Section

HT-400 Pump Description

Figure 1.1 The HT-400 pump is used

in all phases of oilfield operation to
pump water, cement, fracturing fluids,
and other stimulation fluids. The three
main parts of the pump are (1) the
power end, (2) a spacer, and (3) the
fluid end.

Power End

Spacer

Fluid End

Assembled Pump
The HT-400 pump has three main assembliesthe power end, a spacer, and the
fluid end (Figure 1.1). All HT-400 pumps have a power end and a fluid end.
Spacers first became available as an option in the early 1970s. Since the early
1970s, almost all HT-400 pumps have been assembled with spacers between the
two ends, but some older models are still in use without a spacer.
Figure 1.2 (Pages 1-4 and 1-5) is a schematic of an HT-400 pump with a righthand power end, an L-4 Cone drive spacer, and a 6-in. (15.240-cm) fluid end.
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HT-400 Description

1-1

Figure 1.2 is referred to throughout this manual with Loc.-x identifying the
location of parts.

Power End
The power-end assembly reduces speed, multiplies torque, and changes rotary
action into reciprocating action. It takes energy delivered by the engine and
transmission and changes it into energy that can be used by the fluid end.
Power ends are customized to meet job requirements and conserve space on the
trailer or truck unit. Cases are available in right- and left-hand versions. Since
the early 1970s, fracturing pumps have been equipped with Cone drive (8.4:1)
gears, while cementing pumps have Holroyd or Delroyd gear sets (8.6:1).
Other customizing features include the following:

lube systems

companion flanges

worm- and ring-gear ratios

heat exchanger design

Spacer
On most pump configurations, a steel spacer assembly is used between the fluid
end and the power end. The spacer helps prevent fluids from escaping from the
fluid end into the power-end cavity (sump).
All new pumps require spacers. Fracturing pumps require L-2 spacers and
cement pumps require L-4 spacers.
Some spacers require push-rod noses uniquely designed to match the fluid-end
size used, while other spacers may use more than one type of wiper gland.

Fluid End
The fluid end uses energy that has been modified by the power end to move
cement, fracturing mediums, and other liquids and materials.
The HT-400 pump fluid end, which is available in five sizes, can be customized
for many applications. The fluid end accepts a variety of discharge flanges and
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plunger lubricators. Different lengths of plungers and tie bolts are used. A
variety of valve and seat combinations are available, and different springs and
inserts can be installed on these valves.

Design Features
The following features are unique to the HT-400 pump:

It can pump at pressures as high as 20,000 psi (137.895 MPa).

It is lightweight and compact, and can be airlifted into remote areas.

It provides high performance and long life.

It has three separate fluid-end sections that can be replaced individually.

HT-400 Power End

Case
The case is a weldment made of high-strength steel. It has bores for the worm
gear, crankshaft, and crossheads. It has lifting eyes on the top and four legs on
the bottom that are used for machining and mounting. Eight access covers
facilitate maintenance and repairs to specific parts. Twelve studs secure the fluid
end to the power end.

Worm-Gear/Input-Shaft Drive Flange

The engine and transmission deliver energy to the pump through the worm-gear
input shaft. This shaft can be equipped with sheaved or unsheaved companion
flanges (Figure 1.2, Loc. 1). Unsheaved flanges are more commonly used;
sheaved flanges are used for driving pumps that lubricate the fluid-end packing.

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HT-400 Description

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1-4

HT-400 Pump Maintenance and Repair Manual

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10

19

9
15

39

26

42

43

27

41
32

28

31

To Heat Exchanger

View A

38

25

40

33

34

33

35

29

30

37

30
31
32

29

36

Figure 1.2AHT-400 right-hand power end with an L-4 Spacer, Cone drive, and 6-in. fluid end. Slight differences in the right-hand and left-hand
pumps are discussed on Page 1-10.

11

21

22

Table 1.1List of Locations on Cross-Sectioned Pump (Figures 1.2A and 1.2B)

Loc

Description

Loc

Description

Loc

Description

Companion Flange

16

Thrust Ring

31

Valve Seat

Worm Gear

17

Gear-Support Bearing

32

Valve-Seat O-ring

Ring Gear

18

Flanged Stud

33

Guide-Bushing Retainers

Flange-Gear/Spline-Drive Coupling

19

Crosshead

34

Suction-Valve Stop

Connecting Rod and Bearings

20

Injector

35

Discharge-Valve Cover

Connecting-Rod Pins

21

Bypass Valve

36

Cover Retainer

Crosshead Shoes

22

Gauges

37

Cylinder-Head Cover

Crosshead Slides

23

Gear Lugs

38

Packing

Worm-Thrust Bearing

24

Gear Washers

39

Wiper Seal

10

Worm Radial BearingThrust End

25

Fluid-End Section

40

Top Tie-Bolt

11

Worm Radial BearingDrive End

26

Plunger

41

Bottom Tie-Bolt

12

Crankshaft Main BearingNarrow

27

Plunger Tie-Bolt

42

Wiper Gland

13

Crankshaft Main BearingWide

28

Plunger Nose

43

Packing Nut

14

Gear-Support Bearing

29

Frac Valve

44

Crankshaft/Spline-Drive Coupling

15

Oil Pump

30

Valve Insert

Note: Location numbers correspond to numbers in Figures 1.2A and 1.2B.

3
23

24

14
17

16

12

13

18

12

20

44

View B

Figure 1.2BSection view of an HT-400 pump power-end section through the crankshaft.

