Triplex Pump Part 1

Triplex Pump
Training Module
PAGE : 1
December 1999
Schlumberger Confidential
Introduction
This module introduces you to the Dowell PG Series of Triplex Pumps
commonly used in our Cementing, Acidizing and general pumping
work. The aim is to give you a thorough understanding of the ratings,
limitations, care and maintenance of one of the most important pieces
of machinery used by Dowell. More than 90% of our revenue is
pumping related. So you need to know all about our Triplex Pumps,
caring for them and maintaining them according to our standards.
Objectives:
To provides an overview of the Triplex Pump, its main components
and operating principles.
To describe the basic specifications and ratings of the Triplex
pump.
To review the lubrication system for this piece of machinery.
To discuss STEM operations.
To explain and teach the proper care and maintenance of the
Triplex Pump and its ancillary equipment, including how to repack
a fluid end correctly.
The Appendix includes color diagrams of the Triplex Pump and
Fluid End, with part numbers. There is a Trouble-shooting Guide
for the more common problems you might encounter in everyday
service, relevant Maintenance Bulletins.
1.0 An Overview of the Triplex Pump
The Triplex Pump is the general name given to any type of pump
assembly having three (cylinders) plungers. By the same reasoning,
the Quintiplex Pump will have five cylinders and the Duplex Pump
(seen working as mud pumps) will have two cylinders.
Triplex Pump
Training Module
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December 1999
Triplex Fluid End
Triplex Pump
Training Module
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December 1999
Quintuplex Fluid End
Triplex Pump
Training Module
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December 1999
The purpose of any pump is to convert mechanical energy, provided by
motors, engines, turbines and other prime movers into fluid energy as
efficiently as possible. The pump assembly has to be light, compact,
simple and easy to maintain whilst providing the efficiency and the power
required. It is the most efficient type of pump for pumping abrasive laden
fluids at high pressures (1000 psi and above) and requiring the least
maintenance is the Reciprocating Plunger type pump. For maximum
smoothness (no pulsations), at least 3 plungers are required for proper
balancing of the load.
Most Reciprocating pumps such as the Triplex pump are considered to
be positive displacement pumps, this means that as the pump is working,
100% of the fluid that enters each cylinder will exit each cylinder. In a
Centrifugal Pump fluid exiting the pump can be stalled and the fluid in
the pump will relieve to the suction side of the pump. In the Triplex pump
the fluid on the discharge side cannot be stalled, as the plunger will apply
as much force as that being applied to through the power-end. This is the
reason we must utilize safety devices such as burst disc in the suction
valves of the Fluid end and Over-pressure shut-downs on the controls of
the Triplex pumps.
Every type of pump assembly has a designed operating limitation based
on pressure, rate or horsepower ratings.
Triplex Pump
Training Module
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December 1999
There are mechanical limitations as to how much horsepower can be
supplied to any given pump, and the pump cannot add or create any more
horsepower than what is put into it.
A simple explanation is:
Horsepower output = Horsepower in efficiency lost.
Conventional prime movers output their power by means of rotation and
torque on a shaft. A pump assembly needs to convert this rotational
power by some means into fluid hydraulic power, which is measured by
the combination of volume of output and pressure at that output rate.
Most types of plunger pump assemblies have 3 main components:
1. A Speed Reducer to reduce the input shaft rpm, i.e. to change the high
speed low torque shaft output from a prime mover to a low speed high
torque shaft input to a pump. Dowell uses Chain Cases and gear type
speed reducers.
2. On a reciprocating pump, a device called the Power End converts this
rotational power into reciprocating power, which is transferred to the
Fluid End to transfer the power to the fluid.
3. The Fluid End receives the power from the Power End, and by using
the plungers, fluid received at low pressure is forced or pushed by the
plungers so that it exits the fluid end at a much higher pressure.
Triplex Pump
Training Module
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December 1999
Dowell uses various combinations of transmissions, chain cases and
power ends to cover our range of pumping requirements efficiently. By far,
the most commonly used pump in our business is the PG Series of
Triplex Pumps, which we use to pump fluids such as cement slurries and
corrosive fluid systems at high pressures and rates.
1.1 The Chain Case
Most of Dowell's Triplex Pumps (with the exception of Turbine-driven
units and some Stimulation units) use Chain Cases as the first stage of
inputting power from the output shaft of a prime mover, which could be an
engine/transmission combination, or a electric motor being used to drive a
pump.
