Gardner Denver GD-2500Q QUINTUPLEX Service manual

ECN 1026734
GARDNER DENVER®
300FWF996 Rev C
August, 2005
WELL SERVICING PUMP
MODEL
GD-2500Q QUINTUPLEX
OPERATING AND
SERVICE MANUAL
HALLIBURTON EXHIBIT 1013, Page 1

300FWF996 Page i
GD-2500Q QUINTUPLEX
WELL SERVICING PUMP
MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER
PARTS AND SUPPORT SERVICES
Gardner Denver
®
genuine pump parts are manufactured to design tolerances and are developed for
optimum dependability. Design and material innovations are the result of years of experience with
hundreds of different pump applications. Reliability in materials and quality assurance is incorporated
in our genuine replacement parts.
Your authorized Gardner Denver Sales Office offers all the backup you ll need. The Fort Worth
and Tulsa Manufacturing Facilites maintain a large inventory of genuine parts.
Gardner Denver supports your needs with these services:
1. Trained parts specialists to assist you in selecting the correct replacement parts.
2. Repair and maintenance kits designed with the necessary parts to simplify servicing your pump.
Authorized service technicians are factory trained and skilled in pump maintenance and repair. They
are ready to respond and assist you by providing fast, expert maintenance and repair services.
For the location of your local authorized Gardner Denver distributor, refer to the yellow
pages of your phone directory or contact:
Factory (Tulsa): Service Center (Odessa): Factory (Ft. Worth):
Gardner Denver Well Servicing Pumps
4747 South 83
rd
East Avenue
Tulsa, Oklahoma 74145
Chaparral
2121 West 44
th
Street
Odessa, Texas 79768
Geoquip
7533 Kathy Lane
Ft. Worth, Texas 76126
Phone: [phone]
[phone]
Phone: [phone]
[phone]
Phone: [phone]
[phone]
Fax: [phone] Fax: [phone] Fax: [phone]
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Pump MODEL and SERIAL NUMBER (see nameplate on unit).
The Serial Number is also stamped on top of the cylinder end of the frame (cradle area).
All orders for Parts should be placed with the Fort Worth or Tulsa facility.
Where NOT specified, quantity of parts required per pump or unit is one (1); where more than
one is required per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER
OF PARTS REQUIRED.
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FOREWORD
Gardner Denver® pumps are the result of advanced engineering and skilled manufacturing. To
be assured of receiving maximum service from this pump the owner must exercise care in its
operation and maintenance. This book is written to give the operator and maintenance personnel
essential information for day-to-day operation, maintenance and adjustment. Careful adherence
to these instructions will result in economical operation and minimal downtime.
DANGER
Danger is used to indicate the presence of a hazard, which will cause severe
personal injury , death or substantial property damage if the warning is ignored.
WARNING
Warning is used to indicate the presence of a hazard, which can cause severe
personal injury , death or substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard, which will or can cause
minor personal injury or property damage if the warning is ignored.
NOTICE
Notice is used to notify people of installation, operation or maintenance
information which is important but not hazard related.
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TABLE OF CONTENTS
Maintain Pump Reliability and Performance with Genuine Gardner Denver Parts and
Support Services ........................................................................................................................ i
Instructions For Ordering Repair Parts ...................................................................................... i
Foreword .................................................................................................................................... ii
Index .......................................................................................................................................... iv
List of Illustrations ...................................................................................................................... v
Section 1, Danger Notices ......................................................................................................... 1
Section 2, Design, Description and Specifications .................................................................... 9
Section 3, Preparation, Operation and Maintenance ................................................................ . 15
Section 4, Service Procedures .................................................................................................. 21
Section 5, Trouble-Shooting ...................................................................................................... 29
Section 6, Rebuilding Data, Recommended Running Clearances and Torques ...................... 35
Warranty ................................................................................................................................ . 37
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INDEX
Crankshaft Assembly .................................... 26
Crosshead Assembly ............................... 25
Crosshead Guide and Stay Rods .. ........... 26
Daily Routine Maintenance Schedule ........... 19
DANGER NOTICES, SECTION 1 .................. 1
Covers and Guards ................................ .2
Equipment Moving and Lifting ................ 2
Flammable, Hot, Cold or Corrosive
Fluid Pumping ................................ .5
Hammer Lug Fasteners .......................... 1
High Pressure Liquid Jetting,
Blasting and Cleaning ..................... 6
