Weatherford MP-16 Manual

Operations & Maintenance Manual
Model MP-16
Triplex Pump
Two Piece Fluid End - 5,000 PSI
Manual Part Number 1923778
January 2013

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Chapter 1: Introduction
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Table of Contents
Chapter 1:Introduction...........................................................................................1
1.1 Product Details.....................................................................................................1
1.1.1 Specifications .........................................................................................................1
1.1.2 General Dimensions ...............................................................................................2
1.2 Scope...................................................................................................................1
1.3 Manual Organization ............................................................................................1
1.4 Safety Summary...................................................................................................2
1.4.1 Safety Symbols and Terms.....................................................................................2
1.4.2 General Safety........................................................................................................3
1.4.3 Common Hazards...................................................................................................4
1.4.4 Pump Specific Safety..............................................................................................5
Chapter 2:Storage & Installation............................................................................7
2.1 Installation ............................................................................................................7
2.1.1 Transport Skid ........................................................................................................7
2.1.2 Location and Orientation.........................................................................................7
2.1.3 The Prime Mover ....................................................................................................8
2.1.4 Suction System.......................................................................................................9
2.1.5 Discharge System.................................................................................................11
2.1.6 Power End Preparation.........................................................................................13
2.1.7 Auxiliary or Ancillary Systems...............................................................................13
2.1.8 Installation Checklist.............................................................................................14
2.2 Storage...............................................................................................................15
2.2.1 General Storage Guidelines..................................................................................15
2.2.2 Special Conditions & Procedures..........................................................................16
2.2.3 Upkeep.................................................................................................................16
2.2.4 Returning to Service .............................................................................................17
Chapter 3:Operations ......................................................................................... 18
3.1 Starting Procedure..............................................................................................18
3.1.1 Initial Startup.........................................................................................................18
3.1.2 Pre-Start Checklist................................................................................................19
3.1.3 Start Up Procedure...............................................................................................20
3.2 General Operations............................................................................................21
3.3 Basic Troubleshooting........................................................................................22
3.3.1 Excessive Vibration ..............................................................................................22
3.3.2 Knocking in the Fluid end......................................................................................23
3.3.3 Knocking in the Power End...................................................................................24
3.3.4 Rapid Piston & Liner Wear....................................................................................25
3.3.5 Difficulty Installing Liners in Liner Retention Flanges ............................................26
Chapter 4:Maintenance ...................................................................................... 27
4.1 Tools & Equipment.............................................................................................27
4.1.1 Tools & Equipment Used......................................................................................27
4.2 General Maintenance Guidelines .......................................................................27
4.2.1 Initial Operations Maintenance..............................................................................28
4.2.2 Fastener Torque Specifications ............................................................................28

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4.2.3 Biannual Inspection ..............................................................................................28
4.3 Lubrication..........................................................................................................29
4.3.1 Prestart Lubrication...............................................................................................29
4.3.2 Minimum Operating Speed ...................................................................................29
4.3.3 Power End Lubrication Guidelines........................................................................29
4.3.4 Pistons & Crosshead Extension Lubrication..........................................................30
4.3.5 Temperature Maintenance....................................................................................30
4.4 Maintenance Schedules .....................................................................................31
4.4.1 Daily Maintenance Checklist.................................................................................31
4.4.2 Biweekly Maintenance Checklist...........................................................................32
4.4.3 Monthly Maintenance Checklist ............................................................................32
4.4.4 Semiannual Maintenance Checklist......................................................................33
4.4.5 Annual Maintenance Checklist..............................................................................33
4.5 Routine Maintenance Procedures ......................................................................34
4.5.1 Venting Pressure in the Fluid End.........................................................................34
4.5.2 Pre-Installation Procedure ....................................................................................34
4.6 Piston & Liner Maintenance Procedures ............................................................35
4.6.1 Removing the Piston & Liner as a Unit..................................................................35
4.6.2 Removing the Liner & Wear Plate.........................................................................37
4.6.3 Piston Disassembly & Parts Replacement............................................................39
4.6.4 Piston Cup Replacement......................................................................................40
4.6.5 Installing the Liner Retainer & Wear Plate.............................................................41
4.6.6 Installing the Liner & Piston...................................................................................42
4.7 Valve Maintenance Procedures..........................................................................45
4.7.1 Valve Assembly....................................................................................................45
4.7.2 Removing the Valves............................................................................................46
4.7.3 Installing the Valves..............................................................................................47
4.8 Charts & Diagrams.............................................................................................49
4.8.1 Torque Chart ........................................................................................................49
4.8.2 Lubrication Chart ..................................................................................................50
Chapter 5:Assembly/Disassembly...................................................................... 51
5.1 L-Style Fluid End Maintenance Procedures .......................................................51
5.1.1 Removing the Discharge Manifold ........................................................................51
5.1.2 Removing the Suction Manifold ............................................................................53
5.1.3 Removing the Fluid Modules.................................................................................54
5.1.4 Installing the Fluid Modules & Manifolds...............................................................57
5.1.5 Discharge Cross Installation .................................................................................60
5.1.6 Installing the Liner Wash System..........................................................................60
5.2 Power End Maintenance Procedures.................................................................61
5.2.1 Removing the Wiper Box & Diaphragm Plate........................................................61
5.2.2 Removing the Crosshead .....................................................................................64
5.2.3 Removing the Crosshead Guides .........................................................................67
5.2.4 Removing the Crankshaft Assembly.....................................................................68
5.2.5 Removing the Main Bearing..................................................................................70
5.2.6 Removing the Connecting Rods ...........................................................................72
5.2.7 Removing the Wrist Pin Bearings..........................................................................74
5.2.8 Turning the Main Gear..........................................................................................75

