Weir SPM TWS600S Technical manual

Document P/N: 2P121260
Release Date: 02/27/2017
Revision: E
Service manuals 2P121260 and 2P121262 replace 4P105066, and revision E supersedes all previous versions
Copyright © 2017, S.P.M. Flow Control, Inc.. All rights reserved. S.P.M. Flow Control, Inc. is the owner of the copyright and all confidential information in
this document, which must not be copied in whole or in part, in any form or by any means, and the information in it must not be used for any purpose
other than the specific purpose for which it has been provided without the prior written consent of the copyright owner. SPM, SAFETY IRON, SAFETY
HAMMER, SUR-DROP, DESTINY, STAMPEDE, DURALAST and GLADIATOR are trademarks and/or registered trademarks of S.P.M. Flow Control,
Inc.. WEIR and WEIR (logo) are trademarks and/or registered trademarks of Weir Engineering Services Limited. Certain features of some of the products
disclosed in this document may be protected worldwide by patents pending and registered in the name of S.P.M. Flow Control, Inc..
SPM
®
Well Service Pumps & Flow Control Products
TWS600S Fluid End
Operation Instruction and Service Manual

Document P/N: 2P121260
Release Date: 02/27/2017
Revision: E
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Most SPM®products generate, control, or direct pressurized fluids; therefore, it is critical that those who work
with these products be thoroughly trained in their proper application and safe handling. It is also critical that
these products be used and maintained properly!
WARNING: DO NOT HANDLE, LIFT, INSTALL, OPERATE, OR MAINTAIN THIS WELL SERVICE PUMP
WITHOUT READING THIS “WELL SERVICE PLUNGER PUMP SERVICE MANUAL” THOROUGHLY.
TRAINING IN THESE DOCUMENTS IS A MUST FOR PACKAGERS, OPERATIONS, AND MAINTENANCE
PERSONNEL. FAILURE TO DO SO CAN LEAD TO SERIOUS INJURY, DEATH, EQUIPMENT DAMAGE,
PROPERTY DAMAGE, OR DAMAGE TO THE ENVIRONMENT.
WARNING: MISUSE, SIDE LOADING, IMPROPER MAINTENANCE, OR DISASSEMBLY UNDER PRESSURE
CAN CAUSE SERIOUS INJURY OR DEATH.
The following information is given in good faith and should aid in the safe use of your SPM®products. This
information is not meant to replace existing company safety policies or practices.
Hot Surfaces: A SPM®well service pump is capable of pumping fluids with temperatures up to 65°C/150°F with
normal trim. The power end of the pump can be operated at temperatures up to 79°C/175°F. It is the
responsibility of the packager to provide adequate guarding around the fluid end as well as the inlet and
discharge piping to protect against burn injury.
A SPM®well service pump operates at very high pressure and features some external moving parts. It is the
customer's responsibility to provide adequate warning and protection for personnel for when the unit is
operated.
All images and drawings shown in this document are for representation and illustration purposes only. They
don’t reflect the actual part/component.
The bill of materials and part numbers in this document can change without notification. For details contact Weir
Oil & Gas.
Personal Responsibilities:
1. When working on the pump, safety glasses, approved safety shoes, gloves, and hard hat must be worn.
Fall prevention and protection should be in place when working on the pump in raised areas. Surfaces
can become slippery when servicing the pump. Hammering on any part or component may cause
foreign material or steel pieces to become airborne.
2. Personnel should only hammer on the SPM®hammer wrench provided and never directly on the pump
itself. Fractures can occur from repeated misuse. Only soft-type hammers should be used.
3. Personnel should never hammer on one of the valve retainer nuts or any other pump components when
any pressure is present.
4. When servicing the pump, do not manually lift any part in excess of 40 pounds. A lift device must be
used in these cases. For parts weighting 40 pounds or less, proper leg type lifts are essential. Do not
lift with a back type lift.
SPM
®
PRODUCT SAFETY GUIDE FOR WELL SERVICE PUMPS

