178 Series Pumps Manual, pgs. 6-11

lubricatedat least once a day. lt is best
to installa spring loadedgreasecup to
automaticallylubricatethe packing.As
you fill the grease cup a spring is
compressedand a stem rises. As the
grease is used the spring forces new
grease to the packingand the stem
lowers.When the stem is low the cup
needsrefilling.Greaseshouldbe pumped
into the box while turningthe shaft until
it comes out aroundthe packinggland
(approximately
20 shots).
lf the packingleakeageis excessive,a
thick water pump greaseshouldbe used
ratherthan the generalpurposegrease.
ln most cases general purpose is
acceptable.
WaterLubrication
It is bestto injectwaterintothe lanternring
from an externalsource when pumping
drillingmud.Thiswillkeepmostof thesolids
out of the packing.PACKINGAND SHAFT
LIFEWILLBE INCREASED
UP TO 5OO%.
willnot
Also,waterleakagefromthe packing
be as objectionable
as mud.
PARTIV
MAINTENANCE
Disassembly
The fluidend of the pump is so constructed
that those parts subject to wear may be
readilyreplacedin the field. To replacethe
casing, wear plate, and impeller, the
followingproceduresshouldbe followed.
1. Stop the pump and drain all the lines
leadingto the pump..
2. Loosen the bolts at the suction and
discharge flanges of the pump and
movethe pipe clear of the pump casing.
Removethe pumpfrom the system.
3. Separatethe coupling and loosen the
coupling half mounted to the PumP
shaft.
4. Remove the casing stud nuts and
removethe casing.
5. Loosen the packing gland nuts and
swing the packing gland bolts clear of
packing gland. Remove the packing
gland.
6. Slide the water slingeralong the shaft
awayfrom the bearingcap.
7. Loosen the bearing cap bolts on both
ends and slide the bearingcaps along
the shaft.This will exposethe bearings,
I
II
which are locked to the shaft by an
eccentriclockingringandsetscrew.
8. Loosenthe bearingset screw and tap
the bearinglockingring with a punch
and a smallhammerso that it turnsin
the directionoppositeto thatof theshaft.
When the bearinglocking ring has
turnedTt revolution
the bearingis freed
from the shaft. Both bearingsmust be
released.File off any upsetcausedby
the collarset screwbeforeattempting
to
slidetheshaftthroughthebearings.
9. Removethe impellerandshaftfromthe
pedestal,
thus freeingthe lanternring,
water slinger,bearingcaps, bearings
andcouplings.
10. Remove
theimpeller
nutsandwasher.
11. Removethelanternringandpacking.
12. Removethewearplateby usingthejack
boltsin the stuffingbox.The wear plate
is pressedinto the stuffing box and
formsthe bottomof the stuffingbox.
13.Thebearings
maynowbe removed
from
the pedestalfor inspection
by tapping
lightly
witha woodenor brassrod.
Inspection
Impeller: Replace if, impeller shows
excessive
erosion(especially
on the pumpout vanes on the back of the impeller),
corrosion,
wear,or vanebreakage.
extreme
Shaft: Checkfor runoutto see that the
shafthas not beenbent.lf runoutexceeds
0.002inch,replacethe shaft.Bearingseats
andoilsealareamustbe smoothandfreeof
scratches
or grooves.Shaftthreadsmustbe
in good condition. Replace shaft, if
necessary.
Ball Bearings:Replaceif worn,loose,or
roughandnoisywhenrotated.
Newbearings
shouldnotbe unwrapped
untilreadyfor use.
Replacement
bearingsmustbe of the proper
size and type as suppliedwith the original
equipment.
Seals: lt is recommended
that all O-ring
and gasket seals be removed during
disassembly
and replaced.In thosecases
the old
wherenew sealsare not available,
ones can be reusedif they are not torn or
otherwise
damaged.
General:All partsshouldbe cleanbefore
assembly.This is especiallyimportantfor
retainingringsand O-ringgrooves,threads,
gasket surfaces, bearings, and bearing
surfaces.Any burrsshouldbe removedwith
crocuscloth.
I
I
MCM 178 MaintenancePage6
----i
Assembly
To reassemble the pump, follow the
disassemblyinstructionsin reverse order.
New gasketSshould be used throughout.
Gaskets should be 1/16 inch thick and
shouldbe made of a materialsuitableto the
pumpoperatingconditions.
