National Oilwell 165T Reciprocating-Plunger-Pumps-Installation-Care-and-Operation-Manual PDF
National Oilwell 165T Reciprocating-Plunger-Pumps-Installation-Care-and-Operation-Manual PDF
National Oilwell 165T Reciprocating-Plunger-Pumps-Installation-Care-and-Operation-Manual PDF
Plunger Pumps
Installation, Care and
Operation Manual
200T-5
300Q-5
250T-5
Covering the
following pumps:
165T-5
60T-3
30T-2
60T-3
80T-3 Atex Certified
100T-4
130T-4
165T-5
200T-5 Atex Certified
250T-5
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300Q-5 Atex Certified
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130T-4
80T-3
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Sales / Technical Information
USA Tollfree: 1-800-324-4706
Phone: 1 (918) 447-4600
Fax: 1 (918) 447-4677
Internet: http://www.nov.com
30T-2
100T-4
P.O. Box 4638
SUPPLEMENT FOR
ALL PUMP MANUALS
! WARNING !
PRESSURE
RELIEF
VALVES
! NOTICE !
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.
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! WARNING !
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 (13th
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.
3.
2.
4.
3.
2.
3.
4.
5.
6.
2.
1.
2.
PUMP TYPE:
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Foreword
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 McAlester, 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.
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! ATTENTION !
PUMP NOMENCLATURE:
ALL PUMP SIZES WITHIN THIS MANUAL WILL BE DESCRIBED WITH THE NEW OR CURRENT
NOMENCLATURE. THE OLD 'J' MODEL 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.
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60 T- 3 L 14 S F
RATED INPUT
HORSEPOWER
*F = FLANGED, T = THREADED
*S = SPHERICAL SEAT VALVES
*A = CAGE VALVES
*B = NEW CAGE VALVES
*C = TAPERED SEAT VALVES
T = TRIPLEX
Q = QUINTUPLEX
**CYLINDER MATERIAL
NUMBER
*L = LOW PRESSURE
*M = MEDIUM. H = HIGH
*STROKE LENGTH (IN.)
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Table of Contents
ATEX WARNING STATEMENTS
PAGE
I. PUMPS and PUMP UNITS
A. 80T Pump
1. Nameplate ................................................................................................................................................ 10
2. Declaration of Incorporation ..................................................................................................................... 11
B.200T Pump
1. Nameplate ................................................................................................................................................ 12
2. Declaration of Incorporation ..................................................................................................................... 13
C. 300Q Pump
1. Nameplate ................................................................................................................................................ 14
2. Declaration of Incorporation ..................................................................................................................... 15
INSTALLATION
I. GENERAL
A. Lifting ........................................................................................................................................................ 16-17
B. Pump Mounting ............................................................................................................................................. 18
C. Alignment ...................................................................................................................................................... 18
D. Suction Line .................................................................................................................................................. 18
E. Discharge Line .............................................................................................................................................. 19
F. Power End ..................................................................................................................................................... 19
G. Fluid End....................................................................................................................................................... 20
H. Plunger Packing ............................................................................................................................................ 20
I. Plunger Packing Lubrication........................................................................................................................... 20
J. Suction Pulsation Dampener
1. Low Pressure - Plastic Body................................................................................................................ 20-21
2. High Pressure - Aluminum Body .............................................................................................................. 21
LUBRICATION
I. GENERAL
A. Oil .................................................................................................................................................................. 22
OPERATION
I. GENERAL
A. Operation Check List .................................................................................................................................... 23
MAINTENANCE
I. GENERAL
A. Daily Maintenance ........................................................................................................................................ 24
B. Monthly Maintenance .................................................................................................................................... 24
C. Storage ......................................................................................................................................................... 25
D. Start-Up After Storage .................................................................................................................................. 25
II. TROUBLE SHOOTING GUIDE ...................................................................................................................... 26-28
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DISASSEMBLY
I. POWER END
A. Intermediate Rods and Oil Wiper Retainers ..................................................................................................31
B. Crankshaft Assembly .....................................................................................................................................31
30T, 60T, & 80T ...........................................................................................................................................32
J-100 & J-150 ..............................................................................................................................................32
100T, 130T, 165T, 200T, 250T & 300Q ......................................................................................................33
C. Crankshaft Bearings (All Pumps) ..................................................................................................................33
II. FLUID END
A. Fluid Cylinder Removal
30T, 60T, & 80T ...........................................................................................................................................34
100T, 130T, J-150, 165T, 200T, 250T & 300Q ...........................................................................................34
B. Stuffing Boxes and Plunger Removal
30T, 60T, & 80T ...........................................................................................................................................34
100T, 130T, J-150, 165T, 200T, 250T & 300Q ...........................................................................................35
C. Fluid End Valve Removal ..............................................................................................................................35
ASSEMBLY
I. POWER END
A. Crankshaft Main Bearings
30T, 60T, & 80T ...........................................................................................................................................36
100T, 130T, J-150, 165T, 200T, 250T & 300Q ...........................................................................................37
B. Crankshaft and Center Support Bearings
200T, 250T & 300Q .....................................................................................................................................38
100T, 130T, 165T, 200T, 250T & 300Q ......................................................................................................38
C. Connecting Rod and Crosshead Assembly ...................................................................................................39
D. Connecting Rod to Crankshaft Assembly
J-30 and J-60 (with Old Style straight cut connecting rods) ........................................................................39
J-100, & J-150 (with Old Style straight cut connecting rods) .......................................................................39
30T, 60T, 80T, 130T, 165T, 200T, 250T & 300Q (with New Style connecting rods) ............................ 40-41
E. Intermediate Rods and Oil Seal Retainers
30T, 60T, 80T, 100T and 130T ....................................................................................................................41
100T, 130T, 165T, 200T, 250T & 300Q ......................................................................................................41
All Pumps .....................................................................................................................................................42
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Table of Contents
ASSEMBLY (Continued)...
PAGE
II. FLUID END
A. Stuffing Boxes and Plungers......................................................................................................................... 42
30T, 60T, 80T ........................................................................................................................................ 42-43
100T, 130T, 165T, 200T, 250T & 300Q...................................................................................................... 43
B. Fluid Cylinders (All Pumps)........................................................................................................................... 44
C. Fluid Valves Spherical, Tapered Seat Bottom Guided and Cage Type .................................................... 44
D. Piping Installation .......................................................................................................................................... 44
E. Plunger Packing Installation
1. 850-N Packing .......................................................................................................................................... 45
2. 1045 Packing ............................................................................................................................................ 46
3. 699 Packing .............................................................................................................................................. 47
4. Spring Loaded Kevlar Reciprocating Packing ..................................................................................... 47-48
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P-55U LUBRICATOR
I. PUMP OPERATING INSTRUCTIONS
A. Operating Instructions ....................................................................................................................................74
1. Box Suction Pumps ...................................................................................................................................74
2. Flow Rate Adjustment ...............................................................................................................................74
3. Sight Glass ................................................................................................................................................74
4. Overfilling of Sight Glass ...........................................................................................................................74
5. Reservoir Oil Level ....................................................................................................................................74
6. Pump Displacement ..................................................................................................................................74
STORAGE OF PUMPS
I. GENERAL
A. General ..........................................................................................................................................................75
B. Recommended Protection and Initial Storage ...............................................................................................75
C. Six Month Servicing .......................................................................................................................................76
D. Pre-Installation Check After Storage .............................................................................................................76
Revisions effective August 27, 2010 replaced the word multiplex with reciprocating.
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Where a pump or pump unit is to be installed in a potentially explosive atmosphere ensure that this has been specified
at the time of purchase and that the equipment has been supplied accordingly and displays an ATEX nameplate or is
supplied with a certificate of conformity. If there is any doubt as to the suitability of the equipment please contact
National Oilwell Varco before commencing with installation and commissioning.
2.
