WS-600SH

OPERATION AND MAINTENANCE MANUAL

3/13/2017
Rev: A
 TABLE OF CONTENTS

Section Page No.

INSTALLATION PROCEDURE .............................................................................................................. 1

1.0 Introduction ................................................................................................................................... 1

2.0 Parts and Service ........................................................................................................................... 1

3.0 General ......................................................................................................................................... 1

3.1 Storage ............................................................................................................................. 1
3.2 Location of Pump............................................................................................................. 1
3.3 Protection of Pump against Seepage or Flood ................................................................. 1
3.4 Provision for Servicing Space .......................................................................................... 2
3.5 Power End Mounting ....................................................................................................... 2
3.6 Couplings ......................................................................................................................... 2
3.7 Drive Shaft ....................................................................................................................... 2
3.8 Gearbox............................................................................................................................ 2
3.9 Lubrication ....................................................................................................................... 2

4.0 Piping ......................................................................................................................................... 2

4.1 General ............................................................................................................................. 2
4.2 Suction Piping and Charge Pump .................................................................................... 3
4.3 Discharge Piping .............................................................................................................. 3
4.4 Flange Fittings ................................................................................................................. 3

5.0 Accessories ................................................................................................................................... 4

5.1 Pressure Relief Valve (PRV) ........................................................................................... 4
5.2 Strainer ............................................................................................................................. 4
5.3 Pulsation Dampeners ....................................................................................................... 5
5.4 Gaskets, Pipe Dope and Pipe Tape .................................................................................. 5

START-UP PROCEDURE .....................................................................................................................6-7

LUBRICATION SPECIFICATIONS ........................................................................................................ 7
MAINTENANCE INSTRUCTIONS ........................................................................................................ 8

1.0 Scope ......................................................................................................................................... 9

2.0 Oil Change .................................................................................................................................... 9

3.0 Inspection Intervals and Descriptions ......................................................................................9-10

3.1 Daily or Every 24 Hours of Pump Operation .................................................................. 9
3.2 Weekly or Every 170 Hours of Pump Operation ............................................................. 9
3.3 Monthly or Every 750 Hours of Pump Operation.......................................................... 10
3.4 Quarterly or Every 2250 Hours of Pump Operation ...................................................... 10
3.5 Semi-Annual or Every 4500 Hours of Pump Operation ................................................ 10
3.6 Annual or Every 9000 Hours of Pump Operation.......................................................... 10

i
 TABLE OF CONTENTS
Continued
Section Page No.

4.0 Service Procedures ...................................................................................................................... 11

4.1 Discharge Valves ........................................................................................................... 11
4.2 Suction Valves ............................................................................................................... 12
4.3 Plungers ......................................................................................................................... 12
4.4 Packing........................................................................................................................... 14
4.5 Fluid End........................................................................................................................ 15
4.7 Wiper Box ...................................................................................................................... 15
4.8 Connecting Rod Bearings .............................................................................................. 15
4.9 Crosshead, Connecting Rod and Wrist Pin .................................................................... 15
4.10 Crosshead Slide and Lubrication Assembly .................................................................. 16
4.11 Gearbox.......................................................................................................................... 17
4.12 Crankshaft and Bearing Assembly................................................................................. 18
4.13 Lubrication System ........................................................................................................ 18
4.14 Packing Lubrication ....................................................................................................... 22

5.0 Fastener Torques ......................................................................................................................... 23

LOCATING TROUBLE .....................................................................................................................24-26

APPENDIX
Appendix A
Table 3-1 Recommended Lubrication Oils............................................................27
Appendix B
Short Term Storage……………………………………………………….……28-33
Appendix C
Long Term Storage…………….………………………………………….……34-40

General Dimension Drawing ................................................................................................................... 41

Pump Specifications................................................................................................................................. 42
Performance Charts ................................................................................................................................. 43

ii
 INSTALLATION PROCEDURE

1.0 INTRODUCTION

NOV WSP’s are manufactured in accordance with the highest standards demanded by the
industry. Proper maintenance and care will prolong the period of satisfactory service, and reduce
costs.

These instructions were written to promote the care, operation, and maintenance of your pump.
When trouble arises outside the scope of this manual, our Engineering Department and all factory
facilities are ready to help you. Please contact us for assistance.

To improve our products we must be informed of the problems and solutions which occur in the
field. We request that you send us short reports of your experiences. Include the pump model
and serial numbers, operating conditions, problems and the solution

2.0 PARTS AND SERVICE

NOV WSP maintains a large inventory of replacement parts at all times for prompt service of its
product line. To ensure prompt delivery you must include the following information when you
place an order.
1. Part number and description (see the Parts List drawings in the Appendix).
2. Quantity of each part required.
3. Fluid end or power end model number and serial number (see the identification tags on
the pump).
4. Your purchase order or requisition number.
5. Designation of the shipping method you prefer. If overseas shipment is involved,
designate the name of the export and crating company you prefer.

Parts and Service orders may also be placed through:

MW-USA-PPSystemSales@nov.com

NOV has qualified service personnel and service facilities for maintenance and repairs on NOV
WSP.

3.0 GENERAL

NOV WSP pumps, when properly installed, given proper care and regular maintenance will operate
satisfactorily for a long period of time. The following paragraphs discuss the general principles
that must be considered to ensure trouble-free operations.

3.1 Storage
All NOV WSP pumps are tested, inspected and protected against corrosion for the period of
shipment and installation only. If the pump is not to be installed at once, refer to the section
entitled "Long Term Storage of Pumps" in the Appendix.

3.2 Location of Pump

Locate the pump in a clean, accessible place, so it can be inspected at regular intervals
during operation. Place the pump as close to the liquid supply as possible, so as to make
suction piping short and direct. Provide ample headroom for crane, hoist, or tackle.

3.3 Protection of Pump against Seepage or Flood

If it is necessary to place the pump in a pit, provision should be made to protect the pump
1
 from water that may come into the pit from seepage or flood.

3.4 Provision for Servicing Space

Whether mounted on mobile equipment, a foundation, or in a pit, sufficient room should
be allowed for removal of plungers, rods, crank- shafts, etc., and/or inspection of wearing
parts as recommended in this manual.

3.5 Power End Mounting

The following is a general guideline for installing a pump on mobile or skidded units. Bolt
each bracket on the power end securely to its platform or skid. Weld alignment bars to the
platform or skid to secure by contact the sides of the mounting brackets on the power end.
This will limit lateral movement and help in realignment during removal and assembly.

3.6 Couplings
On pumps where couplings are used, do not connect the coupling until all pump and driver
alignment operations have been completed. Check the coupling faces and flanges of the
pump for true horizontal and vertical position by means of a level. Correct the positions
by adjusting the supports as required.

3.7 Drive Shaft

Both short-coupled and tube-type Splicer 1810 drive lines are used to couple the engine
clutch or transmission to the gearbox. Drive lines are flanged on each end for bolting to
mating flanges on the transmission or gearbox.
As a general rule keep joint angles small for maximum life. Angles should not exceed 5
degrees for normal operations.
Do not neglect drive shaft lubrication. Use a quality of EP grease meeting the NLG1 grade
2 specifications. Grease every one to three months depending on service.

3.8 Gearbox
An enclosed gearbox with a 4.6:1 ratio is mounted on either the left or right side of the
power end. Provided the input shaft clears the pump housing, the gearbox is reversible.
Recommended lubricant under normal operation is 85W-140 gear oil. If equipment is kept
in long term storage or is inactive, then keep gearbox 90-95% filled.
The lubricant in a new gearbox should be changed after 500 hours of operation. Clean with
flushing oil.
Under normal operating conditions, change the lubricant every six months. Refer to
gearbox manual for specific recommendations.
Parts list and assembly of the gearboxes are included at the back of the manual in the
gearbox manual.

3.9 Lubrication
Read and follow lubrication instructions as they appear throughout this manual. The power
end and gearbox are pressure lubricated and are dependent on a properly operating system
with correct lubricants.

4.0 PIPING

4.1 General
Pipes must line up naturally. They must NOT be forced into place with flange bolts, as
this may force the pump out of alignment. Pipes should be supported independently of
pump thereby not producing any strain.

Variations in flow and pressure, changes in direction of flow, cavitation, worn plungers,
2
 pump valves, etc., all contribute to piping vibration. Therefore, suction and discharge
piping must be rigidly fixed in all directions and not just lightly strapped down. Flush,
clean and blowout all piping before connecting to pump. Use pipe dope and tape sparingly,
and on the male threads only.

After the piping is installed, the pump driver and speed reducer alignment should be
rechecked and corrected as required.