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5. It is a personal responsibility to use the proper tools when servicing the pump. Any special tools
required are furnished with the pump when new, and should be kept with the pump for its routine
maintenance. It is your personal responsibility to be knowledgeable and trained in the use and proper
handling of these tools for all maintenance of the pump. A pump is made up of internal and external
moving parts. All personnel should be located away from the pump while in operation.
On Location:
1. Each pump is clearly marked with a maximum pressure and temperature rating. This pressure must not
be exceeded or SERIOUS INJURY OR DEATH CAN OCCUR.
2. Each pump is clearly marked with a maximum horsepower rating. This horsepower rating should not be
exceeded or mechanical damage can occur, leading to SERIOUS INJURY OR DEATH.
3. The pump's discharge connections should be properly cleaned, and lightly oiled before the downstream
piping is attached. Any worn, damaged or missing seals should be replaced before engaging the
pump's drive.
4. The pump's suction connections should be properly cleaned, and lightly oiled before the supercharge
hoses are attached. Any worn, damaged or missing seals should be replaced prior to pumping.
Leaking connections can cause pump cavitation leading to equipment failure and subsequent INJURY
OR DEATH.
5. Any fluid cylinder which has been pressured beyond its specified working pressure should be returned
to Weir Oil & Gas for disassembly, inspection and recertification.
6. Welding, brazing, or heating any part of the pump, with the exception of driveline companion flanges, is
prohibited. If accessories must be attached, consult Weir Oil & Gas factory prior to installation.
7. The SPM®pump suction supply flow, and pressure minimums in the pump service manual must be
maintained or equipment damage will occur and can lead to SERIOUS INJURY OR DEATH.
8. A complete visual inspection of the pump's power end and fluid end must be made prior to each use.
Any leaking seals, broken bolts, leaking hoses, or improperly tightened parts must be remedied prior to
rotating the pump.
9. Any oil and other contaminants from pump should be contained during operation, and throughout the
maintenance process. Improper containment can lead to serious injury, equipment damage, property
damage, or damage to the environment.
10. If a pump is used in a place where permanent piping is to be attached, frame flexing or structure
movements must be considered. Do not place the discharge or suction connections in a bind. Inspect
all components of such piping structure, including any valves, every 90 days for wash, erosion,
corrosion, etc. Replace if worn. For mobile mounted units; discharge line swivels are required.
11. SPM®well service pumps are to be installed and operated in a horizontal position only, as shown in the
pump's service manual. Operation in an extreme inclined position could cause equipment failure,
leading to injuries due to improper oil flow and/or improperly sealing valves.

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12. Any repairs or service (even routine maintenance) performed on the pump must be performed by a
trained service technician who is qualified to work on high pressure reciprocating plunger pumps. All
such service and repairs must be supervised by qualified management personnel or returned to Weir Oil
& Gas for service. Only SPM®replacement parts should be utilized. Failure to do so may result in
loss of warranty as well as SERIOUS INJURY OR DEATH. Weir Oil & Gas provides a Pump
Maintenance Mechanic Training School to qualify pump service mechanics.
13. SPM®well service pumps should never be used to pump gaseous, explosive, or uninhibited corrosive
fluids. These may result in equipment failure, leading to INJURY OR DEATH.
14. Never place hands in area of reciprocating pony rod or plunger path. If work must be done in this area,
make sure pump is disengaged from driver and isolated from suction and discharge pressure prior to
initiating activity (locked out and tagged out).
Special Precautions:
1. The modifications to or unauthorized repair of any part of an SPM®pump, or use of components not
qualified by Weir Oil & Gas, can lead to pump damage or failure and SERIOUS INJURY OR DEATH.
2. The pump's fluid end and related piping must always be flushed with clean water after every job. If
freezing temperatures are anticipated the fluid cylinder must be completely drained of any fluid. Failure
to do this may result in fluid cylinder damage from fluids which have hardened or frozen.
3. All SPM®threaded components are right hand threaded unless specifically designated otherwise. Any
turning counterclockwise will unscrew the assembly. Always make sure any threaded component is
made up properly with the proper torque.
4. All products should be properly cleaned, greased, or oiled after each use and inspected prior to each
use. Do not put oil or grease on the valve seat, or fluid end valve seat tapered area.
5. Pressure seal (line pipe) threads are not recommended for pulsating pressure service above 10,000 PSI
or where side loading or erosion are suspected. Non-pressure seal (round tubing) threads or straight
integral connections are recommended under these conditions. In order to achieve the recommended
Non-Shock Cold Working Pressure, power-tight make-up is required on all threaded connections.
Consult the factory for any usage other than normal constant flow working conditions. Integral
connections are recommended in lieu of pipe threaded connections for all pump applications.
6. Each integral union connection is clearly marked with a pressure code (i.e. “1502”, 15,000 psi). This
pressure must not be exceeded. This code should also be used with mating unions. Improper mating
can result in failures. All integral union connections used must match (according to size, pressure
rating, etc.). These connections must also match the service of the designated string they are installed
in.

