Induction/Refresher Drilling Training Programme

Foreman(Drilling)

Preventive maintenance of
Hydraulic pumps and motors
maintenance can be approached several
different ways
• Reactionary or Breakdown Maintenance - The equipment has failed and
you have to fix it right now!

• Preventative Maintenance - You'll take appropriate actions and thereby

prevent the unit from failing . Most companies are still trying to figure
out what those appropriate actions are.

• Predictive Maintenance - By taking selected readings we hope to be able

to predict an impending problem and calculate how much longer the
unit will run before failure.
Machinery History –

By keeping good records we hope to predict the life of

the unit or its individual components. This system
assumes that the life of the previous unit somehow
relates to the life of the present one.
The type of information we can gather for analysis.

You can monitor :

Heat - Especially in the seal chamber and bearing case. A changing reading
at the pump suction would be helpful in predicting cavitation. Volute casing
readings could indicate internal recirculation and minimum flow problems as
well as an indication of impeller rubbing.

Pressure - You can take readings at the pump discharge, suction and stuffing
box to determine where you are on the pump curve and see if you're within
the operating range of your mechanical seal.

Speed - To see how it affects pump curve data. The pump curves were
generated with a variable frequency motor at a speed different than your
induction motor.

Noise - To indicate cavitation, rubbing, location on the pump curve, bad

bearings, or some other abnormal condition.
 You can monitor :

Flow - To check the status of wear rings, impeller adjustment and the
discharge recirculation system.

Strain - To anticipate rubbing and stress corrosion problems.

Liquid level - To anticipate npsh, bep and air ingestion problems.

Leakage and Fugitive Emissions - To check the seal performance in both the
stuffing box and bearing case locations.

Product contamination- To monitor the performance of dual seals and

flushing controls.
 You can monitor :

Functioning of stuffing box environmental controls - To anticipate seal failure.

Power Consumption - To check pump efficiency and to anticipate heat

problems.

Vibration - At multiple locations in the system to indicate that a failure has

already started.
Many problems become visible when we look at the
disassembled hardware.
An inspection of individual components is still one of the best
methods of troubleshooting. You can see :
• Wear.
• Corrosion.
• Discoloration
• Evidence of rubbing.
• Damage.
• Clogging
• Product attaching to the hardware.
• The presence of foreign objects.
• Missing parts.
• A wrong part.
There are things you can measure as well as things that
can be monitored or observed:

Clearances - At the wear rings and bearing fits.

Dynamic balance - of the entire rotating assembly or the individual

components

Alignment - Between the pump and the driver as well as the piping and the
pump flanges.

Settings - For the seal face loading and impeller clearance.

Shaft deflection - To insure that rotating parts will not contact stationary parts.

Shaft axial movement - Especially equipment with sleeve or babbitt bearings.

Both impellers and mechanical seals are sensitive to this movement.
START-UP OF A PUMP

• Pumps are shipped from the factory without oil in the crankcase. All nuts
and screws should be tightened.

• Be sure all valves in the discharge line are open. No valve should be installed
between the pump and pressure relief valve in discharge line.

• To prevent excessive wear on the fluid pistons and packing when starting,
remove a suction valve cover plate on each side of the fluid end and prime
the pump.
 START-UP OF A PUMP

• Pump should be started slowly, if possible, and should be operated for

several hours with practically no discharge pressure.

• Check oil level as it may be necessary to add a small quantity of oil to

compensate for that adhering to the walls of the crankcase the moving
parts.

• The pump may then gradually be brought up to full speed and full
working pressure.

• Watch for undue heating or abnormal noise in the working parts. Check
all joints in the suction line to be sure there are no air leaks.
ECCENTRIC CAM BEARINGS –

• These bearings are mounted on, and remain with the eccentric and gear
• assembly during dismantling and reassembly of the power end.

• The bearings are of the cylindrical roller type, with the rollers retained in
the outer race.

• The inner races are shrunk on the eccentric cams.

• The outer races with rollers slide off the end or outer eccentric cam bearing
inner races.

• The centre bearing is slipped over the adjacent eccentric cam after its
bearing race has been removed.
MAINTENANCE OF VALVES –

• In order to keep the pump in its best operating condition, it is necessary

to examine the suction and discharge valves occasionally to see that
excessive wear or cutting by the slush or mud has not impaired their
efficiency.