4.2 Suction Piping and Charge Pump

The pump suction piping should be direct, free of bends and restrictions, also, as short as
possible. All bends or turns required should be either long radius or 45 elbows. The piping
should be pressure tested. Adequate provisions should be made for anchoring and
supporting the piping spans.

The suction piping diameter should be equal to or larger than the pumps suction diameter.
The pipe should be routed without high spots, and have a continual rise upward toward the
pump. The pump must be able to be isolated for servicing; therefore, a fully opening block
valve should be located in the suction piping. All valves in the suction system should have
flow areas equal to or greater than that of the inlet line with minimum pressure drop across
them.

The suction piping system should provide a NPSH that exceeds the sum of the NPSH of
the pump, all frictional losses, acceleration head, and the negative peak of the complex
wave pulsation of the plungers. Cavitation is most often caused by the detrimental effects
of pulsation in the suction piping system. Additional suction head may be required if the
liquid contains dissolved gases.

A charge pump should be installed as close as possible to the supply source. Improper
selection or location of the booster pump can result in increased pulsation and attendant
problems. The capacity of the charge pump should be in excess of the capacity of the
reciprocating pump. The pressure of the charge pump shall be no less than 20 psi at the
reciprocating pump suction at maximum operating capacity.

To prevent mutually reinforcing pulsation in multiple pump installations, each pump

should be provided with a separate inlet line from the liquid source rather than connecting
two or more pumps to a common manifold. If manifolding is required, the manifold and/or
suction pipe should have a cross-sectional area equal to or greater than the sum of the cross-
sectional areas of the suction lines to each individual pump.

4.3 Discharge Piping

The pump discharge piping should be direct, free of bends and restrictions, and as short as
possible. All bends or turns required should be either long radius or 45o elbows. All "dead
ends" should be avoided. The piping should be pressure tested.

Adequate provisions should be made for anchoring and supporting the piping spans. The
pump must be able to be isolated for servicing; therefore, a fully opening block valve
should be located in the discharge piping. Also, to protect the pump, a check valve should
be employed. To facilitate starting and to eliminate air, a vent or bypass valve should be
installed close to the pump.

4.4 Flange Fittings

Flange fittings, unions and flexible connectors should be located close to the pump in all
pipelines, so as to facilitate removal of pump.
3
 Alignment must be rechecked after suction and discharge piping have been bolted to the
pump, to test the effect of piping strains. When handling hot or extremely cold liquids,
disconnect the nozzle flanges after the unit has been in service to check the direction in
which the piping expansion is acting. Correct for strain effect, as required, to obtain true
flange alignment.

5.0 ACCESSORIES

5.1 Pressure Relief Valve (PRV)

The use of a discharge relief valve of suitable size for the full rated capacity of the pump,
set to open at a pressure above the operating discharge pressure required of the pump, is
mandatory because of the safety it affords. The relief valve should be placed in the
discharge line close to the pump and ahead of any other valves.

Full opening, pilot operated, or shear pin relief valves, or burst discs, which require little
or no over-pressure to develop fully open flow capacity are often preferable to spring
loaded relief valves. Spring types may require considerable over-pressure to compress the
spring, before becoming fully open, creating much pump overload.

Pressure relief valves have a "set" pressure, which may be described as the pressure at
which the relief valve cracks and begins to open, allowing some flow to pass through.

As additional pressure is applied, above this "set" or "crack" pressure, the spring-loaded
relief valve will gradually increase its port area until fully open.

When fully open, the relief valve must have sufficient capacity so it will relieve the full
capacity of the pump without excessive over-pressure. Available spring loaded relief
valves differ among manufacturers in extent of over-pressure needed to fully open the
valve. This range is generally 10% to 25% above the set pressure depending on spring
design. By choosing a larger valve this increase may be reduced.

If an attempt is made to set a relief valve too close to the average discharge pressure, the
valve may leak slightly due to pump pulsation. Leakage will quickly ruin the relief valve
seat and this condition should be corrected.

If plunger size is reduced or increased the relief valve setting must be altered accordingly.

Always install a liquid filled pressure gauge ahead of the relief valve so it reads the true
pump pressure while relieving.

The exhaust from the relief valve should always be directed to the supply tank - NOT to
pump suction.

The line from the relief valve to the tank must be the same size as the discharge line.
Calculate all pressure drops in the relief valve line when sizing the PRV. Where possible,
pipe the relief valve exhaust so that any leakage can be observed.

5.2 Strainer
To protect the pump from foreign matter, a suction strainer may be installed with a net area
three or more times the area of the suction pipe.

The strainer must be cleaned frequently to maintain a flow area exceeding the suction pipe
4
 area. A clogged strainer will result in pump cavitation and serious damage. Therefore, the
strainer must be readily accessible for cleaning and inspection.

A pressure gauge should be installed near the pump in the suction line. If the pressure falls
below the original start-up pressure, the strainer must be inspected. Where a suction lift is
involved, a compound or absolute pressure gauge must be used.

5.3 Pulsation Dampeners

A good suction and discharge pipe layout for reciprocating pumps of conventional type
frequently require no devices to compensate for normal variations in velocity of flow in
the piping system. However, in some pump piping systems, especially multiple pump
installations, there can be considerable pulsations that are generated due to the system
acoustical natural frequencies, and pulsation dampeners are necessary.

The type of pulsation control device (dampener or accumulator) required to control

pulsation should be based on the type, size, and speed of the pump, the properties of the
liquid, the pressures, operational conditions, and the layout of the piping. The dampener
or accumulator best suited to control pulsations in the piping system should be determined
from an analysis of the acoustical characteristics of the entire pump piping system,
including all of the interconnected pump systems. If pulsation dampeners or accumulators
are used, they should be installed as close as possible to the pump flange connection and
should be considered as a part of the piping system and not as an accessory of the pump.

If pulsation dampeners or accumulators are a function of the line pressure, provisions

should be made to keep the unit(s) charged with nitrogen or similar inert gas in accordance
with the equipment manufacturer's recommendation.

In multiple pump systems, the effectiveness of gas charged bladder dampener or

accumulator can be compromised unless all accumulators are optimally tuned; therefore,
the use of acoustically tuned, all liquid filters should be considered.

In systems that have a variable discharge static pressure, the gas charged bladders on
dampener or accumulator devices can become ineffective and the use of acoustically tuned
all-liquid filter devices should be considered.

5.4 Gaskets, Pipe Dope and Pipe Tape

The gaskets, pipe dope and pipe tape used in the piping system are exposed to the same
conditions of high or low temperature, pH values, etc., as the pump parts. Careful selection
is necessary to avoid joint failure.

5
 START-UP PROCEDURE

1.0 Verify pump has been properly installed and that related equipment is operational.

2.0 Open the suction line block valve and the discharge line vent or bypass. If the discharge line is
under pressure close the discharge line block valve to fill all lines and force air out of system. Close
vent (or bypass) valve. Open the discharge line block valve. Start pump driver and check direction
of crankshaft rotation against arrow on power frame. If driver is at three-phase electric motor,
rotation can be reversed by switching the connection of any two motor leads.

3.0 Pumps must undergo a break-in run before being put into service at rated load. The first few hours
of testing are usually performed at the factory. However, additional break-in occurs up to
approximately 100 hours of service. For example particles off of various internal parts are emitted
into the oil. Eventually, this will cause contamination of the lubrication system and potential pump
failure if not frequently checked during the break-in run.

The following steps should be followed:

1. Fill the pump oil reservoir and stuffing box lubricator reservoir with the lubricants as
indicated in Table 1. Prime the power end lubrication pump. Check all drain plugs for any
leakage and tighten as necessary.

2. Be sure that all guards, covers, and shields are in place. Remove only the inspection over
on the power end to observe oil flow.

3. Lock the pump drive (transmission or clutch should be in neutral). Start engine, and run at
idle. Check all crossheads, wrist pin bushings, main bearings, rod bearings, pine bearings,
and gears for proper oiling.

4. Increase engine RPM to full RPM. Check the vacuum gauge reading at the power end
lubrication pump suction. Reading should be less than 10 in HG. Check lubrication pump
discharge gauge reading. Pressure should be 60-80 psi. Check the entire lubrication
system for leaks. Relief valve on discharge side of lubrication pump should be set at 100-
125 psi.

5. Check oil reservoir level. Add oil if necessary.

6. Clean plungers at back of stuffing box. Squirt oil on plungers.

7. Reduce engine speed. Operate triplex pump at 70-80 RPM and no pressure for 1/2 hour.
Oil temperature should not climb above 140o F (60o C). Observe power end for leakage
an unusual noise. Lubrication pump vacuum gauge reading should not fall below 10 in
HG (35 kPa). If it does, filters may be clogged; change as necessary. Discharge pressure
of lubrication pump should exceed 50 psi (3.4 bar).