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Inspection & Testing:
1. Each pump, its drive system, and its fluid piping should be visually checked each time before operating.
All worn, damaged or missing parts should be remedied before starting the pump.
2. All fluid cylinder mounting nuts must be checked routinely with a certified torque wrench. Loose fluid
cylinder mounting nuts can cause the fluid end to separate from the power end resulting in SERIOUS
INJURY OR DEATH.
3. All studs and stay rods require tightening to the proper torque. Without proper torque, the fluid end will
"breathe" or flex against the power end resulting in stud failure, stay rod failure and/or even premature
fatigue failure in the power or fluid end. Ensure all stay rods are not damaged, cracked, or loose.
Consult Weir Oil & Gas for torque information (see assembly drawings for torque values).
4. All covers must be tight and properly torqued. Otherwise, premature fatigue and possible fluid end or
component failure can result.
5. All fluid ends must be disassembled, and dimensionally inspected routinely. Any fluid cylinder or
discharge flanges which exhibits any loss in wall thickness due to washing or corrosion pitting in any
area must be returned to Weir Oil & Gas for repair and recertification prior to operating again.
6. All fluid cylinders in operation must be disassembled and inspected for cracks. Fluid cylinder inspection
should occur on a monthly basis or every 100 hours of operation. The operation of any pump with even
small surface cracks in any area of the fluid cylinder can result in equipment failure and SERIOUS
INJURY OR DEATH.
7. All fluid cylinders should be hydrostatically tested at least twice each year by a qualified technician.
Prior to any pressure testing, all air must be evacuated from the system. Failure to do so could result in
PERSONAL INJURY OR DEATH. The maximum test pressure must not exceed the equipment's rated
working pressure. The hydrostatic pressure test must be followed with an ultraviolet light/magnetic
particle inspection of the internal bores prior to reinstalling and operating under pressure.
8. Once an SPM®fluid end assembly has been pressurized, transfer of the following components into any
other fluid end assembly is prohibited:
Packing Nuts
Retainer Nuts
Discharge Flanges
Discharge Gauge Connections
Discharge Gauge Connection Retainer Nuts
Discharge Flange Studs and Nuts
Suction Covers
Discharge covers.
NOTE: It is always best practice that sealing/ soft components such as D-Rings, O-Rings, and Discharge
Flange Seal Rings be replaced each time they are disassembled

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

SECTION I: GENERAL INFORMATION..................................................................................................................................7
USEFUL PUMP DATA FORMULAS:.............................................................................................................................................7
SHIPPING AND STORAGE: ........................................................................................................................................................9
SECTION II: INSTALLATION AND OPERATION.................................................................................................................10
SPM®TWS600S PUMP DESCRIPTION:.................................................................................................................................10
INSTALLATION HIGHLIGHTS: ...................................................................................................................................................12
LIFTING REQUIREMENTS:.......................................................................................................................................................14
RECOMMENDED PLUNGER LUBE OILS:...................................................................................................................................16
RECOMMENDED PLUNGER GREASE LUBE SYSTEM: ................................................................................................................17
PLUNGER LUBE CIRCUIT DIAGRAM:........................................................................................................................................18
SUPERCHARGING SYSTEM REQUIREMENTS:...........................................................................................................................18
SUPERCHARGING SYSTEM OPERATIONAL PARAMETERS: ........................................................................................................21
RECOMMENDED PRACTICE FOR PUMP PACKING: ....................................................................................................................22
STARTUP AND BREAK-IN PROCEDURE:...................................................................................................................................24
SECTION III: MAINTENANCE AND REPAIR: ......................................................................................................................28
ROUTINE PREVENTATIVE MAINTENANCE: ...............................................................................................................................28
TROUBLESHOOTING GUIDE:...................................................................................................................................................31
SPM®TWS600S FLUID END REPAIR PROCEDURES: .............................................................................................................33
SUCTION VALVE STOP INSTALLATION FOR GROOVED FLUID ENDS:..........................................................................................37
SECTION IV: SERVICE AND SUPPORT..............................................................................................................................39
GENERAL INFORMATION: .......................................................................................................................................................39
SPARE PARTS AND USAGES ..................................................................................................................................................40
FLUID END DRAWINGS: .........................................................................................................................................................41
TABLE OF CONTENTS

