Drilling Services

SDS PMS
Equipment: Mud Pump Department: Mechanical
Manufacturer: Gardner Denver Frequency: Annually
Model: PZ-8/9 Issued:
PSS Code: GA-327-32 Completed:
Item Level Inspect Description

Safety Considerations

1. [M3] [ ] Insure proper work permits are obtained before performing maintenance on this equipment.
2. [M3] [ ] Insure personnel performing this maintenance is familiar with the equipment and manufacturer's
operation and maintenance manual before beginning.
3. [M2] [ ] Make arrangements with the Rig Superintendent before performing this task and insure that it will
not affect the drilling operations.
4. [E2] [ ] Isolate and tag out the electric power to the mud pump.
5. [M3] [ ] Close and tag out the pump suction and discharge valves.

Resources:

A Task Items: Mud Pump Condition Evaluation

1. [M3] [ ] Complete a complete condition evaluation of the mud pump.

Condition Evaluation Particulars

Equipment Description:
Manufacturer
Model:
Serial Number
PSS Code & Tag Number:
Maximum Input Power
Driven By:
Rig Name
District
Date of Condition Evaluation:
Cummulative Hours on Pump:
Hours/Date of Last Condition Evaluation
Person in Charge of Condition Evaluation

File: Document1 Last Revised: November 14, 2017 Page 1 of 9

 Drilling Services

SDS PMS
Equipment: Mud Pump Department: Mechanical
Manufacturer: Gardner Denver Frequency: Annually
Model: PZ-8/9 Issued:
PSS Code: GA-327-32 Completed:
Item Level Inspect Description

1. [M3] [ ] Inspect condition of lube oil. If in good condition take a representitive sample and send for
laboratory analysis.

Note: Contamination of the oil might indicate that the cross head extension
rod diaphragm assemblies needs replacement.

2. [M3] [ ] If lube oil is contaminated, drain and flush the crankcase. Clean out the settling chamber in the
forward part of the power end floor. Thoroughly clean the oil troughs and the compartment in top
of the crosshead guide. Clean the element in the breather cap and clean the suction screen.
Refill using Shell Omala 220.or equivalent oil; 130 US gallons.
3. [M3] [ ] Drain and flush clean the chain drive case. Clean the breather element. Refill using Shell Vitrea
150 or equivalent oil
4. [M3] [ ] Remove the all bearing and crankcase covers for inspection of the following components. Insure
nothing drops inside.
1. Check the safety retaining wires on all bolts including the main bearing hold down bolts,
eccentric bearing retainer bolts and gear retainer bolts. Replace any broken wires after re-
tightening the bolts. Refer to crankshaft assembly section for torque values.
2. Visually inspect all bearings for damage or wear while rotating pump slowly. With a feeler
gauge check and record all bearing diametrical clearances. Record the condition and
clearances on the Checking Form below.
3. Inspect the ring wear and oil seal condition on the left and right side main bearings.
4. Inspect all main and eccentric bearings for cracked inner & outer bearing races. Inspect the
bronze bearing cages for damage or cracks.
5. Make a complete visual inspection of all components checking for looseness, wear or
damage.
6. Check the main and pinion gears for condition and wear. Measure and record the backlash.
7. Check each connecting rod retaining bolts for tightness and retaining wires for proper
installation.
8. Run lube oil pump and insure all nozzles are free and clear and have a good spray pattern.
5. [M3] [ ] Remove the diaphragm stuffing box and plate. Check the safety retaining wires of the extension
rods insuring none broken or missing. Where wire is broken or missing inspect all bolts for crack
and thread damage. Retorque to 350 - 370 ft/lbs. Re-install all safety retaining wires.
6. [M3] [ ] Renew lip oil seal and "O" rings, clean and replace plate and stuffing box. Torque bolts to 12 -
18 ft/lbs.