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5.2.9 Removing the Main Gear......................................................................................76
5.2.10 Removing the Pinion Shaft & Bearings .................................................................77
5.3 Power End Assembly Procedures......................................................................80
5.3.1 Installing the Pinion Shaft & Bearings...................................................................80
5.3.2 Mounting the Main Gear .......................................................................................83
5.3.3 Installing the Connecting Rods & Bearings...........................................................85
5.3.4 Installing the Main Bearing....................................................................................88
5.3.5 Installing the Wrist Pin Bearing.............................................................................90
5.3.6 Installing the Crankshaft Assembly.......................................................................91
5.3.7 Installing the Crossheads & Crosshead Guides....................................................93
Chapter 6:Glossary............................................................................................. 96
Chapter 7:Parts Lists........................................................................................ 102
7.1 Power End Assembly .......................................................................................102
7.1.1 Power Frame Assembly......................................................................................103
7.1.2 Crankshaft Assembly..........................................................................................104
7.1.3 Main Bearing Assembly......................................................................................105
7.1.4 Pinion Assembly.................................................................................................106
7.1.5 Crosshead Assembly..........................................................................................107
7.2 L-Style Fluid End Assembly..............................................................................108
7.2.1 L-Style Suction Module Assembly.......................................................................109
7.2.2 L-Style Valve Plug Assembly..............................................................................109
7.2.3 L-Style Discharge Module Assembly...................................................................110
7.2.4 Liner Assembly...................................................................................................111
7.3 Expendable Components Assemblies..............................................................112
7.3.1 Piston Assembly.................................................................................................112
7.3.2 Valve Assemblies ...............................................................................................113

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Chapter 1: Introduction
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Chapter 1: Introduction
This manual is designed to provide instruction in the use of the Weatherford MP-16 pump.
All personnel tasked with pump operation and maintenance should study all relevant sections
in order to ensure the pump continues to operate at peak efficiency.
1.1 Product Details
The Weatherford MP-16 Pump is a single acting triplex piston pump rated at 1,600
horsepower in continuous duty service. It is offered in a wide variety of design options, and
as a result, some components may vary from unit to unit. Check the specifications sheet
included with this manual to determine the exact configuration of your particular pump.
1.1.1 Specifications
General Information
Operational Statistics
Pump Type
Triplex
Maximum Rated Power
1,600 HP
Pump Weight
59,700 lbs.
Maximum Discharge
5,000 psi
Oil Capacity
100 gal
Maximum Rated Speed
120 SPM
Max Fluid Temp.
140° F
Minimum Rated Speed
20 SPM
Mechanical Efficiency
90%
Stroke Length
12 IN
Liner
Size
(in/mm)
Rated
Pressure
(psi/Mpa)
Rated Capacity GPM (BPD)
120 RPM
115 RPM
110 RPM
105 RPM
100 RPM
95 RPM
90 RPM
1,600 HP
1,520 HP
1,454 HP
1,388 HP
1,322 HP
1,255 HP
1,189 HP
7.00
3,360
720
690
660
630
600
570
540
178
23.20
24,689
23,660
22,631
21,603
20,574
19,545
18,517
6.50
3,900
621
595
569
543
517
491
465
165
26.890
21,294
20,403
19,511
18,619
17,728
16,836
15,945
6.00
4,575
529
507
485
463
441
419
397
152
31.50
18,139
17,385
16,631
15,876
15,122
14,368
13,613
5.50
5,000
444
426
407
389
370
352
333
140
34.50
15,223
14,608
13,956
13,339
12,687
12,070
11,419
5.00
5,000
367
352
337
321
306
291
275
127
34.50
12,583
12,069
11,554
11,006
10,491
9,977
9,429
4.50
5,000
297
285
273
260
248
235
223
114
34.50
10,183
9,771
9,360
8,914
8,503
8,057
7,646