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Useful Pump Data Formulas:
Definition of Symbols Used:
A - Area (sq. in.)
BHP - Brake horsepower
BPM - Barrels per minute (U.S.)
FV - Flow velocity (feet per second)
GPM - Gallons per minute (U.S.)
GPR - Gallons per revolution (U.S.)
HHP - Hydraulic horsepower
ID - Inside diameter (inches)
ME - Mechanical efficiency
NC - Number of cylinders (per pump)
PD - Plunger diameter (inches)
PSI - Pounds Per Square Inch
RL - Rod load (pounds)
RPM - Crankshaft revolutions per minute
SL - Stroke length (inches)
T - Torque (foot pounds)
Pump Data Formulas:
To calculate the HHP output when the volume and pressure are known:
GPM x PSI = HHP
1714
To calculate the BHP input required when the volume, pressure, and mechanical efficiency are known:
GPM x PSI = BHP
(1714 x ME)
To calculate the maximum possible pressure when the BHP, flow, and ME are known:
BHP x (1714 x ME) = PSI
GPM
To calculate the maximum possible flow when the BHP, PSI, and ME are known:
BHP x (1714 x ME) = GPM
PSI
To calculate rod load when the plunger diameter and pressure are known:
PD x PD x .7854 x PSI = RL
To calculate the maximum possible pressure at a given rod load when the RL rating and plunger
diameter are known:
RL = PSI
PD x PD x .7854
SECTION I: GENERAL INFORMATION

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To calculate the flow in gal/rev or GPM when the plunger diameter, stroke length, and number of
cylinders is known:
PD x PD x .7854 x SL x NC = GPR
231
GPR x RPM = GPM
To calculate the fluid flow velocity through a pipe or hose when the GPM and pipe size are known:
Pipe I.D. x Pipe I.D. x .7854 = Internal Area = A
GPM x .3208 = Flow Velocity
A
To calculate the size pipe of hose required to maintain a specified flow velocity when the GPM and
desired flow velocity are known:
GPM x .3208 = Internal Area Required
FV
To calculate the maximum allowable GPM through a specified hose or pipe at a specified flow velocity
when the internal area of the pipe and the desired flow velocity are known:
FV x A = Max GPM
.3208
To calculate pinion shaft or driveline torque when the input BHP and pinion shaft RPM are known:
BHP x 5252 = Torque
Pinion Shaft RPM
Conversion Factors:
Multiply: By: To Obtain:
Barrels (U.S.) 42 Gallons (U.S.)
Gallons (U.S.) .023809 Barrels (U.S.)
Gallons (U.S.) 231 Cubic Inches
Cubic Inches .004329 Gallons (U.S.)
Cubic feet per second 448.831 GPM
GPM .002228 Cubic Feet per Second
Head Feet (water) .4331 PSI
PSI 2.309 Head Feet (water)
Kilowatts 1.341 Horsepower
Horsepower .7457 Kilowatts

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Shipping and Storage:
WARNING: DO NOT HANDLE, LIFT, INSTALL, OPERATE, OR MAINTAIN THIS WELL SERVICE PUMP
WITHOUT READING THIS “OPERATION INSTRUCTION AND SERVICE MANUAL” THOROUGLY.
TRAINING WITH THESE DOCUMENTS IS A MUST FOR PACKAGERS, OPERATIONS, AND
MAINTENANCE PERSONNEL. FAILURE TO DO SO CAN LEAD TO SERIOUS INJURY, DEATH,
EQUIPMENT DAMAGE, PROPERTY DAMAGE, OR DAMAGE TO THE ENVIRONMENT.
All SPM®pumps are shipped dry, and must be flushed and filled with the proper lubricant before operating
(refer to Installation and Operation Section). Pumps may be flushed with diesel or light oil. When pumps are
shipped by ocean cargo, care should be taken to crate the pump in a watertight container and ship below deck
to prevent salt-water contamination. Care should be taken to prepare the pump for possible long term storage.
New pumps are not prepared for long periods of storage and should be put in service as soon as possible.
Follow the SPM®preservation guide for pump storage recommendations; SPM®document number 2P121266
CAUTION: PUMPS THAT HAVE SAT IDLE FOR ANY APPRECIABLE PERIOD OF TIME (TWO WEEKS OR
MORE) MUST HAVE THE PLUNGERS AND VALVES REMOVED, COATED WITH A LIGHT LUBRICANT,
AND REINSTALLED PRIOR TO OPERATING. THE ELASTOMERIC PLUNGER PACKING AND VALVE
INSERTS WILL STICK TO THE MATCHING METAL PARTS AND BECOME DAMAGED UPON STARTUP IF
NOT DISASSEMBLED AND LUBRICATED FIRST.