Process liquids or fluids should be kept within specified temperature limits, otherwise the surface of pump or system
components may become an ignition source due to temperature rises. Where the process liquid temperature is less
than 90C the maximum surface temperature will not exceed 194F (90C) provided the pump is installed, operated
and maintained in accordance with this manual.
3.
Electrical installation and maintenance work should only be carried out by suitably qualified and competent persons
and must be in accordance with relevant electrical regulations.
4.
All electrical equipment, including control and safety devices, should be suitably rated for the environment in to which
they are installed.
5.
Where there may be a risk of an accumulation of explosive gases or dust, non-sparking tools should be used for
installation and maintenance.
6.
To minimize the risk of sparking or temperature rises due to mechanical or electrical overload the following control and
safety devices should be fitted. A control system that will shut the pump down if the motor current or temperature
exceed specified limits. An isolator switch that will disconnect all electrical supply to the motor and ancillary electrical
equipment and be capable of being locked in the off position. All control and safety devices should be fitted, operated
and maintained in accordance with the manufacturers instructions. All valves on the system should be open when
the pump is started otherwise serious mechanical overload and failure may result.
7.
It is important that the pump rotates in the direction indicated on the nameplate. This must be checked on installation
and commissioning and after any maintenance has been carried out. Failure to observe this may lead to dry running
or mechanical or electrical overload.
8.
When fitting drives, couplings, belts, pulleys and guards to a pump or pump unit it is essential that these are correctly
fitted, aligned and adjusted in accordance with the manufacturers instructions. Failure to do so may result in sparking
due to unintended mechanical contact or temperature rises due to mechanical or electrical overload or slipping of
drive belts. Regular inspection of these parts must be carried out to ensure they are in good condition and
replacement of any suspect part must be carried out immediately.
9.
Seals should be suitably rated for the environment. The seal and any associated equipment, such as a flushing
system, must be installed, operated and maintained in accordance with the manufacturers instructions.
10. Where a packed gland seal is fitted this must be correctly fitted and adjusted. This type of seal relies on the process
liquid to cool the shaft and packing rings so a constant drip of liquid from the gland section is required. Where this is
undesirable an alternative seal type should be fitted.
11. Failure to operate or maintain the pump and ancillary equipment in line with the manufacturers instructions may lead
to premature and potentially dangerous failure of components. Regular inspection, and where necessary
replacement, of bearings and lubrication is essential.
12. The pump and its components have been designed to ensure safe operation within the guidelines covered by
legislation. Accordingly National Oilwell Varco has declared the machine safe to use for the duty specified as defined
by the Declaration of Incorporation or Conformity that is issued with this instruction manual.
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A. 80T PUMP
1. NAMEPLATE
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98/37/EC
94/9/EC
97/23/EC
EN 12100-1, EN 12100-2
EN 1127-1, EN 13463-1, EN 13463-5
Exempt per Article 1, Clause 3.10
NOTIFIED BODY
Bureau Veritas, ATEX NB 0081 retains a copy of the Technical File: ATEX 0004
ATEX product marking:
II 2G c T4
The equipment described in this Declaration of Incorporation complies with the Applicable European Directives and relevant sections
of the Applicable International Standards. Integration instruction are provided that contain requirements and specifications that must
be implemented prior to putting this equipment into service; this equipment must not be put into service before the machinery into
which it is to be incorporated has been declared in conformity with the provisions of the Machinery Directive. The EHSRs related to
this equipment have been addressed; a Technical Construction File is available for inspection by designated bodies.
Authorized Signature:
Date:
October 4, 2007
Chris Cackler
Important safety information is contained in the installation, operation and service manuals; read and understand this
information prior to installing or using this equipment
This Document applies only to the equipment described above and is invalid if not reproduced in its entirety.
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98/37/EC
94/9/EC
97/23/EC
EN 12100-1, EN 12100-2
EN 1127-1, EN 13463-1, EN 13463-5
Exempt per Article 1, Clause 3.10
NOTIFIED BODY
Bureau Veritas, ATEX NB 0081 retains a copy of the Technical File: ATEX 0005
ATEX product marking:
II 2G c T4
The equipment described in this Declaration of Incorporation complies with the Applicable European Directives and relevant sections
of the Applicable International Standards. Integration instruction are provided that contain requirements and specifications that must
be implemented prior to putting this equipment into service; this equipment must not be put into service before the machinery into
which it is to be incorporated has been declared in conformity with the provisions of the Machinery Directive. The EHSRs related to
this equipment have been addressed; a Technical Construction File is available for inspection by designated bodies.
Authorized Signature:
Date:
This Document applies only to the equipment described above and is invalid if not reproduced in its entirety.
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98/37/EC
94/9/EC
97/23/EC
EN 12100-1, EN 12100-2
EN 1127-1, EN 13463-1, EN 13463-5
Exempt per Article 1, Clause 3.10
NOTIFIED BODY
Det Norske Veritas, ATEX NB 0575 retains a copy of the Technical File: ATEX 0003
ATEX product marking:
II 2G c T4
The equipment described in this Declaration of Incorporation complies with the Applicable European Directives and relevant sections
of the Applicable International Standards. Integration instruction are provided that contain requirements and specifications that must
be implemented prior to putting this equipment into service; this equipment must not be put into service before the machinery into
which it is to be incorporated has been declared in conformity with the provisions of the Machinery Directive. The EHSRs related to
this equipment have been addressed; a Technical Construction File is available for inspection by designated bodies.
Authorized Signature:
Date:
March 1, 2007
Matthew Bryce
Important safety information is contained in the installation, operation and service manuals; read and understand this
information prior to installing or using this equipment
This Document applies only to the equipment described above and is invalid if not reproduced in its entirety.
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Installation
I. GENERAL
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. LIFTING
Lifting Arrangement
With Gear Reducer,
Rear View
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Lifting Arrangement
Without Gear Reducer,
Rear View
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Installation
I. GENERAL
A. LIFTING (Continued)
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Lifting Arrangement
With Gear Reducer,
Side View
Lifting Arrangement
Without Gear Reducer,
Side View
Lifting Arrangement
With Gear Reducer,
Top View
Lifting Arrangement
Without Gear Reducer,
Top View
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Installation
I. GENERAL (Continued)
B. PUMP MOUNTING
1.
The skid or foundation must be level. Angular installation and operation may be detrimental to the lubrication of
equipment and may impose high stresses causing equipment failure.
2.
The skid or foundation must be of sufficient strength to prevent flexing of the equipment.
3.
The skid or foundation must be of sufficient size and design to maintain the equipment free of strain.
4.
The equipment must be adequately secured to the foundation. High strength bolts or capscrews with locking devices
are generally employed.
5.
Consideration should be given to the location of the equipment with its proximity to the associated equipment, fluid
supply, fuel supply, environmental contamination, etc.
6.
Avoid environmental contamination by providing the proper disposition of drainage from the crankcase, gear case,
chain case, sludge sump and any other lubrication reservoirs as well as from the flushing media sump, the pump
cradle, the suction line and the discharge line.
C. ALIGNMENT
1.
It is most important that the pump be accurately aligned with the prime mover.
2.
Follow the recommended alignment procedures provided by the manufacturer of the belts and sheaves or couplings.
D. 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.
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.
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Installation
I. GENERAL (Continued)
E. 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.
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.
F. POWER END
1. The pump must be mounted level and should be grouted in and be free of strain. This applies to a skidmounted 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
Lubrication Section in this manual) 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.
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Installation
I. GENERAL (Continued)
G. 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.
H. PLUNGER PACKING
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 the Assembly, Fluid End, Plunger Packing
Installation section of this manual for correct procedure for packing used.
I. 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.
J. SUCTION PULSATION DAMPENERS
1. Low Pressure - Plastic Body
a. Some National Oilwell Varco plunger pumps are equipped with suction pulsation dampeners.
dampeners do an excellent job when properly charged and should be kept filled during operation.