Pressurized Pump Systems .................... 3
Valve Seat Pulling ................................... 2
DESIGN DESCRIPTION AND
SPECIFICATIONS, SECTION 2 ............. 9
Fluid End Description .................................... 13
Fluid End Removal and Installation .............. 21
Fluid End Service .......................................... 21
Foreword .. . .. ii
Gear Reduction Components ................. 11, 26
General Requirements and Safety Rules ..... 21
Introduction ..................................................... 9
Lube Pump Suction Piping Sizing and
Requirements ........................................ 16
Lube System Pump ....................................... 16
Lubrication, Plunger / Packing ...................... 17
Monthly Routine Maintenance Schedule ...... 19
Oil Stop Head Seal Retainer and
Gear Covers .......................................... 24
Ordering Instructions, Repair Parts ................. I
Performance Rating ......................................... 14
Periodic Routine Maintenance Schedule ........ 18
Plunger / Packing Lubrication .......................... 17
Plunger Packing Lubrication Recommendation
Chart .......................................................... 20
Plungers and Packing Replacement ............... 22
Power End .................................................. 10,24
Power End and Gear Reduction
Components Lube System ........................ 12
Power End Lubrication System ....................... 16
Preparation after Shipping and Storage .......... 15
PREPARATION, OPERATION AND
MAINTENANCE, SECTION 3 ................... 15
Pump Design ................................................... 10
Pump Mounting Instructions ............................ 15
Quarterly Routine Maintenance Schedule ....... 19
Rebuilding Data ............................................... 35
REBUILDING DATA, RECOMMENDED
RUNNING CLEARANCES AND
TORQUES, SECTION 6 ........................... 35
Recommended Running Clearances .............. 35
Repair Parts, Ordering Instructions ..................... i
SERVICE PROCEDURES, SECTION 4 ......... 21
Specifications, General .................................... 14
Startup and New Pump Run-In Procedure ...... 17
Torques ............................................................ 36
TROUBLE-SHOOTING, SECTION 5 .............. 29
Warranty .......................................................... 37
Valve and Seat Replacement .......................... 23
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LIST OF ILLUSTRATIONS
Figure # Description Page
Figure 2-1 GD-2500Q Quintuplex Pump .................................................................... 9
Figure 2-2 GD-2500Q Power End Section View ........................................................ 10
Figure 2-3 GD-2500Q Power End Rear Section View ................................................ 11
Figure 2-4 GD-2500Q Gear Reduction Components ................................................. 12
Figure 2-5 GD-2500Q Fluid End ................................................................................. 13
Figure 3-1 Lubricant Recommendations ..................................................................... 17
Figure 4-1 GD-2500Q Fluid End Tightening Sequence .............................................. 22
Figure 4-2 Typical Packing Assembly ......................................................................... 22
Figure 4-3 Fluid End Valve Stop ................................................................................. 24
Figure 4-4 GD-2500Q Crosshead Assembly .............................................................. 25
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SECTION 1
DANGER NOTICES
DANGER
Read and understand the following
DANGER NOTICES before moving or
operating the pump or any pump package
unit equipment.
Reciprocating pumps are machines capable
of producing high fluid pressures and flow
rates and are designed to be used with
proper care and caution by trained,
experienced operators. TO AVOID
PERSONAL INJURY, DEATH AND/OR
EQUIPMENT DAMAGE, READ AND
THOROUGHLY UNDERSTAND THE
FOLLOWING DANGER NOTICES PLUS
THE ENTIRE OPERATING AND SERVICE
MANUAL BEFORE ATTEMPTING TO
MOVE OR OPERATE THE PUMP. Contact
a Gardner Denver service representative if
you are unable to comply with any of the
danger notices or procedures described in
these documents.
Closely examine the pump performance
data upon pump delivery to become
thoroughly familiar with the operating limits
for this pump model. The pump must
never be operated at speeds, pressures
or horsepower exceeding the maximum
values or at speeds below the minimum.
Failure to observe the operating limits
could result in personal injury, death,
and/or equipment damage and will void
the warranty. Alterations to the pump, or
application of the pump outside the limits,
must not be made without Gardner Denver
written approval, together with a new set of
performance data, as dangerous operating
conditions could result.
Keep in mind that full operator attention and
alertness are required when operating high
pressure pumping equipment. Operators
should not begin or continue operations
when tired, distracted or under the influence
of alcohol or any type of prescription or
nonprescription drugs.
The timely replacement of expendable parts
and any other worn or damaged parts can
prevent equipment damage and possible
injury. The original parts used in Gardner
Denver pumps are designed and tested to
exacting standards to provide high quality
performance and durability. Your best
insurance in maintaining these
characteristics is to use genuine Gardner
Denver replacement parts.
