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

Pump and Fluid Systems
Chapter 1: Introduction
weatherford.com ii MP-16 2-Piece 5000 psi January 2013
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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Chapter 1: Introduction
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1.1.2 General Dimensions

Pump and Fluid Systems
Chapter 1: Introduction
weatherford.com 1 MP-16 2-Piece 5000 psi January 2013
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.