8. Run pump at 70-80 RPM and 25%, 50%, 75%, 100% of operating pressure for 1/2 hour
each. Observe oil pressures and temperatures. Oil temperature should not exceed 180 o F
(82o C).

9. On pumps equipped with a transmission, run pump for 1/2 hour in each gear range at 100%
operating pressure. Again observe oil pressures and temperatures.

10. Shut pump down and let cool before beginning normal operations. Change oil and filter

6
 elements within the first 50 hours of operation. Clean strainers when changing oil.

If power end is too hot to touch, check temperature. If oil temperature is above 180 O F
(82O C), stop pump and allow cooling to ambient temperature. Repeat break-in run. If oil
temperature continues to exceed 180O F (82O C), stop the pump and refer to "Locating
Trouble" in Maintenance Instructions.

4.0 The electric motors driving most pumps are capable of starting the pump against line pressure.
However, due to electrical supply considerations, it may be advisable to use a manual or automatic
bypass valve to unload the pump until it has reached operating speed.

5.0 See "Inspection Intervals and Descriptions" in Maintenance Instructions.

POWER END LUBRICATION

Safe Viscosity Timken

Type of SUS @ Centi- Pour Point ISO AGMA
Ambient Temp. F Operating Rating
Service Stokes F Grade Grade
Temp. F 100o F 1 bl.
0-95 Up to 180
General 1165 252.00 10 (-12o C) 65.00 220.00 5 EP
(-18 C to 35o C)
o (82o C)
Above 95 Up to 200
Hot 1710 370.00 10 (-12o C) 65.00 320.00 6 EP
(35o C) (93o C)
Below 0 Up to 130
Cold 350 76 5 (-15o C) 60.00 68.00 2 EP
(-18o C) (54o C)
SSU=Centistokes *4.62

PACKING LUBRICATION

Liquid Pumped Ambient Temp. F Lubricant

Water, Saltwater Above 0 (-18o C) Rock Drill Oil 100

General Service Below 0 (-18o C) Rock Drill Oil 46

Petroleum Products Above 10o (38o C) Straight Mineral Oil

Any Below –20 (-29o C) Brake Fluid

Table 1: Lubrication Specifications

7
MAINTENANCE INSTRUCTIONS

Drawing 1-050342

8
 ROUTINE INSPECTION AND SERVICE INTERVAL

1.0 SCOPE
The following maintenance checklist is intended to serve as an INITIAL GUIDELINE ONLY
under nominal usage and operating conditions. Additional items or inspection interval changes
should be recorded in the pump service logs. In addition, some items may be replaced at
regularly scheduled intervals to prevent their costly emergency replacement. Consult factory for
specific recommendations.

2.0 OIL CHANGE

Numerous factors determine oil change intervals. Should the oil become contaminated by any of
the following operating and/or environmental conditions, immediate oil draining and replacement
(after thorough flushing and cleaning of the power end with kerosene) is recommended. Daily oil
inspection is recommended below, and oil change intervals are stated in 3.4.

2.1 Water - from oil seal, wiper seal, breather cap or gasket leakage.
2.2 Solids - from initial break-in as a result of first use as a new or rebuilt power end.
2.3 Dust, Sand or Dirt - from air-borne sources through the shaft and wiper seals or breather
cap.
2.4 Corrosives - from pumpage vapors or gases through the crankshaft seals or breather cap.

3.0 INSPECTION INTERVALS AND DESCRIPTIONS

3.1 Daily or Every 24 Hours of Pump Operation
Normal power end and fluid end operating conditions (temperatures, quiet and smooth
operation).
Crankcase and, if applicable, packing lubricator and gear reducer (oil Levels).
Power end and fluid end gaskets (leakage).
Packing and gland nuts snug (excessive leakage, unsuitable materials). Always check with
pump driver off.
Cradle area (clean and properly draining).
V-belts (not slipping) and/or drive couplings (for oil or grease leakage).
Fluid end operating pressures (not above specified nameplate values).
All fasteners (secure), especially power end to fluid end and bearing housings (leakage and
movement). Always check with pump driver off.
Pumps with power end pressure lubrication to be 40 PSIG (2.8 bar) minimum at normal
operating temperature.
Packing lubricator pumps (all functioning, proper drip rate).

3.2 Weekly or Every 170 Hours of Pump Operation

Crankcase and gear reducer (solids and/or liquids contamination, sample oil from drain
connection preferably while pump is running).

IF THE PUMP IS NEW OR HAS RECEIVED A RECENT MAJOR OVER-HAUL

(SHELL BEARINGS, WRIST PINS, BUSHINGS, END BEARINGS, ETC.,) OIL
SHOULD BE CHANGED AT THIS INTERVAL. PRIOR TO ADDING NEW OIL,
CRANKCASE COVER SHOULD BE REMOVED AND ALL EXPOSED INTERIOR
SURFACES WIPED CLEAN. PRIOR TO CRANKCASE COVER REPLACEMENT,

9
 CHECK TORQUE OF ALL CONNECTING ROD BOLTS. CLEAN OR REPLACE OIL
FILTER ELEMENT.

All strainers, foot valves and any other suction line piping components (free of restrictions
and in proper working order).
Drive coupling (joint secure).
Plungers and pony rod connections (tight).

3.3 Monthly or Every 750 Hours of Pump Operation

Crankcase breather screen (clear and free of debris).
Lubricator lines and connections (for leaks and crimps).

3.4 Quarterly or Every 2250 Hours of Pump Operation

Power end and, if applicable, gear reducer (change oil).
Oil filter element (clean in kerosene or replace).
Crankshaft oil seals (leakage, free of paint, cracked or weather checked, excessive heat).

3.5 Semi-Annual or Every 4500 Hours of Pump Operation

Drive couplings (lubricate and, if applicable, check seals and bolt torques).
Valve disc/body and seat sealing surfaces (excessive wear, pitting, wire drawing and solids
imbedding).
Valve springs (broken or compressed).
Plungers and pony rods (scored, worn or damaged).
Wiper box seals/packing and O-rings to include wiper box O-rings (leakage from and/or
into power end).

3.6 Annual or Every 9,000 Hours of Pump Operation

Schedule disassembly and inspection of complete pump, concentrating especially on:

- Crankshaft throw/pin surfaces;
- Crankshaft end bearings & oil seals;
- Wrist pins and wrist pin bushings;
- Power end pressure lube pump internals and shimming (if applicable);
- Center main crankshaft journals and bearing bores (if applicable);
- Plungers and, pony rods;
- Wiper box seals and O-rings;
- Stuffing box packing, brass and springs (if applicable);
- Valve assemblies;
- Fluid end gaskets and seals;
- Speed reducer gears, bearings and shaft seals.

10
4.0 SERVICE PROCEDURES

4.1 Discharge Valves

The discharge valve is located just beneath the valve cover in the upper part of the fluid
end (see Fig. 1). Replacement of the spring or valve body can be accomplished without
removing the valve seats. If it is necessary to remove the discharge valve seat, remove
with valve seat puller available from National Oilwell Varco (see Fig. 2). Be careful not
to mar the tapered deck-seating surface.

008
105

006
105

007

105

105

009

010

008
033

028

105
011
004
105
105
005 105

105
031

105
032

030

105 002 015

105 014

023

022
021

018

019

Figure 1: Cross-section of Fluid End

11
4.2 Suction Valves
The suction valve is accessible after removing the cylinder head retainer nut and cover.
To remove the suction valve seat, it is necessary to first remove the discharge valve. To
get the plunger out of the way, rotate the pump until the plunger reaches its full back
position. Stop it before beginning the forward stroke. The next step is to disassemble the
valve components from the valve seat. Seat removal is accomplished by the use of a
puller available from the factory.

Refer to Fig. 3 when installing valve seats. Take care to avoid damage of tapered deck-
seating surfaces.

Valve seats should be DRIVEN into the seat deck until firmly seated. This is done by
using a flat disc and driving with a piece of pipe and a hammer.

 CAUTION 
Never drive on the valve body and do not use any method that will distort valve seats.
Taper surfaces must be CLEAN AND DRY! Use clean solvent or diesel fuel. Then wipe
dry with a clean rag before assembly.

4.3 Plungers
Plungers are removed through the fluid cylinder bore as shown in Fig. 1. First, remove
the cylinder head retaining nut and cover. Using the spanner wrench, loosed the gland nut
one full turn. Unscrew each plunger from the crosshead and remove the plunger through
the fluid end.