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1.1.2 General Dimensions

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Chapter 1: Introduction
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1.2 Scope
This manual is intended to provide instruction and guidance on standard and frequently
used procedures and processes regarding the MP-16 pump. These include the setup and
installation of the system, basic operations, storage, routine maintenance and basic
troubleshooting, as well as a parts list for the various components of this system.
The information contained in this document has been expanded to include not only the
core systems and functions of the MP-16 pump, but also optional features that may be
incorporated into the system. This information is included to ensure that the guidance
provided remains applicable in most expected operating conditions and situations. As a
result, some of the features described may not be present on a specific unit, and allowances
should be made accordingly.
This document was designed for use by pump operators, maintenance personnel and
other personnel familiar with the equipment and its expected use. As such, this document will
not go very deeply into theory and basic processes, but will focus primarily on equipment-
specific issues and procedures. Individuals without proper training or experience should
always have experienced personnel supervising their use of this or any other powerful and
potentially hazardous equipment.
This manual has been prepared with the system’s expected uses in mind. For help with
events, situations and uses not typical to this system, or for advanced troubleshooting issues,
please contact your local Weatherford representative.
1.3 Manual Organization
This manual has been laid out in accordance with the expected need of its users. It is
divided into seven sections, each of which is intended to cover one aspect of the equipment’s
use and functions.
Chapter 2: Storage & Installation covers the non-operational aspects of using and
maintaining the system, from basic storage to installing the system on location.
Chapter 3: Operations covers the basic operating procedures, from the standard startup
sequence to the general operations procedures and troubleshooting tips.
Chapter 4: Maintenance covers all aspects of the regular preventative maintenance that will
help to ensure that the system operates at peak efficiency for as long as possible, including
the tools used, operational guidelines and basic replacement procedures.
Chapter 5: Assembly & Disassembly covers the assembly and disassembly of the pump and
its components, including advanced repair and replacement procedures.
Chapter 6: Glossary provides a list of standard terms and definitions regarding triplex pumps
in general and the MP-16 pump in particular.
Chapter 7: Parts Lists provides a comprehensive inventory of all the standard components
used in the MP-16 pump.

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1.4 Safety Summary
Every year, the Unites States Occupational Safety & Health Administration (OSHA)
receives reports of millions of worker related injuries and deaths associated with the use and
misuse of mechanical and industrial equipment. Many of these incidents occur due to either
carelessness on the part of the operator or as a result of the operator not understanding the
equipment and processes he or she was using. In many cases, such incidents could have
been prevented through the use of basic, commonly-accepted safety procedures.
When working with industrial equipment, or indeed at any time you are working, it is
important to employ all appropriate safety measures. These exist not only to protect the
operator of the equipment, but also co-workers, supervisors, contract personnel and anyone
else who happens to be in the area where the work is being performed.
Always use good, sound mechanical practices when working with industrial equipment,
and as an absolute minimum, follow all of the safety guidelines outlined below. Failure to
follow the established safety guidelines can result in damage to equipment, employee injury
and/or death.
At the same time, it is important to remember that no set of procedures is perfect. While
these guidelines should help to significantly reduce the chance of an incident, they are no
match for an aware and reasoning human mind. Always use your best judgment, and if
something seems unsafe or dangerous, do not do it.
1.4.1 Safety Symbols and Terms
Throughout this document, you will regularly see a number of information boxes labeled
with safety-specific terms. These are the standard terms and conventions that will help to
ensure the safety and health of those working with or near this equipment. It is important to
make sure that the operator and others know what each one means.
WARNING
WARNING safety notes MUST be followed carefully. Failure to do so
may result in catastrophic equipment failure, serious injury and/or
death.
CAUTION
CAUTION safety notes are very important and should be followed
carefully. Failure to do so may result in equipment damage and/or
personal injury.
NOTE
NOTE safety notes are used to notify personnel of information that is
important, but not hazard related.