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SPM®TWS600S Pump Description:
The SPM TWS600S is a reciprocating, positive displacement, horizontal single-acting, triplex plunger pump that
is rated at 600 Brake Horsepower input maximum. The TWS600S is designed for intermittent duty well service
applications such as acidizing, cementing, fracturing, well killing, gravel packing, etc.
The TWS600S Pump consists of a Power End/Speed Reducer Assembly and a Fluid End Assembly. The
Speed Reducer can be installed on either the right hand or left hand side of the pump and can be positioned in
any one of 17 different input shaft locations to accommodate a number of different pumping unit drive train
configurations. Two different fluid cylinders are available to accommodate several plunger sizes for a variety of
pressures and volumes.
Optional packing assemblies, valve assemblies, discharge flanges, suction manifolds, etc. are available for a
wide variety of unitization arrangements; for the pumping of various specific fluids; and for service in a wide
range of ambient conditions. The weight of the pump will vary slightly depending on plunger size and other
options but will not vary more than plus or minus 5% of the advertised weight.
The SPM TWS600S basic design and construction details are as follows:
SECTION II: INSTALLATION AND OPERATION

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Fluid Cylinder
Low maintenance “Valve Over Valve” monoblock design. Precision machined from high strength one-piece
alloy steel forging.
Plungers
Machined from steel w/precision ground hard overlay (60 Rc) acid resistant packing surface.
Plunger Packing
“Self-adjusting” type packing assemblies. Precision molded fiber reinforced V-type pressure rings. Supported
by precision machined bronze adapter rings. Various compositions available for all common well service fluid
media such as hydrochloric acid, cement, frac sand slurries, hydrocarbons, toluene, etc. and a wide range of
ambient temperatures and fluid temperatures.
Valve Assemblies
Wing guided well service type valves w/replaceable, or bonded urethane or neoprene inserts. Tapered well
service type valve seats w/auxiliary seal ring.
Valve Springs
Long lasting coil springs engineered for a wide range of well service applications. Designed for spring rates,
installed spring loads, and valve cracking pressures unique to well service pumps.
Suction Valve Keepers
Low fluid restriction type keepers located out of the high stress plane of the fluid cylinder.
Discharge Flanges
Dual outlet (RH & LH) design. Replaceable type discharge flanges precision machined from heat treated alloy
steel. Available in male or female with a variety of common well service connections such as LPT and integral
hammer union thread connections.
Suction Manifold
Dual inlet (RH & LH) design. Replaceable type manifold fabricated from steel, precision machined, and
pressure tested. “Quick Disconnect” Victaulic grooved “ES” connections on both ends.
Fluid Seals
Precision molded high pressure acid resistant fluid seals made from a superior Polyurethane/Molydisulfide seal
compound.
Packing Lubrication
Equipped for a pressurized oil base packing lube system.

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Installation Highlights:
The proper installation of your SPM well service pump is a must in obtaining long life and trouble free service.
Particular attention must be given to the following items:
A. Power Source:
The prime mover (usually a 2100 RPM diesel engine) should not be rated at more than
725 BHP intermittent service in order to avoid overpowering the pump.
B. Drivetrain:
The drivetrain which connects the pump to the engine should include a transmission (5 speed or more)
and a mechanical driveline with universal joints and a slip joint in order to fully utilize the pump's wide
range of pressure and flow capabilities.
A powershift type transmission with integral torque converter and automatic lock-up clutch will provide the
most trouble-free means of shifting under pressure. When using an ordinary mechanical transmission
with manual clutch, extreme caution must be exercised when clutching and shifting in order to avoid
introducing severe shock loads to the pump's input shaft. When using any transmission with a “high
gear” or “overdrive” ratio greater than 1.0:1, the “overdrive” gear range must be blocked out in order to
avoid overspeeding the pump. When using a transmission with a torque converter and/or a low gear
ratio of 5.0:1 or lower, extreme caution should be exercised to avoid over-pressuring the pump when
operating in low gear or converter mode.
The mechanical driveline should have a “Diesel Engine Use” torque rating of approximate 1250 to 1700
ft. lbs. (6500 to 8900 ft. lbs. Short Duration) and should have no less than 1” slip capacity. The
manufacturer's recommendations for maximum installed angle, maximum RPM, etc. must not be
exceeded.
C. Power End Mounting:
The pump must be securely bolted to the skid or vehicle at all four power end mounting hold locations
(Refer to pump installation drawing).
D. Power End Lubrication:
SPM®well service plunger pumps are shipped dry, do not include an integral oil pump, and are designed
for a pressure lubricated dry sump system. An auxiliary oil reservoir and engine driven oil pump must be
provided for proper lubrication. More information pertaining to the power end lube system and power end
lube oils is included in this manual.

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E. Plunger Lubrication:
SPM®well service plunger pumps require a force fed oil plunger lube system. The unit is internally and
externally plumbed so that the correct oil source provided by the customer will supply lube to all
appropriate surfaces.
SPM®supplied hosing (both internal and external) is normally medium pressure Teflon with a stainless
steel outer braid. This type hose has the following ratings:
Size Working Burst
1/4" 3000 psi 12000 psi
5/16" 2500 psi 10000 psi
3/8" 2000 psi 8000 psi
1/2" 1750 psi 7000 psi
3/4" 1000 psi 4000 psi
More information pertaining to the plunger lube system and plunger lube oils is included in this manual.