These
! ATTENTION !
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.
! ATTENTION !
HANDLE WITH CARE.
This is a plastic part and can be broken.
c.
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Installation
I. GENERAL
J. SUCTION PULSATION DAMPENERS
1. Low Pressure - Plastic Body (Continued)
! ATTENTION !
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.
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Lubrication
I. GENERAL
NATIONAL OILWELL VARCO Plunger Pumps are "splash" lubricated. The main bearings receive oil through ports
in the frame. Crankshaft bearings are fed by splash and at low speed through roll pins from the crosshead reservoir.
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. At speeds under 200 rpm, special
auxiliary oil systems are required except on the 300Q Initial filling should be into the crosshead reservoir on top of the
crossheads.
A. OIL
Use "extreme pressure" gear oil.
surrounding the pump.
Temperature
+50F to +155F
+20F to +100F
-20F to + 60F
The chart below shows the recommended grades for various temperatures
AGMA No. 6 EP or ASTM/ISO Grade No. 320 (viscosity 1335 to 1632 SSU 100F)
AGMA No. 5 EP or ASTM/ISO Grade No. 220 (viscosity 918 to 1122 SSU 100F)
AGMA No. 2 EP or ASTM/ISO Grade No. 68 (viscosity 284 to 347 SSU 100F)
200T - 8
250T - 8
300Q - 12
Temperature
+10C to +68C
-7C to +38C
-29C to +16C
100T - 5-1/2
130T - 5-1/2
165T - 8
AGMA No. 6 EP or ASTM/ISO Grade No. 320 (Viscosity 228-352 cSt at 37.8C)
AGMA No. 5 EP or ASTM/ISO Grade No. 220 (Viscosity 198-242 cSt at 37.8C)
AGMA No. 2 EP or ASTM/ISO Grade No. 68 (Viscosity 61-75 cSt at 37.8C)
30T - 5.7
60T - 7.6
80T - 7.6
100T - 20.8
130T - 20.8
165T - 30.3
200T - 30.3
250T - 30.3
300Q - 45.4
Oil must pour freely at minimum operating temperature. Change oil every six months or as frequently as
operating conditions require to maintain a clean, sludge-free oil of proper viscosity.
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Operation
I. GENERAL
! ATTENTION !
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. If an auxiliary lubrication pump is used for slow speed
operation, make sure it is connected and is operating properly.
2. Make sure pump is filled with clean oil of the proper viscosity (see above).
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 (refer to the Assembly, Fluid End, Plunger Packing Installation
section of this manual).
13. Check the suction and discharge dampeners for proper charge as this is very important for long dampener life
and good pump operation.
14. Make sure the hex nuts holding the cylinder in place are tight.
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23
Index
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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 by means of the dipstick in the rear cover. 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 of the plunger for lubrication. (See Lubrication Section in this manual 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.
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Index
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Maintenance
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.
necessary.
! ATTENTION !
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.
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Index
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Maintenance (Continued)
II. TROUBLE SHOOTING GUIDE
PROBLEM
POSSIBLE CAUSE
CORRECTION
(1, 2, 3, 4)
1. TRASH, SCALE BUILD UP, ETC.
2. PARTIALLY CLOSED VALVE IN SUCTION
LINE
KNOCKING OR
POUNDING IN FLUID
END AND PIPING
WORN VALVES
BROKEN PLUNGER
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Index
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Maintenance
II. TROUBLE SHOOTING GUIDE (Continued)...
PROBLEM
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POSSIBLE CAUSE
CORRECTION
REPLACE AS REQUIRED
CORROSION
ABRASIVES IN FLUID
FILTER AS REQUIRED
IMPROPER INSTALLATION
REPLACE AS REQUIRED
ABRASIVES IN FLUID
FILTER AS REQUIRED
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Index
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Maintenance
II. TROUBLE SHOOTING GUIDE
PROBLEM
(Continued)...
POSSIBLE CAUSE
PLUNGER CRACKED AT INSTALLATION.
CORRECTION
INSTALL NEW PLUNGER USING CARE TO AVOID
ANY SHARP BLOW OR FORCE ON PLUNGER.
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.
BROKEN OR PITTED
FROM IMPLOSIONS
CAUSED BY IN
EXCESSIVE GAS OR
AIR ENTRAINED
FLUID.
RAPID WEAR OF
HARD-COATED
PLUNGER
PACKING FAILURE.
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29
Index
Next
30T
60T
80T
100T
130T
165T
250T
200T
300Q
PUMP
30T
60T
80T
100T
130T
165T
200T
250T
300Q
CRANKSHAFT O.D
MAXIMUM CLEARANCE
in
2.500
2.499
3.250
3.249
4.125
4.124
mm
63.500
63.475
82.550
82.525
104.775
104.750
5.000
4.999
127.000
126.975
in
1.3765
1.3760
1.8765
1.8760
2.5635
2.5630
mm
34.963
34.950
47.663
47.650
65.113
65.100
3.0015
3.0010
76.238
76.225
mm
.305
in
.003
mm
.076
.013
.330
.003
.076
.018
.457
.007
.178
.020
.508
.0064
.163
MAXIMUM CLEARANCE
Home
MINIMUM CLEARANCE
in
.012
MINIMUM CLEARANCE
in
.007
mm
.178
in
.001
mm
.025
.007
.178
.0015
.038
.007
.178
.0015
.038
.008
.203
.002
.051
30
Index
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Disassembly
I. POWER END
It is not necessary to remove the fluid end when disassembling the power end. The plungers may be disconnected
from the intermediate rods and left in the stuffing boxes.
A. INTERMEDIATE RODS AND OIL WIPER RETAINERS (ALL PUMPS)
1. Loosen the plunger lock screws (if used), disconnect the plunger from the intermediate rod, and
remove the baffle plate.
! ATTENTION !
A BACK-UP WRENCH MUST BE USED FOR REMOVAL OF PLUNGER AND INTERMEDIATE ROD TO PREVENT
DAMAGE TO THE CONNECTING ROD.
2. The oil wiper retainer is piloted into the frame and held in place by two capscrews or a metal clip.
3. Remove the intermediate rod from crosshead lock screw (if used), and using a back-up wrench on
the crosshead, unscrew the rod. Remove the rod and oil wiper retainer as one assembly.
B. CRANKSHAFT ASSEMBLY
! ATTENTION !
COVER KEYWAYS TO PROTECT OIL SEALS DURING REMOVAL.
4. Rotate No. 1 throw to front, support the crankshaft, and remove it from either side, tapping it out with a brass
bar to prevent damage to the end. This will automatically remove one of the main bearing outer races. The
other race may be removed by knocking it out with a brass bar. Tag the outer bearing races so they may be
reassembled with the same bearing cone and roller assembly.
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Index
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Index
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Disassembly
I. POWER END
B. CRANKSHAFT ASSEMBLY (Continued)...
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Index
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Disassembly (Continued)
II. FLUID END
A. FLUID CYLINDER REMOVAL
! ATTENTION !
USE BACK-UP WRENCH ON THE CROSSHEAD TO PREVENT DAMAGE TO CONNECTING ROD.
2. Slide the plunger forward in the stuffing box. Unscrew the intermediate rod. Remove the clip holding the
intermediate rod wiper retainer; remove the rod and retainer as one assembly.
3. The plunger can now be slid back out of the stuffing box and removed through the cradle chamber.
4. Remove stuffing box nut and packing.
5. For removal of the stuffing box, the fluid cylinder must be first removed.
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Index
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Disassembly
II. FLUID END
B. STUFFING BOXES AND PLUNGER REMOVAL (Continued)...
! ATTENTION !
A BACK-UP WRENCH MUST BE USED ON THE CROSSHEAD.
2. With the intermediate rod in the forward position, slide the plunger forward in the stuffing box.
3. Rotate the crankshaft until the intermediate rod is in the back position of its stroke. Unscrew at the intermediate
rod and the intermediate rod wiper retainer capscrews then remove the rod and retainer as one assembly.