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1.4.2 General Safety
The following are general safety practices which should always be used when working.
Qualified Personnel Only
Personnel without a thorough understanding of all processes and procedures required to
operate and maintain equipment can unintentionally create hazards for themselves and
others. Only individuals with proper training should ever operate or perform maintenance on
industrial equipment in a workplace environment. This includes not only the appropriate
procedures for the equipment being used, but also requires an understanding of all attached
systems, equipment in the area, and general safety and hazard recognition training.
Equipment Ratings & Guidelines
Always follow all of the manufacturer’s instructions when using a piece of equipment or
machinery. Never use any equipment or machines for any purpose for which they are not
specifically designed without first receiving approval from the manufacturer. When using
equipment and machinery, always ensure it is properly rated for the work performed, and
never exceed the listed ratings and guidelines.
Safety Systems & Countermeasures
All equipment should have guards and other safety systems to protect personnel from
exposed moving parts and other dangers. It is the responsibility of every employee on site to
ensure that all safety systems and countermeasures are in place, secure and effective.
Lock Out Tag Out
Before performing repairs or maintenance on any industrial equipment, you should always
follow standard “Lock Out/Tag Out” procedures. This includes not only shutting down the
equipment, but also isolating it from any potential power sources (electric, hydraulic,
mechanical etc…). In addition, be sure to lock controls and tag the equipment as under
maintenance to ensure that it is not accidentally reconnected or activated by a third party.
Never activate systems tagged out of service.
Environmental Hazards
Never attempt to perform work in an environment in which your senses are significantly
impaired, that is, if you cannot adequately visualize the area you are working in, the work you
are performing, or you cannot be adequately alerted to potential dangers and hazards.
Appropriate Dress
It is the responsibility of employees to ensure that their clothing, hair and accessories do
not pose a potential safety hazard when on the job. In industrial environments, this includes,
but is not limited to, wearing all appropriate clothing and PPE, keeping hair short or
restrained, avoiding jewelry and loose clothing like skirts or ties. Consult with the site
supervisor or safety coordinator to ensure you meet all safety requirements.
Exercise Good Judgment
Especially when working in an industrial environment, it is important to remain alert and
aware to avoid causing or entering potentially hazardous situations. Always be alert for
potentially unsafe activities and situations, and do not attempt to work or operate equipment
when sick, taking certain medications or in any other circumstances in which your senses or
your judgment is in any way impaired.

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1.4.3 Common Hazards
The following are major risks and hazards that may occur in an industrial environment.
Each of the following is a WARNING level hazard, meaning personnel should obey all
regulations or risk serious injury or even death.
Securing Equipment
Unsecured equipment can shift and move during operation, not only causing damage to
the components but serious injury or death to personnel. All truck, trailer or skid mounted
equipment should be secured with blocks and/or moorings prior to use, which should be
inspected for damage before equipment is activated.
Hoisting and Lifting Equipment
Equipment that swings or falls while being hoisted can crush body parts caught between
the equipment and other objects, causing serious injury and death. Always use lifting
equipment not only rated for load to be lifted, but also complying with all applicable
regulations, both governmental and corporate.
Before lifting, check to ensure that all parts of the load are secure. Any time a piece of
equipment is being hoisted or lifted; all personnel should clear all locations in which the
equipment could swing, fall or any combination of the two.
Drive Systems
Body parts and loose clothing can become caught on moving and rotating parts of the
pump drive systems, dragging personnel into the system and inflicting serious injury or death.
When working with drive systems, keep all guards in place and in good condition, and keep
hands and clothing clear of the drive system cavity at any time when the drive is in motion.
Hydraulic & Pneumatic Systems
Hydraulic and Pneumatic systems operate by means of high-pressure fluids that can
cause serious injury or death if vented improperly. Avoid striking or puncturing any hydraulic
or pneumatic components or connections. When performing any work on these systems,
even tightening a leaking joint, fitting or connection, slowly drain to zero pressure before
commencing work, and disconnect and tag systems as “Out of Service.”
Electrical Systems
Electrical systems contain high voltage current which can cause serious injury and death
when improperly grounded. Avoid striking or puncturing any electrical components or
connections, and ensure that the power is turned off, the system is disconnected and that it is
tagged out of service before commencing work.
Lubrication & Filtration Systems
Failure to properly maintain lubrication and filtration systems can result in various types of
catastrophic system failures which themselves can cause serious injury and death. Institute a
complete lubrication program at regular intervals, and inspect all systems before operation.