Threaded holes on the cylinder head cover are for attaching a lifting bar to assist in
removal.
 CAUTION 
Handle the plunger carefully. Any nicks in the main body of the plunger will cause
immediate and frequent packing failure.

12
 Figure 2: Valve Seat Removal

Figure 3: Valve Seat Installation

13
4.4 Packing

Packing is available in a v-ring style as shown in Fig. 4. The v-ring set consists of a lantern
ring, a poly-pack seal, a metal packing ring, O-rings, backup rings, a single stack v-ring,
and a double stack v-ring.

INSTALLATION PROCEDURES−V-RING STYLE

1. Check packing rings, lantern rings, and gland nuts for nicks and dings. Rework (if
possible) or replace excessively worn parts.

2. Thoroughly clean and check all plungers and gland nut bores for excessive wear or
contaminant build up. Replace or rework any damaged or excessively worn parts.

3. Care must be taken installing the packing ring with new O-rings and backup rings
into the fluid end.

4. Care must be taken not to damage the outer packing lips during installation. This is
facilitated by using a puller plate, nut, all-thread and puller disc.

Each of the packing rings must be pulled into the box individually. The gland nut is
installed and made up tight to the fluid end. Install the plunger.

5. During priming of the pump, the plungers should be lubricated again. Start the
pump; continue lubrication at 2-3 minute intervals during the first 10-15 minutes of
operation to provide proper packing break-in. No further adjustments are required.

026 002 015

027
014
024
025
023

022
021

019
020
018

Figure 4: Stuffing Box Assembly

14
4.5 Fluid End

Disable the power unit before doing any maintenance work. To remove the fluid end from
the cradle area of the power end, refer to Fig. 1 and the previous section 4.3 on plunger
removal.

Disconnect suction and discharge flanges and accessories such as the pressure gauges.
Unscrew the plunger from the crosshead and slide the plunger forward a short distance into
the fluid end. Connect hoist to fluid end and tighten until snug.

Remove the eight 12-point cap screws from the fluid end. Raise and lower fluid end to
clear the fluid end adapters from the power frame.

When installing fluid end be sure the power frame and fluid end faces are clean.

Lift the fluid end and match the fluid end adapters to the power frame bores. Push the fluid
end toward the power frame. Install the eight cap screws and torque to value in torque
table.

4.6 Wiper Box

Each wiper box assembly is attached to the cradle by four 3/8" cap screws. After removing
the plungers and the wiper box cap screws, the wiper box will slide out. It is necessary to
disconnect the plunger when installing oil seals. The seals are press-fit into the wiper box,
and the use of a seating disc is necessary to avoid damage or distortion to seal case.

Oil the plungers before installation of wiper seals and to avoid damage of seal lips. Worn,
pitted, or scored plungers must be replaced to avoid damaging seals and to retain and
protect the crankcase oil.

4.7 Connecting Rod Bearings

Disable the power unit before doing any maintenance work. The connecting rod and rod
bearings are in the Parts List in the back of this manual

Remove the rear cover from the power frame.

Remove the two cap screws joining the connecting rod cap to the connecting rod base.
Remove the rod cap and bottom connecting rod bearing.
NOTE: The rod cap and rod base are matched and marked for correct re-assembly.

Be careful not to lose dowel pins during disassembly. Use a rubber or wooden hammer to
tap a bearing away from cap or base (bearing housing). Clean the new bearings and
housings before replacing.

When replacing rod cap, keep both dowel pins in place. Match the marks on the rod cap
and base. Refer to torque table for the torque on the rod cap screws. Move the bearing
housing from side-to-side to check that the bearings turn freely on the crankshaft.

If new bearings have been installed, refer to the "Start-up" procedure before operating the
pump.

4.8 Crosshead, Connecting Rod and Wrist Pin

15
 Disable the power unit before doing maintenance work.

Refer to power end Parts List for parts assembly of the crosshead, connecting rod, and wrist
pin. The crosshead slide should be inspected whenever a crosshead is removed and
replaced if wear exceed specified tolerances.

To inspect power end components, removing the wiper boxes, plungers, and connecting
rod bearings.

Rotate the crankshaft until crosshead and wrist pin are centered inside the inspection
window on the side of the power frame. Remove the outside snap ring from the crosshead,
and pull the wrist pin from the crosshead and connecting rod

Remove the connecting rod cap screws and cap.

Remove one connecting rod at a time.

Rotate the crankshaft to the end of stroke of the rod to be removed. Push the rod forward
until it clears the crankshaft throw. Lower the connecting rod to the bottom of the power
end. Again, rotate the crankshaft until the crankshaft throw is on top. Remove the
connecting rod out the back of the power end.

To remove the crosshead, rotate it until it is free of the guides on the crosshead slide. Be
careful with your hands as pinching can occur. Remove the crosshead through the
inspection cover.

NOTE: On some power ends the gearbox blocks the inspection cover on one side.
All crossheads can be removed, in order from the opposite side.
Use a hydraulic press to remove and replace the wrist pin bushing on the connecting rod.
When replacing the bushing, be certain that the groove is in line with the drill hole on the
connecting rod for proper lubrication.
Clean and inspect all bearings and bearing surfaces.
Replace components as necessary. Excessive scoring or grooving of crossheads or
crosshead slides is generally caused by contamination of the lubrication system. Change
oil at specified intervals and keep filters clean.
Reinstall the crosshead with one snap ring in place. Rotate the crosshead until it falls into
the matched grooves on the crosshead slide. Push as far toward the wiper box as possible.
With the crankshaft throw in the top position, lift the connecting rod into a position as far
forward toward the crosshead as possible. Rotate the crankshaft to the end of the
backstroke. Install the connecting rod bearings and cap onto the crankshaft.
Lift the wrist pin end of the connecting rod, slide the crosshead back and align the wrist
pin bores. Install the wrist pin and snap ring.
Install main bearing, retaining fasteners, pony rods and plungers. Run pump at slow speed
and check for complete oil lubrication.
Follow "Start-up" procedure on page. 7.

4.9 Crosshead Slide and Lubrication Assembly

16
 The Parts List shows the crosshead slides and the lubrication assembly that connects the
power end lubrication system to the slide and crosshead.

Each bore has a top and bottom crosshead slide. The crosshead slides should be inspected
for wear and dimensional tolerance whenever the crosshead is removed.

To remove a crosshead slide, first disconnect the bulkhead fitting and free the slide from
the lubrication system. Then remove the two cap screws from the end of the slide.

Lift the crosshead slide and shims through the inspection window. Inspect guide for pits,
cracks or scoring and replace if necessary.

To replace crosshead slides and crosshead, correct shims must be used. Install crosshead
slides, crosshead and plunger. With a micrometer, measure the distance from the plunger
to the wiper box seal bore on top and bottom. Subtract the smaller measurement from the
larger and divide by two for the correct shim pack. Torque the cap screws for the crosshead
slide to 15-20 ft. lbs. Care must be taken not to over torque.

Install the lower shim packs and lower crosshead slide. Tighten the slide cap screws.
Install the upper crosshead slide with no shims. Measure clearance with a feeler gauge.
Clearance should be .008" to .012" (0.2-0.3 mm). Adjust upper shim packs to achieve this
clearance.

Remove crosshead and slide. Add shim packs. Reassemble and check clearance. Install
cap screws and tighten. Reassemble crossheads, connecting rods, etc., per previous
instructions.

The lubrication assembly consists of lubrication tube and piping to allow oil to flow from
the power end lubrication system to the crosshead and crosshead slide. When starting
pump system, inspection should reveal that oil is flowing to all crossheads. Check hoses
at regular intervals (daily) and oil pressure to ensure proper working order. A pressure
switch should be incorporated into the power end lubrication system to shutdown unit if
pressure falls below 20 psi (1.4 bar) at the far end of the lubrication tube (end opposite oil
supply).

4.10 Gearbox

Gearboxes are available in 4.6:1 ratio. Gearboxes are lubricated as part of the power end
lubrication system on standard pumps.

The gear box is designed to remove from the power end assembly in one piece. This is
accomplished by removing the eight 7/8” nuts from the power end flange. This gearbox
does not have an idler and reverses direction of rotation.

17
4.11 Crankshaft and Bearing Assembly

The crankshaft and bearing assembly are shown in the Parts List in the back of this manual.

Inspect the crankshaft and bearings at regular intervals for wear and discoloration. Observe
oiling with covers off whenever starting the pump after overhaul. Oil should flow freely
over all four bearings. Calipers can be used for dimensional checks on worn areas under
connecting rod bearings.