4. The plunger can now be slid back out of the stuffing box and removed through the cradle chamber.
5. Remove the stuffing box nut, lube fitting (copper tubing if lubricator is used), and packing.
C. FLUID END VALVE REMOVAL
Refer to valve section located in the middle of this manual.
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Index
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Assembly
I. POWER END
A. CRANKSHAFT AND MAIN BEARINGS
the
8. Place the crankcase main bearing shims, amounting to approximately .050" (1.27 mm) in thickness, on either
same amount
crankshaft bearing retainer. If the old bearings and retainers are being re-installed, use the
of shims as before.
NOTE: The following steps (9, 10a and 10b) are necessary only if new bearings are being installed. When the
same crankshaft main bearings are being reassembled, use the same amount of shims as were previously
used and use the steps as a check for adjustment.
9. Assemble the crankshaft bearing retainer and shims (less oil seal) to the main frame and tighten in place with
the proper capscrews.
10. Install the other crankshaft bearing retainer (less oil seal) in the same manner as in step nine (9) above. To
determine the correct amount of shims when installing new bearings, the following steps are recommended.
a. When first installing shims, use only enough shims to produce a slight drag when the crankshaft is
rotated. Tap shaft on each end sufficient to ensure that the bearing outer race is tightly against the
retainer.
b. Then add enough shims to remove the slight drag or pre-load (approximately .005" [.127 mm] to .007"
[.178 mm]), depending on the amount of pre-load). The bearings are correctly adjusted when there is
.003" to .005" end-play of the crankshaft and the crankshaft will rotate freely. Do not pre-load bearings.
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Index
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Assembly
I. POWER END
A. CRANKSHAFT AND MAIN BEARINGS (Continued)...
The crankshaft should be clean and free of burrs. The cone and roller assemblies are to be heated in an electric
oven or oil bath to 300F (149C). The use of a thermometer is recommended. Bearing parts are match marked and
should be noted prior to heating. Make sure parts are not interchanged.
1. Right Hand Bearing (Short Shaft Extension):
a. Install chain sprocket on 165T.
b. With a bearing cone and roller assembly at proper temperature, install on the crankshaft with the thick edge
of the taper against the shoulder.
c.
Assemble the bearing spacer and outer race on the crankshaft and against the inboard cone and roller.
d. Install outboard cone and roller assembly; thin edge against the bearing spacer.
e. Tighten the lock nut and lock with lock washer prong. (This can best be done after the shaft is in the
pump). Make sure cone and roller assemblies are tight against the bearing spacer.
2. Left Hand Bearing (Long Shaft Extension):
a. With bearing cone and roller at proper temperature, install on the crankshaft with the thick edge of the taper
against the shoulder.
b. Assemble the bearing spacer against the inboard cone and roller.
c.
Drive outer race into the bearing cage against bottom shoulder.
d. Install the outer race and cage assembly and gasket against inboard cone and roller.
e. Install outer cone and roller assembly; thin edge against the bearing spacer.
f.
g. Tighten lock nut and lock with prong of lock washer. Make sure cone and roller assemblies are tight against
the bearing spacer.
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Index
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Assembly
I. POWER END (Continued)
B. CRANKSHAFT AND CENTER SUPPORT ROLLER BEARING ASSEMBLY
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Assembly
I. POWER END (Continued)
C. CONNECTING ROD AND CROSSHEAD ASSEMBLY (ALL PUMPS)
1. Press the crosshead pin bushing into the connecting rod.
2. Ream bushing to size (refer to the tables shown the Overhaul and Repair, Check Points and Adjustments section of
this manual for dimensions). Apply bluing with crosshead pin and scrape bushing to reveal high spots. (If service
bushings are used, reaming will not be necessary in most cases).
3. Install the crosshead pin by pressing into crosshead or to facilitate assembly, the crosshead may be heated to no
more than 300 F (149C) in an electric oven or bath.
NOTE: Crossheads are marked "TOP" on extension rod end. Connecting rods and bearing caps are match marked
as units. Install connecting rod in crosshead so match marks on top of crosshead correspond.
D. CONNECTING ROD TO CRANKSHAFT ASSEMBLY
The connecting rod bearings are precise fitting inserts requiring no adjustment. When reinstalling the same inserts,
assemble them in pairs at their original location. Make sure the match marks on connecting rod and cap are the same
and on the same side.
1. Install rod half of bearing, seat connecting rod on the shaft and install bolts.
2. Install other half of bearing and bearing cap, making sure dowel pins in the bearings are properly joined.
Using a torque wrench, tighten to the torque specified in the chart below.
TORQUE: FT-LBS
PUMP
Straight, Cut Rod w/ Bolts & Locknuts
Straight, Cut Rod w/ Capscrews
Slant Cut Rod w/ Capscrews
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39
30T
60T
80T
100T
130T
20
-30
45
-75
85
150
150
Index
165T, 200T,
250T, 300Q
--250
Next
Assembly
I. POWER END
D. CONNECTING ROD TO CRANKSHAFT ASSEMBLY (Continued)
30T, 60T, 80T, 130T (New Style), 165T, 200T, 250T and 300Q
The connecting rod bearings are precision fitting inserts requiring no adjustment. When re-installing the same
inserts, assemble them in pairs at their original location. Make sure the match marks on the connecting rod and cap
are the same on the corresponding sides.
Figure 1
NOTE: It is possible to install these bearing shells incorrectly. Please follow instructions carefully.
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Assembly
I. POWER END
D. CONNECTING ROD TO CRANKSHAFT ASSEMBLY
30T, 60T, 80T, 130T (New Style), 165T, 200T, 250T and 300Q (Continued)
1. Check bearing halves for pin engagement and fit over the dowel pin in the cap half of the connecting rod.
Please note the drawing and match marks.
2. Install both bearing halves on the crankshaft with the dowel pins engaged as shown. Position crankshaft throw
to the rear.
3. With bearing shells in position (as shown in drawing, pg. 38), fit the cap half of the connecting rod over the
bearing shells. Make certain the dowel pin is seated properly and the lubrication hole in the bearing is toward
the front so as to match the oil hole in the connecting rod.
NOTE: Later model connecting rods have the dowel pin located in the rod half. With this pin, the location of the
rod is positioned first on the bearing shell.
4. Slide the connecting rod back over the crankshaft throw using caution so the outer surface of the aluminum
insert is not damaged. Note the match numbers of the cap and rod to be certain the rod is assembled correctly.
5. Install the two (2) capscrews and torque as shown in chart. Lockwire the capscrews securely.
Install two oil wipers; lips facing the power end. Open one from the power end side and one from the fluid side.
On the power end side the wiper O.D. should be flushed with the face of the retainer. On the fluid end side, the
wiper should be pressed in the retainer until it contacts the shoulder in the middle of the retainer. Install the third
wiper on the fluid end side of the retainer with lip facing the fluid end.
NOTE: Make sure O.D. wiper and I.D. of retainer are clean and dry before installation of the wiper.
Install two (2) oil wipers, lips facing the power end, and two (2) oil wipers with lips facing the fluid end. The inner
wipers should shoulder against the raised area in the center of the retainer. Make certain the retainer and wipers are
clean and dry before installation. An oily or greasy surface can cause the wipers to become loose.
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Assembly
I. POWER END
E. INTERMEDIATE RODS AND OIL SEAL RETAINERS (Continued)
ALL PUMPS
Rotate the crankshaft until the crosshead is all the way forward and install the retainer and rod as a unit.
NOTE:
Make sure retainer gasket is in place prior to installation. Tighten rod and the crosshead using a back-up
wrench on the crosshead to the following torques:
Threads
Dry (ft-lbs)
Lubricated (ft-lbs)
60T
80T
200
150
30T
175
150
100T
130T
400
325
! ATTENTION !