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Lifting Requirements:
The SPM®TWS600S fluid end assembly with suction manifold weighs approximately 1,700 Lbs./ 771 Kg.
CAUTION: DO NOT MOUNT THE PUMP ON AN INCLINE OR VERTICALLY.
WARNING: LIFTING THE SPM®TWS600S PUMP AND/OR FLUID END WITHOUT USING EQUIPMENT
RATED FOR THIS LOAD CAN CAUSE EQUIPMENT DAMAGE, PERSONAL INJURY OR DEATH.
WARNING: DO NOT HANDLE, LIFT, INSTALL, OPERATE OR MAINTAIN THIS FLUID CYLINDER WITHOUT
READING THIS “OPERATION INSTRUCTION AND SERVICE MANUAL” THOROUGHLY. TRAINING IN
THESE DOCUMENTS IS A MUST FOR PACKAGERS, OPERATIONS AND MAINTENANCE PERSONNEL.
FAILURE TO DO SO CAN LEAD TO SERIOUS INJURY, DEATH, EQUIPMENT DAMAGE, PROPERTY
DAMAGE OR DAMAGE TO THE ENVIRONMENT.
NOTE: A LIFTING PLUG ASSEMBLY IS REQUIRED TO LIFT THE FLUID END. SEE TABLE BELOW FOR
PART

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Plunger Lube System Requirements:
SPM®well service plunger pumps are designed for packing lubrication with oil rather than grease.
Exceptionally long packing life can be expected providing proper lubrication is supplied to the plunger packing
lube port above each stuffing box. Ample plunger and packing lubrication can be achieved with an inexpensive
relatively trouble-free low-pressure air operated “lubricant pump” type system. Mechanically driven plunger
lubricators are not recommended due to the well service pump’s extreme variations in pump speeds. A
properly designed packing lube system will meet the following specifications:
1. Oil Reservoir:
Should be a minimum of 15 gallon capacity.
Should be equipped for the vertical installation of an air-operated pump.
Should be equipped with a sight glass or dipstick.
Should be equipped with a breather/filler cap that has a built-in strainer to prevent trash from
entering the reservoir.
2. Air Operated Lubricant Pump:
Vertical air operated 12 oz. per minute / 150 PSI / 40:1 ratio lubricant pump.
Must be equipped with a 1/4” adjustable air pressure regulator in order to adjust the pump speed
and packing lubricant flow rate.
Should be installed so that the bottom of the pump is no closer than 1” to the bottom of the
reservoir.
3. Packing Lubricant Flow Lines:
Should be 1/4” I.D./1250 PSI minimum/fiber or wire reinforced hose to prevent crimping.
Should be a common line from the lubricant pump to the plunger pump at which point it will
branch off to each individual packing lube port.
4. Flow Control Needle Valves:
Should be a 1/4” needle valve which can be locked at any given setting after adjustment.
Must be installed in each lubricant flow line which leads to the individual packing lube ports in
the plunger pump fluid cylinder.
5. High Pressure Check Valves:
Must be rated at or above the- well service plunger pump’s maximum pressure rating.
Must be installed in the packing lube port so that the direction of flow is into the fluid
cylinder.
6. Packing Lube System Flow Requirements/Adjustments:
After filling with the proper grade of rock drill packing oil, and before rotating the well service
plunger pump, the lube system should be adjusted to supply oil to each plunger and packing
assembly.
Weir Oil & Gas recommends a minimum of 1 pint per plunger per hour for adequate packing
lubrication. Results from SPM®internal tests support this although variables in packaging and
field operations may result in higher consumption rates.
Minimum consumption rate 1.0 pint per plunger per hour
Rates as high as 3 times the minimum recommended have been reported, and this should be
considered when sizing the lube reservoir.