If removal and possible rebuilding or replacement of the crankshaft is required or removal

of bearings is required, the pump will have to be removed from its skid. Disable the power
unit before doing maintenance work. Drain oil from the power frame. Disconnect suction
and discharge flanges. Disconnect the drive line from the gearbox. Remove pump from
skid and if possible do further maintenance in a repair shop with a clean environment.

Remove the gearbox per the previous section. Disconnect the connecting rods, crossheads,
plungers and remove as previously described

Remove the lube bearing housing.

Turn the pump on its side with the crankshaft extension up. Attach a lifting eye to the end
of the crankshaft, lift up on the crankshaft. If necessary apply heat to the bearing retainer
to break it loose from the power end. Keep temperature under 250o F (120o C). Slowly
lift, pulling the cylindrical bearings through their races. It may be necessary to rotate the
crankshaft to allow the bearings to separate from the races.

Remove the bearing retainer, shaft bearing housing, spherical bearing, and cylindrical
bearings from the crankshaft. Low heat may be required for removal.

If required, remove cap screws, lock nut and retaining washers from cylindrical bearing
races still in power end. Remove the races by tapping with a bronze bar.

Follow above directions in reverse order for re-assembly. Use start-up procedures to
"break-in" power end after any major overhaul.

4.12 Lubrication System

The standard WSP pump is not equipped with a sump on the power end. Optional bolt-on
sumps and reservoirs can be purchased or are part of skidded pump units.

Refer to Table 1 for lubrication specifications. Approximately 40 gallons (150 liters) of

oil are needed for the WS-600SH lubrication system.

Fig. 5 shows a typical power end lubrication diagram with engine drive. Pumps that are
shipped as part of a package will include parts lists for the lubrication components.
Components may differ for various applications and power supplies.

The major components of a lubrication system as numbered in Fig. 10 include a gear pump
P02, oil sump or reservoir P11, relief valve P16, oil cooler P25, filter P21, vacuum gauge
P05, pressure gauge P07 and shutdown switch (not shown).

Select a gear pump with a flow of 12 to 18 USGPM capacity at rated speed. This should
result in a pressure reading of a minimum of 50 psi at the pressure switch mounted on the

18
lubrication tube on the triplex power end. Pressure switch should be mounted on the end
opposite the gearbox end. Gear pump can be drive by a PTO drive of an engine
transmission, or can be driven by pulley drive off the front of an engine, or powered
separately by electric motor on electric pump units.

The oil reservoir should have a minimum capacity of 30 US gallons (110 liters).

Hoses, cooler and filters will add approximately 10 US gallons (38 liters) to the system.
Reservoir will connect to power end, gearbox, gear pump, filter and cooler. Suction hose
to the gear pump should be 2 inches (50 mm) in diameter and as direct as possible. A
suction strainer of 125 (.12 mm) mesh should be located at the oil reservoir.

A sump heater may be incorporated into the oil reservoir for operation where ambient
temperatures fall below 32o F (0o C).

The use of heavy gear oil requires careful selection of the oil filter. Filter should be rated
100 US gallons per minute (380 1/min.) at 300 psi (20 bar). An internal bypass of 30 psi
(2 bar) should be included. Filter element should be 25 micron.

It is necessary for both equipment protection and personnel safety to incorporate a relief
valve in the lubrication system. Relief valve should be set at 125 psi (8 bar) and should
connect directly from the gear pump discharge to the oil reservoir.

It is recommended that an oil cooler be part of the lubrication system. A check valve or
full flow thermostat valve, either integral with the cooler or external, should be included to
bypass full oil flow from the cooler when the oil is cold (no need to cool cold oil) during
warm-up.

Three gauges should be part of the system. The vacuum gauge connected to the gear pump
suction should read between zero and 10 inches (0-130 kPa) of Hg when oil temperature
exceeds 120o F (50o C). Pump cavitation and damage will occur if the vacuum exceeds
20 inches of Hg (260 kPa). Clean suction strainer or repair gear pump if high vacuum
persists. A gauge on the gear pump discharge will assist with troubleshooting. A normal
reading would be 60 to 100 psi (4-7 bar). A combination pressure switch and gauge on the
lubrication tube will protect the power end from damage if the lubrication system fails. It
is recommended that shutdown be set at 20 psi (1.4 bar). Normal reading will be 35 to 60
psi (2.4 bar - 4.1 bar).

Pressure hose or piping should be either 1-inch, one-wire hydraulic hose or 1-inch schedule
40 pipe.

A temperature gauge is a good addition to the system. Maximum temperature is 175 o F

(80o C) with a normal operating temperature of 130 to 160o F (54-71o C). A temperature
safety switch set at 180o F (82o C) is recommended.

19
Figure 5: Typical Power End Lubrication Diagram

20
Typical Power End Lubrication Assembly for Figure 5:

Item Number Quantity Part Description

01 1 CHELSEA PTO
02 1 GEAR PUMP
03 2 NIPPLE
04 1 TEE
05 1 VACUUM GAUGE
06 2 REDUCER
07 2 REDUCER
09 1 HOSE
10 2 HOSE
11 1 OIL RESERVOIR
12 2 PIPE SWIVEL
13 2 TEE
14 2 STREET ELBOW
15 1 PRESSURE GAUGE
16 1 RELIEF VALVE
17 3 SWIVEL ELBOW
18 1 HOSE
19 1 REDUCER
20 2 REDUCER
21 1 FILTER
22 2 HOSE
23 1 ADAPTER
24 1 SWIVEL NIPPLE
25 1 OIL COOLER
26 3 REDUCER
27 1 STREET ELBOW
31 1 PIPE NIPPLE
32 1 PIPE ELBOW
33 4 HOSE NIPPLE
34 4 HOSE CLAMP
35 1 HOSE, 2" x 9"
36 2 STREET ELBOW
37 1 HOSE, 2" x 11"
39 1 GAUGE BRACKET (NOT SHOWN)
40 1 HOSE
42 1 PIPE NIPPLE
43 1 REDUCER
44 1 PIPE NIPPLE
45 1 TEE
47 1 REDUCER

21
4.13 Packing Lubrication

Packing requires lubrication with lubricant as specified in Table 1 on page 8.

Fig. 6 shows a proven lubrication schematic for automatic lubrication. The equipment
included in this system includes an air supply (usually an air compressor, governor and
tank), a filter regulator, air hose, gauges, check valve, 3-way valve, "air over oil" reservoir,
hydraulic hose, pipe fittings, oil check valves over each stuffing box, and finally the
stuffing boxes and packing.

Pumps powered by diesel engines often will include an air-shifted transmission that will
require an air compressor, governor and tank. The air tank can then be connected to the
"air over oil" reservoir with necessary hoses and valves. Tank should have a valve at
bottom for draining water.

The governor should be set to shift the air compressor into neutral when the pressure
reaches 100 to 125 psi (6.9-8.6 bar). A check valve is required between the compressor
and tank to prevent back flow of air when the compressor is in neutral. The filter regulator
should be set at 30 to 40 psi (2-3 bar) for proper packing lubrication. The 3-way valve
allows venting of the system as well as shut-off for maintenance.

The "air over oil" reservoir and filter-regulator is covered by a separate manual. The filter-
regulator has an adjusting knob on its top to regulate pressure.

Drawing 1-050342 shows the components for the plunger lubrication system offered as an
option on WSP pumps. Check valves are installed over each stuffing box to prevent flow
of high-pressure pumpage if packing failure were to occur. One-wire, 1/4" diameter (6
mm) hose should be used to connect the reservoir to the pipe cross over the middle stuffing
box and to connect the cross to the other two stuffing boxes.

22
 Figure 6: Lubrication Schematic

5.0 FASTENER TORQUES

Refer to parts list drawings for location and item number.

Torque Part Description

ft.-lbs. N-m
250-350 339-475 Plunger
500 678 Fluid End, 1-inch cap screws
3
1300 1763 Fluid End, 1 8 cap screws
15-20 20-27 Crosshead Slide cap screws
135 183 Connecting Rod cap screws

23
 LOCATING TROUBLE

TROUBLE PROBABLE CAUSE REMEDY

Pump vibrates or pounds. Gas in liquid. Submerge return, supply or make-

up lines in suction supply tank.
Pump valve stuck open. Stop. Remove debris beneath
valve.
Pump not filling. Increase suction pressure.
One or more cylinders not pumping. Stop. Prime all cylinders.
Excessive pump speed. Reduce.
Worn valve or seats. Replace or reface.
Broken or missing springs. Replace.
Loose or worn bearings. Tighten or replace.
Worn crossheads. Replace.
Loose wrist pin or crank. Replace or adjust. Check
Loose connecting rod cap bolts. tolerances.
Water in power end crankcase. Drain. Refill with clean oil

Consistent knock. Worn or loose main bearing, Replace or adjust. Check oil
crank pin bearing, wrist pin level in crankcase. Level may be
bushing, piston and/or valve seat. too low or water may have
worked in through the wiper
boxes.