The Chain Case performs 2 important functions:
1. The chain case provides flexibility when mounting the Pump assembly
in different locations with respect to the prime mover output shaft
center-line. Chain case can be assembled to accept the input from
ether side and mounted on either end of the power end as seen in the
picture below.
Triplex Pump
Training Module
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December 1999
2. The chain case converts a low torque high rpm engine output to a high
torque low rpm output more suited to the requirements of the power
end. The ratio of reduction on a P.G. Series Pump is 1:675 (sprocket
27-40 tooth)
This drawing shows a typical chain case. A chain travels over the upper
sprocket mounted on the pump pinion shaft (40 teeth) and over the lower
sprockets driven by the prime mover (27 tooth). When the prime mover
rotates the lower input shaft, the chain transmits the power to the upper
output (pinion) shaft and rotates it as well. This shaft then transfers the
rotation to the Pinion Shaft of the power end. The different diameters of
the two sprockets in the chain case acts to reduce the prime movers
output speed (rpm) and increase the torque input to the pump.
Each chain case is secured to the chassis or skid by means of a pair of
Torque Rods. They prevent the chain case from moving when power is
applied.
Triplex Pump
Training Module
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December 1999
1.2 Power End
The Power End functions very much the same way as does a crankshaft
in a conventional motorcar engine. The output shaft of the chain case is
actually the P.G. Series pump pinion shaft. The pinion shaft drives the
crankshaft via the crankshaft bull gears. The gear ratio between the
pinion shaft and bull gears is 1:4.31 (on the P.G. series pump). By using
eccentrics the rotation of the Mainshaft is changed into a reciprocating
action. This reciprocating force is transferred to the Connecting Rods
and Crossheads, which in turn move the plungers in the Fluid End.
Triplex Pump
Training Module
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December 1999
Most of the load on the triplex pump assembly is taken by the Power End,
especially by the Eccentrics. It can be easily seen that the Crossheads
and Connecting Rods exert a force back to the eccentrics while pumping
under pressure, and if this force exceeds a certain design limit, the power
end will quickly fail. This limitation is commonly called the Maximum Rod
Loading.
One of the limiting factors of Rod load is the amount of force that the
Connecting rod can withstand before the lubrication is squeezed out from
between it and the eccentric bushing causing metal-to-metal contact.
When this occurs, failure is imminent.
The centerline of the Main Shaft in relationship to the centerline of the
eccentrics determines the length of the Stroke of the power end.
There are basically three types of power ends made by Dowell.
They are:
(a) The 5-inch stroke (PG Series with Rod Load = 110,000 lbs), rated at
285 BHP (Brake Horsepower) input and are the most commonly used in
cementing operations. They are available in either Steel for offshore
application or Magnesium for truck applications where weight is a
consideration.
(b) The 6-inch stroke (PC, PT with a Standard Rod Load = 195,000lbs
and the upgraded version with Rod load = 237,000) and PQ Series
with Rod Load = 165,000 LB)
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December 1999
(c) The 8-inch stroke (PD Series with Rod load = 115,000 LB).
Triplex Pump
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December 1999
Most of the P Series power ends except for the PG Series are being
phased out as the new generation of power ends and fluid ends will take
their place. The Gardner Denver GD 700 Lite Weight is one of the
replacement power ends being installed on some of the new equipment
today.
The GD 700 is available with ether a right angle drive gear as shown above and
also available with the standard direct drive into the pinion shaft
Triplex Pump
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December 1999
Two other common type of Power ends are:
OPI (Odessa Pump Inc) which was the original Manufacture of this
Crankshaft style Fracturing Triplex pump in the early 70s. Later other
manufactures made similar versions of the OPI style power end. Dowell
at the time was purchasing the power ends but manufacturing our own
fluid ends to use with the OPI power ends.
In the past Gardner Denver has purchased a number of the
manufactured OPI style Power Ends and today GD manufactures the
GD1250, GD2000 as replacements for the OPI 1300 and 1800 series
power ends. The Number indicates the Max Brake Horsepower input. For
example GD 1250- 1250 brake horsepower input.
The GD 1250 power ends have a Rod Load rating = 200,000 lbs.
Triplex Pump
Training Module
PAGE : 13
December 1999
The GD2000 power end have a Rod Load rating = 237,000 lbs. This is a
direct replacement for the OPI 1800 power end.
The SD2000 Power Ends were manufactured for Dowell by Twentieth
Century Manufacturing for use with the In-Line Fluid ends. Although the
life of the In-Line fluid end was short lived the SD2000 with its 325,000 LB
Rod Load was refitted to accept a cross-bore style fluid end and is a very
good Frac pump in our fleet today.