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1.4.4 Pump Specific Safety
The following are standard guidelines and practices which should be used when working
with the MP-16 triplex pump.
Disengage / Vent Pressure
As per standard Lock Out/Tag Out procedures, be sure to completely shut down the pump
and vent all pressure from the pump and piping before performing any work on the
equipment, and tag all equipment being worked on as “Out of Service.”Failure to do so may
result in electrical shocks, crushing injuries or the sudden release of potentially hot fluids at
high pressure.
Pressure Relief
Never operate the pump without a pressure relief valve, rupture disk or other type of over-
pressure safety device installed. All such equipment must be properly sized and fitted before
use, and operators must ensure that there are no valves of any type between the pump and
the safety device.
Fluid, Lubricant & Solvent Use
Only use fluids, lubricants or solvents approved for the equipment. Always exercise
extreme care when using solvents to clean or degrease equipment. Many solvents are
flammable or toxic, and some solvents may damage or deteriorate system components. Both
of these conditions can lead to system failures and injury, so be sure to use only approved
solvents, read all safety precautions before using and follow all appropriate procedures.
Never mix fluids, lubricants or solvents.
Fluid, Lubricant and Solvent Disposal
Follow all normal health and environmental guidelines when disposing of fluids, lubricants
or solvents. In the event of a spill, follow the appropriate steps and procedures to ensure the
spill is cleaned up with minimal risk to fellow employees or the local environment.
Polished Areas
Never grip polished areas with tongs or other gripping devices, as it can result in
equipment failure and potential injury.
Shields and Covers
When pumping hot fluids, it is important to always use shields and covers to protect
service personnel from any accidental exposure.
Guards
Likewise, guards should always be used on belt drives, couplings and shafts to prevent
personnel or objects from becoming entangled in rotating or reciprocating parts. Failure to do
so can result in severe injury or death.
Battery Connections
Always ensure the battery connections are made correctly, with the positive (+) connector
hooked up to the positive terminal and the negative connector (-) hooked up to the negative
terminal. Failure to do so can result in equipment damage and potential injury.
Zerk Fittings
Do not leave Zerk fittings installed on this high-pressure equipment, as the extreme
pressures handled by these systems can cause the Zerk check ball to blow out.

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Teflon Tape
In general, it is better to use pipe sealant rather than Teflon Tape due to the chance of
pieces of the tape coming loose and clogging the lube system. However, if the situation
mandates the use of Teflon Tape, always start the wrap two (2) or more threads from the
opening to prevent Teflon contamination of the hydraulic system.
Do Not Modify
Never modify the pump to perform beyond the rated specifications or use substitute parts
or components without first consulting and receiving written consent from Weatherford.
Failure to do so may put too much stress on certain components, which can result in
catastrophic equipment failure, serious injury and/or death.

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Chapter 2: Storage & Installation
This section shall provide a basic guide to all of the non-operational aspects of utilizing the
MP-16 triplex pump. It includes general guidelines and procedures for installing the pump, as
well as a general guide to storing the equipment, including recommendations for dealing with
severe environments.
2.1 Installation
The proper installation of the MP-16 triplex pump is essential to ensuring optimal
performance and a long service life, as well as significantly reducing required maintenance.
This can require some precise values, and so it is important to plan ahead before the pump is
brought to location and the rig-up is made. It is difficult, expensive and time consuming to
correct errors in piping, pulsation dampener mounting and tie downs after they have been
fabricated and welded in place.
2.1.1 Transport Skid
The MP-16 comes mounted on a small I-beam style oilfield skid. This skid is designed to
protect the pump during transport, but may be incorporated into the larger structural skid on
site. However, this is not required, and users may remove the transport skid and mount the
pump directly to a larger skid, usually one with power and inlet piping to reduce the overall
size and weight of the equipment package.
2.1.2 Location and Orientation
CAUTION
Always make sure pumps are mounted on a level surface and are locked down
evenly. Failure to do so can cause twisting, which places unnecessary strain on
the frame and the pump, and can result in equipment damage and injury.
Pumps should be mounted on a flat, level surface in a clean, dry, well-illuminated and
well-ventilated area for optimum performance. Ensure that the mounting surface is at least
strong enough to withstand the forces and vibrations generated during pump operations.
Temporary Installations
For temporary installations, the pump may be mounted on a mat of 3” x 12” boards laid
crosswise to the skid. These boards should be a few feet wider than the width of the skid
runners. Wet, marshy or otherwise unstable location may require a more stable foundation.
Permanent Installations
The pump should be secured using clamps or the bolt holes provided in the skid base. If
there are any gaps between the pump skid and the foundation, never draw the skid down to
the foundation. Instead, apply shims to the skid until the pump sits solid with all bolts loose,
then affix to the surface. Shims should extend the full width of the skid and must have a
minimum length of 12 inches (305 mm).