1. lnstallthe bearingsin the pedestal.
2. Installnew grease seals in the bearing
caps .
3. With the impellerinstalledon the shaft
and rigidly keyed in place, insert the
shaft from the front through the shaft
hole in the wear plate.Feed on parts in
the followingorder:
WaterSlinger
FrontBearingCap
BearingCap Gasket
FrontEccentricLockWasher
Then feed the sheiftthroughthe front and
then rear bearing and add the remaining
partsin the followingorder:
RearEccentric
LockWasher
RearBearing
CapGasket
RearBearing
Cap
lmpeller Adjustment With The
CasingOff ThePump
1. Pushthe rearagainstthe shoulder
with
therearbearing
cap.
2. Pushthe impellerbackagainsta 0.020
inch shim betweenthe rear impeller
pump-outvanesand the front of the
wearplate.
3. Push the rear bearingin againto be
sureit is againstthe shoulder.
Lockthe
bearing eccentriclock ring in the
direction
of rotation.
4. Tightenthe set screwin the eccentric
lock.
lmpeller Adjustment With The
CasingOn ThePump
1. Put on the casingwith the casing
gasketandtightenthecasingstudnuts
uniformly.
2. Push the shaft forward until the
impeller
hitsthecasing.Marktheshaft.
Pull the shaft back untilthe impeller
hits the wear plate.Mark the shaft
again.
3. The shaft should be set halfway
betweenthe shaft marksso that the
clearance
betweenthe impellerandthe
casing is approximatelythe same as
the distancebetweenthe impellerand
the wear plate.
4. Make sure the rear bearingis seated
againstthe pedestalshoulderand then
lock it against the shaft with the
bearingeccentriclock ring. The lock
ringshouldbe set in the samedirection
of rotationas the shaft. Lock the ring
with the set screw.
5 . The front bearing should not seat
against the housing shoulder. The
bearing should be free to float along
with the shaft to compensate for
expansion and contractionof caused
by temperature changes. The outer
race clearanceis about 1/16 inch on
each side. Push the bearingin until it
seats againstthe shoulderand pull it
out 1/16inch.
o . Lock the front bearing to the shaft in
the samemanneras the rearbearing.
PackingThePump
1. Makesurethe box is cleanedof all old
packing
andtheplasticlantern
ring.
2. Greaseall five shaftpackingrings(5).
Insertthreepackingringsalternating
the
splitsin the ringsfrom top to bottom
starting
withthe spliton thefirstringon
thebottom.lf Kingtypepacking
is being
usedthe ringsshouldbe installed
with
thelipstowardtheimpeller.
3. Installthe
lantern
ringwiththesplitin the
verticalposition.The two halvesof the
packingglandmaybe usedto pushthe
packingand the lanternring together
andto the bottomof thebox.
4 . lnsertthe finaltwo packingrings.The
objective
is to havethe lastsplitdownso
thatleakage
willdripdownandnot,have
to go overthe shaftand possiblyin the
bearings.
lf Kingpackingis beingused,
insertthe final King ring with the lip
towardstheoutsideandspliton top,and
follow with the single ring of square
packing
splitdown.
5. Withthepacking
glandin position,
swing
the glandboltsintoplace.Initially
tighten
the glandhardto compressthe packing.
Then back off the gland bolts and
retightenonly finger tight. Caution:
Tightenthe glandagainstthe packing
finger tight only. lf packingis overtightenedit may be burnedwhen the
pumpis started.
PageT
MCM 178 Maintenance
Excessive Packing Leakage And
Rapid Packing Wear
Mostearlypackingfailuresare causedby
over{ighteningor poor installation.
Packing Appearance
lf the packing being removed is hard and
brittle,it has been run dry some time in its
life. This is often done in the first hour of
service. The packing has more ability to
grow with heat during its early life. Even if
the packing is adjusted just right before
startingthe pump, in the first few minutesof
operationthe packingwill growwith heat and
becomeover{ight. It will then run droptight
and the packing will burn. ONCE THE
PACKING IS BURNED IT WILL NEVER
SEAL PROPERLYAGAIN. Let new packing
leak more in the first few hours and then
adjustit to 10-12dropsper minute.