Excessive heat in Oil in crankcase. Check level, quality,

power end. contamination, etc.
Normal operating temperature
from ambient to approximately
180o F maximum.
Overloaded. Check conditions of service.
Pump crankshaft turning backwards. Check arrow on pump or on
elevation drawing.
Poor lubrication. Check power end lubrication
system.

24
 LOCATING TROUBLE

TROUBLE PROBABLE CAUSE REMEDY

Pump fails to deliver Speed incorrect. Belts slipping. Check with tachometer and
required capacity. change drive ratio or tighten belts
if loose.
Air leaking into pump. Check all joints. Hydrotest. Seal
with compounds.
Fluid cylinder valves, seats or Replace valves and seats.
plunger packing worn. Replace packing or plungers.
Not enough suction pressure above Increase static head or use a
vapor pressure. booster pump.
Pump not filling. Prime pump. Install foot valve at
bottom of suction pipe if suction
lift is used. Make-up in section
tank less than displacement of
pump. Capacity of booster pump
less than displacement of pump.
Vortex in supply tank.
One or more cylinders not pumping. Stop. Prime all cylinders.
Stuck foot valve. Clean.
Fluid valve stuck open. Stop. Remove debris beneath
valve.
Clogged suction strainer. Clean or remove.
Relief or bypass valves leaking. Check and repair.
Low volumetric efficiency. Liquid with low specific gravity
or high discharge pressure
compressing and expanding in
pump. Worn valves or seats. Air
in fluid.

Suction and/or discharge Piping too small and/or too long. Increase size and decrease length.
piping vibrates or pounds. Too many elbows. Use booster pump. Use suction
and/or discharge pulsation
dampeners. (See Sec. 4.5)
Worn valve or seats. Replace.

25
 LOCATING TROUBLE

TROUBLE PROBABLE CAUSE REMEDY

Wear of fluid end parts Abrasive or corrosive action of Check valves and seats frequently
(excessive). the fluid. at start-up to determine schedule
for replacement.
Eliminate sand, abrasives, or air
entering pump.
Broken valve springs. Replace.
Bypassing to suction. Replace worn parts.
Incorrect material. Check with pump manufacturer.

Wear of power end parts Poor lubrication. Check. Replace oil as

(excessive). recommended in instructions.
Examine for water, sand, dirt,
paint, etc. Be sure oil is reaching
all bearings. Check power
lubricator system.
Overloading. Check operating conditions
against conditions of service on
original order. If operating
conditions greater, check with
pump manufacturer.
Fluid entry into power end. Stop. Replace packing and parts
affected. Continued operation
with excessive leaking rod
packing will ultimately allow
entry of fluid into power end.

26
 APPENDIX A
TABLE 3-1 RECOMMENDED LUBRICATION OILS

Oils Recommended for Extreme Warm-Weather Service

Shell Sprax HD 140

Texaco Meropa 460

Exxon Spartan EP 460

Mobil Mobilube HD 140 Mobilube SHC 634*

Chevron NL Gear Compound 460

Amoco Amoco EP Grand 5

OIL COMPANY BRAND NAME OF OIL

Oils Recommended for Extreme Cold-Weather Service

Shell Sprax HD 80

Texaco Multigear EP 80W

Exxon Gear Oil GX 80

Mobil Mobilube SHC 626*

Standard Oil (Chevron) Universal Gear Lubricant 80W 90

Conoco ND 600 Gear Oil

*These are synthesized hydrocarbon lubes and are relatively expensive. They do provide
excellent lubrication under adverse conditions.

27
 APPENDIX B
SHORT TERM STORAGE

1.0 Purpose:
All NOV well service pumps, fluid end assemblies, and power end assemblies shall be
prepared for short-term storage unless otherwise indicated in the Engineering Quality
Requirement (EQR).

2.0 Scope:

2.1 Short Term Storage is defined as storage and/or transient time not exceeding six
(6) months in an environment as defined in paragraph 3.0. If a longer period is
expected, the procedure given in SEP-6.4.7 should be followed.

2.2 Short Term Storage procedures for any other unit components or accessories
(gear reducers, engines, etc.) are to be to the specific manufacturer's
recommendations.

2.3 National Oilwell Varco recommends that all pumps, fluid end assemblies, and
power end assemblies are inspected for any signs of corrosion and for proper
preservation at a minimum every three (3) months. At this time, it is recommended
that all pumps have their cranks rotated at least ten (10) to fifteen (15) revolutions.

3.0 Storage Environment:

3.1 A minimal environmental condition, to be met by the customer or purchaser, is a

closed shelter to eliminate effects of sun, wind, sand or other debris. Large
temperature and humidity changes should be avoided to prevent inhibitor
deterioration or contamination by moisture.

3.2 If outside storage is required, ensure pump is stored away from salt water spray,
sand blast or other adverse conditions. It is also recommended to store the pump
off of the ground and cover the entire pump with plastic sheeting.

4.0 Preservative Inhibitor:

Vapor phase inhibitors, in the form of oil additives, are to be used to protect internal power
end parts from corrosion due to atmospheric moisture. These may be left in the pump
when filled with appropriate lubricant and placed into service.

4.1 The following known supplier & product trade name, or equivalent, is specified for
use in NOV well service pump power ends.

Manufacturer: INDUSTRIAL OILS UNLIMITED, INC.

P. O. BOX 3066
TULSA, OK 74101 USA
TEL: (918) 583-1155
FAX: (918) 583-6457

Product Trade Name: SRPO 655 VP

28
 4.1.1 Read and observe the product MSDS (Material Safety Data Sheet)
before using this inhibitor.

4.2 The following known supplier & product trade name, or equivalent, is specified for
use in NOV well service pump fluid ends.

Manufacturer: HOUGHTON INTERNATIONAL INC.

MADISON & VAN BUREN AVES.
VALLEY FORGE, PA 19482 USA
TEL: (601) 666-4000
FAX: (601) 666-1376

Product Trade Name: RUST VETO 377-HF

4.2.1 Read and observe the product MSDS (Material Safety Data Sheet)
before using this inhibitor.

4.3 The following known supplier & product trade name, or equivalent, is specified for
use on NOV well service pumps, power ends, and fluid ends.

Manufacturer: DR. SHRINK, INC.

315 WASHINGTON STREET
MANISTEE, MI 49660 USA
TEL: (231) 723-2685
FAX: (231) 723-9586

Product Trade Name: DS-206100WCI

4.3.1 Read and observe the product MSDS (Material Safety Data Sheet)
before using this inhibitor.

5.0 Power End Procedures (Individual):

5.1 Preparation from factory testing, or to/from inventory.

5.1.1 Drain any oil that may be in the power end.

5.1.2 Remove and clean oil level gages, pressure gages and breather caps.

29
 5.1.3 Openings:

5.1.3.1. Breather Openings: No vents are to be installed, as it is

important that the corrosion inhibiting vapors be contained in the
closed space.
a. Threaded type: Install either threaded metal/plastic pipe
plug or thread protector plug.
b. Bolted type: Installed on the pump/power end protected by
VCI heat shrink wrap.

5.1.3.2. Other Openings: Replace other items removed in 5.1.2 with

pipe plugs in threaded openings, where applicable, or VCI heat
shrink wrap.

5.1.4 Remove the crankcase cover plate. Clean the bottom of crankcase and
strainer; inspect the power end. Spray the appropriate quantity of
inhibitor in the power end, allowing it to collect in the bottom of the
crankcase and oil galleys over the crossheads. See Paragraph 10.0
for the quantity of inhibitor used in each pump model. Rotate the crank
one half turn while spraying to ensure all sides are coated. Replace
crankcase cover. Use a new gasket, if required, to maintain a good
seal.

5.1.5 Clean the pump outer surfaces prior to painting.

5.1.6 Mask the crank and lubricator shaft surfaces and keyways as well as
oil seal lips and pony rods to prevent coating, if painting is required. If
painting is not required, go to paragraph 5.1.8.