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2.1.3 The Prime Mover
The Prime Mover should be installed with great care to ensure maximum operating life
and minimal difficulties. Before locking the pump into position, check that the prime mover
has been aligned properly in relation to the pump, and that all burrs, rough spots, grease and
rust preventative has been removed from the drive shaft, bore, key and keyway.
When installing, check that the pump rotation is set to drive the top of the crankshaft
towards the fluid end, as this will go a long way towards establishing proper splash lubrication
and crosshead loading. Then verify that no damage has occurred to the components and
systems, including all safety devices and guards, and fit keys into the keyways as
appropriate. Finally, lightly coat the pinion shaft with an anti-seize compound or light oil and
install the drive sheave or sprocket hub.
CAUTION
Never operate the pump without proper guards in place.
Belt Drives
Before installing the sheaves, check to ensure that the sheave grooves are not worn or
damaged, that the sheave side walls are straight and that the sheaves are free of rust, dirt or
other extrusions, as all of these will cause the V-belts to deteriorate rapidly.
Belts should be tensioned as recommended by the supplier. Do not use worn or
damaged belts or chains. Do not exceed the recommended tension rating, as it can result in
damage to the shafts.
Once tensioned, perform a final alignment check and ensure all mounted bolts are secure.
To do so, first verify that the sides of the sheaves are equidistant from the centerline of the
groove. Then simply stretch two lengths of string or wire along one side of the sheaves, one
above and one below the centerline. These wires should touch all four points on the sheave
rims.
If it does not touch all four points, adjust move ONE of the sheaves until the string makes
four-point contact. Leave the other sheave in place while performing this procedure.
Chain Drives
When installing chain drives, the chain alignment must be held as close to perfect as
possible. Use the procedures listed under Belt Drives to help ensure a proper alignment,
particularly the two-wire procedure, though the wires should be aligned with the sprockets,
and one sprocket’s position should be adjusted as needed.
Chain drives will utilize their own lubrication systems. Follow all manufacturer instructions
when installing this system. If the ambient temperature is expected to drop below 0°F, consult
the manufacturer or a reputable lubrication dealer for recommendations.
Direct-Coupled Installations
For direct coupled installations, ensure that the coupling is secure, then install all cages
and guards and secure into position. Check the parts list sheet that came with this particular
unit for recommended guards and cages used. Do not operate pump with loose cages or
guards.

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2.1.4 Suction System
Single acting reciprocating pumps perform best when supplied with an appropriate level of
fluid. Inadequate fluid supplies may lead to cavitations, which is one of the primary causes of
premature pump failure. When setting up the pump, it is very important to ensure that there is
sufficient fluid running through the pump at all times.
The fluid supply tank should be large enough to allow dissolved air and other gases to
escape from the liquid, and allow suspended solids to settle out before entering the pump.
For this reason, a system employing dams and settling chambers is desirable.
Charging Pumps
A centrifugal charging pump should be used to boost fluid supply and ensure proper
operations. This pump should be sized to 150% of the main pump volume for the largest
piston size expected to be used to allow for the varying flow demands of the triplex pump.
The charging pump should be set to ensure the suction manifold pressure is between 20 and
30 PSI to ensure maximum volumetric efficiency and expendable parts life.
The charging pump may be driven using V-belts or chains off the mud pump input shaft,
but this is not recommended as it makes mounting the pump and inlet system piping difficult,
and may not provide sufficient RPMs to the charging pump for proper operation when the
mud pump is operating at lower speeds. For this reason, it is recommended that a booster
pump be used, powered by an electric AC motor.
The mud pump control panel should be configured so that the mud pump cannot be
started until the charging pump is running and has developed at least 20 PSI. For full
operating instructions and guidelines for using a particular charging pump, see the
documentation provided by the manufacturer.
Piping
The suction piping can be connected to any of the available flanged connections on the
suction manifold. The length of the suction piping should be minimized as much as possible
to enhance pump efficiency, and utilize 45° long radius elbows to help reduce frictional
pressure drops at the inlet. The suction piping should be supported to prevent unnecessary
loads on the pump suction manifold.
Common Suction Manifolds
Two or more pumps can have their suction connections made to a common manifold
provided that the manifold has a cross-sectional area greater than the sum of the individual
pump inlet areas.
NOTE
Never use a common manifold with a smaller cross-sectional area
than the sum of the individual pump inlet areas, as this will significantly
decrease the efficiency of all the pumps used.
Gauges and Meters
It is recommended that a pressure gauge be installed at the pump suction, and a low-
suction pressure alarm be mounted in the suction line. However, do not install any metering
device that causes a flow restriction on the suction piping. For full operating instructions and
guidelines for this equipment, see the documentation provided by the manufacturer.