File: Document1 Last Revised: November 14, 2017 Page 2 of 9

 Drilling Services

SDS PMS
Equipment: Mud Pump Department: Mechanical
Manufacturer: Gardner Denver Frequency: Annually
Model: PZ-8/9 Issued:
PSS Code: GA-327-32 Completed:
Item Level Inspect Description

7. [M3] [ ] Remove the ispection covers for the crossheads and carry out the following ispections:
1. Check crosshead pin retainer bolt tightness using torque wrench. Torque value 210 ft/lbs.
Insure all locking wire is properly installed
2. Measure the play of the bearing, roller and crosshead pin. Record the readings on the
checking form below.
3. Check crosshead clearance, use a feeler gauge between crosshead and upper crosshead
guide. Do not operate pump with less than 0.010" clearance. Record the clearances on the
Checking Sheet below. They should be .010 - .020.
4. Inspect crosshead and guides for condition and uniform wear. Insure there are no scratches
or abnormal wear on the upper or lower slide guides.
5. Check the crosshead slide to frame bolts for tightness.
6. Check the pony rod (extension rod) surface condition for damage or scratches. A deterirated
surface will cause premature failures of seals.
7. Check the pony rod to crosshead bolts for correct tighness.

8. [M3] [ ] Check for proper crosshead alignment. Refer to manufacturer's manual for correct method to
use. Record below:
Top Front Top Back
#1 Cylinder
#2 Cylinder
#3 Cylinder
Note: If the centreline of the extension rod
exceeds 0.015" low, re-shimming of guides is
necessary

Misalignment can be detected by uneven wear on the pony (extension)

rods. Premature liner wear will also be a result. Refer to the mud pump
fluid end log book for signs of premature liner wear.

9. [M3] [ ] Check all drive chain and sprockets for wear. New chain - 20 P. = 30" Worn out chain =
30.750" Record the measurements on the Checking Sheet below.
10. [M3] [ ] Inspect and test run the chain oil pump. Overhaul and align as necessary.
11. [M3] [ ] Inspect and test run the gear oil pump. Overhaul and align as necessary.
12. [M3] [ ] Renew the oil pump filter element.
13. [M3] [ ] Inspect and test run the flushing pump. Overhaul, repack and align as necessary.

File: Document1 Last Revised: November 14, 2017 Page 3 of 9

 Drilling Services

SDS PMS
Equipment: Mud Pump Department: Mechanical
Manufacturer: Gardner Denver Frequency: Annually
Model: PZ-8/9 Issued:
PSS Code: GA-327-32 Completed:
Item Level Inspect Description

14. [M3] [ ] Inspect the pony rod end and clamp for wear, damage and cracks. It is essential that a good face
to face spigot connection of these rods is maintained. Improper tightening, dirt or debris on the
faces when clamped up or the mixing of clamp halves, can lead to fatique cracking of the clamp
area.
Insure that drilling department is installing the clamps correctly. They must always be torqued
evenly with equal gaps between clamp halves is maintained.

Caution: The pony rod clamps MUST remain in pairs, they are machined as
a pair and odd halves will cause misalignment.

15. [M3] [ ] Clean breathers on chain case and gear box.

16. [M3] [ ] Restore power to unit and remove tag.
17. [M3] [ ] Check chain lube oil pressure and record ________ psi.
18. [M3] [ ] Check gear box lube oil pressure and record ________ psi.
19. [M3] [ ] Simulate electric driven gear lube oil pump failure:
Record pressure_________ psi. Min 30 psi, max 40 psi.
20. [M3] [ ] Make a complete internal inspection to insure all tools and rags have been removed. Replace all
covers and reconnect the pony rod clamp. Make a complete inspection around unit insuring
pump condition is ready for operation.

CAUTION: Use extreme caution whenever using RTV for sealing the
gaskets faces. Do not use RTV if possible. In many cases pumps have
been totally ruined, when too much RTV is applied; the excess gets
squeezed into the pump mixing in the oil and eventually plugging oil
passages resulting in failures.

Maximum Allowable Bearing Wear

The following are figures found to be pactical and acceptable in determining the condition of the bearings. These
figures apply provided that the bearings have passed a visual inspection. The highest values are extreme outer
limits and in some cases the bearing may begin to spall which will result in damage to other components.
Bearing wear and spalling will first be detected in a lube oil analysis.

0.008 - 0.010 Okay to run untill the next annual inspection

0.011 - 0.013 Replace at the next scheduled maintenance.
0.014 - 0.016 Replace at first opportunity.
0.017 and greater Stop Pump and replace immediately.

21. [M3] [ ] Enter details of completion on PMS history card. and file a copy of the completed Condition
Evaulation form in the maintenance file.

