Manual Triplex Pump

JET Manual 02 – Reciprocating
Pumps
Reference: InTouch content ID# 4127825
Version: 2.2
Release Date: 07-Aug-2015
EDMS UID: 1656100842
Produced: 16-Oct-2015 13:51:54
Owner: WS T&D, WIS T&D
Author: Joe Hubenschmidt, Zhiming Rao
Private
Copyright © 2015 Schlumberger, Unpublished Work. All rights reserved.

JET Manual 02 / Legal Information
Legal Information
WS T&D, WIS T&D\Joe Hubenschmidt, Zhiming Rao\InTouch content ID# 4127825\2.2\Release Date:07-Aug-2015\EDMS UID: 1656100842\Produced: 16-Oct-2015 13:51:54
This work contains the confidential and proprietary trade secrets of Schlumberger
and may not be copied or stored in an information retrieval system, transferred,
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to identify the products and services described herein are either trademarks,
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property of their respective owners. These marks may not be copied, imitated
or used, in whole or in part, without the express prior written permission of
Schlumberger. In addition, covers, page headers, custom graphics, icons, and
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of Schlumberger, and may not be copied, imitated, or used, in whole or in part,
without the express prior written permission of Schlumberger.
A complete list of Schlumberger marks may be viewed at the Schlumberger

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Marks of Schlumberger include but may not be limited to PumperPOD*.
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JET Manual 02 / Document Control
Document Control
Owner: WS T&D, WIS T&D
Author: Joe Hubenschmidt, Zhiming Rao
Reviewer: Jeff Beckel, Olivier Desplain, Prasanna Nirgudkar, Tom Rebler, Eric Shelley
Approver: Shri Kelkar
Contact Information
Name: WS T&D, WIS T&D
LDAP Alias: WS-PPC-TechCom
Revision History
Version Date Description Prepared by
2.2 07-Aug-2015 Updated Figure 4-4. Author: Andre Simanjuntak;

TechCom: Daphne Chang
2.1 14-Nov-2013 Updated the manual in response to the Author: Jeff Beckel (WS-InTouch
release of Tech Alert 2013–28. In Sections Stimulation), Jocelyn Campitelli
5 and 7, added a reference to the Positive (PPC-TechCom)
Displacement Pumps reference page on
InTouch.
2.0 18-Feb-2013 Converted the training manual from InDesign Author: Joe Hubenschmidt
to XML format in EDMS, added quintuplex (PPC-SET), Zhiming Rao
pump information, and updated with the latest (PPC-SET), Jocelyn Campitelli
triplex pump information. (PPC-TechCom)
1.1 31-Jul-2006 Minor update Author: WS T&D
1.0 19-May-2006 Initial release Author: WS T&D
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JET Manual 02 / Regulatory Compliance
Regulatory Compliance
Waste management
IMPORTANT INFORMATION FOR CORRECT DISPOSAL OF THE EQUIPMENT
This symbol means that the equipment cannot be discarded in a rubbish-bin. At
its end of life, the equipment and/or its components must be treated, following
Schlumberger Environmental procedures, in compliance with Schlumberger QHSE
Policy and applicable laws and regulations on waste management.
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i JET Manual 02 / Foreword i
Foreword
Well Ser vices, PPCG, PPC, for eword
New releases of this document supersede any other version. The most current
version of the document is in www.InTouchSupport.com.
If you have a printed copy, check the "Release Date" against the content in
InTouch to be sure you have the most current version.
This document is OBSOLETE when printed.
Private
v JET Manual 02 / Table of Contents v
Table of Contents
Regulatory Compliance __________________________________________ iv
Foreword _________________________________________________________ iv
1 Introduction ____________________________________________________ 1-1

1.1 Learning Objectives __________________________________________ 1-1
1.2 Definition of Terms ___________________________________________ 1-1
2 Service quality and HSE ________________________________________ 2-1

2.1 Training and competencies ___________________________________ 2-1
2.2 Environment _________________________________________________ 2-1
2.3 Location safety ______________________________________________ 2-2
2.4 Service quality and maintenance ______________________________ 2-2
3 About Reciprocating Pumps ___________________________________ 3-1