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Suction Stabilizer
A suction pulsation dampener should always be utilized, as it will significantly extend the
pump’s operational life and efficiency. This system will typically be installed directly inside the
suction manifold, though external models are available. Pre-charge the pulsation dampener
in accordance with the manufacturer’s instructions before beginning operations, and ensure
that no valves or turns are placed between the suction pulsation dampener and the suction
manifold inlet.
WARNING
The use of a high pressure source or nitrogen bottle to charge the
suction line pulsation dampener can result in catastrophic equipment
failure and serious injury to personnel.
For full operating instructions and guidelines for this equipment, see the documentation
provided by the pulsation dampener manufacturer.
Line Valves
Only full open valves should be used on the suction line to prevent any reduction or
interruption of flow and thereby ensure the efficient operation of the pump. Drain valves
should be installed at the lowest point in the piping, while vents should be located at the
highest point available. Do not under any circumstances use any valve that has the potential
to choke the flow of fluid through the line.
Suction Pressure Relief Valve
It is recommended that a suction pressure relief valve be used in the suction line to
prevent damage to either pump in the event of a high pressure surge occurring in the line. It
is recommended that the valve be located on the suction manifold of the pump, but may be
located elsewhere on the suction line at the customer’s discretion. The outlet line from the
relief valve should gradually slope down to the tank level, and should be supported to prevent
any dips or low spots where mud could collect, harden and potentially block flow.
The relief valve should be set to 50% greater than the normal operating pressure (70 psi
for normal operations, but this value may vary depending on the specifics of the job).
WARNING
The pressure relief valve outlet must not connect back to the pump
suction line. This can cause uncontrollable pressure surges, which
can result in equipment damage and significant injury to personnel.

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2.1.5 Discharge System
The discharge piping is subject to damage due to the pulsations from the pump as well as
loads imposed by thermal expansion of the pipe. Generally, a single pulsation dampener
should be sufficient to handle such loads, but in cases of high output rates, two pulsation
dampeners may be required. By correctly handling these issues, the user can improve the
pump’s overall performance and longevity.
Strainer Cross
The discharge piping setup can be simplified by using a Strainer Cross. This system
provides two outlets for mud lines, a mounting for the discharge pulsation dampener and
incorporates a side connector for mounting a pressure gauge. In addition, it provides easy
access to the strainer, which should be checked and cleaned at least once a month.
Alternately, a standard discharge cross is available, which has many of the above benefits
but does not include a strainer.
The complete assembly may be flanged directly to either side of the pump discharge
manifold and is provided with an integral support mounted between the cross and the pump
skid. For full operating instructions, see the documentation provided by the manufacturer.
Piping
All discharge piping should be the same size as the outlet on the pump. Gradual turns
should be used to prevent unnecessary frictional pressure buildup and pipe erosion, and no
immediate turns next to the pump discharge should be used. 45° long radius elbows should
be used to minimize flow frictional pressure concerns. Furthermore, discharge piping should
be supported, but allowed to move along the axis of the pipe to ensure that any thermal
expansion will not unnecessarily load the fluid end connections.
Discharge Pulsation Dampener
A discharge pulsation dampener should always be utilized, as it will prevent harmonic
vibration from damaging the discharge piping and significantly extend the pump’s operational
life. This system should be mounted on a discharge cross or strainer cross flanged directly to
the discharge manifold, before any valves or turns are placed in the discharge line.
For full operating instructions and guidelines for this equipment, see the documentation
provided by the pulsation dampener manufacturer.
WARNING
Always use a regulator in the line when charging the discharge
pulsation dampener. An uncontrolled increase of pressure can result
in catastrophic equipment failure and serious injury or death.
WARNING
Do not use air or oxygen to fill bladder, especially when pumping
flammable fluids, as it may combust and cause catastrophic equipment
failure and serious injury to personnel. In most cases, it is
recommended that nitrogen is used to fill the bladder.
Bypass Line
It is highly recommended that a bypass line be utilized. It will help to ease the start up
torque requirements on the primary driver, allow a low discharge of pressure to help pump
priming and ensure that lubrication is established prior to the load being applied.