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HT-400 Description

1-5

Worm and Ring Gears

Energy is transferred through splines of the companion flange to the steel worm
gear (Figure 1.2, Loc. 2). From there, the energy passes through the teeth to the
bronze ring gear (Figure 1.2, Loc. 3). At that time, speed reduction and torque
multiplication occur in the gear set.
Four gear sets have been used in the power ends. The predominant worm-gear to
ring-gear operating ratios are 8.4:1 and 8.6:1; therefore, the worm gear revolves 8.4
times or 8.6 times to every revolution of the ring gear.

Crankshaft
Energy moves from the ring gear to the crankshaft through a splined drive
coupling (Figure 1.2, Loc. 4). The crankshaft is rough-machined from a forged
billet. It is heat-treated and then machine-finished, drilled, and ground.
The three crankshaft journals are spaced 120 apart. Journal positioning from the
center of the crankshaft out limits the stroke to 8 in.

Connecting Rods, Crossheads, and Slides

The connecting rods (Figure 1.2, Loc. 5) are made of forged aluminum. The rods
have split caps and insert bearings. Crosshead ends of the rods are press-fitted
with bronze bushings. The connecting rods convert the rotary motion of the
crankshaft to a reciprocating action at the crosshead.
The cast-steel crossheads are connected to the rods by steel pins (Figure 1.2,
Loc. 6). Crosshead upper and lower faces are covered by bronze shoes (Figure
1.2, Loc. 7). Steel slides, secured in the case by expanding clamps, contain and
guide the crossheads in their movement (Figure 1.2, Loc. 8).

Bearings
Roller bearings support the rotating parts and keep them in position. The three
smaller bearings are located on the worm gear: the thrust bearing for positioning
and the two support bearings (Figure 1.2, Loc. 9 through 11). Four larger main
bearings support the crankshaft (Figure 1.2, Loc. 12 and 13). The gear support
bearing supports and positions the ring gear and limits the ring gears lateral
movement (Figure 1.2, Loc. 14).

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Shims
Seven groups of shims are used in the power end to adjust clearance and align
parts. Shims are used in the following locations:

behind the worm thrust-bearing retainer on the Cone drive gears to adjust
the relationship of the worm-to-ring gear

behind the oil pump to adjust clearance in the thrust bearing

under the thrust ring to adjust clearance in the gear-support bearing

under the bearing support to align the ring gear on the worm gear

on the end of the flanged stud to position the connecting rods in the crossheads

under the shoes of the crossheads to adjust clearance between the crossheads and the slides

on the ends of the slides to make them stick out from the case

When the shims are on the ends of the slides, the fluid end (or spacer) presses
against the protruding slides to hold them securely in place.

Lube System
The oil-filter system on the current HT-400 pump power end is a Schroeder
Brothers filter and strainer (Figure 1.3, Page 1-8).
The worm gear, support, and thrust bearings are submerged in sump oil. The
ring gear, the crankshaft, and bearings are awash with sump oil from the oil
pump. Forced lubrication is also provided.
Drilled passages in the crankshaft convey pressurized oil to the main bearings
and to the connecting-rod bearings. Oil travels through the connecting rods to
the bushings and crosshead pins.
Crosshead shoes and slides are oiled by nozzles that project through the top
slides. At the highest point of travel, the rollers of the gear-support bearing are
lubricated by another nozzle.

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HT-400 Description

1-7

Strainer

Filter

Figure 1.3The Schroeder strainer and filter are used on HT-400 pumps built after
April 1974.

Injector and Magnetic Seal

Oil moves to the revolving crankshaft through the injector (Figure 1.2, Loc. 20).
The injector is a mandrel that has been drilled for oil passage. The injector fits
into the end of the crankshaft. A magnetic seal restrains the oil between the
injector and crank.
One part of the seal is an O-ring in the ID that contacts the injector. The other
part is an O-ring around the OD that contacts the crankshaft. Oil pressure and
magnets in the seal keep the parts together while the crankshaft moves.
The crankshaft drives a small shaft in the injector. The shaft can be used to drive
a counter that registers approximate total volume discharged by the fluid end.
Counters can be calibrated in barrels, gallons, cubic feet, cubic meters, or cubic
liters. A rate meter can be operated off the injector.

Oil Pump
Pressure for all forced lubrication comes from the oil pump (Figure 1.2, Loc. 15).
This pump, driven either off the end of the worm gear or driven remotely,
retrieves lubricant from the power-end cavity (sump). The lubricant is then
discharged through external lines into the bypass valve on pre-1974 pump
models or through the strainer and into the bypass on most later models.

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Bypass Valve
The bypass valve (Figure 1.2, Loc. 21) maintains lubricant pressure at 80 to 100
psi (0.552 to 0.689 MPa). Pumps built before April 1974 maintain lubricant
pressure at 35 to 45 psi (0.241 to 0.310 MPa). The pressure depends upon the
spring used in some bypass valves or on shims behind the spring in others.
When the HT-400 pump is running slowly, the worm gear also turns slowly. If
the oil pump is driven by the worm gear, the output volume is relatively low. At
such times, the bypass remains closed and all lubricant passes on to the injector
and nozzles.
When the pump is running fast, the worm gear runs fast, and the oil pump
produces excessive pressure. Excessive oil pressure is also produced when
temperatures are low and lubricant is thick. At such times, the bypass opens to
bleed off some of the volume and relieves to the set pressure. Oil dumped by the
bypass helps cool and lubricate the ring gear.