File: Document1 Last Revised: November 14, 2017 Page 4 of 9

 Drilling Services

SDS PMS
Equipment: Mud Pump Department: Mechanical
Manufacturer: Gardner Denver Frequency: Annually
Model: PZ-8/9 Issued:
PSS Code: GA-327-32 Completed:
Item Level Inspect Description

Condition Evaluation Recording Table

Front
#1 Crosshead #2 Crosshead #3 Crosshead
Maximum alloable .007" Maximum alloable .007" Maximum alloable .007"
bearing clearance (.125mm) bearing clearance (.125mm) bearing clearance (.125mm)
Bearing Bearing Bearing
Clearance Clearance Clearance
General General General
Condition Condition Condition
Guide Clearance Guide Clearance Guide Clearance
Min .037" (.940mm) Cold Min .037" (.940mm) Cold Min .037" (.940mm) Cold
Rear Rear Rear
Front Front Front

Left Chain Right Chain

Max Elongation 3 % Max Elongation 3 %
Measured Measured
Lenth Lenth
General General
Condition Condition
Sprockets Sprockets
Bull Bull
Pinion Pinion

Left Jackshaft Bearing

Maximum alloable .004"
bearing clearance (.102mm)
Right Jackshaft Bearing
Maximum alloable .004"
Bearing bearing clearance (.102mm)
Clearance Bearing
General Clearance
Condition General
Left Main Bearing Condition
Maximum alloable .008"
bearing clearance (.203mm)
Right Main Bearing
Maximum alloable .008"
Bearing bearing clearance (.203mm)
Clearance Pinion Gear Bearing
General Clearance
Condition % Worn
General
#1 Excentric Bearing Condition Condition
Maximum alloable .008"
#2 Excentric Bearing Bull Gear #3 Excentric Bearing
bearing clearance (.203mm) Maximum alloable .008" Maximum alloable .008"
Bearing bearing clearance (.203mm) % Worn bearing clearance (.203mm)
Clearance Bearing Condition Bearing
General Clearance Clearance
Backlash
Condition General Maximum alloable .020" General
Condition bearing clearance (.508mm) Condition

Rear

File: Document1 Last Revised: November 14, 2017 Page 5 of 9

 Drilling Services

SDS PMS
Equipment: Mud Pump Department: Mechanical
Manufacturer: Gardner Denver Frequency: Annually
Model: PZ-8/9 Issued:
PSS Code: GA-327-32 Completed:
Item Level Inspect Description

Guidelines for Replacing a Roller Chain

Roller chain is recognized as an exceptionally dependable means for the positive transmission of power. To
assure optimum performance and maximum efficiency, it is desirable to anticipate the occasional need for
chain replacement, thereby avoiding unexpected interruption or delays in operation. Joint wear, certain
overload conditions, metal fatigue, or pitch elongation will limit the useful life of any chain; therefore, the
following information will aid in determining when chain replacement is advisable.
Effects of Chain Wear
During operation, chain pins and bushings slide against each other as the chain engages, wraps, and
disengages from its sprockets. Even when the parts are well-lubricated, some metal-to-metal contact does
occur, and these parts eventually will wear. This progressive joint wear elongates chain pitch, causing the
chain to lengthen and ride higher on the sprocket teeth. The number of teeth in the large sprocket
determines the amount of joint wear that can be tolerated before the chain jumps or rides over the ends of
the sprocket teeth. When this critical degree of elongation is reached, the chain must be replaced.

Determination of Chain Wear

An evaluation of a chain's useful service life requires an analysis of pitch elongation. By placing a certain
number of pitches under tension, elongation can be measured. When elongation equals or exceeds the
limits in Table 1, chain should be replaced.
The following procedure is suggested:
1. Remove chain from sprockets and lay on smooth, horizontal surface or suspend vertically. To remove
slack from a chain measured in a horizontal position, refer to Table2 and apply the load indicated for
the size chain involved. If chain must be measured while on sprockets, remove slack on a span of chain
and apply sufficient tension to keep chain taut. See Figure below.
2. When chain is properly tensioned, consult Table 1 for the number of pitches which should be
measured. This number is determined by chain size and number of teeth in largest sprocket. Pitches
should be measured from center to center of pins as shown in Figure above. A steel tape will facilitate
accurate measurement. If chain has offset links, do not include them in the measured segment.
Select the appropriate column according to number of teeth in largest sprocket and compare published
figure with measurement taken. If measurement equals or exceeds figure in Table 1, chain should be
replaced.