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Line Valves
When selecting valves for the piping, personnel should ensure that only full open valves
are used. Plug type and full opening gate valves are good candidate types.
Pressure Relief Valve
A pressure relief valve should be installed on the opposite side of the pump discharge
manifold from the strainer cross, and incorporate a high pressure relief line. The valve should
be a full-opening reset type valve, and set to a pressure no greater than 15% of the working
pressure of the piston size that is being used.
The Pressure Relief Valve discharge line should be short, straight securely anchored and
slope downwards at least ¼” per foot in order to prevent solids from settling in the line. The
piping should be the same size as the valve discharge opening, and lead back to the supply
tank, but not the pump suction.
WARNING
The Relief Valve must not be connected to the strainer cross, as the
systems can interfere with one another, resulting in potentially life-
threatening situations.
WARNING
Do not put any type of shut-off valve between the pressure relief valve
and the discharge manifold, in order to protect the system against
damage resulting from accidental or incorrect start-up
WARNING
The Relief Valve outlet must not be connected to the pump suction
line. This can cause uncontrollable pressure surges in the suction line,
which can result in equipment damage and significant injury to
personnel.
For full operating instructions and guidelines for this equipment, see the documentation
provided by the pressure relief valve manufacturer.
Gauges and Meters
A pressure gauge should be installed on the pump discharge, and a high-low pressure
alarm system should be utilized to address problem conditions that could lead to pump failure.
For full operating instructions and guidelines for this equipment, see the documentation
provided by the manufacturer.

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2.1.6 Power End Preparation
The pump power end should arrive assembled and tested, but without expendables or
lubrication. Before operating the pump, check the following.
Lubrication
Check the oil reservoir for the possible accumulation of condensation, and drain and flush
by removing the pipe plugs on either side. Fill the power end with lubricant to the proper level
with a clean EP gear oil of the proper viscosity (see 4.3: Lubrication on page 29). Make sure
the oil is poured into the crosshead reservoir and worked into all of the bearings.
Recheck oil level after first 15 minutes of operation, and add more as needed.
Extension Rod and Diaphragm Stuffing Box Seals
Ensure the extension rod and diaphragm stuffing box seals are properly installed as per
5.3.7: Installing the Crossheads & Crosshead Guides.
2.1.7 Auxiliary or Ancillary Systems
Any Auxiliary or Ancillary systems, such as liner wash systems and jib cranes, should be
installed in accordance with the manufacturer’s guidelines. If those come into conflict with the
regulations here, default to the manufacturer’s specifications, unless those come into direct
conflict with the safety and operational guidelines outlined here. When in doubt, contact a
Weatherford professional or manufacturer agent for information regarding the systems used.

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2.1.8 Installation Checklist
Pump Checklist
□Ensure the location for installation is dry, flat and well-illuminated, and as close to the
fluid source as possible.
□Check that the pump is level.
□Ensure the pump rotation is set to drive the top of the crankshaft towards the fluid end.
□Ensure that the prime mover drives are properly aligned and configured (see 2.1.3: The
Prime Mover)
□Ensure all guards on the drives are in place and secure.
Suction Checklist
□Check that any charge pumps used are of suitable size and are configured correctly.
□Check that the suction stabilizer is installed and inflated correctly.
□Ensure that the piping is as short as possible and properly supported.
□Ensure that vents and drain valves are installed at the proper locations and clear for use.
□Ensure a pressure gauge is installed at the suction point, preferably with a thermometer
and a low-pressure alarm.
□Check that the suction piping is properly sized and that there are no components that
may choke or disrupt flow (tight elbows, partial valves, metering devices, etc…)
Discharge Checklist
□Ensure the discharge piping is properly sized and supported.
□Ensure the pressure gauge is correctly installed at the pump discharge, along with the
high-low pressure alarm (if used).
□Install a discharge pulsation dampener as close to fluid end as possible.
□Ensure the pressure relief valve is installed and set to the appropriate pressure.
□Ensure the line from the pressure relief valve directs back to a supply tank and not the
pump suction.
□Ensure the bypass line is properly installed and functioning.
□Check that the discharge piping is properly sized and that there are no components that
may choke or disrupt flow (tight elbows, partial valves, metering devices, etc…)