Oil Filter/Strainer System

Lubricant is discharged from the oil pump into the strainer. It then goes to the
bypass through a 25-micron filter and on to the delivery points.
The strainer is a coarse mesh screen element with magnetic inserts. All of the oil
delivered from the oil pump circulates through the strainer.
The filter cleans the oil that goes into the crankshaft, bearings, and crossheads.
The filter uses three 25-micron disposable elements. Each disposable element is
expected to have a life of approximately 6 months between element changes.
New elements should be purchased from stock.

Important

Similar elements purchased from automotive suppliers are not equivalent.

Heat Exchanger
During startup on cold days, the lubricant in the power end is cold, thick, and
unable to coat moving parts. It may be so thick that it cannot be poured or
pumped.
The heat exchanger heats the lubricant to a minimum operating temperature of
no less than 40F (4.44C). Coolant warmed in the engines cooling system
circulates through the heat exchanger core, causing oil around the core to warm
and become more liquid.
When the pump is in operation, the heat exchanger removes heat from the oil.
This heat is dissipated by the engine radiator or by other means.
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HT-400 Description

1-9

The standard heat exchanger is an external tube-and-shell unit. On some older

installations, the heat exchanger is attached to the bottom of the case. Sometimes,
pump coolant does not come from the engine. Seawater is often used to cool
pumps on offshore rigs. Many fracturing units use an air-to-oil cooling system.

Gauges
Two gauges monitor the lube system (Figure 1.2, Loc. 22). The mechanical
temperature gauge has a sensing bulb located in the worm-gear housing. The
mechanical pressure gauge is connected to the lube line leading to the nozzle of
the gear-support bearing. The gauge needles sweep across areas of the gauge
faces that are color-coded to show operating ranges and danger zones.

Right- and Left-Hand Pumps

Power ends are built in right- and left-hand units so that they can be located to
maximize available space. The main difference between the two is the location of
the gears and the gear housing (enlarged, round part of the case).
A right-hand power end viewed from the fluid-end end has the housing on the
right (Figure 1.4, Page 1-11). Housing of the left-hand power end is on the left.
Units are often mistakenly identified as right or left because of the position they
occupy on the truck, skid, or trailer.
The ring gear is assembled differently for right- and left-hand power ends. The
right-hand ring gear assembly is secured with lugs, washers, and the clamp ring
adapter. Only washers are used on left-hand units.
Another difference between right- and left-hand pumps is that more shims are
used under the support for right-hand power ends. These shims offset the ringgear outward to center it on the worm gear when the worm gear is acting upon
it. Fewer shims are used under supports for left-hand power ends since the ring
gear needs to be offset to the inside.
A ring of welding rod is used to fill the gap between the gear support and the
race of the first main bearing on right-hand power ends. Left-hand power ends
rarely require enough shims to warrant the use of this ring.

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Right

Left

Figure 1.4To maximize available space, operators can choose a right- or left-hand
power end. The difference between the units is the position of the housing from the fluidend view.

Fluid End
Fluid-End Sections
The fluid-end section (Figure 1.2, Loc. 25) is the chamber that the pumped liquid
moves through. The section is a steel forging that is heat-treated, machined, and
prestressed.
Sections are manufactured in five sizes. Size does not indicate the measurement
of the outside of the section, since all sizes are machined from identical forgings.
Size refers to the horizontal bore cut for the plunger. The numbering system
designating size reflects this measurement.

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HT-400 Description

1-11

Caution

A 3 3/8-in. (8.573-cm) section is bored for a 3 3/8-in. (8.573-cm) diameter

plunger.

A 4-in. (10.160-cm) section is bored for a 4-in. (10.160-cm) diameter plunger.

A 5-in. (12.700-cm) section is bored for a 5-in. (12.700-cm) diameter plunger.

A 6-in. (15.240-cm) section is bored for a 6-in. (15.240-cm) diameter plunger.

The 4/4 1/2-in. (10.160/11.430-cm) section can accommodate both 4-in.

(10.160 cm) and 4 1/2-in. (11.430-cm) plungers. This situation can lead to some
confusion, since assemblies with 4-in. plungers are usually called 4-in. fluid
ends and those with 4 1/2-in. plungers are called 4 1/2-in. fluid ends.

Do not use a 4-in. (10.160-cm) plunger in a 4 1/2-in. (11.430-cm) section for highpressure/long-duration pumping. The fatigue life of the fluid end is shortened
if the HT-400 pump is operated above 11,200 psi (77.221 MPa). This style is
obsolete.
In addition to a horizontal bore, a fluid-end section has a vertical bore on which
the valves are located. At the top of the vertical bore is the discharge passage.

Plungers
The plunger (Figure 1.2, Loc. 26) causes fluids and materials to move through the
fluid-end section. The plunger is attached to the crosshead by an arrangement
consisting of a plunger tie-bolt (Figure 1.2, Loc. 27) and a nutlike device called a
plunger nose (Figure 1.2, Loc. 28). The plunger is pushed by the crosshead and
pulled by the tie bolt and nose.
Several diameters of plungers are available to accommodate a wide range of
pressure/volume outputs. In general, high-pressure/low-volume operations are
performed with smaller plungers and low-pressure/high-volume operations are
performed with the larger plungers.
Two plunger lengths are in production. Tie-bolt lengths vary according to the
plunger length. Short plungers are used with the L family of spacers (Section 8,
Page 8-2). Most of the 5-in. (12.700-cm) and 6-in. (15.240-cm) plungers are made
so that the noses are flush. On the other plunger sizes, the noses protrude beyond the ends.
Plungers have a hard surface that is flame-sprayed and fused with a hard,
metallic powder onto the plungers and then ground for smoothness. Hardsurfaced plungers can be used for all kinds of pumping.