NATIONAL OILWELL VARCO DOES NOT RECOMMEND THE USE OF CERAMIC PLUNGERS FOR PUMPING
FLAMMABLE LIQUIDS.
! ATTENTION !
PREVENT DAMAGE BY PLACING A BLOCK OF WOOD OVER THE STUFFING BOX FACE.
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Assembly
II. FLUID END
A. STUFFING BOXES AND PLUNGERS
165T, 200T,
250T & 300Q
800
640
100T, 130T
Dry (ft-lbs)
Lubricated (ft-lbs)
400
325
4. Install rubber baffle (if used) on intermediate rod and connect plunger to intermediate rod with threaded
connection or clamped connection. Make sure the mating surfaces are clean and free from nicks and burrs.
Tighten plunger rod using the following torques (threaded plungers):
Threads
100T, 130T
Dry (ft-lbs)
Lubricated (ft-lbs)
400
325
100T, 130T
15 ft.-lbs.
5. Adjust stuffing box nut. (Adjusting nut should be tightened with the bar furnished with the pump). Refer to
the Assembly, Fluid End, Plunger Packing Installation section of this manual for proper packing procedure
and lubrication practices.
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Assembly
II. FLUID END (Continued)...
B. FLUID CYLINDER (ALL PUMPS)
1. Install fluid cylinder, check stuffing box seals as cylinder is moved into place.
2. Tighten nuts alternately, pulling fluid cylinder up evenly; torque nuts to the following values:
THREADS
30T
Dry (ft-lbs)
Lubricated (ft-lbs)
300
240
60T
80T
500
450
100T
130T
400
325
165T, 200T,
250T & 300Q
800
640
3. When installing the suction discharge piping, always use the capscrews furnished with the pump as they are
special high-strength and double heat-treated.
C. FLUID VALVES SPHERICAL, TAPERED SEAT BOTTOM GUIDED AND CAGE TYPE (ALL PUMPS)
See Valve section of this manual.
D. PIPING INSTALLATION (ALL PUMPS)
1. Install flanges on fluid cylinder with special high carbon double heat-treated capscrews furnished with the pump.
2. Install suction and discharge lines to flanges.
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Assembly
II. FLUID END (Continued)...
E. PLUNGER PACKING INSTALLATION
1. 850-N Packing
It is important that the following procedure be observed when replacing old packing to prevent rapid packing
wear:
a. Remove front crosshead reservoir cover plate and rotate pump to bring the desired plunger to the forward
position.
b. Back off locking setscrew (if used) at intermediate rod crosshead connection and intermediate rod plunger
connection. Using back-up wrenches, loosen connection one-fourth (1/4) turn.
c.
Rotate crankshaft until plunger is all the way back. Unscrew plunger or remove clamp assembly and slide
plunger forward.
d. Remove intermediate rod and intermediate rod seal retainer from as one assembly.
e. Remove plunger and old packing, making sure stuffing box is clean. Plungers and boxes may be removed as
an assembly by rotating the pump so the intermediate rod is all the way back, thereby disconnecting the
plunger and sliding the stuffing box back and out.
f.
Oil each ring with light oil (DO NOT GREASE), and install packing per sketch included with the packing. Make
sure the lips on the sealing rings face pressure shown.
Install intermediate rod and retainer. Connect plunger and torque properly as outlined in the Power End,
Intermediate Rods and Oil Seat Retainers section of this manual.
j.
For 850-N packing, start pump and operate under pressure; retighten adjusting nut. After pump has been
running for two (2) or three (3) hours under pressure, packing will seat itself and the adjusting nut should be
tightened as much as possible to eliminate any movement of the packing in the stuffing box. Use the bar
furnished with the pump. Do not use a cheater!
k.
The adjusting nuts should be checked and each tightened for the first 2 or 3 days until the packing is completely
seated and the adjusting nuts cannot be tightened any further. Use the bar furnished with the pump. Do not
use a cheater!
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Assembly
II. FLUID END
E. PLUNGER PACKING INSTALLATION (Continued)...
2. 1045 PACKING (also called No. 265)
It is important that the following procedure be observed when replacing old packing to prevent rapid packing
wear:
a. Remove crosshead reservoir and rotate crankshaft to bring plunger forward.
b. Back off locking set screw (if used) at intermediate rod crosshead connection and intermediate rod plunger
connection. Using back-up wrench, loosen this connection one-fourth (1/4) turn.
c.
Rotate crankshaft until plunger is all the way back, unscrew plunger or remove clamp assemblies and slide
plunger forward.
d. Remove intermediate rod and intermediate rod seal retainer from pump as one assembly.
e. Remove plunger and old packing, making sure stuffing box is clean. Plungers and boxes may be removed as
an assembly by rotating the pump so the intermediate rod is all the way back, disconnecting the plunger and
sliding the stuffing box back and out.
f.
Starting with the first Phenolic ring, seat each ring individually in the order packaged. Eliminate the No. 1
Phenolic ring when using a sleeve washer with ceramic plungers.
g. Install plunger and make-up the adjusting nut tight to ensure the entire packing set is properly seated. The nut
should be loosened and adjusting hand tight.
h. Install intermediate rod and retainer. Connect plunger and torque properly as outlined in the Power End,
Intermediate Rods and Oil Seat Retainers section of this manual.
i.
Start the pump and run with normal system pressure. Tighten the adjusting nut, carefully watching for
excessive heat build-up. Continue to tighten the nut until it is a good, snug fit and the nut shows no movement
in the threads.
! IMPORTANT !
IF THE ADJUSTING NUT LOCKS AND CANNOT BE MOVED, IMMEDIATELY REMOVE THE PRESSURE FROM THE
PUMP, BACK OFF THE NUT ONE-HALF (1/2) TURN, AND START AGAIN.
j.
This packing may or may not leak, depending on the circumstances, and it does not require continuous
adjustment. It should be checked and re-tightened the first day or two after installation of new packing, but
should require very little attention after this.
k.
This packing can be used on hard coated or ceramic plungers without lubrication, but as with any packing,
extended life is possible through the use of lubrication. When using a mechanical or drip type lubrication
system in water service, use rock Drill (Air Drill) Oil of the proper viscosity. Drip five to seven drops per minute.
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Assembly
II. FLUID END
E. PLUNGER PACKING INSTALLATION (Continued)...
3. 699 PACKING
For top performance from the soft packing of "Teflon" fiber read and carry out the following instructions. Use the
above method to remove and re-install intermediate rod and plunger.
a. Packing may be butt or diagonal cut. Stagger joints in successive rings at least 90.
b. Slide rings into stuffing box, but do not tap or drive rings into place. Tests have shown that this
method gets maximum performance from soft packing of "Teflon" fiber.
c.
Tighten stuffing box nut finger tight and start pump. Packing should be leaking, if not, loosen
stuffing box nut. Remember, install this soft packing with a minimum of gland pressure to
minimize friction and heat build-up.
d. Reduce leakage to desired level by tightening stuffing box nut about 1/6 turn at a time every few
minutes.
e. If gland heats up to a temperature that will boil water, back-off stuffing box nut and repeat run-in
until temperature remains after nuts are re-tightened.
"Teflon" is DuPont's registered trademark for TFE- Fluorocarbon fiber.
4. SPRING LOADED KEVLAR RECIPROCATING PACKING
- Recommended Packing Procedure a. Before re-packing, determine cause of failure.
b. Remove plunger, stuffing box nut, and all internal parts in stuffing box. Remove stuffing box itself if necessary
to clean.
c.
Clean all parts and determine if parts are worn or reusable. Replace all worn parts.
Install parts into stuffing box in the following order: spacer (if needed), spring, follower (small end first), Kevlar
ring and brass ring (with care), (alternate these items three (3) times, twice for 30T), and then add the bushing
(gland ring).