Triplex Pump
Training Module
PAGE : 14
December 1999
1.3 Fluid End
The Fluid End of the pump assembly is the part of the pump, which
receives fluid at low pressure, applies horsepower to the liquids, and
discharges the liquid at high pressure. The mechanical pumping action is
again very similar to that of a conventional piston-type internal
combustion engine or a reciprocating piston type air compressor. This
type fluid end is referred to as a Cross-Bore Type fluid end because the
two borings intersect each other to create the cylinder.
Triplex Pump
Training Module
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December 1999
As the plunger is drawn towards the Power End (suction stroke), the
pressure inside the chamber between the Suction and Discharge Valves
is reduced. This causes the suction valve to lift and the fluid to be drawn
into the suction manifold, through the suction ports, around the suction
valves, and into the chamber. At this moment, the suction valve is opened
by the fluid entering the fluid end, and the discharge valve is kept closed
by its check valve-type action and the discharge valve spring.
When the plunger starts to move in the opposite direction towards the
Fluid End (discharge stroke), the fluid inside the chamber, being
incompressible is forced out. The suction valve closes immediately like a
check valve, and the fluid then lifts the discharge valve from its valve seat
and is forced out around the discharge valve and into the pump discharge
chamber.
The usual suction or intake pressure is low (about 30 psi) but the
discharge pressure can be in the range of thousands of psi. Some Fluid
Ends made by Dowell are rated to work at 15,000 psi working, pressure
and some can even go as high as 20,000 psi.
Triplex Pump
Training Module
PAGE : 16
December 1999
The plungers, in the fluid end, receive energy from the power end. Each
time the main shaft makes one revolution, all the plungers in the pump
makes a complete cycle (i.e. a stroke forward and backward). Therefore,
by counting the revolutions of the main shaft and multiplying the RPM
(revolutions per minute) times a volume factor, we can get a volume
amount in BPM (barrels per minute), liters per minute or accumulative
amount of fluid pumped. This volume is only a mechanical indication of
volume, not an actual volume, so if the supply to the pump is restricted,
the volume calculated this way can be inaccurate. That is why in Dowell
we also use absolute volume measures like unit displacement tanks.
Fluid ends are designed for specific series of power ends, that is, the
stroke length of the fluid end is always the same as the stroke length of
the power end. Fluid ends are manufactured with various plunger
diameters for each series of power end. Plunger diameters range from the
smallest diameter of 2 inch to the largest of 7 inch. Obviously, the
larger the plunger diameter, the larger the volume of liquid displaced per
stroke of the plunger(s). However, the largest diameter plunger does not
necessarily mean the best. By making simple calculations, it can be seen
that for a particular Maximum Rod Load (as limited by each power end
series), the maximum pressure the fluid end can pump is limited by the
diameter of the plungers. So, the larger the plunger diameter, the lower is
the Maximum Pressure Rating of the fluid end. Should the Fluid End be
used to pump fluids in excess of its designed working pressure rating, the
first component of the triplex assembly that will fail is the power end.
Therefore, it is extremely important that the fluid end is not taken beyond
its maximum pressure ratings. Failure will occur because the force
exerted on the eccentric bushing (bearing) and the crosshead pin bushing
causes the lubrication to be squeezed out creating a metal-to-metal
contact. Once this occurs there is no reversing the damage and
catastrophic failure is inevitable.