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Figure 1.5Valves direct the fluid that is moved by the plunger.

(A.) As the plunger is withdrawn from a fluid-end section, a partial vacuum is created.
(B.) As the plunger re-enters the fluid-end section, the fluid is pressurized.

Valves
Plungers move the fluid, and valves direct the fluid. As a plunger is withdrawn
from a fluid-end section, a partial vacuum is created (Figure 1.5a). The suction
valve at the bottom of the vertical bore is drawn up and away from its seat,
which allows fluid to enter the chamber. At the same time, fluid already in the
chamber moves in to fill the space where the plunger was.
As the plunger re-enters the fluid-end section, the fluid is pressurized (Figure
1.5b). Fluid would go out the way it entered the chamber, but the suction valve
moves into contact with the seat. As pressure increases, the fluid pressure forces
the discharge valve to move.
The discharge valve moves off its seat, and the fluid is expelled from the chamber. Loss of pressure inside the chamber and the force of the spring moves the
valve down to form a seal with the seat as the cycle starts again.
Valves are machined from forgings and are carburized, which means that they
are treated with a hot chemical that builds up the carbon content of the metal to
a shallow depth. The surface is hard and long-wearing, but the core remains soft
and ductile.
Valves are available in three diameters. The smallest (#3) is used with 3 3/8-in.
(8.573-cm) and 4-in. (10.160-cm) fluid ends. The intermediate valve (#4) is used
with 4 1/2-in. (11.430-cm) fluid ends. The largest (#5) is used with 5-in.
(12.700-cm) and 6-in. (15.240-cm) fluid ends.

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HT-400 Description

1-13

The frac valve (Figure 1.2, Loc. 29) has become standard for all pumps, replacing
the single- and double-guided valves. The frac valve has two stems, as does the
double-guided valve. Unlike the double-guided valve, however, it has no retaining clip or ring. Instead, the oversized insert is held in place by its own elasticity.
A flange, built into the valve, backs the insert. Frac valves last longer than other
valves, especially when they are used in oilfield formation fracturing services.

Ball Valves
Ball valves (Figure 1.6) are used in low-rate/high-sand concentration service.
Low rates are considered 2 to 5 bbl/min (0.318 to 0.795 m3/min) per pump. Ball
valves are designed for temporary installation. A pump may be outfitted for a
special high sand-concentration job and then returned to normal after the job is
completed.

Special Discharge Cover

Special Suction Stop

Wave Spring
Short Cage

2-in. Ball
Ball Valve Insert
Drop-In Seat
Frac Valve Insert

Suction
Discharge

Figure 1.6Typical 2-in. ball valve.

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While ball valves are expedient for low-rate/high sand-concentration service,

the use of ball valves restricts all sizes of pumps to a maximum recommended
pumping rate of 5 bbl/min (0.795 m3/min). Higher rates, even during prime-up
or wash-up, can cause insert malfunction. Even a 5-bbl/min rate causes some
parts to erode, especially in the discharge area.
Ball-valve/frac-valve configurations and installation in relationship to sand
concentration is explained in Section 5.

Valve Springs
Valve springs, in conjunction with the fluid in motion, cause the valves to contact the seats. Most cylinder-shaped springs can go into the chamber with either
side up, but the cone-shaped springs must be installed with the small end toward the plunger. Improper or opposite installation prevents the valves from
fully opening because the coils of conical springs become stacked before the
valves reach the end of travel.
A stiff stainless-steel spring is used on most valves. A limber stainless-steel
spring can be used on the suction valve when no centrifugal pump is used to
charge (boost) the HT-400 pump, which makes priming somewhat easier.

Valve Seats
The valve seat (Figure 1.2, Loc. 31) used with frac valves is not the same as the
seat used with single- and double-guided valves described in earlier manuals.
Because the ID is smaller, the seating area is greater. The frac valve seat is completely hardened (carburized), but only the surfaces subjected to wear are carburized on the seat for single- and double-guided valves.
The frac-valve seat OD is tapered. It wedges into the adapter that expands
against the bore. O-rings on the OD of the seat and adapter seal the seat and
adapter and reduce erosion caused by the fluids being pumped. New fluid ends
are tapered, and the adapter is eliminated. In contrast, the OD of the seat for
single- and double-guided valves is cylindrical. A seal is made with the bore by
an O-ring and a copper seal ring on older pumps. Tapered valve seats were first
used in early 1977. Single- and double-guided valves can be used with frac-valve
seats, but frac valves deteriorate rapidly when used with the seat for single- and
double-guided valves.

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HT-400 Description

1-15

Guide-Bushing Retainers
Guide-bushing retainers are installed in the bores beneath the valve seats (Figure
1.2, Loc. 33). They look like wagon wheels with all but two spokes missing.
Rubber guide bushings in the hubs guide the lower stems of the valves.
Retainers are available in two styles, but both have the same part number. The
newer style has identical top and bottom sides that can be installed with either
side facing upward. The older style must be installed with the notched side of the
spokes up and the larger chamfer of the rim down. The older style is stamped
THIS SIDE UP.