A broad range of danger notices are
covered on these pages, however, they
cannot substitute for training, experience
and common sense in the safe operation of
high pressure pumping equipment.
HAMMER LUG FASTENERS
DANGER
On pumps equipped with hammer lug
unions and/or hammer lug valve covers the
following precautions must be observed to
avoid personal injury, death and/or
equipment damage due to contact with the
hammer, broken parts from the hammer,
lugs or other objects propelled by hammer
blows. When tightening or loosening
hammer lug unions and valve covers,
operators or maintenance personnel should:
Inspect the hammer and hammer lugs
to insure they are all in good condition.
Replace any of these parts which are
cracked, damaged or badly worn.
Wear safety shoes and safety glasses.
Alert other personnel to move away
from the area.
Check to insure they have safe footing.
Fully engage the hammer bar, if one is
used, to prevent it from disengaging
violently from the cover as a blow is
struck.
Wipe their hands and the hammer
handle and maintain a firm grip on the
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handle to avoid losing control of the
hammer while swinging and striking.
Carefully swing the hammer to avoid
striking themselves, another person and
objects other than the targeted lugs or
hammer bar.
Avoid swinging the hammer above
shoulder height.
VALVE SEAT PULLING
DANGER
The following precautions must be observed
by operators and maintenance personnel to
avoid personal injury, death and/or
equipment damage from contact with the
puller, hammer, wedge or broken parts from
these components when using either a
hydraulic or wedge valve seat puller.
Operators or maintenance personnel
should:
Hydraulic Seat Puller
Wear safety shoes and glasses.
Chain or tie the jack down as it will jump
violently when the valve seat
disengages from the valve deck.
Check to insure the pressure applied by
the hydraulic pump does not exceed the
hydraulic ram maximum pressure rating.
Wedge Seat Puller
Grind off any mushroomed material from
the wedge before use.
Inspect the hammer and wedge to
insure they are in good condition.
Replace any of those parts which are
cracked, damaged or badly worn.
Wear safety shoes and goggles.
Check to insure they have safe footing.
Fully engage the wedge to prevent it
from disengaging violently from the
cover as a blow is struck.
Wipe their hands and the hammer
handle and maintain a firm grip on the
handle to avoid losing control of the
hammer while swinging and striking.
Carefully swing the hammer to avoid
striking themselves, another person and
objects other than the targeted wedge.
Avoid swinging the hammer above
shoulder height.
COVERS AND GUARDS
DANGER
Personal injury, death and /or
equipment damage can result from
contact with moving parts. All
moving parts must be equipped with
covers and guards. All covers and
guards must be securely positioned
at all times when the unit is in
operation.
Covers and guards are intended to not only
protect against personal injury or death, but
to also protect the equipment from foreign
object damage
EQUIPMENT MOVING AND LIFTING
DANGER
Heavy equipment including pumps, pump
packages and components should only be
moved or lifted by trained, experienced
operators, who are physically and mentally
prepared to devote full attention and
alertness to the moving and lifting
operations. An operator should be fully
aware of the use, capability, and condition of
both the equipment being moved and the
equipment being used to move it.
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DANGER
Failure to follow safe and proper
pump, pump package or component
lifting or moving procedures can lead
to personal injury, death and /or
equipment damage from shifting,
falling or other unexpected or
uncontrolled equipment movements.
Make sure the hoist, lift truck, ropes, slings,
spreader bar or other lifting equipment you
are using is in good condition and has a
rated lifting capacity equal to or greater than
the weight being lifted. Lifting devices must
be checked frequently for condition and
continued conformance to rated load
capacity. They should then be tagged with
the rated capacity together with the date of
inspection.
Fully assembled pumps and pump
packages are heavy and should only be
moved using the specified lifting lugs or
attachments.
Many individual components have lifting
eyes or lugs, which must not be used to
lift assemblies, as they are designed to
bear the weight of the component only .
Before lifting the individual component
check to insure the lifting attachment is
firmly secured to the component with
undamaged, properly torqued fasteners,
sound welds, or other secure attachments.
Examine the lifting eyes, lugs, slots, holes or
other projections to insure they are not
cracked, otherwise damaged or badly worn.
The repair of existing or addition of new
welded lifting eyes, lugs or other projections
should only be performed by experienced,
qualified welders.
Package units should be lifted with
spreaders connected to the lifting
attachments normally built into the package
unit support skid. Packages too large to lift
as fully assembled should be separated into
smaller loads.