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Assembly
II. FLUID END
E. PLUNGER PACKING INSTALLATION
4. SPRING LOADED KEVLAR RECIPROCATING PACKING (Continued)...
i.
Tighten packing nut. Bushing should seat and shoulder against stuffing box face. Back off the nut one-half
turn.
j.
k.
l.
m. Fill lubricator with Rock Drill Oil for normal temperature or steam cylinder oil for high temperature fluids. Fill
lubricator lines by pumping it manually. Check its operation.
n. Start pump at slow speed and low pressure if possible, tighten stuffing box nut and insert stop pin in hole. Watch
for a short period of time. Oil if needed.
o. Set lubricator to twice normal rate. After 24 hours, resume normal operation. Check stuffing box for excessively
high temperatures and abnormal leakage.
Figure 2
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! ATTENTION !
NOISY VALVES, DUE TO IMPROPER FILLING, CAN LEAD TO SHORT LIFE AND RAPID MECHANICAL WEAR
OF THE POWER END PARTS.
B. VALVE COVERS
CAUTION
THE VALVE COVERS, AS USED WITH THE NATIONAL OILWELL VARCO PLUNGER PUMPS, MUST BE KEPT
TIGHT AT ALL TIMES. DUE TO THE DISCHARGE PRESSURE APPLYING A CONSTANT LOAD TO THE
COVERS, IT IS NOT POSSIBLE TO CHECK THEIR TIGHTNESS WITH THE PUMP RUNNING OR WITH
PRESSURE IN THE CYLINDER.
Bleed off the discharge pressure and check the tightness of the covers as outlined under the assembly procedure
for the type of cover used.
C. VALVE CAGE AND COVER SEALS
1. Cage Type Valves
There are three identical seals in each valve stack. The seals perform a very important function in this
design valve and we recommend that they be changed any time they are removed from the pump.
2. Cover Seals
The cover seals should be replaced as required.
D. VALVE SPRINGS
The springs used with the NATIONAL OILWELL VARCO valves are made of inconel alloy or stainless steel.
! ATTENTION !
THESE SPRINGS SHOULD BE CHANGED APPROXIMATELY ONCE A YEAR IN ORDER TO ASSURE PROPER
VALVE ACTION AND ELIMINATE THE POSSIBILITY OF A SPRING BREAK.
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Acme threaded valve cover with center bolt. (One piece solid cover used on 30T, 60T or 80T).
Retainer (not used on 30T, 60T or 80T).
Cover and Cage Seal, Suction or Discharge (interchangeable).
Disc Valve Cage, Suction or Discharge (interchangeable).
Valve Spring, Suction or Discharge (interchangeable).
Stop, Valve Disc, 30 Taper Cut in Cage, not used in Ball Valve Cages.
Valve Disc, Valve suction or Discharge (interchangeable).
Valve Seat, Discharge only - Small bore (I.D.) used to retain Suction Spring.
Valve Seat, Suction Only - Large Bore (I.D.) same as Suction Throat Bore.
Valve Seat Suction and Discharge (interchangeable).
Figure 3
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The valve servicing tools referred to on the following pages are listed below:
CAGE TYPE VALVES
(SPHERICAL, BOTTOM GUIDED, BALL, & DISC)
Valve
Kit
Cage
Puller
Cage
Seat
Bumper Drive
Magnet
Retriever
1710292
1711251
1710249
1711249
1790080
1790080
1790040
1790041
1790034
1790034
1712342
1712242
1790080
1790042
1790034
1713068
1713069
1790085
375T-7H
1715338
1715339
1790085
1713351
1713352
1790085
1790043
1790034
1790053
G-1790062 1790034
G-1715342
G-1790064 1790034
Pump Size
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Figure 4
Figure 5
Figure 6
Figure 7
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! ATTENTION !
A LOOSE COVER WILL ALLOW CAGE MOVEMENT AND WILL CAUSE EXTENSIVE DAMAGE TO CAGE AS
WELL AS FLUID END.
Each cage that is removed should be inspected at the following points referred to in the drawing, Figure 8.
a. Inspect for wear in this area. It is best to do this with the valve and seat in the cage, therefore, a more
accurate decision can be made. The wear in this area, which can be judged by the sideways movement
of the disc, should not exceed 1/2 the width of the seating surface of the disc valve or more than 1/8" to
3/16" for the ball valve. These are maximum figures and could result in poor valve action and some loss
of efficiency. If in doubt, change the cage.
b. Inspect the valve seat shouldering area for signs of wear or hammering. If this portion of the cage is
cracked or battered, the cage should be replaced. This will only happen if the cage is allowed to move
in the bore due to loose covers.
Figure 8
c.
Inspect cage bore for excessive spring. In most cases this area will wear only if there is poor valve
action or extremely corrosive water that attacks the cage material in this wear zone.
d. Inspect O.D. of cage for nicks, burrs or washers. Clean cage thoroughly before replacing.
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Inspect the outside surface of the valve and seat for nicks, burrs or washers, and thoroughly clean
before assembly.
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! ATTENTION !
IT IS BEST YOU CHANGE SPRINGS AND DESTROY THE OLD ONES APPROXIMATELY ONCE A YEAR. IF
THE SPRINGS FATIGUE AND BREAK, THE RESULTING VALVE ACTION CAN DAMAGE THE CAGE AND
VALVE. HERE AGAIN, IF IN DOUBT, CHANGE THE SPRING; THEIR COST IS VERY MODERATE.
7. SEALS, VALVE CAGE
The NATIONAL OILWELL VARCO cage-type valves are of a stacked design and depend on the seal at the
top, middle and bottom of the stack to isolate the suction and discharge valves and their associated changes in
pressure. These seals should be changed every time the valves are removed from the pump. If it is absolutely
necessary to re-use these seals, install the best seal in the middle stack, the next best at the bottom and the
worst seals on the top covers. Replace used seals with new ones as soon as possible.
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TORQUE (Dry)
PLUNGER PUMP SIZE
30T-2H, 30T-2L, 60T-3H, 60T-3M, 80T-3H, 80T-3M
100T-4H, 100T-4M, 130T-4H, 130T-4M, 165T-5M,
300Q-5HA, 200T-5H, 250T-5H
165T-5M, 300Q-5M, 200T-5M, 250T-5M
165T-5H, 200T-5H, 250T-5H, 300Q-5HB
375T-7H
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TORQUE (Lubricated)
500 ft-lbs
400 ft-lbs
550 ft-lbs
450 ft-lbs
650 ft-lbs
900 ft-lbs
1300 ft-lbs
525 ft-lbs
735 ft-lbs
1060 ft-lbs
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Remove spring(s) and valve with the retriever. See Figure 18.
d. Remove seat by placing the puller head through the seat opening and engage lugs to the underside of the
seat. Pull seat or bump seat loose and remove. See Figure 19.
2. INSTALLATION PROCEDURE
a. Make certain cylinder tapers are clean and dry. Inspect for corrosion or damaged areas. Repair or replace
as required.
b. Clean and dry spherical seat tapers and with retainer and spring(s) removed, place seat in place making
certain it is straight.
c.
With a bar and a driver tap seat in place with 2 or 3 strokes. NOTE!! Seat does not have to be completely
seated. Pump start-up pressure will drive seat home. See Figure 20.