Suction-Valve Stops
The upper stem of the valve used in the suction end of the chamber is guided by
a rubber guide bushing in the suction-valve stop (Figure 1.2, Loc. 34). The stop is
what the valve spring pushes against.
The stop has protrusions, or ears, that are covered by rubber boots and fit into a
groove cut in the ID of the chamber. A lock spring extending beyond one of the
ears snaps into a vertical groove to lock the stop in position.

Valve Covers
The upper stem of the valve used in the discharge end of the chamber is guided
by a rubber guide bushing in the discharge-valve cover (Figure 1.2, Loc. 35). The
cover backs up the valve spring and plugs the top of the chamber. The covers,
like the chambers, vary in diameter.
Threads in the top of the chamber secure the discharge-valve cover. A gasket
and spacer ring seal it. To minimize damage to the gasket, the cover has two
pieces; the cover assembly remains stationary while the cover retainer is screwed
in (Figure 1.2, Loc. 36).

Cylinder-Head Covers
A cylinder-head cover (Figure 1.2, Loc. 37), which looks like a valve cover without a guide bushing, seals the end of the horizontal bore for the plunger. It uses
the same gasket and spacer ring as the valve covers. Cylinder-head covers vary
in diameter, as do the bores.
A pump can be damaged during a high-sand concentration job when sand
builds up in front of the plunger. The plunger bottoms out against the sand and

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either stretches the fluid-end attachment studs or pushes the fluid end off the
unit. In addition, the plunger can be severely damaged.
A special protective cylinder-head cover is available for high sand-concentration
pumping. The cover ruptures before the plunger or fluid-end attaching studs are
damaged. A special cylinder-head cover retainer is required for the protective
covers. This retainer catches the center portion of the cover when a sandout occurs.

Pressure Packing
Pressure packing prevents fluid from getting out around the moving plunger.
Packing is shaped like a ring and has a V cross section (Figure 1.2, Loc. 38).
Single-stack height packing is about 1/4 in. (0.635 cm) thick. Double-stack height
packing, as the name implies, is twice as thick. Sometimes the thicker packing is
especially useful in older, worn fluid ends.

Short Packing
Later model pumps are being equipped with a short-stack packing arrangement
that uses fewer packing rings than conventional arrangements. The short stack
offers improved packing life, especially at pressures greater than 6,000 psi
(41.369 MPa). This arrangement can be used in all pump services. The shortstack arrangement (Figure 1.7, Page 1-18) uses a homogeneous rubber ring
(header ring), a single ring of double-stack (or double-thick) V-type packing, a
thin brass backup ring, and a steel carrier. The backup ring and steel carrier
secure the plunger-lube seal.
Important

Do not overtighten the short-stack packing arrangement. Overtightening the

short packing arrangement will overheat the header ring and will cause the
header ring to fail prematurely.

Conventional V Packing
Squeezing the packing rings, which are nested, decreases height and increases
the width of the V. The packing presses harder against the bore and against
the plunger. In this way, the packing is adjustable.
Three types of packing rings are most popular:

June 1997

Rings made of hard rubber and reinforced with cotton duck are best as long
as no acid is being pumped. Acid attacks the cotton duck.
HT-400 Description

1-17

Figure 1.7The short-stack arrangement uses a homogeneous rubber ring, a single ring
of double-stack V-type packing, a thin brass backup ring, and a steel carrier.

Rings made of soft rubber and reinforced with cotton duck are better for
low-pressure pumping. They are never used alone but are mixed with the
hard rubber rings.

Rings made of Garlock 8140 are superior to the previously used Teflonasbestos and other competitive acid-resistant packing, especially in highpressure pumping.

Five or six packing rings, combined with packing adapters (brass) are used on
each plunger. Brass consists of a male adapter that fits into the first packing
ring, the lantern ring that goes between the fourth and fifth rings, and the female
adapter that fits over the sixth ring. Section 2 of this manual details particular
sizes of packing sets.
The male adapter adapts the packing set to the square end of the backing bore.
The lantern ring is the point of entrance for lubricant. The female adapter mates
with the wiper-gland nut (Figure 1.2, Loc. 43) to adjust the packing set.

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Wiper Glands
Wiper glands have two purposes (Figure 1.2, Loc. 42):

adjusting the pressure packing

protecting the plunger from excess fluid or oil

The latter purpose is achieved by a seal or packing.

When the plunger is withdrawn, leaked fluid is removed before it can enter the
power end. When the plunger re-enters, oil is removed before it can exit the
power end.
An evolutionary process has replaced the packing with a seal. The original
sleeve required two plastic spacer rings to make the seal fit properly into the
sleeve, which was designed for packing. Sleeves built since the early 1970s are
designed to secure the seal without spacer rings. On pumps with spacers, the
wiper packing is replaced by a wiper seal (Figure 1.2, Loc. 39) attached to the
power end.

Flanges
For simplicity, the fluid-end information is presented in terms of one fluid-end
section and its contents, but actually, the pump is a triplex. Every fluid-end
assembly has three sections. Pressure strokes of the single-acting plungers in the
sections are staggered to make the fluid-end discharge and the power-end load
more constant.
Discharge passages of the sections are united by seals and spacers. Flanges bolt
to the two outside sections and are sealed into the passage with more seals.
Blank flanges seal off the end of the passage. The blank is used when clearance is
extremely limited.
The discharge manifolding is connected by straight flanges (single outlets) and
ell flanges (two outlets).