For these smaller loads the lifting devices
should be fastened to the lifting attachments
normally built into the individual motor,
engine, pump or transmission / torque
converter, or their separate support skids.
When lifting sub-assembled components, for
example a suction stabilizer attached to
suction piping or a discharge pulsation
damper attached to a strainer cross and
piping, use special lifting slings designed to
safely support the combined weight of the
components.
If a crane or hoist is being used to lift large
components or assemblies, one or more
persons should assist the operator from the
ground with guide lines attached to the
equipment being moved to properly position
it and prevent uncontrolled movement.
When you start to lift a pump, package unit,
subassemblies or individual components
and you observe the equipment is tilting, or
appears unbalanced, lower the equipment
and adjust the lifting device to eliminate
these improper lifting conditions before
proceeding to move the equipment.
It is poor practice and dangerous to allow
the equipment to pass over or close to your
body or limbs. Be prepared to move quickly
out of danger if equipment starts to fall, slip
or move unexpectedly toward you.
PRESSURIZED PUMP SYSTEMS
DANGER
Fluids under high pressure can
possess sufficient energy to cause
personal injury, death and/or
equipment damage either through
direct contact with escaping fluid
streams or by contact with loose
objects the pressurized fluid propels.
Operating a pump against a blocked or
restricted discharge line can produce
excessive pressures in the entire discharge
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300FWF996 Page 4
system, which can damage or burst
discharge system components.
DANGER
Never operate a pump without a
properly sized pressure relief valve or
working overpressure shutdown in
the discharge line immediately
adjacent to the pump discharge.
The relief valve should be placed in the
flowing discharge line and not at the
opposite end of the discharge manifold in a
dead end connection. The dead end may
become clogged with solid material carried
in the fluid, which could prevent proper relief
valve operation.
DANGER
Never place a shut-off valve or any
other component between the pump
discharge connection and the
pressure relief valve.
Make sure the pressure relief valve is
installed so any pressurized relief discharge
from the valve is directed away from
possible contact with people or equipment.
The relief valve must be set to relieve at a
pressure equal to or below the maximum
pressure values shown on the pump data
plate. However, if a component is used in
the discharge system with a lower rated
pressure capability than that listed on the
pump data plate, the pressure relief valve
must be set to relieve at a pressure equal to
or below the rated capability of the lowest
rated component.
Before starting the pump every time,
check to insure:
The pressure relief valve is in good
operating condition and has been set to
the proper relief pressure.
Any pipe line used to direct pressurized
relief flow to another location, such as a
collecting tank, is not blocked.
The discharge system is not blocked
and all the discharge line valves are
open.
Check all fluid end discharge system
components including pipes, elbows
connections, threads, fasteners, hoses,
etc., at least once every six months to
confirm their structural adequacy. With
time, wear, corrosion and fatigue can reduce
the strength of all components. Magnetic
iron and steel components should be
checked with magnetic particle or dye
penetrates crack detection equipment.
Nonmagnetic materials should be checked
for cracks with dye penetrates. All metallic
components should also be visually checked
during these inspections for signs of
corrosion. If a component shows evidence
of cracking or loss of material due to
corrosion it must be replaced with a new
part.
Continually monitor suction and discharge
hose assemblies when the pump is
operating for leakage, kinking, abrasion,
corrosion or any other signs of wear or
damage.
Worn or damaged hose assemblies
should be replaced immediately. At least
every six months examine hose assemblies
internally for cut or bulged tube, obstructions
and cleanliness. For segment style fittings,
be sure that the hose butts up against the
nipple shoulder, the band and retaining ring
are properly set and tight and the segments
are properly spaced. Check for proper gap
between nut and socket or hex and socket.
Nuts should swivel freely. Check the layline
of the hose to be sure that the assembly is
not twisted. Cap the ends of the hose with
plastic covers to keep them clean until they
are tested or reinstalled on the pump unit.
Following this visual examination, the hose
assembly should be hydrostatically tested,
on test stands having adequate guards to
protect the operator, per the hose
manufacturer's proof test procedure.
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Fluid end component inspections should
be performed more frequently than every
six months if pressures above 2500 psi
are used in the discharge system or if
corrosive, abrasive, flammable or hot
(over 110º F) fluids are being pumped.
Proper stuffing box packing selection is
important for safe pump operation. Contact
a Gardner Denver service representative for
assistance in selecting the proper packing
before beginning operation.