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Recommended Plunger Lube Oils:
Selecting the proper plunger lube oil is very important to obtaining long life from the pumps plungers and
packing assemblies. The use of a superior plunger lubricant will also reduce horsepower robbing friction,
reduce fuel consumption, and increase the net amount of hydraulic horsepower delivered by the pump. Weir
Oil & Gas highly recommends the use of a modern “Rock Drill” for improved lubrication of the plungers and
packing. If “Rock Drill” is not available, a suitable “Way Oil” may be substituted.
Weir Oil & Gas recommends the use of Rock Drill or Way Oil that meet the following specifications:
ISO Grade 68 100
API Gravity 29.4 28.2
Viscosity, Kinematics
cSt at 40°C 70 104
cSt at 100°C 9 12
Viscosity, Saybolt
SUS at 100°F 362 556
Viscosity Index 103 99
Flash Point, C(F) 248 (478) 254 (489)
Pour Point, C(F) -27 (-17) -24(-11)
The following types of plunger lube Rock Drill oil are recommended for use in various ambient conditions as
shown:
General Service – for ambient conditions above 32 degrees F:
“Rock Drill 100” or equivalent
Cold Temperature Service – for ambient conditions below 32 degrees F:
“Rock Drill 68” or equivalent
NOTE: LUBRICANTS WHICH DIFFER SIGNIFICANTLY FROM THOSE SHOWN ABOVE ARE
UNACCEPTABLE AND MAY RESULT IN A MUCH SHORTER PLUNGER AND PACKING LIFE OR
PREMATURE FAILURE OF THESE COMPONENTS.
NOTE: STARTUP IS A CRITICAL TIME FOR PLUNGER PACKING. LUBRICATION SHOULD FLOW FREELY
TO PLUNGERS/PACKING PRIOR TO STROKING THE PUMP. STROKING DRY PLUNGERS CAN CAUSE
THE HEADER RING, PACKING, AND ELASTOMERS TO TEAR AND FAIL.
NOTE: PROPER LUBRICATION IS CRITICAL TO DURING THE STARTUP OF THE PLUNGER PUMP. THE
PLUNGER LUBRICANT MUST BEGIN TO FLOW FREELY TO THE STUFFING BOX LUBE INLET PRIOR TO
THE PUMP’S STARTUP AND STROKING OF THE PLUNGERS.
CAUTION: PUMPS WHICH HAVE SAT IDLE FOR ANY APPRECIABLE PERIOD OF TIME (TWO WEEKS OR
MORE) MUST HAVE THE PLUNGERS REMOVED, BE HAND COATED WITH PLUNGER LUBE OIL, AND
REINSTALLED PRIOR TO OPERATION UNDER POWER. THE ELASTOMERIC PACKING RINGS WILL
EVENTUALLY STICK TO THE PLUNGER SURFACE AND WILL BECOME DAMAGED UPON STARTUP IF
NOT RE-LUBRICATED AS NOTED ABOVE.

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When using a SPM®air operated plunger lube system, the audible sound of the air operated lubricant pump
stroking once every one to two seconds will be an indicator of satisfactory plunger and packing lubrication.
For all styles of packing, the plunger lube is absolutely critical for good packing and plunger life. Failure to
provide adequate or appropriate lube will cause the packing to fail and cause damage to mating components.
NOTE: LUBRICANTS THAT FAIL TO MEET THE PACKING LUBRICATION SPECIFICATIONS, AND
ESPECIALLY “USED CRANKCASE OILS”, ARE UNACCEPTABLE.
Recommended Plunger Grease Lube System:
If the end-user is going to modify the lubrication system to use grease, at their discretion, the plunger packing
wiper ring MUST be flipped in the packing nut to allow a path for the excess grease to escape the packing bore
chamber. Weir Oil & Gas recommends the use of a double or triple “ought” grease, 00 or 000.

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Plunger Lube Circuit Diagram:

