Project: Power End Repair on Frac Pump
Sector: Oil and Gas
Role: Primary Contractor
Description
The frac pump was received and a visual inspection on the power end was conducted. It was observed the planetary seal was leaking and there was a failed patch weld on the crank housing. The pony rod cover was removed on hole #1 and discovered the broken bolt damaged the pony rod and shoes. The driver side cover on the power end was removed for inspection. It was observed the crank housing needs repair due to a crack.
Once the pump end was disassembled, we then inspected the crank hose, bearing cases and all of the crossheads for discrepancies. We found damage to the support rings and the front structure, as well as, the crosshead, the crosshead thrust
The frac pump was received and a visual inspection on the power end was conducted. It was observed the planetary seal was leaking and there was a failed patch weld on the crank housing. The pony rod cover was removed on hole #1 and discovered the broken bolt damaged the pony rod and shoes. The driver side cover on the power end was removed for inspection. It was observed the crank housing needs repair due to a crack.
Once the pump end was disassembled, we then inspected the crank hose, bearing cases and all of the crossheads for discrepancies. We found damage to the support rings and the front structure, as well as, the crosshead, the crosshead thrust brushing and the crosshead shoe all needed to be replaced due to damage. We cleaned all the loose parts when we disassembled the crosshead section and extracted all of the broken bolts. We then disassembled the crosshead section for welding, disassembled the planetary ring gears, removed leaking seal and cleaned all of the parts. We resealed the ring gear halves and reassembled planetary. Once the sealing surfaces were all buffed we installed a new seal at the spacer to crosshead section and installed the new crosshead onto the crank shaft and torqued trunnion bolts. The crosshead slides were installed and all of the new bolts were torqued. Once the crank was installed into the housing, we moved to installing the crank section onto the crosshead section and connected con rods to the crank.
The frac pump was received and a visual inspection on the power end was conducted. It was observed the planetary seal was leaking and there was a failed patch weld on the crank housing. The pony rod cover was removed on hole #1 and discovered the broken bolt damaged the pony rod and shoes. The driver side cover on the power end was removed for inspection. It was observed the crank housing needs repair due to a crack.
Once the pump end was disassembled, we then inspected the crank hose, bearing cases and all of the crossheads for discrepancies. We found damage to the support rings and the front structure, as well as, the crosshead, the crosshead thrust brushing and the crosshead shoe all needed to be replaced due to damage. We cleaned all the loose parts when we disassembled the crosshead section and extracted all of the broken bolts. We then disassembled the crosshead section for welding, disassembled the planetary ring gears, removed leaking seal and cleaned all of the parts. We resealed the ring gear halves and reassembled planetary. Once the sealing surfaces were all buffed we installed a new seal at the spacer to crosshead section and installed the new crosshead onto the crank shaft and torqued trunnion bolts. The crosshead slides were installed and all of the new bolts were torqued. Once the crank was installed into the housing, we moved to installing the crank section onto the crosshead section and connected con rods to the crank.
We assembled the power end and wire tied all the con rod caps. We then installed the planetary spacer section, planetary adapter gear and the gear box with new O rings. Once those were torqued, we installed the new rotating union seal, fluid end studs and the gear box drain hose along with new O rings. The power end assembly was then washed and we installed the power end onto the trailer. We connected the driveline, lube lines and transducers and installed the drive line guard and other brackets that we removed during disassembly.
We installed the fluid end using three step torque procedure and measuring bolt stretch, recorded measurements and indicated on fluid end. We installed the iron rack D.S and then installed the grease fittings onto packing glands, installed plunger guard and grease lines. The lube return line for pump relief valve and then installed the suction manifold and discharged the iron.
The unit was then tested on the test stand and passed.
We assembled the power end and wire tied all the con rod caps. We then installed the planetary spacer section, planetary adapter gear and the gear box with new O rings. Once those were torqued, we installed the new rotating union seal, fluid end studs and the gear box drain hose along with new O rings. The power end assembly was then washed and we installed the power end onto the trailer. We connected the driveline, lube lines and transducers and installed the drive line guard and other brackets that we removed during disassembly.
We installed the fluid end using three step torque procedure and measuring bolt stretch, recorded measurements and indicated on fluid end. We installed the iron rack D.S and then installed the grease fittings onto packing glands, installed plunger guard and grease lines. The lube return line for pump relief valve and then installed the suction manifold and discharged the iron.
The unit was then tested on the test stand and passed.
brushing and the crosshead shoe all needed to be replaced due to damage. We cleaned all the loose parts when we disassembled the crosshead section and extracted all of the broken bolts. We then disassembled the crosshead section for welding, disassembled the planetary ring gears, removed leaking seal and cleaned all of the parts. We resealed the ring gear halves and reassembled planetary. Once the sealing surfaces were all buffed we installed a new seal at the spacer to crosshead section and installed the new crosshead onto the crank shaft and torqued trunnion bolts. The crosshead slides were installed and all of the new bolts were torqued. Once the crank was installed into the housing, we moved to installing the crank section onto the crosshead section and connected con rods to the crank.
We assembled the power end and wire tied all the con rod caps. We then installed the planetary spacer section, planetary adapter gear and the gear box with new O rings. Once those were torqued, we installed the new rotating union seal, fluid end studs and the gear box drain hose along with new O rings. The power end assembly was then washed and we installed the power end onto the trailer. We connected the driveline, lube lines and transducers and installed the drive line guard and other brackets that we removed during disassembly.
We installed the fluid end using three step torque procedure and measuring bolt stretch, recorded measurements and indicated on fluid end. We installed the iron rack D.S and then installed the grease fittings onto packing glands, installed plunger guard and grease lines. The lube return line for pump relief valve and then installed the suction manifold and discharged the iron.
The unit was then tested on the test stand and passed.