Before starting the pump the first time, and
periodically thereafter check the pump,
suction and discharge system fastener
torque versus the values listed on page 35
to insure proper tightness. Over and under
torquing can damage threaded pipes,
connections and fasteners, which may lead
to component damage and/or failure.
Replace all components found to be
damaged or defective. On pumps equipped
with stuffing boxes, the gland must be
engaged by at least three (3) threads to hold
the discharge pressure of the pump.
DANGER
Do not attempt to service, repair or
adjust the plunger packing or other-
wise work on the pump while the unit
is operating. Shut off the pump drive
engine and relieve the fluid pressure
in the suction and discharge systems
before any work or investigation is
performed on the pump or pump
systems.
Block the crankshaft from turning and make
certain that all pump drive motor or engine
start switches or starter controls are clearly
tagged with warnings not to start the pump
while repair work is in process.
Whenever the pump is operating, continually
monitor the entire suction, discharge and
pump lubricating systems for leaks.
Thoroughly investigate the cause for
leakage and do not operate the pump until
the cause of the leak has been corrected.
Replace any parts which are found to be
damaged or defective. When a gasketed
joint is disassembled for any reason, discard
the used gasket and replace it with a new,
genuine Gardner Denver gasket before
reassembling the joint.
Due to the high working pressures
contained by the fluid end, discharge
manifold and discharge piping, welding on
these components is not recommended. If
welding on the discharge system cannot be
avoided, only experienced, qualified welders
should be used. In addition, the welded part
should be hydrostatically proof tested in the
shop with water or hydraulic fluid to one and
one half times maximum discharge system
working pressure, with no observable fluid
leakage, before the part is reinstalled in the
pump system.
In summary, high pressure fluid streams can
possess sufficient energy to cause personal
injury, death and/or equipment damage.
These results can occur either through
direct contact with the fluid stream or by
contact with loose objects the fluid stream
has propelled, if the pump system is
improperly used, or if the fluid is
misdirected, or allowed to escape from
defective or improperly maintained
equipment.
FLAMMABLE, HOT, COLD OR
CORROSIVE FLUID PUMPING
DANGER
Extreme caution must be exercised
by trained and experienced operators
when flammable, hot, cold or
corrosive fluids are being pumped to
avoid personal injury, death an/or
equipment damage due to explosion,
fire, extreme cold or chemical attack.
Never operate a pump that is pumping
hydrocarbons or other flammable, hot, cold,
or corrosive fluids when any part of the
pump, suction system or discharge system
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300FWF996 Page 6
is leaking. Stop the pump immediately if any
leakage, other than a few drops per minute
of packing seepage, is observed. Keep all
flame, sparks, or hot objects away from any
part of the pump, suction system, or
discharge system. Shield the pump, suction
system and discharge system to prevent
any flammable, hot, cold or corrosive fluid
leakage from dripping or spraying on any
components, flame, sparks, hot objects or
people. Inspect the plungers, packing,
gaskets and seals for fluid leakage
frequently and replace all worn or leaking
parts.
Selection of the proper gaskets, seals and
stuffing box packing is even more critical
when flammable, hot, cold or corrosive fluids
are being pumped than when other,
inherently less dangerous fluids are used.
Contact a Gardner Denver service
representative for assistance in selecting the
proper gaskets, seals and packing before
beginning operation.
Since some packing seepage into the cradle
area is inevitable, a drain pan located at the
bottom of the cradle must be connected to a
drain line which conducts the fluid leakage
to a collection container located in a
protected area. The entire drain system and
container must be constructed of materials
resistant to attack from the pumped fluid or
from explosion or fire of the pumped fluid.
Before beginning pumping operations or
starting the pump power source (whether an
engine or electric motor) check the
atmosphere all around the pumping site for
the presence of flammable or explosive
vapors. Do not begin operation and stop
ongoing operation if flammable or explosive
vapors are detected. Hot surfaces, sparks,
electric current or engine exhaust could
ignite flammable or explosive vapors. Each
engine used as a power source on pumping
units where flammable or explosive vapors
could form should be equipped with an air
inlet shut-off. If flammable or explosive
vapors are present in the pumping site
atmosphere, an engine could continue to
run on these vapors even after the engine
fuel line is shut-off if an air inlet shut-off is
not used.
In addition, on pumping units used where
flammable or explosive vapors could form,
all electric motors used as power sources
must be of explosion proof construction and
all electrical components and wiring must
meet the current National Electrical Code for
explosive atmospheres.
These precautions must be taken to avoid
possible personal injury, death and/or
equipment damage from explosion, fire or
burns.