Fluid-End Assembly
Suction manifolding is connected to the lower ends by means of a suction
header, and is considered part of the unit that the pump is installed on rather
than part of the pump. Most suction headers are pipes with flanges along one
side for attachment to open ends of the fluid-end vertical bores. Ends of the
headers have connections for manifolding or blanking plugs.
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HT-400 Description

1-19

Fluid-end assemblies have two possible tie-bolt configurations. The first configuration has a top and bottom tie-bolt (Figure 1.2, Loc. 40 and 41). The second
configuration has three top tie-bolts. Both configurations secure the flanges and
tie the upper ends of the fluid-end sections together. The single top tie-bolt
configuration requires a smaller bottom tie-bolt running through holes in the
bottom of the sections to tie the lower ends together.
The three fluid-end sections used in a fluid-end assembly are the same size. They
are identical and interchangeable. Fluid-end assemblies take their size designation from the plungers that have been installed in them.
Maximum working pressures have been assigned to each of the five available
sizes of fluid-end assemblies. The amount of load the power end can withstand
determines the maximum working pressure.
Fluid-end assemblies are secured with internal wrenching nuts that fasten to the
studs of the power ends. Shock mounts for supporting the pump assembly
sometimes fasten to studs in the bottom of the two outside fluid-end sections.

Seal Plates
When the fluid-end assembly is bolted to the power end, one or two aluminum
seal plates are installed between. A single 1/2-in. (1.270-cm) thick plate is now
being used. Previously, two 1/4-in. (0.635-cm) thick plates were used. The diameter of holes bored for the plungers varies with the fluid-end size.
Seal plates help secure the power-end slides. They produce the necessary clearance between the plungers and the cylinder-head covers. They seal off the power
end by forming a gasket between the fluid end and power end. These plates also
provide a contact point for the seals behind the wiper glands.

Plunger Lubrication
Most pumps have a pneumatic lube system that provides oil to the three plungers. The reservoir, which is remotely located, is kept partially filled with oil and
is energized by compressed air. The air, which remains on top, forces the oil
down and out the bottom of the reservoir. The rate of oil injection is controlled
by an air regulator, which is set by a built-in pressure gauge.
Oil leaving the reservoir is delivered to the three fluid-end sections. Drilled passages in the sections carry oil into the lantern rings in the middle of the packing
sets. A check valve on each section prevents the pressure developed during the
power stroke from driving fluid into the lube lines.

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A shutoff valve is installed in the reservoir discharge line, especially when the
pumps are mounted lower than the reservoir. The valve can be closed at shutdown to prevent lubricant loss resulting from gravity flow. It also keeps the oil
from running out when the fluid end is being repaired.
The air valve on the reservoir has a safety feature. It has a long handle that
extends above the oil filler cap when the valve is open and the reservoir is
pressurized. Adding oil is possible only if the valve is turned off to exhaust the
pressure.
On some pumps, a mechanically driven lube system provides oil to the packing
and plungers. The oil pump used in this system is driven either off the end of the
worn shaft or by a sheave on the power-end companion flange. All fluid ends
produced since the early 1970s are being made so that they can be easily converted to this recirculating lube system.

Spacer Assemblies
Most HT-400 pumps have a spacer assembly to keep fluid from the fluid end
from getting into the power-end sump. As with other components of the HT-400
pump, the spacer assemblies can be customized. While all L Series spacers are
similar, some are only appropriate for specialized work while others may appropriate for several different tasks.

Similarities
Spacer assemblies have a common function and construction. All contain the
following components:

wiper glands

seal plates

mounting pads

Function
All spacer assemblies have the same functionto keep fluid from the fluid end
from getting into the power end where it can contaminate the oil. When the oil
becomes contaminated (especially by acid, cement, or sand), damage to the
power end can occur rapidly.
If fluid enters the power end, it is usually through the plunger. The moving
plunger carries the fluid past the pressure packing and the wiper seal (or packing). Fluid can go through the center of the plunger if a nose seal starts leaking.
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HT-400 Description

1-21

Spacers eliminate the problem of contamination through the plungers by

separating the power end and fluid end

keeping the plungers out of the power end

Construction
All spacer assemblies have steel frames. Some frames are welded, and some are
not. Some frames are constructed of heavy rods separating two thick plates. The
plates are cut out for three push rods that, together with the tie bolts and noses,
connect the plungers of the fluid end to the power-end crossheads.
Wiper Glands
All spacers have wiper glands for each of the push rods. The wiper gland
workload is light because most of the potential contaminants drain harmlessly
off the plunger end without contacting the push rods.
Wiper glands have either packing rings or seals. The seal requires a sleeve with a
lock ring. The packing requires a sleeve with an adjusting nut.
Since the seals (or packing) of wiper glands in the spacers keep oil in and dirt out
of the power end, there is no need to put a seal in the wiper gland of the fluid
end. The gland, however, is mounted so that the nut can be used to adjust the
pressure packing.

Important

Fluid ends with 6-in. (15.240-cm) diameter plungers use a modified sleeve in the
gland because of an alignment problem when spacer assemblies are used. The
fluid end, and consequently the plungers and push rods, can get off-center. The
modified sleeve has been reamed so the possibility of the plunger dragging on
the gland ID is minimized.

Seal Plates
Spacer assemblies generally take the place of seal plates. Adequate clearance
between plungers and cylinder-head covers is built into most spacer frames or
into their push rods.
When seal plates are used, they are installed between the spacer and the fluid
end. Installing them between the spacer and power end would make changing
sizes of fluid ends harder, since changing or removing seal plates often has to be
done at the same time.