3.1 Reciprocating Pump Main Components _______________________ 3-2
3.2 Hydraulic Horsepower, Rate, and Pressure ____________________ 3-9
4 Pump Types ____________________________________________________ 4-1

4.1 Pumps Used in Cementing/Completion Services _______________ 4-1
4.2 Pumps Used in Stimulation/Fracturing Services _______________ 4-10
4.3 Pumps Used in Coiled Tubing Services _______________________ 4-16
5 Maintenance ___________________________________________________ 5-1

5.1 Service and Maintenance Manuals from the Pump Vendor ______ 5-1
5.2 Well Services and Well Intervention Services Requirements ____ 5-1
6 Operational Guidelines _________________________________________ 6-1

6.1 Pumping at High Rate/High Pressure __________________________ 6-1
6.2 Duty Cycle and Pump Life ____________________________________ 6-1
7 References _____________________________________________________ 7-1

7.1 InTouch _____________________________________________________ 7-1
7.2 Books _______________________________________________________ 7-1
7.3 High-Pressure Pumping SIG __________________________________ 7-1
7.4 WS QHSE Std 05: Wellsite Operations ________________________ 7-1
7.5 WS QHSE Std11: Pumping Nitrogen __________________________ 7-2
7.6 Positive Displacement Pumps Reference Page ________________ 7-2
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vi JET Manual 02 / Table of Contents vi
8 Glossary _______________________________________________________ 8-1

9 Check Your Understanding _____________________________________ 9-1
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vii JET Manual 02 / List of Figures vii
List of Figures
3-1 Reciprocating Pump _______________________________________________ 3-1

3-2 Reciprocating Pump Components __________________________________ 3-2
3-3 Reciprocating Pump (Internal Components) _________________________ 3-3
3-4 Stroke ____________________________________________________________ 3-4
3-5 Rod Load _________________________________________________________ 3-4
3-6 Reciprocating Pump (Fluid End – Details) ___________________________ 3-5
3-7 Flow-Through Fluid End: Suction Stroke (Left) and Discharge Stroke
(Right) ____________________________________________________________ 3-6
3-8 Internal Gear Reduction____________________________________________ 3-7
3-9 GD1250 External Gear Box ________________________________________ 3-8
3-10 600 Compact Pump External Gear Box _____________________________ 3-8
3-11 Hydraulic Horsepower, Rate, and Pressure (at 1,000 hhp) ___________ 3-10
4-1 5-in-Stroke PG Series______________________________________________ 4-1
4-2 MSI 600 Hybrid (Top) and MSI 600 Standard (Bottom) _______________ 4-4
4-3 600 Shorty Pump (SPM TWS 600S Pump) __________________________ 4-4
4-4 600 Shorty Pumps on the CPS-636 _________________________________ 4-5
4-5 GD1250 Pumps on the CPS-679 ___________________________________ 4-6
4-6 MD1000 Pump ____________________________________________________ 4-8
4-7 8-in-Stroke HD2250/GD2250T Pump ______________________________ 4-10
4-8 GD2250T Pump in the SPS-343 ___________________________________ 4-11
4-9 GD2500Q Quintuplex Pump in the SPF-743 ________________________ 4-12
4-10 Monoblock Quintuplex Fluid End___________________________________ 4-13
4-11 OPI Split Fluid End _______________________________________________ 4-14
4-12 CO2 Suction Manifold _____________________________________________ 4-15
4-13 6-in-Stroke OPI600 Pump _________________________________________ 4-16
4-14 Warm and Cold Ends Components of an LN2 Triplex Pump _________ 4-18
4-15 Cold End Pump in an NPF-374 ____________________________________ 4-18
6-1 Relative Life Versus Increase in Rate or Pressure____________________ 6-3
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viii JET Manual 02 / List of Tables viii
List of Tables
4-1 PG Series Pump Head Capacities __________________________________ 4-2