HIGH PRESSURE LIQUID JETTING,
BLASTING AND CLEANING
DANGER
Extreme caution must be exercised if
any type of wand, gun, nozzle or any
other pressure and flow-directing
device is attached to the pump
discharge system for use in jetting,
blasting, cleaning, etc. This type of
equipment must be used by trained,
experienced operators with the
utmost care. High-pressure fluid
streams can either by direct contact
or by propelling loose objects, cause
serious personal injury or death to
operators and/or other persons.
Pressure or flow directing devices often
receive pressurized flow through flexible
hoses, which can burst if they are kinked,
cut, abraded or are otherwise worn,
damaged or pressured above their rated
capacity. Protect the hose and connections
from damage by people, objects and
vehicles. A broken, cut or otherwise burst
hose can release pressurized fluid, which
may cause personal injury, death and/or
equipment damage.
High pressure fluid from hand held or hand
directed pressure and flow directing devices
may overpower an operator s ability to
control or direct the device, which could lead
to personal injury, death and/or equipment
damage. The operator must brace against
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300FWF996 Page 7
the backward thrust of a hand held device.
In addition, a safety harness or safety net
must be used when working in an area
where the operator could be injured in a fall.
Stand to the side of any tubing or container
being sprayed to avoid back spray and
never operate a hand held device above
shoulder level.
Never direct the pressurized fluid stream at
yourself or any other person, control valves,
the pump, pump drive, suction or discharge
systems. The pressurized stream can
cause serious personal injury or death and
can also change valve or control settings
which could dangerously increase the
delivery pressure to the pressure and flow
directing device.
When operating a pressure and flow
directing device, use only equipment which
automatically shuts off flow when an
operator releases hand or foot pressure on
the pressurized flow trigger control to
prevent injury if the operator is overpowered
or becomes disabled.
Check to insure this automatic shut-off
equipment is operating properly before
every use and never circumvent the
automatic shut-off for any reason or by any
means when operating the equipment.
When operating any type of high pressure
liquid jetting, blasting or cleaning devices,
the operators must always wear protective
clothing including, but not limited to, a hard
hat with full face visor, heavy duty rain coat
and pants, boots with nonskid sole and
safety toe, rubber gloves with rough grip
surface and ear noise protection.
Full operator attention and alertness are
required when operating this equipment to
avoid personal injury, death and/or
equipment damage. The operators should
take frequent rest breaks and cease
operations when they become tired or
distracted.
Before the equipment is started, the work
area must be inspected and properly
prepared to avoid personal injury, death,
and/or damage to equipment. Make sure
the work area is checked for hazardous
fumes, has adequate ventilation for engine
exhaust and sufficient drainage for released
fluid. Check the work area for electrical
equipment, connections, outlets, fixtures, or
lines. If any are present they must be made
watertight and the electrical power to these
devices must be shut off to avoid electrical
shocks from fluid contact. The work area
should be clearly marked and roped off to
keep unauthorized people and vehicles from
entering. Remove all loose parts, tools and
equipment from the work area before
beginning operation.
All pressure containing devices including
wands, nozzles, guns, hoses, connections,
etc ., should be regularly checked for
condition. These components should all be
tagged with their tested pressure capabilities
together with the date testing was
performed. Always be aware of the
pressure level in the system and never
connect any equipment to the system
which has a rated or tested pressure
capability below the system operating
pressure. The equipment must be shut
down and the system pressure released
before changing or disconnecting wands,
nozzles, guns, hoses, connections or any
other pressurized system components.
All pressure containing devices including
wands, nozzles, guns, connections, etc.,
plus all automatic shut-off, pressure and
control equipment should be treated with
care. Protect them from damage by people,
objects and vehicles. Never lay them in dirt,
mud, ice or other loose material that could
plug the fluid opening or interfere with their
operation. Never use the wand, nozzle,
gun, etc. to pry loose material off items
being cleaned.
Before starting operation in a cold
environment, check to make sure there is no
ice in the fluid system and repeat this
inspection each time before operation is
restarted.
Before purchasing wands, nozzles, guns,
connections, hoses, etc., manufacturers of
these components should be contacted for
detailed information on the design and
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300FWF996 Page 8
safety features incorporated in their
products. After careful study of various
manufacturers products, we recommend
that only those wands, nozzles, guns,
connections and hose, etc., be considered
for purchase that you judge to offer the
highest quality of design, construction and
safety, since these components are among
the most critical to the safe operation of high
pressure liquid jetting, blasting and cleaning
equipment.
After you have selected and purchased
these components, follow the
manufacturer s instructions completely in
their use.