Triplex Pump
Training Module
PAGE : 17
December 1999
Each type of fluid end can easily be identified by a code of letters and
numbers, which are stamped on each fluid end. An example: a fluid end
stamped TG06 would mean it is a 3 3/4 diameter plunger rated at a
maximum working pressure of 10,000 psi and a maximum output of 5.8
BPM for a 5 inch stroke (PG series) pump. There is also a serial number
stamped with the code to keep track of individual fluid ends. The fluid end
specifications, identification codes, volume factors, plus the rate and
maximum pressure ratings for each fluid end are given in the appendix of
this manual, the Dowell treating Equipment Manual or on a "quick
reference" card ratings shown below for different power end series:
Power end data:
Power end = 5 stroke PG series
Maximum rod loading = 110,000 lb
4.32 ratio, internal gears
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main
shaft
TSO 2-1/2 20,000 2.6 0.00170 0.0074
TRO 3 15,000 3.7 0.00245 0.0106
TGO 3-3/4 10,000 5.8 0.00383 0.0166
TLO 4-1/2 7,000 8.3 0.00552 0.0238
THO 5 5,500 10.3 0.00681 0.0294
Power end data:
Power end = 6 stroke MD 1000
Triplex Pump
Training Module
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December 1999
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main shaft
M 3 20,000 7.1 0.00308 0.0127
F 3-3/4 12,200 11.1 0.00482 0.0199
E 4-1/2 8,500 15.9 0.00694 0.0286
D 5 6,800 19.7 0.00856 0.0353
Power end data:
Power end = 6 stroke MD 1000
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main
shaft
M 3 20,000 5.3 0.00232 0.0127
F 3-3/4 12,200 8.3 0.00363 0.0199
E 4-1/2 8,500 12.0 0.00523 0.0286
D 5 6,800 14.8 0.00645 0.0353
Triplex Pump
Training Module
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December 1999
Power end data:
Power end = 8 stroke GD 700 series
10:1 Ratio
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main
shaft
FGD 3-3/4 15,800 7.9 0.00265 0.0265
XGD 4 13,900 9.0 0.00301 0.0301
EGD 4-1/2 11,000 11.4 0.00381 0.0381
HGD 5 8,900 14.1 0.00471 0.0471
IGD 5-1/2 7,400 17.1 0.00570 0.0570
YGD 6 6,200 20.3 0.00678 0.0678
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December 1999
Power end data:
6:1 Ratio
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main
shaft
FGD 3-3/4 18,000 7.9 0.00441 0.0265
XGD 4 16,000 9.0 0.00502 0.0301
EGD 4-1/2 12,500 11.4 0.00636 0.0381
HGD 5 10,000 14.1 0.00785 0.0471
IGD 5-1/2 8,400 17.1 0.00950 0.0570
YGD 6 7,000 20.3 0.01130 0.0678
Power end data:
Power end = 8 stroke PD 1250 series
5.0 Ratio, internal gears
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main
shaft
TTO 2-1/2 20,000 3.1 0.00235 0.0118
TMO 3 15,000 4.4 0.00339 0.0170
TFO 3-3/4 10,500 6.9 0.00530 0.0265
TEO 4-1/2 7,500 9.9 0.00763 0.0381
TDO 5 6,000 12.2 0.00942 0.0471
TNO 5-3/4 4,500 16.2 0.01246 0.0623
TJO 6-3/4 3,500 22.3 0.01716 0.0858
TKO 7-3/4 2,500 29.4 0.02263 0.1131
Triplex Pump
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December 1999
Power end data:
Power end = 8 stroke OPI 1800, HD 2000 series
Maximum rod loading = 195,000 lb (standard), 237,000 (upgraded)
6.353 : 1 Ratio
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main
shaft
FOPI 3-3/4 17,500 8.7 0.00417 0.0265
EOPI 4-1/2 12,000 12.6 0.00600 0.0381
HOPI 5 10,000 15.5 0.00741 0.0471
IOPI 5-1/2 8,000 18.8 0.00897 0.0570
UOPI 6-1/2 6,000 26.3 0.01253 0.0796
JOPI 6-3/4 5,500 28.3 0.01351 0.0858
Power end data:
Power end = 11 SD 2000 series, In-line pump
Maximum rod loading = 350,000 lb (standard)
8.4958: 1 Ratio
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main
shaft
H-205 5 16,500 14.5 0.0647
I-255 5-1/2 13,500 17.5 0.0783
U-265 6-1/2 10,000 24.5 0.1094
Triplex Pump
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December 1999
Power end data:
Power end = 11 SD 2000 series, Cross Bore pump
Maximum rod loading = 350,000 lb(standard)
8.4958: 1 Ratio
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main
shaft
H-205 4-1/2 20,000 12 0.0536
I-255 5-1/2 15,000 17.5 0.0783
U-265 6 12,500 21.2 0.0946
Note: Pumps volumetric efficiency = 97%
Many fluid end parts such as valves, valve seats, springs are interchangeable
with fluid ends of different series (stroke length) pumps. Other parts such as
packings, adaptor rings, spacers, gland nuts and lantern glands are also
interchangeable for use in pumps with plungers of the same diameter regardless
of the stroke length. (A chart showing interchangeable parts is included in the
appendix:
Triplex Pump
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December 1999
PG Series Fluid End Assembly
Triplex Pump
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December 1999
The GD lite weight series fluid ends utilize a different concept in fluid end
adaptability. They use a stuffing box as shown below that threads into the fluid
end, this stuffing box is were the packing seals seat. Some have different size
stuffing boxes as listed below. The pressure rating will due to the power ends
Rod load Rating. The same fluid end will fit on a GD 700 or GD 1250 powerend.