• Any worn or damaged parts should be replaced.

CROSSHEAD SLIDES –

• The crosshead slides are cast of tough bearing bronze.

• Top and bottom slides are interchangeable and are bolted into the
frame.

• Slides are also interchangeable end for end.

LINER CLAMP AND LINERS –

• When liner clamps are reinstalled or replaced, it is advisable to check

cylinder to frame stud nuts and tighten if necessary.

• Liners are replaced by removing the liner clamp. Liners should be cleaned
and oiled after removal to protect against rusting during storage, so they
can be used again.

• Pump liners are to be clean both inside and out when installed. Also clean
the liner clamp bore and lightly oil all surfaces.
PISTONS –

• Single-acting pistons consist of a steel piston body with insert retained by

a washer and snap ring.

• Pistons, with piston rods, can be removed or installed through suction

valve opening after valve upper guide is removed by turning it 90_.
 TROUBLE-SHOOTING GUIDES

• The following charts are arranged in five main categories.

The heading of each one is an effect which indicates a
malfunction in the system.

• For example, if a pump is exceptionally noisy, refer to

Chart-I titled EXCESSIVE NOISE. The noisy pump appears in
Column A under the main heading.

• In Column “A ”there are four probable causes for a noisy

pump. The causes are sequenced according to the
likelihood of happening or the ease of checking it. The
first cause does not exist, check for cause number 2 etc.
 REMEDIES:-

A: Any or all of the following : Replace dirty filters – Wash strainers in solvent
compatible with system fluid – Clean clogged inlet line – Clean reservoir breather
vent – Change to proper pump drive motor speed – Overhaul or replace
supercharge pump – Fluid may be too cold.

B: Any or all of the following : Tighten leaky inlet connections – Fill reservoir to
proper level (with rare exception all return lines should be below fluid level in
reservoir) Bleed air from system – Replace pump shaft seal (and shaft if worn at
seal journal)

C: Align unit and check condition of seals, bearings and coupling

 
D: Install pressure gauge and adjust to correct pressure
 
E: Overhaul or replace.
 REMEDIES:-
A: Any or all of the following : Replace dirty filters –Clean clogged inlet line – Clean
reservoir breather vent –Clean system fluid- Change to proper pump drive motor speed –
Overhaul or replace supercharge pump

B: Any or all of the following : Tighten leaky inlet connections – Fill reservoir to proper
level (with rare exception all return lines should be below fluid level in reservoir) Bleed
air from system – Replace pump shaft seal (and shaft if worn at seal journal)

C: Align unit and check condition of seals and bearings. Locate and correct mechanical
binding – Check for work load in excess of circuit design 

D: Install pressure gauge and adjust to correct pressure (keep at least 125 PSI
difference between valve settings)

E: Overhaul or replace.
F: Change filters and also system fluid if of improper viscosity – Fill reservoir to
proper level
G: Clean cooler and/or cooler strainer – Replace cooler control valve – Repair or
replace cooler.
INCORRECT FLOW
 REMEDIES:-
A: Any or all of the following: Replace dirty filters – Clean clogged inlet line – Clean
reservoir breather vent. Fill reservoir in proper level – Overhaul or replace supercharge
pump.

B: Tighten leaky connections – Bleed air from system

C: Check for damaged pump or pump drive – replace and align coupling

D: Adjust

E: Overhaul or replace
F: Check position of manually operated controls – Check electrical circuit on solenoid
operated controls – Repair or replace pilot pressure pump
G: Reverse rotation

H: Replace with correct unit

 REMEDIES:-

A: Replace dirty filters and system fluid.

 

B: Tighten leaky connections (fill reservoir to proper level and

bleed air from system)
 

C: Check gas valve for leakage – Charge to correct pressure –

Overhaul if defective
 

D: Adjust
 

E: Overhaul or replace.
 FAULTY
OPERATION
 REMEDIES:-

A: Fluid may be too cold or should be changed to clean fluid of

correct viscosity
 
B: Locate bind and repair

C: Adjust, repair, or replace

 
D: Clean and adjust or replace – Check condition of system
fluid and filters
E: Overhaul or replace
F: Repair command console or interconnecting wires
G: Lubricate
H: Adjust, repair, or replace counterbalance valve.