File: Document1 Last Revised: November 14, 2017 Page 6 of 9

 Drilling Services

SDS PMS
Equipment: Mud Pump Department: Mechanical
Manufacturer: Gardner Denver Frequency: Annually
Model: PZ-8/9 Issued:
PSS Code: GA-327-32 Completed:
Item Level Inspect Description

Table 1. Maximum Chain Elongation Limits

Up to 67 68-73 74-81 82-90 91-103 104-118 119-140 141-173

Chain Measuring Length Number of Teeth in the Largest Sprocket

Number
ANSI Pitch Number Nominal Length of Chain (inches) When Replacement is Required
Inches Of Length
Pitches Inches
35 .375 32 12.00 12.38 12.34 12.31 12.28 12.25 12.22 12.19 12.16
40 .500 24 12.00 12.38 12.34 12.31 12.28 12.25 12.22 12.19 12.16
50 .625 20 12.50 12.88 12.59 12.81 12.78 12.75 12.72 12.69 12.66
60 .750 16 12.00 12.38 12.34 12.31 12.28 12.25 12.22 12.19 12.16
80 1.00 24 24.00 24.75 24.69 24.63 24.56 24.50 24.44 24.38 24.31
100 1.250 20 25.00 25.75 25.69 25.63 25.56 25.50 25.44 25.38 25.31
120 1.500 16 24.00 24.75 24.69 24.63 24.56 24.50 24.44 24.38 24.31
140 1.750 14 24.50 25.25 25.19 25.13 25.06 25.00 24.94 24.88 24.81
160 2.000 12 24.00 24.75 24.69 24.63 24.56 24.50 24.44 24.38 24.31
180 2.250 11 24.75 25.50 25.44 25.38 25.31 25.25 25.19 25.13 25.06
200 2.500 10 25.00 25.50 25.44 25.38 25.31 25.25 25.19 25.13 25.06
240 3.000 8 24.00 24.75 24.69 24.63 24.56 24.50 24.44 24.38 24.31

If a chain breaks or fails due to broken pins, sidebars, or rollers, emergency temporary repairs may be
required in order to avoid a long shutdown. However, replacement of the entire chain is preferred for the
following reasons:
1. If one section of a chain has broken because of fatigue, other sections probably have suffered fatigue
damage as well and are subject to early failure.
2. If the chain has been broken by a single high overload, parts other than those at the point of failure are
usually bent or severely weakened.

Guidelines for Installing a Replacement Chain

Before installing a new chain, carefully check sprocket teeth. If teeth are worn to a hooked shape, the
sprockets should be replaced to assure full-capacity performance and satisfactory life from the new chain.
Proper tension is essential when installing new chain. Tight chain causes an additional load which
increases wear on chain joints, sprocket teeth, and shaft bearings. Slack chain produces vibration which
may result in excessive chain wear, noise, or shock loading.

Visually inspect the chain checking for broken or cracked side bars, missing pins. If chain
appears worn, pull 1 link and inspect the two pins. If they are cut or worn through the case
hardening, then the complete chain should be replaced.

File: Document1 Last Revised: November 14, 2017 Page 7 of 9

 Drilling Services

SDS PMS
Equipment: Mud Pump Department: Mechanical
Manufacturer: Gardner Denver Frequency: Annually
Model: PZ-8/9 Issued:
PSS Code: GA-327-32 Completed:
Item Level Inspect Description

Proper chain tension is obtained by adjusting the sag (catenary) in the unloaded span. For most horizontal
and inclined drives, chain should be installed with a depth of sag amounting to approximately 2% of the
sprocket centers. See Table 3 for proper sag for various sprocket centers.
To measure sag, pull the bottom span of the chain taut, allowing all of the excess chain to accumulate in
the upper span. Then, place a straightedge on top of the sprockets and use a scale to measure sag. See
figure below.
For drives on vertical centers, or those subject to conditions such as shock loads, rotation reversals, or
dynamic braking, install chain almost taut. It is essential to inspect such drives regularly for correct chain
tension.

Table 3. Chain Sag Based On 2% of

Sprocket Centers
Sprocket Centers, Sag in Inches
Inches
20 .50
30 .63
40 .88
60 1.25
80 1.63
100 2.00
125 2.50

File: Document1 Last Revised: November 14, 2017 Page 8 of 9

 Drilling Services

SDS PMS
Equipment: Mud Pump Department: Mechanical
Manufacturer: Gardner Denver Frequency: Annually
Model: PZ-8/9 Issued:
PSS Code: GA-327-32 Completed:
Item Level Inspect Description

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File: Document1 Last Revised: November 14, 2017 Page 9 of 9