5.1.7 Paint with standard enamel coating system, unless otherwise specified
in the EQR.

5.1.8 Apply a thin layer of grease to the exposed oil seal lips.

5.1.9 Apply a thin layer of rust preventative to the exposed crank and
lubricator shaft surfaces, keyways, and any other non-painted/non-
primed surfaces consisting of exposed ferrous metal (steel). The power
end (short) assemblies are now ready to be placed into stock. For
power ends complete and pumps continue with 5.1.10.

5.1.10 Wrap the exposed crank and lubricator shafts with VCI heat shrink
wrap.

5.1.11 Carefully wrap the following parts prior to placing them into
polyurethane bags: Oil level gages, lube pressure gages, breather
caps (where applicable).

5.1.12 Finish box, crate and mark the parts from paragraph 5.1.11 after final
inspection.

6.0 Fluid End Procedures (Individual):

6.1 Preparation from factory testing, or to/from inventory.

1
 6.1.1 Drain any water that may be in the fluid end.

6.1.2 Remove fluid end valve covers, seals, valve springs, and valves.

6.1.3 Remove any excess water from the fluid end cavities and dry all fluid
end components removed in 6.1.2 with compressed air. Remove any
surface rust/corrosion with a “scotch brite” pad or equivalent and wipe
clean.

6.1.4 Coat the fluid end cavities with rust preventative.

6.1.5 Coat the fluid end internal components (valves, valve springs, etc.) and
the bottom of the valve covers with rust preventative and re-assemble.
Use grease on the valve cover sealing diameters and on the retainer
nut faces.

6.1.6 Coat threads with anti-seize and re-assemble as applicable.

6.1.7 Clean the fluid end outer surfaces prior to painting.

6.1.8 Mask the plungers, discharge connections, and any exposed seals, if
painting is required. If painting is not required, go to paragraph 6.1.10.

6.1.9 Paint with standard enamel coating system, unless otherwise specified
in the EQR.

6.1.10 Apply a thin layer of grease to any exposed seals.

6.1.11 Coat any un-coated/unpainted surface with rust preventative (plungers,

discharge connections, suction manifold, etc.).

6.1.12 Install protective caps to the discharge and suction connections where
applicable. Wrap the discharge and suction manifold connections with
VCI heat shrink wrap.

6.1.13 Plug any other openings with pipe plugs, where applicable, or cover
with VCI heat shrink wrap.

7.0 Pump Procedures (Assembly):

7.1 Preparation from factory testing, or to/from inventory – Power End.

7.1.1 Reference 5.0 above.

7.2 Preparation from factory testing, or to/from inventory – Fluid End.

7.2.1 Reference 6.0 above.

7.3 Preparation from factory testing, or to/from inventory – Pump Assembly.

31
 7.3.1 Wrap the pump in VCI heat shrink wrap from the stay rod nuts to the
face of the power end immediately after coating any
uncoated/unpainted surfaces in that envelope with rust preventative.

8.0 Shipping/Receiving

8.1 Shipping/Receiving ~ Power Ends Complete, New Pumps, & Pump Units

8.1.1 All pumps, power ends, fluid ends, and accessories, as specified on the
EQR, will be final inspected by Quality/Engineering personnel prior to
shipping. Any witnessed or third party inspection will be signed-off by
the representative prior to final crating and shipment.

8.1.2 Any third party inspection will be coordinated with the source.

8.1.3 Upon receipt of the shipment, the purchaser or customer is responsible

for inspection and repair of damaged coatings at the expense of the
shipper.

9.0 Warranty/Start-Up

9.1 Pumps prepared per the above procedure qualify for NOV "Standard Terms &
Conditions" in force on the date of shipment.

9.2 If an expected Short-Term Storage period turns into a Long-Term Storage period
(more than 6 months), this procedure must either be repeated every 6 months or
replaced by S.E.P. 6.4.3.

9.3 Prior to start-up:

9.3.1 Inspect all power end elastomeric seals (shaft oil seals, wiper box seals,
o-rings, etc) and replaced if required.

9.3.2 Install the crankcase drain plug, lubrication level site glass and breather
cap.

9.3.3 Install, if applicable, oil pressure gage.

9.3.4 Check connection of the plunger and pony rod to the crosshead prior
to and after initial run-in of the pump.

9.3.5 Fill the crankcase with lubricant as specified on the pump and
lubrication nameplates.

10.0 Quantity of vapor phase inhibitor used in each type power end.

10.1 Plunger Pumps

MODEL Number/Series OUNCES PINTS LITERS

32
 W350, WS-600, WS-600SA, WS-600SH, WS-
10 4.7
1000SH, W1300, W2250
C1000, WS-2400 10 4.7
WS-2600 13 6.2

10.2 Piston Pumps

MODEL Number/Series OUNCES PINTS LITERS

D750, D750LA, D850LA, D1400LA 10 4.7

33
 APPENDIX C
LONG TERM STORAGE

1.0 Purpose:
Procedure for preparing pumps for long term storage; applies to all NOV well service
pumps, fluid end assemblies and power end assemblies.

2.0 Scope:

2.1 Long-Term Storage is defined as storage and/or transient time of more than six
(6) months in an environment defined in paragraph 3.0. Unless storage and/or
transient time for the pump can be assured to be less than six (6) months,
preparation of the pump to the procedures stated in paragraphs 5.0, 6.0, and 7.0
is required. If a shorter storage period is expected, not exceeding six (6) months,
the procedure given in SEP-6.4.6 should be followed.

2.2 Long Term Storage procedures for any other unit components or accessories
(gear reducers, engines, etc.) are to be to the specific manufacturer's
recommendations.

2.3 National Oilwell Varco recommends that all pumps, fluid end assemblies, and
power end assemblies are inspected for any signs of corrosion and for proper
preservation at a minimum every three (3) months. At this time, it is
recommended that all pumps have their cranks rotated at least ten (10) to fifteen
(15) revolutions.

3.0 Storage Environment:

3.1 A minimal environmental condition, to be met by the customer or purchaser, is a

closed shelter to eliminate effects of sun, wind, sand or other debris. Large
temperature and humidity changes should be avoided to prevent inhibitor
deterioration or contamination by moisture.

3.2 If outside storage is required, ensure pump is stored away from salt water spray,
sand blast or other adverse conditions. It is also recommended to store the pump
off of the ground and cover the entire pump with plastic sheeting.

4.0 Preservative Inhibitor:

Vapor phase inhibitors, in the form of oil additives, are to be used to protect internal power
end and fluid end parts from corrosion due to atmospheric moisture.

4.1 The following known supplier & product trade name, or equivalent, is specified for
use in NOV pump power ends.

Manufacturer: INDUSTRIAL OILS UNLIMITED, INC.

P. O. BOX 3066
TULSA, OK 74101 USA
TEL: (918) 583-1155
FAX: (918) 583-6457

Product Trade Name: SRPO 655 VP

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 4.1.1 Read and observe the product MSDS (Material Safety Data Sheet) before
using this inhibitor.

4.2 The following known supplier & product trade name, or equivalent, is specified for
use in NOV well service pump fluid ends.

Manufacturer: HOUGHTON INTERNATIONAL INC.

MADISON & VAN BUREN AVES.
VALLEY FORGE, PA 19482 USA
TEL: (601) 666-4000
FAX: (601) 666-1376

Product Trade Name: RUST VETO 377-HF

4.2.1 Read and observe the product MSDS (Material Safety Data Sheet)
before using this inhibitor.

4.3 The following known supplier & product trade name, or equivalent, is specified for
use on NOV well service pumps, power ends, and fluid ends.

Manufacturer: DR. SHRINK, INC.

315 WASHINGTON STREET
MANISTEE, MI 49660 USA
TEL: (231) 723-2685
FAX: (231) 723-9586

Product Trade Name: DS-206100WCI

4.3.1 Read and observe the product MSDS (Material Safety Data Sheet)
before using this inhibitor.

5.0 Power End Procedures (Individual):

5.1 Preparation from Factory Testing or Field Operation

5.1.1 Fill the power end with a preservative oil mixture, consisting of
lubricating oil (to the normal operating level) and vapor phase inhibitor
(in the quantity Paragraph 10.0).

5.1.2 Either run the power end for 15 seconds or turn the crankshaft from 10
to 15 complete rotations. Liberally splash all roller bearings with the oil
preservative mixture if the hand rotation method is used.

5.1.3 Leaving the preservative oil mixture in the power end, inspect for any
gasket, plug or cap leaks and address as needed.

5.1.4 Drain the preservative oil mixture from power end, and then wipe out
the crankcase with a lint free cloth.

5.1.5 Remove and clean oil level gages, pressure gages, etc. Replace with
pipe plugs in any NPT threaded openings. Replace with plastic/metal

35
 thread protectors or cover with VCI heat shrinkwrap for any other
threaded openings.