In summary, high pressure jetting,
blasting and cleaning are inherently
dangerous, as the pressures and flow
rates needed to remove scale, clean, etc.
are sufficient to cause personal injury,
death, and/or equipment damage
resulting from, but not limited to, any of
the conditions described in the above
Danger Notices.
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300FWF996 Page 9
SECTION 2
DESIGN, DESCRIPTION AND SPECIFICATIONS
INTRODUCTION
The new Gardner Denver GD-2500Q is a
high horsepower, high rod load multi-
purpose pump for various applications such
as oil and gas well fracturing and acidizing
and potentially as a light weight drilling
pump . The pump was designed using
modern analytical and engineering methods
and techniques. The gear drive was
designed in accordance with the most
recent standards, procedures, and computer
software developed by American Gear
Manufacturers Association.
The issue of personnel safety is the most
important topic covered in this manual.
Therefore, in the beginning of this manual
the user is introduced to dangers inherent in
the operation of a high-pressure pump. To
avoid accidents and injuries, all safety rules
listed in this section and also all other
applicable safety rules and regulations must
be carefully observed.
The sections on Pump Design, Description,
and Specifications, describe the pump
design, list the pump specifications, and
present drawings depicting the pump
external views and all essential cross-
sectional drawings.
FIGURE 2-1: GD-2500Q Pump
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Section 3, "Pump Preparation, Operation,
and Maintenance," addresses the issues of
preparing the pump for operation after
shipping or storage, the lubrication system
design and specifications, the new pump
run-in procedures, and the periodic routine
maintenance schedule. The recommended
oils, viscosity data, and crankcase oil
temperature requirements are also
presented in this section.
Section 4, "Service Procedures," describes
the various assembly / disassembly
procedures.
Section 5, Trouble Shooting, describes
possible problems, causes and solutions
related to pump performance.
Section 6, Rebuilding Data, Recommended
Running Clearances and Torques, presents
information useful for pump rebuilding and
assembly, including dimensional and
tolerance data, running clearances for all
bearings, and recommended fastener
torques.
PUMP DESIGN
The GD-2500Q quintuplex pump uses only
two major assemblies: power end and fluid
end. The gear reducer is located inside the
power end. The pump is designed with a
modular concept. Each assembly is a
module that can be assembled, handled,
installed, fixed, or transported separately
from the rest of the pump (See FIGURE 2-1,
page 9). The following is a brief description
of the essential design features for each
modular assembly.
POWER END (FIGURE 2-2,FIGURE 2-3)
The power end design is a fabricated steel
frame made from high-strength low-alloy
steel plate, joined by heavily welded cross-
members to provide stiffness and strength.
This design concept provides maximum
durability with minimum weight.
FIGURE 2-2 GD-2500Q Power End Section View
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FIGURE 2-3: GD-2500Q Power End Rear Section View
NOTICE
The direction of rotation must be
such that the top side of the
crankshaft is moving toward the fluid
end.
The crossheads and crosshead-guides are
full-cylindrical design for minimum PV
loading and maximum lubrication. The
connecting rods are automotive type. The
connecting rods are accessible through the
rear of the pump, and the crossheads
through the nose or front of the pump. The
crankshaft is a forged steel automotive type
crankshaft with six cylindrical roller-bearing
mains. The main bearings consist of four
floating and two outside held bearings.
The connecting rod bearings are automotive
journal bearings, and the wrist-pin bearings
are hi-alloy bronze journal bearings.
The crankshaft and crossheads are on the
same centerline. The fluid end is held in
place and in alignment with the power end
by the twenty (20) stay-rods. (See
FIGURE 2-1).
The power end is fully enclosed to contain
the power end oil, collecting the oil and
draining out the bottom skin through two
NPTF weld-let connections. This is a dry-
sump pump. An external oil sump and lube
pressure and filter system is required.
GEAR REDUCTION COMPONENTS
(FIGURE 2-4)
The internal gear reduction consists of two
helical bull-gears located on either end of
the crankshaft, and one input pinion shaft
with helical pinion gears on each end. The
overall ratio of the reduction gear unit is
6.353:1 This arrangement offers a good
power to weight ratio and flexibility in using
different prime movers such as diesel
engines as well as electric motors. All
gears are heat-treated, hardened, and
ground to AGMA quality level 10 or better to
insure the highest reliability and long life of
the gear box.