You should reference either the Treating Equipment manual or the Pump Card
via the Web for the latest and most accurate ratings.
The High Pressure Fluid End
3-3/4- (FGD) not Stuffing Box design (Conventional Design)
The Medium Pressure Fluid End
4-1/2- (EGD)
5 - (HGD)
5-1/2 (IGD)
The Low Pressure Fluid End
5-1/2 (IGD)
6 (YGD)
6-1/2 Under development
Incidentally the new fluid ends were designed to accept and use the same
packing and brass as that used in the same size fluid end in the PG series
Power End.
The plungers are different.
Triplex Pump
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December 1999
10:1 Ratio
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main
shaft
FGD 3-3/4 15,800 7.9 0.00265 0.0265
XGD 4 13,900 9.0 0.00301 0.0301
EGD 4-1/2 11,000 11.4 0.00381 0.0381
HGD 5 8,900 14.1 0.00471 0.0471
IGD 5-1/2 7,400 17.1 0.00570 0.0570
YGD 6 6,200 20.3 0.00678 0.0678
6:1 Ratio
Fluid
end
Plunger
size/diameter
(inches)
Standard
maximum
pressure
(Psi)
Pump
rate
(Bpm)
bbl/rev.
Pinion
Shaft
bbl/rev
Main
shaft
FGD 3-3/4 18,000 7.9 0.00441 0.0265
XGD 4 16,000 9.0 0.00502 0.0301
EGD 4-1/2 12,500 11.4 0.00636 0.0381
HGD 5 10,000 14.1 0.00785 0.0471
IGD 5-1/2 8,400 17.1 0.00950 0.0570
YGD 6 7,000 20.3 0.01130 0.0678
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December 1999
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December 1999
2.0 Specifications and Ratings for the PG Series Triplex Pump
2.1 Chain case
Case Steel (fabricated)
Chain Diamond 80-4
Ratio 27:40
RPM Maximum input 2240 RPM
RPM Maximum output 1512 RPM
Rated HP 353
Rotation Normal rotation is counter clockwise facing drive end of
the triplex pump pinion shaft.
Coupling input: spicer 1700 series drive flange output: chain case
sprocket mounted on triplex pump pinion shaft.
Weight 500 lbs (227 kg)
The Chain Case can be extended by adding a spacer and increasing the
chain length. Most Dowell Twin Pump Cement Units (CPS, CPT) use a
standard 23.15" center-to-center Chain Case for the Down Hole Pump,
which has a chain that is 90 pitches long. The Mixing Pump uses an
extended Chain Case (6" extension section) which increases the Chain
Case length to 29.15" center-to-center and uses a chain that is 95 pitches
long. Both chains are known as Quad 80 chain, which means 80 pitch
(length from pin to pin) and 4 links wide.
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December 1999
Typical Twin P.G. Pump Layout
The torque arms are designed to stabilize and control the reaction of the torque
being applied through the chain case. The torque arms are to be adjusted as
follows. The torque arms have left hand threads on one end so they will change
length when rotated. Set one of the torque arms to the desired position. Assuring
the driveshaft clears all obstructions. Then adjust the other torque arm in any
direction to tighten and lock the chaincase into position. Tighten all locking nuts
in position.
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December 1999
2.2 Power End
Pump Model PG05 (steel)
PG03 (magnesium)
Type Single Acting Triplex Reciprocating
Positive Displacement
Configuration Horizontal-in-Line
Stroke 5"(127mm)
Maximum Input Speed 2240 RPM
Maximum Mainshaft Speed 350 RPM
Maximum Pinion Shaft Speed 1512 RPM
Maximum Rod Load 110,000 lbs (50 tonnes)
Maximum Recommended Oil Temperature 160 degF (70 deg C)
Maximum Input Horse Power (HP) 353 HP
Rated Output Hydraulic Horsepower 300 HHP (224 kW)
Mechanical Efficiency (with Chain Case) 85%
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December 1999
The P.G. Pump can be configured in two different ways so that the power
end can be driven from the left or right hand side. These two
configurations do not require different parts but is distinguished by the
way the pinion shaft is installed in the power end frame. When changing
the position of the pinion shaft the timing gears must be re-timed.
Note:
There are a few instances where the P.G. series power end turns in the
opposite direction (Reverse Rotation). This is not common, but you will
find it on units where the two P.G. Pumps face each other (mirror image)
and are driven by conventional diesel engines.

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