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Supercharging System Requirements:
Due to the high-speed design characteristics associated with well service plunger pumps, supercharging the
SPM®well service pump is necessary. The nature of well service operations (extreme variations in flow rates
coupled with the pumping of heavy slurries) requires a well-designed supercharge system. The supercharging
system must deliver an adequate supply of fluid to the plunger pump’s suction manifold at high enough
pressures and flow velocities to prevent the pump from starving for fluid while at the same time, maintaining
fluid flow velocities high enough to keep solids suspended in the fluid slurry. A well designed supercharging
system is extremely important in avoiding the harmful effects of cavitation and ensuring trouble-free service of
the SPM®well service pump. A well-designed supercharging system will meet the following guidelines:
Primary Suction Piping and Hoses:
These are defined as the piping where the fluid first begins to flow from its source through gravity flow or
atmospheric pressure only. This portion of the system is usually a pipe or hose that connects the fluid reservoir
to the charge pump or blender suction pump. The flow velocity (based on the plunger pump’s maximum flow
rating with the size plunger being used) in this portion of the system must not exceed 4 feet per second in order
to flow freely under atmospheric pressure or gravity flow. Other guidelines are as follows:
Hoses must be oil and chemical resistant wire reinforced combination vacuum/discharge hose rated at
305inHg/150 PSI minimum.
If steel piping is used; all piping runs must be installed so that they are level or progressively higher
toward the plunger pump in order to prevent air traps in the system. When used, reducer fittings should
be of the eccentric type and installed “belly down” in order to prevent air traps. All welded connections
must be air and fluid tight.
All piping or hoses in this portion of the system should be kept as short as possible (10 feet or less and
should be free of excessive bends and turns).
Centrifugal Supercharge Pump/Mixing Pump:
Some well servicing operations require the use of two centrifugals - one for mixing a slurry and the other for
supercharging the plunger pump. When two centrifugals are used, they must both meet the following
guidelines:
Must be capable of delivering the rated maximum flow of the plunger pump while maintaining 80 PSI
(185 feet head) minimum at the plunger pump suction inlet during all phases of the well service
job. Must be sized appropriately to overcome any friction losses in the piping between the centrifugal’s
discharge and the SPM®plunger pump’s suction inlet. For example, depending on the length and the
layout of the piping, the centrifugal may have to be sized to deliver the required flow at higher pressures
at its discharge in order to maintain 80 PSI (185 feet head) at its discharge in order to maintain 80 PSI
(185 feet head) at the plunger pump suction inlet.
Must be operated at a speed which will deliver the required flow within the upper 25% of its efficiency
range in order to assure adequate fluid acceleration on demand from the plunger pump.
Must be adequately powered to deliver the plunger pump’s fluid requirements based on volume,
pressure, and the specific gravity of the fluid or slurry.

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Secondary Suction Piping and Hoses:
These are defined as the piping that carries fluid under pressure from the discharge of the centrifugal pump to
another point in the system. This is the piping which connects the centrifugal charge pump to the SPM® plunger
pump suction inlet and can also be the piping which connects the centrifugal mixing pump’s discharge to a
mixing tub inlet. The flow velocity in this portion of the system (based on the plunger being used) should range
from 8 to 12 feet per second. Other guidelines are as follows:
Hoses must be oil and chemical resistant wire reinforced combination vacuum/discharge hose rated at
203inHg/100 PSI minimum.
If steel piping is used; all piping runs must be installed so that they are level or progressively higher
toward the plunger pump in order to prevent air traps in the system. When used, reducer fittings should
be of the eccentric type and installed “belly down” in order to prevent air traps. All welded connections
must be air and fluid tight.
All piping and hoses in this portion of the system should be kept as short as possible (10 feet or less)
and should be free of excessive bends and turns.
Suction Pulsation Dampener (when a suction stabilizer dampening manifold is not used):
Due to the plunger pump’s positive displacement design, a naturally occurring fluid rhythm is generated in the
supercharge system as the fluid stops and starts at each suction valve. The varying pressure signal created by
this fluid rhythm reduces the effectiveness of the charge pump and the SPM®pump unless the pressure signal
is dampened out of the system. A suction pulsation dampener is necessary to ensure adequate fluid
acceleration when each suction valve opens, which will help prevent cavitation, and will result in a much
smoother operating pump and longer lasting expendables. Guidelines for using a suction pulsation dampener
are as follows:
A pulsation dampener of the nitrogen charged bladder type should be rated at 150 PSI minimum, or a
closed cell foam style dampener.
Should be installed above the fluid flow path or in line with the fluid flow path so that solids in the fluid
cannot settle and pack around the bladder.
Should be installed as close to the plunger pump’s suction manifold inlet side, or if not possible as close
as possible to the suction inlet for maximum effectiveness.
Must be pre-charged according to the manufacturer’s recommendations (usually 60% to 80% of the
anticipated supercharge pressure).
CAUTION: BLADDER OR CLOSED CELL FOAM TYPE UNITS ARE NOT RECOMMENDED FOR CO2
SERVICE. CHECK BLADDER COMPATIBILITY TO THE FRAC FLUID BEING PUMPED.
WARNING: FOR CO2SERVICE, USE AN SPM®CO2APPROVED SUCTION MANIFOLD WITHOUT A
SUCTION STABILIZER. USING NON-RATED EQUIPMENT CAN RESULT IN PRESSURE VESSEL FAILURE
DUE TO THERMAL SHOCK. INJURY OR DEATH CAN RESULT FROM USING EQUIPMENT NOT RATED
FOR CO2SERVICE. NO VIC GROOVE END CONNECTIONS, HAMMER UNION ONLY.
Supercharge Pressure Gauge:
Supercharge pressure gauge should always be used in the system and should meet the following guidelines:
Should be a liquid filled 0 to 150 PSI pressure gauge.
Should be installed as close to the plunger pump suction inlet as possible for maximum accuracy.
Should be used with a gauge snubber or a needle valve which can be adjusted to act as a snubber.