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HT-400 Pump Maintenance and Repair Manual

June 1997

When seal plates are used with spacers, reinforcing ribs are not used on them.
The spacer frame takes over the function of keeping the plates from bowing.
Mounting Pads
Mounting pads are located on the bottom of every spacer frame but pads are not
always used. Sometimes they are used to help support the pump assembly;
occasionally, they are used to attach pedestals to airlift skids. The pedestals help
support the spacer and fluid end when the skid is dismantled for transport.

Differences
L Spacers
L spacers were designed for minimal weight. Before they were introduced,
spacers were used only on skid units and some trailers. They could not be used
on trucks because their extra weight put gross vehicle weights (GVWs) over the
maximum allowed in most states.
With a length of 6 3/4 in. (17.145 cm), the L spacer became the lightest of the early
spacers, weighing 254 lb (115.212 kg). Although this spacer did not alleviate the
weight problem on trucks, it could be mounted on more units, especially on
acidizing and fracturing trailers.
Since the L frame is so short, the push rods pass into the wiper glands of the
fluid end. To get adequate push-rod nose-to-gland clearance, the noses must
have the same OD as the fluid-end plungers.
L-2 Spacer
The L-2 spacer was the first improvement on the earlier L-1 design. The twopiece nose of the L-2 spacer makes it possible to replace a fluid end with plungers of one diameter to a second fluid end with plungers of a different diameter.
The piece of the nose that contacts the plungers (the adapters) can be changed
without disturbing plunger alignment. The piece of the nose that secures the
push rods does not have to be loosened.
Short plungers are used with L spacers. A welded steel frame is used with L-2
spacers. The L-1 is no longer stocked.

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HT-400 Description

1-23

L-3 Spacer
The lightest spacer is the L-3, weighing only 88 lb (39.916 kg). It has an aluminum frame and is used in cementing applications where lower horsepower is
sufficient. The L-3 spacer is no longer available.
L-4 Spacer
The L-4 spacer combines some features of all of the earlier L spacers.
The L-4 has a steel-plate/steel-tube frame. It weighs 142 lb (64.410 kg) and
replaces the L-3. It can be used in all pump applications.
Components, other than the frame, are the same as the ones used in the L-3
spacers.

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HT-400 Pump Maintenance and Repair Manual

June 1997

HT-400 Specifications and Data

The following pages contain lists and schematics of the HT-400. Tables 1.2
through 1.7 provide information regarding power-end and fluid-end components, pump assembly weights, and discharge pressures. Table 1.7 (Page 1-26)
provides pump dimensions.
Figures 1.8 and 1.9 (Page 1-26) provide schematics of fluid-end flanges. Figure
1.10 provides general dimension data for the HT-400 pump.

Table 1.2Power End

Companion Flange

1800 Series Spicer

Input Spline

3-in.10 (7.62 cm)

Input Rotation

Clockwise

Maximum Input Torque

7,215 lbf (9,782.227 Nm)

Maximum Input
Horsepower

(8.4 Gear) 800 hp (596.560 kW)

(8.6 Gear) 600 hp (447.420 kW)

Input Speed w/8.4:1

or 8.6:1 Gears

2,400 (Maximum rev/min)

Gear Train

Steel worm and bronze ring w/8.4:1 or 8.6:1 ratio (standard)

Crankshaft

Forged steel, four main bearings

Connecting Rods

Three, forged aluminum, split caps, and insert bearings

Crossheads

Three, cast steel

Case

High-strength steel weldment

Bearing Type

Roller and race

Oil System

Gear pump driven off worm (std) or remote

Oil Filter

Replaceable elements and magnetic strainer (Schroeder)

Oil Capacity

22 U.S. gal (0.083 m3)

Oil Type

Power-End Lubricants, Section 2, Page 2-3 to 2-5

Oil Pressure

80 to 100 psi (0.552 to 0.689 MPa)

Schroeder 35 to 40 psi (0.241 to 0.276 MPa) at
190 worm-gear rev/min

Minimum Oil Flow

36 gal/min (136.275 m3/min)

Weight (wet)

3,864 lb (1,752.681 kg)

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HT-400 Description

1-25

Table 1.3Pump Assembly Weight

Spacer lb (kg)
Size
in. (cm)

No Spacer

L-4 Spacer

L-2 Spacer

3 /8 (8.573)

5,589 (2535.128)

5,731 (2599.538)

5,843 (2650.340)

4 (10.160)

5,414 (2455.749)

5,556 (2520.159)

5,668 (2570.962)

4 /2 (11.430)

5,455 (2474.346)

5,597 (2538.757)

5,709 (2589.559)

5 (12.700)

5,392 (2445.770)

5,534 (2510.180)

5,646 (2560.983)

6 (15.240)

5,331 (2418.101)

5,473 (2482.511)

5,585 (2533.313)

Table 1.4Fluid End

Fluid-End Type

Horizontal, triplex, three-piece forged steel

Plunger Type

Single-acting, hard-surfaced

Valve Type

Double-guided, carburized, high-contact

Valve Seats

Carburized and replaceable

Pressure Packing

Discharge Flange

(1) Hard and soft rubber with cotton ducking reinforcement for nonacid
pumping and (2) hard rubber with cotton-polyester duck for acid pumping.
Have V-shaped cross section and installed in the Fluid-End bore.
(1) Blank, straight with one outlet or (2) ell with two outlets