InstallingWater Flush SYstemTo
Be AcceptableBy Oil GomPanies
willnotallowwaterto be
Manyoil operators
puton the packingbecauseof excesswater
gettinginto the mud, a result of poorly
designedand maintainedsystems.Two
causethiscomplaint:
majorproblems
1. Toomuchlinepressure
2. Not turningwateroff whenpumpis not
in use.
Controlling Water Pressure To The
Packing
is usuallytoo high.The
Thewaterpressure
brakecoolingpumpis normallyusedwhich
operatesat pressuresfrom 50 to 75 psi.
Only5 to 10 psiwateris neededto cooland
the packing.A pressureregulator
lubricate
shouldbe installedto reducethe pressure
cansupplyall
on the packing.Oneregulator
pumpsfroma centralsystem.
centrifugal
Controtting When To Use Water On
Packing
LARGEVOLUMESof waterget into the
mudwhenthe pumPis NOTOPERATING'
theshaftdeflects
Whenthepumpis running,
up
and whenstopped,the shaftstraightens
anda gap occursdownone sideof the shaft
betweenthe packingand the shaft. This
allowsa streamof waterto enter the mud'
You can manuallyturn off the water when
the pumpis shutdownbut a betterway is to
installa solenoidvalve in the water supply
line that turnsthe water on and off as the
motor is turnedon and off. ONLYa small
amountof water (a few drops per minute)
whichgets into the mud whilethe pumpis
to the oil
runningshouldnot be objectionable
companies.
BearingFailures
Except for cavitation problems, bearing
failure is the greatestcause of increased
pumpoperatingcost.lf youcontinue
to run
a pumpwhen bearingfailuresoccur,there
is an excellentchancethe entirepumpwill
Thereforeit is very important
be destroyed.
to changethe bearingswhenfailurestarts.
lf youwaitfor completefailureotherfluidend
parts will be damaged.Bearingfailure is
more often causedby lubrication failure
wear.
thanby normalbearing
Misalignment Between Pump And
Driver
A major cause of bearing failures is
Alignment
betweenthe pump
misalignment.
and motorshouldalwaysbe checkedafter
rechecked.
andperiodically
shipment
Detection Of Bearing Failure When
Pumpls Running
and bearing
of lubricant
Thefirstindication
failure is a rapid rise in operating
Youshouldfeeltheframeonce
temperature.
get
a feelfor howhotthe bearings
a weekto
normallyrun. A suddenhigh increasein
temperaturenormallymeans the bearings
to failandneedchanging.
arebeginning
You cannotholdyourhandfor verylongon
lf youcan keep
temperatures.
unsatisfactory
yourhandon the housingfor 5 secondsthe
temperatureis about 160' F. which is
suitablefor mostpumps.lf you cannothold
yourhandon the housingfor fivesecondsor
if the bearinghousingis so hot you do not
wantto touchit, thereis mostlikelylubricant
and/orbearingfailure.
PARTV
MISGELLANEOUS
INFORMATION
SuctionLine Velocity
Suctionline velocityshouldnot exceed10
for reasonablepump life. This
feeUsecond
means the maximumflow for a 6 inch
MCM I 78 Mainte'nancePage8
suctionis 900 GPMand an 8 inchsuctionis
1600 GPM. lf you want to flow more than
1600GPM a 10 inch or largersuctionline
shouldbeinstalled.
Capacitylimitsfor pumpslistedbelowdo not
consider suction line velocity or NpSH
calculationswtrichmust be madefor everv
installation.
Net PositiveSuctionHead(NPSH)
PUMPSIZE
3x2x13
4x3x13
5x4x14
6x5x14
8x6x14
The systemmust have enoughNPSHfor
the pump requirements
or the pump will
greatlyreducingits life.
cavitate,
r.lt appearsthat most installations
do not
hEveenoughNPSHto run a 5x6 pumpat
flowsabove1400GPMevenwith an I inch
suction.(Thisdoes not meanthat no one
has enough NPSH). The result of
inadequateNPSH is cavitationand early
pump failure. Through observation,the
greatestproblemwith NPSHis encountered
withmudmixingpumps.Mostcompanies
do
not changethe nozzlesin their mud guns
oftenenough.On a 1 inchnoz::le,l/16inch
wearpersidewillincreaseflowby 26%.