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SUCTION
DISCHARGE
SUCTION
DISCHARGE
VALVE (ONLY)
SPRING (SUCTION)
RETAINER
SPRING (DISC)
INNER
OUTER
2-1/2"
3"
3-1/2"
4"
1792520-25
1792522-25
1792521-25
1792523-25
1792527-25
1792525
1792524-6
1792526
1792525
1793020-25
1793022-25
1793021-25
1793023-25
1793027-25
1793025
1793024-6
1793026
1793025
1793520-25
1793522-25
1793521-25
1793523-25
1793527-25
1793525
1793524-6
1793526
1793525
1794020-25
1794022-25
1794021-25
1794023-25
1794027-25
1794025
1794024-6
1794026
1794025
1795020-25
1795022-25
1795021-25
1795023-25
1795027-25
1795025
1795024-6
NONE
1795025
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2-1/2"
3"
180104119
181205709
180104127
181259300
Home
3-1/2"
180104135
181259359
1790034
181205709
20-220-194
75-518-308
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Index
4"
180104143
181259409
180104151
181259410
181205710
20-220-327
75-510-330
Next
Figure 16
Figure 17
Figure 18
Figure 20
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Figure 19
Figure 21
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With bottom guided valve in place, drive the seat, as shown in Figure 25, until it stops driving.
d. Check bottom-guided valve to be sure it is free in the seat and install spring and retainer. Torque retainer to
values shown below using hex head wrench as shown in Figure 26.
TORQUE
ft.-lbs.
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2-1/2"
3"
3-1/2"
4"
100
100
100
100
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2-1/2"
3"
3-1/2"
4"
Suction
1792500-4
1793000-4
1793500-4
1794000-4
Discharge
Suction
1792502-4
1792501-4
1793002-4
1793001-4
1793502-4
1793501-4
1794002-4
1794001-4
1792503-4
1790066
1792505
1792504-26
1793003-4
1713502
1793005
1793004-26
1793503-4
1790067
1793505
1793504-26
1794003-4
1790068
1794005
1794004-26
SEAT ..........................
Discharge
VALVE (Only) ................................................
SPRING .........................................................
RETAINER ....................................................
2-1/2"
1792507
1792506
PULLER KIT
PULLER HEAD
BUMPER
BAR
WRENCH
RETRIEVER
SUPPORT
NUT
FLANGED NUT
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3"
3-1/2"
1793007
1793507
1793006
1793506
1790080
1790081
1790082
1790034
1713109
6300160
6314002
Index
4"
1794007
1794006
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REMOVAL
Figure 22
Figure 23
Figure 24
INSTALLATION
Figure 25
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Figure 26
67
Figure 27
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Gear Reducer
I. LUBRICATION AND MAINTENANCE
A. GENERAL
NATIONAL OILWELL VARCO plunger pump gear reducers are "splash" lubricated. The rotation of the gears
provides adequate lubrication to all working parts. The gear reducer housing and the plunger pump power end are
separated by a labyrinth oil seal on the 30T, and a labyrinth oil seal retainer on the 60T, 80T, 100T, 130T, 165T, 200T,
250T and 300Q. These seals separate the lubricating oils and prevent contamination.
Initial filling should be through the hand hole cover and can be gauged by the high and low level oil plugs in the
housing. Correct level is at the bottom of the high level plug.
1. OIL
Use extreme pressure gear oil. The following chart shows the recommended grades for various temperatures
surrounding the pump.
Temperature
+50F to +155F
AGMA No. 6 EP or ASTM/ISO Grade No.320 (Viscosity 1335 to 1632 SSU at 100F)
+20F to +100F
AGMA No. 5 EP or ASTM/ISO Grade No.220 (Viscosity 918 to 1122 SSU at 100F)
+20F to +60F
AGMA No. 2 EP or ASTM/ISO Grade No.68 (Viscosity 284 to 347 SSU at 100F)
+10C to +68C
AGMA No. 6 EP or ASTM/ISO Grade No.320 (Viscosity 288 to 352 cSt at 37.8C)
-7C to +38C
AGMA No. 5 EP or ASTM/ISO Grade No.220 (Viscosity 198 to 242 cSt at 37.8F)
-29C to +16C
Oil must pour freely at a minimum operating temperature. Change oil every six months or as frequently as
operating conditions require to maintain a clean, sludge-free oil of proper viscosity.
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Gear Reducer
I. LUBRICATION AND MAINTENANCE
A. GENERAL
1. OIL (Continued)
Pump
30T
60T, 80T
100T, 130T
165T
200T
250T
300Q
Gal.
2/3
1
3
3-1/2
3
2-3/4
2-1/4
6-1/2
5
4-1/2
3-1/2
Ltr.
2.5
3.8
11.4
13.3
11.4
10.4
8.5
24.6
18.9
17.1
13.3
2. MAINTENANCE
a. The gear reducer housing is equipped with a magnetic drain plug that will collect any steel particles and
prevent them from being recirculated with oil. This plug should be cleaned every six months.
b. The gear reducer should be drained, flushed and refilled every six months or as often as required to
maintain clean, sludge-free oil of the proper viscosity.
c.
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d. Tap out Timken outer cup and mark all parts for correct replacement position.
e. Pull crankshaft gear. Gear is a .001" to .005" shrink fit to shaft. Puller holes are provided in gear for pulling.
(30T - 5/8" holes; 165T and 300Q - 1" holes). Heat should be used when pulling gears, but a combination of
dry heat and dry ice can also be used. The puller should be attached to the gear and a heavy strain should
be applied. The gear should be heated with a large tip torch starting at the outside gear rim below the root
of the teeth, and working in a circular motion, heat the gear slowly and evenly toward the hub. The torch
should be kept in constant motion to prevent hot spots. The gear rim should always be kept at a
temperature above the hub area to eliminate tensile stresses in the gear rim, which causes the gear to
crack. The gear will break loose from the shaft when enough heat has been applied. The puller should then
be able to remove the gear. Do not exceed 350F at any time on the surface of the gear. Use a tempil stick
to gauge the temperature.
f.
! ATTENTION !
EXCESS HEAT OR SPOT HEATING WILL CAUSE THE GEAR TO CRACK OR DISTORT.
ALLOW GEAR TO COOL SLOWLY.
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Gear Reducer
II. OVERHAUL AND REPAIR
A. GENERAL (Continued)
2. ASSEMBLY
NOTE: Items 1 through 4 may be omitted if the pump is equipped with a new style main bearing
cage; 100T & 130T - Part Number 1711617. Omit items 1 through 4 for all 30T, 60T,
80T, 165T, 200T, 250T and 300Q.
a. Remove crankshaft assembly and left hand main bearing and cage assembly as per pump service manual.
b. Install a new cage and bearing per assembly instructions in pump service manual.
c.
Install new bearing retainer (100T & 130T - Part number 1711622) and gasket onto cage. Check clearance
of Labyrinth seal to shaft. There should not be any metal-to-metal contact.
All other pumps contain labyrinth seal type retainers. No oil seals are necessary. Be sure seal grooves are
clean before installing retainer.
g. Apply liquid gasket to bearing cage and install gear reducer housing over pilot on bearing cage. Insert
special capscrews and tighten securely.
h. Drill and ream for dowel pins - two (2) holes. Dowel pins are standard .25" per foot taper pins and are listed
in the parts list section for each pump.
! ATTENTION !
DO NOT DRILL THROUGH PUMP FRAME. HOLES SHOULD BE REAMED DEEP ENOUGH TO ALLOW PINS
TO BE DRIVEN UNTIL THE TOP OF THE TAPER ON PIN IS FROM FLUSH TO 1/8" STAND-OFF.
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Gear Reducer
II. OVERHAUL AND REPAIR
A. GENERAL
2. ASSEMBLY (Continued)
i.
After taper pins are fitted and driven, re-check tightness of special capscrews by torquing to following values
and wire them in place.
PUMP
SIZE
30T
60T, 80T
100T, 130T
165T
200T, 250T, 300Q
SPECIAL
CAPSCREW
2402010
2402850
2405029
2403190
2405018
TORQUE
(Ft. lbs.)
75
150
75
150
375
j.
Check high-speed pinion for nicks and burrs in bearing areas and remove same.
k.