Oil System

External; uses pneumatic reservoir

Table 1.5Fluid-End Weight

Size
in. (cm)
3

Weight
lb (kg)

3 /8 (8.573)

1,725 (782.447)

4 (10.160)

1,550 (703.068)

4 /2 (11.430)

1,591 (721.666)

5 (12.700)

1,528 (693.089)

6 (15.240)

1,467 (665.420)

Table 1.7Spacer Weight lb (kg)

1-26

L-4

L-2

142 (64.410)

254 (115.213)

HT-400 Pump Maintenance and Repair Manual

Table 1.6Discharge Pressure

Size
in. (cm)

Maximum Working
Pressure
psi (MPa)

3 3/8 (8.573)

20,000 (137.895)

4 (10.160)

14,000 (96.527)*

4 1/2 (11.430)

11,200 (77.221)

5 (12.700)

9,000 (62.053)

6 (15.240)

6,250 (43.092)

*For static pressure testing, such as

testing lines, BOP stacks, etc., the
4-in. (10.160-cm) fluid end is rated to
15,000 psi (103.421 MPa) maximum
pressure.

June 1997

Left-Hand Ell
Part No. 316.23017
Connections
1 @ 3-in.-15,000 psi
1 @ 2-in.-15,000 psi

Left-Hand Ell
Part No. 316.21677
Connections
2 @ 2-in.-20,000 psi

Right-Hand Ell
Part No. 316.23019
Connections
1 @ 3-in.-15,000 psi
1 @ 2-in.-15,000 psi

Right-Hand Ell
Part No. 316.21676
Connections
2 @ 2-in.-20,000 psi

Straight
Part No. 316.27482
Connections
1 @ 3-in.-15,000 psi

Straight
Part No. 316.21013
Connections
1 @ 2-in.-20,000 psi

Blank
Part No. 316.22980
Connections
None

Blank
Part No. 316.21673
Connections
None

Figure 1.8Flanges for 4 to 6-in. fluid ends

Figure 1.9Flanges for 3 3/8-in. fluid ends

Table 1.8Pump Dimensions in. (cm)

3 3/8 (8.573)

4 (10.160)

Fluid-End Size
4 1/2 (11.430)

5 (12.700)

6 (15.240)

4.62 (11.735)

4.62 (11.735)

4.75 (12.065)

4.62 (11.735)

4.62 (11.735)

6.75 (17.145)

6.75 (17.145)

6.62 (16.815)

6.75 (17.145)

6.75 (17.145)

Dimensionsa

8.17 (20.752)

8.17 (20.752)

8.67 (22.022)

8.17 (20.752)

8.17 (20.752)

52.57 (133.528)

52.57 (133.528)

52.57 (133.528)

52.57 (133.528)

52.82 (134.163)

D @ L-4

59.08 (150.063)

59.08 (150.063)

58.83 (149.428)

59.08 (150.063)

59.08 (150.063)

D @ L-2

59.08 (150.063)

59.08 (150.063)

58.83 (149.428)

59.08 (150.063)

59.08 (150.063)

37.02 (94.031)

36.47 (92.634)

36.62 (93.015)

36.28 (92.151)

36.13 (91.770)

E @ L-4

39.39 (100.051)

38.71 (98.323)

38.88 (98.755)

38.58 (97.993)

38.32 (97.333)

E @ L-2

39.50 (100.330)

38.40 (100.330)

39.02 (99.111)

38.65 (98.171)

38.45 (97.663)

17.05 (43.307)

17.37 (44.120)

17.28 (43.891)

17.05 (43.307)

17.05 (43.307)

Dimension letters correspond to letters in Figure 1.10

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HT-400 Description

1-27

CL Crankshaft

2X 7/8-9 NC

4.50
(11.4 cm)

CL

Worm

7.50
(19.0 cm)
23.12
(58.7 cm)

16.25
(41.3 cm)

CG

2X .56
(2X 1.4 cm)

24.37
(61.9 cm)

2X 1.03
(2X 2.6 cm)

Top View

CG

5.12
(13.0 cm)

10.25
(26.0 cm)

23.12
(58.7 cm)
41.60
(105.7 cm)

Front View
Figure 1.10HT-400 general dimensions

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HT-400 Pump Maintenance and Repair Manual

June 1997

HT-400 Duty Ratings

The following operation limits are based on experience working with the HT-400
pump in Halliburton pumping operations.

Warning Do not exceed the operation limits listed for each gear.
Exceeding the operation limits can result in severe or fatal
injury as well as equipment damage.

Operation Limits (8.6:1 gear)

Intermittent: Fewer than 4 hours
600 bhp (577 hhp), 100% maximum pressure, 275 crank rev/min
Intermediate: Between 4 and 8 hours
390 bhp (375 hhp), 75% maximum pressure, 250 crank rev/min
Continuous:

More than 8 hours

275 bhp (264 hhp), 50% maximum pressure (Optimum pump
life is attained at 25% maximum pressure), 75 crank rev/min

Operation Limits (8.4:1)

Intermittent: Fewer than 4 hours
800 bhp (768 hhp), 100% maximum pressure, 275 crank rev/min
Intermediate: Between 4 and 8 hours
520 bhp (500 hhp), 75% maximum pressure, 250 crank rev/min
Continuous:

More than 8 hours

367 bhp (352 hhp), 50% maximum pressure (Optimum pump
life is attained at 25% maximum pressure), 75 crank rev/min

June 1997

HT-400 Description

1-29

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