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POWER END AND GEAR REDUCTION
COMPONENTS LUBE SYSTEM (FIGURE
2-2, FIGURE 2-3, and FIGURE 2-4,)
Both the internal gear reduction components
and the power end have one common lube
oil inlet. The power end inlet is located on
the side of the pump forward of the gear
cover. The inlet is a NPTF tee that divides
the lube flow between the lube manifold for
the main bearing and crosshead guide area
and the rotary unions. Pressurized
lubrication for each crosshead is delivered
from the lube manifold to the top of the
crosshead guides. An aluminum cover
houses the rotary union, which is attached
to the crankshaft. Lubrication for the rotating
power end components comes from forced
lube through the crankshaft. Lube oil enters
the crankshaft and first lubricates the
connecting bearings. Oil from the
connecting rod bearing also lubes the wrist-
pin bearing. As oil reaches the first
crankshaft journal, oil exits the journal oil
hole and lubes the journal and journal
bearings, passes through the center of the
connecting rod to the wrist pin and wrist-pin
bearing. It also connects to the crosshead
oil supply, giving a redundant oiling
pathway. This is repeated for the rest of the
main bearing and crosshead components.
Oil is removed from the power end through
two primary drain connections in the bottom
of the frame. Oil passages at the forward
part of the frame members allow the
crosshead cylinders to drain to the power
end sump. Oil is also drained from the gear
covers through drain holes in the outside
frame plates. These drains are all combined
together and empty into the main drains in
the bottom of the pump frame. From here, it
exits to an external oil sump (supplied by
others).
The two main bull-gears are oiled by spray-
bars located inside the gear covers. These
spray-bars are connected externally to the
oiling system through oil hoses. These spray
bars, nozzles, and orifices provide not only
lubrication for the gears and pinions, but
also provide a vehicle to carry away the
generated heat built up by the heavy loading
of the gears and pinions, along with the
pinion bearings and other load carrying
components.
NOTICE
It is extremely important to maintain
some downward slope in the entire drain
system back to the lube reservoir.
FIGURE 2-4: GD-2500Q Gear Reduction Components
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FLUID END (FIGURE 2-5)
This fluid end incorporates the traditional
flange-mounted fluid end design, which
simplifies installation and removal by simply
removing of the stay-rod nuts. These stay-
rod nuts must be made-up tight and remain
tight during operation. (See Torque
Requirements on page 36). Plungers are
installed and removed through the front
suction covers. Plunger packing is
accessible by removal of the packing nut or
gland. Plunger packing lube holes are
provided in the fluid cylinder.
The conventional fluid end V alve- O ver-
Valve configuration offers field a proven
arrange-ment in terms of the valve and
spring performance. Improvements in the
fluid end life come from increasing fluid
cylinder cross sections in areas of maximum
stresses by reducing internal dimensions
through the use of the twist-type valve stop.
New sophisticated methods of metallurgical
control allow us to obtain steels with very
consistent chemical compositions and
mechanical properties. These forgings have
higher tensile, yield, hardness and low-
temperature impacts than conventional
forgings.
FIGURE 2-5: GD-2500Q Fluid End
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GENERAL SPECIFICATIONS
This section presents the pump basic specifications. The first set of specifications deals with the
pump's power, rod load, plunger stroke, and overall dimensions. The other table presents
allowable pressures and flows for various pump speeds along with data on power requirements.
GD-2500Q PERFORMANCE RATING
Plunger
Size
Displacement
per
Revolution
Displacement at Pump RPM - Well Stimulation Application
100 150 250 330
in. gal/
rev. GPM PSI GPM PSI GPM PSI GPM PSI
3.75 1.91 191 17800 287 13500 478 8100 631 6100
4 2.17 217 15600 326 11800 544 7100 718 5400
4.5 2.75 275 12400 413 9300 688 5600 908 4200
5 3.40 340 10000 510 7600 850 4500 1121 3400
5.5 4.11 411 8300 617 6300 1028 3800 1357 2800
5.75 4.49 449 7600 674 5700 1124 3400 1483 2600
6 4.89 489 6900 734 5300 1223 3200 1615 2400
6.5 5.74 574 5900 861 4500 1436 2700 1895 2000
6.75 6.19 619 5500 929 4200 1548 2500 2044 1900
Input
Power
BHP 2200 2500 2500 2500
Rated Brake Horsepower 2500bhp
Stroke Length 8.0 inches
Maximum Rod Load 196,350 lbs.
Gear Box Ratio 6.353 : 1
Overall Length 86.25 in.(max.)
Overall Width 74.25 inches
Overall Height 43.69 inches
Weight (system dry) 14,570 lbs.
HALLIBURTON EXHIBIT 1013, Page 20