearing housing. The relief valve, located on top of the housing, is adjustable and prevents excessive lube pressure during cold starts. It is adjusted at the factory for normal operating conditions. However, since operating conditions do vary, it may be necessary to adjust after installation. Crankshaft speed, type of oil and oil temperature directly affect the oil operating pressure. To adjust the oil pressure, operate pump until normal operating temperature is reached. Remove the cap and loosen the jam nut. Turn the adjusting screw in or out until the desired pressure is reached. Retighten the jam nut and replace the cap. Under normal speeds and temperatures the oil pressure should be adjusted somewhere between 30 and 40 psi. However, because of the variable factors affecting the oil pressure the pump has been designed to operate safely from 15 psi or more. Print Home 24 Index I Next I e NATIONAL OILWELL VARCO EFTA00795807 NATIONAL OILWELL VARCO Disassembly... I. POWER END D. LUBRICATION OIL PUMP (Continued)... Installation, Care and Operation Manual Sometimes the drive side of the pump must be reversed. When swapping the drive from right hand to left hand or opposite. care must be taken to correctly swap the lube side bearing housing and oil pump. The power frame is machined to be driven from either the right or left side. In order to do this, the power frame is machined symmetrically. This means the port for the oil suction must be plugged on the drive side to prevent oil leakage. When swapping drives, this plug must also change sides. See Figure 3 for details of the plug and strainer/filter changes. TRAINER/FI. DRIVE SWAT- n :A Figure 3 When changing drive side, the lube side bearing housing, oil pump, oil strainer/filter and components from the lube side are swapped to the drive side. The pipe plug, port plug, and 0-ring from the drive side are switched to the opposite side. If the port plug is not removed it will block the oil suction port and the pump will starve for oil when started. If the port plug is not installed on the opposite side oil will leak from under the bearing housing. Print Home I 25 Index I Next I NATIONAL OILWELL VARCO EFTA00795808 Installation, Care and Operation Manual Disassembly... e NATIONAL OILWELL VARCO I. POWER END (Continued)... E. INTEGRAL GEAR REDUCER The 59T-3. 103Q-3, and 110Q-3 may be purchased with an optional integral gear reducer. Because of the gear design these are available in left hand drive only. 1. Drain oil from pump and gear reducer. 2. Remove the 1/2" capscrews around the outside of the gear case cover. 3. Using a support carefully remove the cover. 4. Remove the pinion shaft. 5. Remove the bolt and nut clamping the bull gear to the crankshaft. 6. Use a puller and sling to carefully remove the bull gear. 7. Remove the 5/8" capscrews that hold the gear case to the power frame. 8. Using a sling and jib crane, carefully remove the gear case. II. FLUID END A! ATTENTION !A BEFORE WORKING ON THE FLUID END ENSURE THE PRESSURE HAS BEEN REMOVED FROM THE FLUID END AND THE PUMP BLOCKED OUT WITH APPROPRIATE BLOCK VALVES. ENSURE THE FLUID END IS DRAINED AND ANY POWER SOURCE OR DRIVER IS LOCKED OUT BEFORE PROCEEDING! A. FLUID CYLINDER REMOVAL • ALL PUMPS 1. Disconnect piping. 2. Remove the plungers as described below. 3. Remove the hex nuts holding the fluid end to the power end and slide cylinder forward until free. Print Home 26 Index I Next I 4 NATIONAL OILWELL VARCO EFTA00795809 NATIONAL OILWELL VARCO Disassembly... Installation, Care and Operation Manual II. FLUID END (Continued)... B. PLUNGER REMOVAL • ALL PUMPS 1. Remove the fluid end cylinder head. 2. Loosen the packing gland nuts. 3. Rotate the crankshaft until the knurl area of the plunger/intermediate rod is accessible in the cradle area of the pump. 4. If the pump has intermediate rods a back-up wrench is required. The plunger and intermediate rod separate at the knurl area interface. Using the back-up wrench break the plunger loose and unscrew from the intermediate rod. Remove the plunger through the fluid cylinder opening. 5. If replacing the intermediate rod, use a pipe wrench on the knurled area of the intermediate rod and remove it from the crosshead and power end. 6. If the pump does not have an intermediate rod, use a pipe wrench on the knurled area of the plunger and break it loose from the crosshead. Unscrew and remove through the fluid cylinder opening. C. STUFFING BOXES REMOVAL • ALL PUMPS Most pumps in this series have integral stuffing boxes. A few models do have separate stuffing boxes. On these pumps the stuffing box is clamped between the fluid end body and the power frame. The fit on the fluid end side is a slip fit. The fit on the power end side is a slight press. To remove the stuffing boxes follow this procedure. 1. Remove the plungers and fluid end as previously described. 2. Remove any lube fittings, etc. 3. Support the box with a lifting strap 4. Use a heavy brass bar and drive the box out of the power frame opening. D. FLUID END VALVE REMOVAL Refer to valve section of this manual. Print I Home I 27 Index I Next NOTIONAL OILWELL VARGO EFTA00795810 Installation, Care and Operation Manual Assembly... I. POWER END A. CONNECTING ROD AND CROSSHEAD ASSEMBLY • 59T-3 and 103O-3 e NATIONAL OILWELL VARCO 1. Press the crosshead pin bushing into the connecting rod. 2. Ream bushing to obtain the clearance listed on page 20. (If service bushings are used, reaming will not be necessary in most cases). 3. Assembly the connecting rod to the crosshead by pressing the crosshead pin into the crosshead or to