Example:Volumerequiredincreasesfrom
1500GPMto 1890GPM.A wearof 1/8inch
increasesflow by 56% (from 1500GPMto
2340GPM).lf sizedcorrectly
whennew,the
mudmixingpumpswill soonbe required
to
furnish a greatly increasedvolume and
perhaps
morethanthemaximum
limitof the
pump.We have found customersrunning
6x5 pumps on mud mixingexperiencing
much higheroperatingcosts than those
running8xOpumps.Companies
running
6x5
pumpsat 1750RPMon mud mixingoften
have high maintenance
everysix months,
whilecustomers
running8x6pumpsat 1150
RPM often do not requiremajor repairfor
twoyears.Lookingat the failures,it appears
the problemis inadequate
NPSHat higher
volumes,mostlikelyc€lusedby nozzlewear.
A t 1 5 0 0 G P M a 6 x 5 p u m pa t 1 7 5 0
R P M r e q u i r e su p t o a 2 6 f o o t N P S H
whilea 6xB pumpat 1150RPMrequires
only a 7 foot NPSH. Nearly every
system will have a 7 foot NPSH
a v a i l a b l ew h i l e a l m o s t n o s y s t e mw i l l
have a 26 foot NPSH available,
e s p e c i a l l yi f t h e m u d t e m p e r a t u r e
exceeds 140(,F.
We normallydo not see cavitationas
m u c h w i t h t h e d e s a n d e ra n d d e s i l t e r
p u m p s b e c a u s et h e r u b b e r c o n e s d o
not wear as rapidly as steel cones.
Volumerequirementsare closerto 800
t o 1 0 0 0G P M .
Capacity
Requirements Of
EquipmentIn RigApplications
The chart below lists the normaldesign
requirements
when the equipmentis new
withno wear.
EQUIPMENT
DESIGN
VOLUME
4" CONE
45 to 60 GPM
4H (s',)CONE
80 GPM
6'CONE
125GPM
8'CONE
250GPM
12',CONE
450to 500GPM
6 ' M U DH O P P E R
550GPM
%" NOZZLE
80GPM
1'NOZZLE
140GPM
1 Y2"NOZZLE
3OOGPM
2'NOZZLE
550to 600GPM
MECHANICAL
BMKES
40 to 50 GPM
ELECTRIC
BMKES
50 to 200GPM
SWACODEGASSER
4OOGPM
WELCODEGASSER
7OOGPM
BRANDT
DGsDEGASSER
5OOGPM
BRANDT
DGlODEGASSER lOOOGPM
Long Term Pump And Motor
Storage
1. Pump packagesshould be stored
indoorsin a clean,dry and protected
environment.
2. The storageareais to be freefromany
vibration
andtemperature
extremes.
3. Motorandpumpshaftsareto be rotated
manually
everytwo months.A recordof
therotationshouldbe made.
4. Grease in the motor and the pump
bearingsis to be purgedat the time of
removalfrom storageand replacedwith
an amplesupplyof freshgreasein each
greasecavity.
CapacityLimitsOf Pumps
llCt
MAXIMUMGPM
450
750
1100
1800
2400
I 7€ MahtenancePage9
5. Motorwindingsshouldbe meggedat the
is placedin storage.
timethe equiprnent
At the time of removalfrom storagethe
resistance reading must not have
droppedmore than 50% from the initlal
reading. Any drop below this Point
necessitateselectricalor mechanical
drying of the motor windings.
from hot days and cool
Condensation
nights can fill the motor half full with
water. This is a greater pCtential
proDEmln Oampareas.
6. lf the pumpsare to be storedoutdoors,
the pump suction and discharge
openingsshould be sealedto prevent
any water from entering the pump
housing. This will prevent rust and
corrosion.