5.1.6 Openings:

5.1.6.1 Breather Openings: No vents are to be installed, as it is

important that the corrosion inhibiting vapors be contained
in the closed space.

a. Threaded type: Install either threaded metal/plastic

pipe plug or thread protector plug.

b. Bolted type: Install on the power end protected by

VCI heat shrinkwrap.

5.1.6.2 Other Openings: Replace other items removed in 5.1.5 with

pipe plugs in threaded openings, where applicable, or VCI
head shrinkwrap.

5.1.7 Install vapor phase inhibitor in the quantities given in

Paragraph 10.0.

5.1.8 Clean the pump outer surfaces prior to painting.

5.1.9 Mask the crank and lubricator shaft surfaces and keyways as well as
oil seal lips to prevent coating if painting is required; if not required, then
go to paragraph 5.1.12.

5.1.10 Paint with standard enamel coating system, unless otherwise specified
in the EQR.

5.1.11 Apply a thin layer of grease to the exposed oil seal lips and pony rod
seals.

5.1.12 Apply a thin layer of rust preventative to the exposed crank and
lubricator shaft surfaces, keyways and any other non-painted/non-
primed surfaces (i.e. push rods). Wrap the exposed crank and
lubricator shafts with VCI heat shrinkwrap

5.1.13 Carefully wrap the following parts prior to placing them into
polyurethane bags: Oil level and pressure gages, breather cap (where
applicable), and any other items removed from paragraph 5.1.5. Apply
export preservative (Cosmoline) to any steel or cast iron parts, prior to
wrapping.

5.1.14 Finish box, crate and mark the parts from paragraph 5.1.13 after final
inspection.

5.1.15 Secure a desiccant packet to one or more of the central stayrod(s) with
cable tie(s) or industrial grade adhesive tape. For a pump with cradle
in-lieu of stayrods, secure appropriately. Ensure that either method
does not damage the paint/coating on the stayrod(s).

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 5.1.15.1 For a triplex use one (1) 6.0 cubic foot (capacity) or larger
desiccant packet.

5.1.15.2 For a quintiplex, use two (2) 6.0 cubic foot (capacity) or
larger desiccant packets.

5.1.16 Wrap, with VCI heat shrinkwrap, from the end of the stayrods to over-
lapping the face-plate of the power end.

5.1.17 Secure a desiccant packet to the top of the power end with cable tie(s)
or industrial grade adhesive tape. Ensure that either method does not
damage the paint/coating on the power end.

5.1.17.1 For a triplex use one (1) 6.0 cubic foot (volume protected)
or larger desiccant packet.

5.1.17.2 For a quintiplex, use two (2) 6.0 cubic foot (volume
protected) or larger desiccant packets.

5.1.18 Wrap, with VCI heat shrinkwrap, the entire top of the power end down
to just below the rotary union. Ensure the top of the back cover is
covered and that the hose from the rotary union is not damaged. All
inspection covers on the back cover and gear covers should still be
accessible. It is permissible for this wrap to also cover the previously
wrapped stayrods.

5.1.18.1 This wrap should be a single piece with no seams on the

top.

5.2 Storage

In addition to paragraph 3.0, either enough space should be allowed or

consideration made for performance of the following step:

5.2.1 From 10 to 15 complete rotations of the pump crankshaft, every three

(3) months, is required. Liberally splash all roller bearings.

6.0 Fluid End Procedures (Individual):

6.1 Preparation from factory testing, or to/from inventory.

6.1.1 Drain any water that may be in the fluid end.

6.1.2 Remove fluid end valve covers, seals, valve springs, and valves.

6.1.3 Remove any excess water from the fluid end cavities and dry all fluid
end components removed in 6.1.2 with compressed air. Remove any
surface rust/corrosion with a “scotch brite” pad or equivalent and wipe
clean.

6.1.4 Coat the fluid end cavities with rust preventative.

37
6.1.5 Coat the fluid end internal components (valves, valve springs, etc.) and
the bottom of the valve covers with rust preventative and re-assemble.
Use grease on the valve cover sealing diameters and on the retainer
nut faces.

6.1.6 Coat threads with anti-seize and re-assemble as applicable.

6.1.7 Clean the fluid end outer surfaces prior to painting.

6.1.8 Mask the plungers, discharge connections, and any exposed seals, if
painting is required. If painting is not required, go to paragraph 6.1.10.

6.1.9 Paint with standard enamel coating system, unless otherwise specified
in the EQR.

6.1.10 Apply a thin layer of grease to any exposed seals.

6.1.11 Coat any un-coated/unpainted surface with rust preventative (plungers,

discharge connections, suction manifold, etc.).

6.1.12 Install protective caps to the discharge and suction connections where
applicable. Wrap the discharge and suction manifold connections with
VCI heat shrinkwrap.

6.1.13 Plug any other openings with pipe plugs, where applicable, or cover
with VCI heat shrinkwrap.

6.1.14 Secure a desiccant packet to a central location with cable tie(s) or

industrial grade adhesive tape. Ensure that either method does not
damage the paint/coating on the fluid end.

6.1.14.1 For a triplex use one (1) 6.0 cubic foot (volume protected)
or larger desiccant packet.

6.1.14.2 For a quintiplex, use two (2) 6.0 cubic foot (volume
protected) or larger desiccant packets.

6.1.15 Wrap, with VCI heat shrinkwrap, the entire fluid end.

6.1.15.1 This wrap should be a single piece or no seams on the top.

38
7.0 Pump Procedures (Assembly):

7.1 Preparation from factory testing, or to/from inventory – Power End.

7.1.1 Reference 5.0 above.

7.2 Preparation from factory testing, or to/from inventory – Fluid End.

7.2.1 Reference 6.0 above.

7.3 Preparation from factory testing, or to/from inventory – Pump Assembly.

7.3.1 Wrap the entire pump in VCI heat shrinkwrap. This applies after the
power end and fluid end are prepared and wrapped per their respective
procedures. Reference 5.0 and 6.0 above.

7.3.1.1 This wrap should be a single piece or no seams on the top

and sides.

7.3.1.2 Ensure all inspections of the pump are complete before

wrapping the pump.

8.0 Shipping/Receiving

8.1 Shipping/Receiving - Power Ends Complete, Fluid Ends Complete, New Pumps,
& Pump Units

8.1.1 All pumps, power ends, fluid ends, and accessories, as specified on the
EQR, will be final inspected by Quality/Engineering personnel prior to
shipping. Any witnessed or third party inspection will be signed-off by
the representative prior to final crating and shipment.

8.1.2 Any third party inspection will be coordinated with the source.

8.1.3 Upon receipt of the shipment, the purchaser or customer is responsible

for inspection and repair of damaged coatings at the expense of the
shipper.

9.0 Warranty/Start-Up:

9.1 Pumps prepared per the above procedure qualify for the NOV "Standard Terms &
Conditions" in force on the date of shipment.

9.2 Replacement of vapor phase inhibitor preservative (see paragraph 5.1.7) is

mandatory on an annual basis.

39
 9.3 Prior to Start-Up:

9.3.1 Drain the preservative oil mixture.

9.3.2 Inspect elastomeric seals (power end shaft oil seals, wiper box seals, o-
rings, etc.) and replace as required.

9.3.3 Install crankcase drain plug, lubrication level site glass and breather cap.

9.3.4 Install, if applicable, oil pressure gage.

9.3.5 Check connection of the plunger and pony rod to the crosshead prior to
and after initial start-up and run-in of the pump.

9.3.6 Fill the crankcase with lubricant as specified in the pump manual.

10.0 Quantity of vapor phase inhibitor used in each type power end.

10.1 Plunger Pumps

MODEL Number/Series OUNCES PINTS LITERS

W350, WS-600, WS-600SA, WS-600SH, WS-
10 4.7
1000SH, W1300, W2250
C1000, WS-2400 10 4.7
WS-2600 13 6.2

10.2 Piston Pumps

MODEL Number/Series OUNCES PINTS LITERS

D750, D750LA, D850LA, D1400LA 10 4.7

40
41
PUMP SPECIFICATIONS

42
 PERFORMANCE CHARTS

WS-600SH Hydraulic Horsepower

Pressure vs Flow

Volumetric Rate is based on 100% Volumetric Efficiency. Brake Horsepower/Kilowatts required are based on 85% Mechanical Efficiency. These ratings
are for intermittent service. Pressure up to those shown may be utilized for a period not to exceed a total of 8 hours in 24 hours. Applications above
15,000 psig must be approve by NOV Engineering Department.

43