Heat pinion tapered roller assemblies in electric oven or bath to 300F and install on pinion shaft. Make
sure bearings are shouldered on shaft.
l.
m. With half the shims on the blind retainer, install and secure with screws.
n. Check crankshaft extension, keyway crankshaft gear and key nicks and burrs - remove same.
o. Heat the crankshaft gear to 350F in an oil bath or furnace to ensure even and uniform heating. If these
methods are not available, heat the gear with a large top torch as described in Dissassembly, paragraph 1.
e., of this section of the manual. It is of prime importance that the gear be heated slowly and evenly from
the gear rim to the hub. Use a tempil stick and micrometers to assure a correct fit. Allow gear to cool
slowly.
p. Slip gear on shaft with under cut area on hub facing toward pump; puller holes facing out. Position gear on
shaft so that distance from end of shaft to outside face of hub is as follows:
PUMP
30T
60T, 80T
100T, 130T
165T
200T, 250T, 300Q
q. Insert key with beveled side next to shaft and allow to cool in place.
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Gear Reducer
II. OVERHAUL AND REPAIR
A. GENERAL
2. ASSEMBLY (Continued)
! IMPORTANT !
MAKE SURE GEAR IS HOT ENOUGH AND INSTALLATION IS PERFORMED QUICKLY ON THE SHAFT
BEFORE IT IS POSITIONED.
MAKE SURE KEYWAYS ARE ALIGNED WHEN SHRINKING GEAR ONTO SHAFT.
r.
Position high-speed pinion in housing supporting same with rope or cloth through the hand hole in top of
housing.
s.
Apply liquid gasket between cover and housing. Install the housing cover and secure with capscrews and
taper pins.
t.
Place remaining shims on open retainer and install with screws, making certain the drain slot is at the
bottom. Adjust with shims and retainers until the endplay of the pinion shaft is from .003" to .005" loose on
all reducers except 200T and 300Q where the end play is from .005" to .007" loose. Check clearance of
Labyrinth seal to shaft. There should not be any metal-to metal contact.
! IMPORTANT !
MAKE CERTAIN THE BEARING OUTER CUPS ARE SOLID AGAINST THE RETAINERS AND THE OUTSIDE
RETAINER IS INSTALLED CORRECTLY.
u. Check meshing of pinion and crankshaft gear.
v.
3. INSTALLATION
Since the plunger pump gear reducer is attached to the pump and becomes a part of the pump package, the
installation should receive the same careful consideration that the pump itself does. Careful installation
practices will greatly increase trouble-free operation and reduce maintenance costs. For general installation
recommendations, see Installation Section of the pump manual.
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P-55U Pump
A. OPERATING INSTRUCTIONS
Remove the vent screw and fill the sight glass with oil.
Prime by manually pumping flushing unit until air free oil
is observed from the drip tube and oil level drops in the
sight glass.
Replace vent screw and tighten union nut.
6. PUMP DISPLACEMENT
Maximum output (per stroke):
1/4 Plunger = .018 Cubic Inches
3/8 Plunger = .038 Cubic Inches
The cubic volume for a pint of oil is 28.9 cubic inches
and average drop size is .002 cubic inches.
3. SIGHT GLASS
Vent Screw
Flushing Unit
Lock Nut
Sight Glass
Union Nut
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Storage of Pumps
I. GENERAL
All machinery units require protection from corrosion erosion, natural attrition which causes deterioration of the
surface as well as the working parts. Generally, units in operation are frequently inspected, cleaned, painted and
lubricated while idle units are often more or less neglected. Any degree of neglect is costly, especially if continued over
a sufficient period of time to make restoration of the equipment impossible. It is recommended that preventive measures
of protection be established and the following will guide you in the minimum requirement.
A. GENERAL
Preferably, units should be stored in clean, climatically controlled buildings. This would require the minimum
inspection, but, since storage in older environments is sometimes necessary, more frequent inspections and additional
protection is necessary. The schedule for inspection and protection can be determined only at the point of storage. A
protection and storage log is recommended. Tropical areas require the maximum protection; arid regions require the
least amount of protection. The frequency of inspection is determined after noting the rate of deterioration. Take
positive action immediately when corrosion/erosion appears, do not wait until large areas are covered because usually
the larger the area, the deeper the penetration.
B. RECOMMENDED PROTECTION INITIAL STORAGE
1. Drain all oil and thoroughly clean inside of Power Frame.
2. Coat pinion shaft oil seals with grease.
3. Remove breathers for later installation on pump. Seal all breather holes with greased solid pipe plugs. Remove
extension rods and diaphragm sealing housing; be sure to protect the rods and housings, storing them
separately for later installation on the pump. Seal diaphragms with wooden covers. Mate the wood cover and
diaphragm faces together, thoroughly coating with Rust Veto 342 or its equivalent.
4. Spray two gallons of Shell VSI 100 vapor phase inhibitor or equivalent into power end of pump.
5. Remove valves and valve springs. Clean and wrap in corrosion inhibiting paper. Remove liners and pistons.
Clean and wrap in corrosion inhibiting paper. Clean and dry fluid end bores and thoroughly coat all internal
surfaces with Tectyl 506 or equivalent.
6. Thoroughly coat all threads and end of valve cover and screw into fluid end.
7. Protect all external machine surfaces using Rust Veto 342 or equivalent including pump pads.
8. Inspect complete pump and record all details on the Protection and Storage Log.
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Storage of Pumps
I. GENERAL (Continued)
C. SIX MONTH SERVICING
1. Rotate pump.
2. Renew internal rust inhibitors to specifications and quantities previously stated under the Initial Storage
section.
3. Before replacing top and side covers, inspect for any internal corrosion.
4. Inspect for soundness of external protection, i.e., rust preventative and paint. Renew as necessary.
5. Enter and record all details on the Protection and Storage Log.
D. PRE-INSTALLATION CHECK AFTER STORAGE
1. Repeat six month servicing procedure as stated above.
2. Ensure all necessary parts are complete and in a satisfactory condition for installation on pump.
3. Enter all records and close out the Protection and Storage Log.
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Owners Record
NAME _______________________________________________________________________________________
LOCATION ___________________________________________________________________________________
DATE OF DELIVERY ________________________________ DATE PLACED IN OPERATION _______________
PUMP MODEL ________________________________________________________________________________
PUMP SIZE ________________________________________ SERIAL NO. _______________________________
PRIME MOVER _____________________________________ SERIAL NO. _______________________________
GEAR UNIT ________________________________________ SERIAL NO. _______________________________
DRIVE:
DRIVE SHEAVE P.D. _____________ DRIVEN SHEAVE P.D. ________________ NO. OF GROOVES ________
BELT LENGTH __________________ DRIVE SPROCKET __________________ CHAIN SIZE ______________
CHAIN LENGTH_________________ COUPLING (MAKE) __________________ COUPLING SIZE __________
PRESSURE ____________ VOLUME ________________ PUMP SPEED ___________ DRIVE SPEED _________
PLUNGERS ___________________________________________________________________________________
PACKING ____________________________________________________________________________________
PISTONS _____________________________________________________________________________________
LINERS ______________________________________________________________________________________
VALVES______________________________________________________________________________________
SEATS _______________________________________________________________________________________
LUBRICANTS:
CRANK CASE _______________________________________________________________________________
FLUSHING SYSTEM __________________________________________________________________________
GEAR UNIT _________________________________________________________________________________
LUBRICATOR _______________________________________________________________________________
PRIME MOVER ______________________________________________________________________________
COUPLING__________________________________________________________________________________
NOTES ______________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
All of the above entries are not applicable to a specific unit; therefore, completion of this form must be confined within
the limits of each pump and the specified optional accessory equipment.
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Viscosity Equivalents
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With over 120 locations worldwide, National Oilwell Varco is located near you. To
find the nearest Distribution Service Center, machinery center or repair facility,
please give us a call at our main office listed below.
Or you can access our website at the URL listed below, where you may search
by location or country.
http://www.nov.com/contactus/
Sales/Technical Information:
USA Tollfree: 1 (800) 324-4706
Internet:
http://www.nov.com
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