Relcren& e4anr
?ar* Oaaaa'
Qtv
Itm
No-
I
2
3
4
5
6
7
8
9
t0
It
l2
Rcc
Descrlpdon
178Pcdcstal
lT8BcaringCap
178BcaringCapGaskct
l
2
2
2
I78BcrringAssm,
178Oil & GrcascScal
178BearincCapBolt Assm,
178316-55ShaftF/ 2x3-5x6
178416-55ShaftF/ 2x3-5x6
178CcramicCoatetEl2x3-5X6
178316-S5ShaftF/ 6X8
178416-55ShaftF/ 6X8
178CcramicCoatcdF/ 6X8
178GraphitePacking
178Kinc Packing
178TcflonPacking
178PackingGland
178GlandAdjustingBolt Assm'
l?8 WcarPlatcDuctilclron
178-2X3DuctilcRH ImPcllcr
178-3X4DuctilcRH ImPellcr
neAXS DuctilcRH ImPcllcr
tat5
7l
vt
2
4
FTl8BCBA
I
I
I
I
I
I
l
I
I
I
l
I
DuctilcRH ImPcller
178-6X8
78 HousingGaskct
78-2X3DuctilcHousingOnlY
2
784X5 DuctilcHousingOnlY
78-5X6DuctilcHousingonlY
78-6XqDuctilcHousingOnlY
78-2X3DuctilcFacc
78-3X4DuctitcFacc
784X5 DuctilcFacc
78-SX6Ducfilc Facc
78-6X8DuctileFacc
7&2X3HousingAssm.RH Duct
78-3X4HousingAssm.RH Duct
1g-4XSHousingAssm.RH Duct
RH Duct
f8-5X6 HousingAssm.
lZg-6XAHouringAsm. RH Duct
?f, Oil Slinacr Rinq
178WatcrSlingcrRing
Indicatcs
or
IIelco
H3785
H3790
H10399-23-l
H394/,-3
r/SBCG
P78BA8
r/SOGS
I
7R-?Y4 f)rrctilc Ho[3ine ()n
l5
Mlrdon
L3785
3790
t0399-23.r
3944-3
r/8SH3l65556
178-5X6Ductilc RH lmPcllcr
l3
l4
MCM
FTl8PBD
P788C
H3943-t4
3861-1t3932-2 H386t-1t3932-2
H378644
378644
H4932-2tA
4932-2tA
17238-2rG-74 H 7238-2tG-7/|
H 49284A
t4928-4/'
H 4928-2lA
r4928-2rA
t7343-2tc-tA H 7343.2t.14
E264.17W-OBAH8264-l7W-OBA
8474-t7W-7A H8474-l7W-7A'
H8264-l7W-74
8264-l7W-74
H7406-l3A
7406-13A
H370lA
A370lA
H3779-30
3119-30
3943-14
P785H4l65556
P785H4l65C56
P78SH3l65568
P78SH4l6S568
P785H4l6SC6E
PT8PMSG
PTSPMSK
PTSPMST
P78PG
PTSCABA
P78WPD
P78D23MRXXX 4610-xx-30
P78D34MRXXX 4605-XX.30
PTEDI5MRXXX 4105-XX-30
P78D56MRXXX 4710-xx-30
P78D68MRXXX 5142.XX-30
r/SHG
10399.20.r
YI8D23H
P78D34H
FTEBISH
P78D56H
P/8D68H
VI8D23F
P78D34F
Prl8Dt5F
F78D56F
P78D6EF
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
G4676-304
r8D23HFA
r/8D34HFA.
P78DI5HFA
F/8D56HFA.
rTSD6tHFA
FtSSRO
F78SRW
F4W-304
F4732-304
Fq+z-30A
F5t4-?0A
N/A
c3787A'
Sizc
llGll I 78 MaimenancePagel0
H46t0-XX-30
H4605-XX-30
H4705-XX-30
H47r0-XX-30
H5142-XX-30
Hr0399-20-l
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
H4676-30A
H46//'30A
H4732-30/|
H4742-304
H5t44.-30A
N/A
HC37E7A
Hrrrbburr
I.I7E.PED
2-t7g-BC
3-178-BCG
4A.I?E.BAE
5.17E-OGS
6.178-BCBNA
7A-178.31655
7A-l784l6S5
78-l784l6SSC
7F.r784-3l655
7C-1784-4l655
7D-1784-4l6SSc
8A.I?E.PMSG
8C-t78-PMSK
8D-178-PMST
9.I?E.GPA
l0-178-GABA
llB-178-wPD
t27823[RXXX
l27834IRXXX
I2TM5IRXXX
t27856IRXXX
I2TE6EIRXXX
I3A-I7E.HGF
147823HD
r47834HD
r418r'isHD
t47856HD
r47E68HD
26f1823HFD
267834HFD
2678/.s$FD
267E56HFD
267E68HFD
l4TEZSDIrA
l47E34DltA
l47W'DHA
l,t7t56DHA
l47868DHA
l9-l7E-SRO
2Gl7E-SRW
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1
LOOK AND COMPARE.... WE'REYOUR BESTCHOICE!
Pagell
MCM 178 Maintenance