4-2 General Specifications for the PG Series Pump______________________ 4-2
4-3 6-in-Stroke SPM TWS 600S Pump Compatibility Table _______________ 4-5
4-4 Fluid End Assembly Types _________________________________________ 4-6
4-5 GD1250 Pump Compatibility Table__________________________________ 4-7
4-6 MD1000 Pump Compatibility Table__________________________________ 4-8
4-7 General Specifications for the MD1000______________________________ 4-9
4-8 HD2250/GD2250T & SPM TWS2250 Pump Compatibility Table _____ 4-11
4-9 GD2500Q and SPM QWS2500 Pump Compatibility Table ___________ 4-12
4-10 Split Fluid End Compatibility Table _________________________________ 4-14
4-11 OPI600 Pump Compatibility Table _________________________________ 4-17
4-12 Size of Cold Ends ________________________________________________ 4-19
5-1 Burst Disc Pressure Ratings________________________________________ 5-2
6-1 Maximum Speed Ratings (Manufacturer Versus Field Conditions)_____ 6-1
8-1 Glossary __________________________________________________________ 8-1
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1-i JET Manual 02 / Introduction 1-i
1 Introduction
1.1 Learning Objectives ____________________________________________ 1-1

1.2 Definition of Terms _____________________________________________ 1-1
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WS T&D, WIS T&D\Joe Hubenschmidt, Zhiming Rao\InTouch content ID# 4127825\2.2\Release Date:07-Aug-2015\EDMS UID: 1656100842\Produced: 16-Oct-2015 13:51:54 1-1 JET Manual 02 / Introduction 1-1
1 Introduction
The purpose of any pump is to convert mechanical energy provided by motors,
engines, and other prime movers into fluid energy (hydraulic horsepower) as
efficiently as possible. The pump should be light, compact, simple, and easy to
operate and maintain while providing the efficiency and the power required.
Schlumberger Well Services (WS) and Well Intervention Services (WIS) use
low-pressure pumps (also called centrifugal pumps) and high-pressure pumps
(also called reciprocating pumps). Low-pressure pumps use impellers, while
high-pressure pumps use plungers to displace fluid.
This training manual introduces you to two of the most common high-pressure
pumps in the oilfield industry: the triplex pump and the quintuplex pump.
1.1 Learning Objectives

Upon completion of this training, you should be able to
• explain the function of a reciprocating pump
• identify the various components of the reciprocating pump
• describe how the reciprocating pump operates
• identify different pump models
• identify the sizes and ratings of the different pump models
• understand how job rate and pressure impact pump reliability and life
• know where to find maintenance information for your unit and pump.
1.2 Definition of Terms

Refer to Section 8: Glossary for a list of terms, acronyms, and abbreviations
used in this manual and their definitions.
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2-i JET Manual 02 / Service quality and HSE 2-i
2 Service quality and HSE

2.1 Training and competencies _____________________________________ 2-1

2.2 Environment ___________________________________________________ 2-1
2.3 Location safety _________________________________________________ 2-2
2.4 Service quality and maintenance _______________________________ 2-2
2.4.1 STEM _______________________________________________________ 2-2
2.4.2 Equipment modification requests ______________________________ 2-2
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WS T&D, WIS T&D\Joe Hubenschmidt, Zhiming Rao\InTouch content ID# 4127825\2.2\Release Date:07-Aug-2015\EDMS UID: 1656100842\Produced: 16-Oct-2015 13:51:54 2-1 JET Manual 02 / Service quality and HSE 2-1
2 Service quality and HSE Well Services

Interv ention, PPCG,
, Well Intervention
PPC, HSE Serv ic es, Well
Due to the many hazards involved in the oilfield industry, all Schlumberger
personnel must be familiar with the relevant safety regulations and precautions.
To ensure optimum health, safety, and environmental (HSE)

compliance, you must review and adhere to the standards and
guidelines found on the Schlumberger QHSE Standards and Guidelines
(http://www.hub.slb.com/display/index.do?id=id14651), Schlumberger HSE
Reference Page (InTouch content ID# 3312250), and Well Services Quality
Management System Reference Page (InTouch content ID# 4055049).
Quality Note
Anyone who feels that an operation is unsafe has the right, and the duty to stop
the operation.
2.1 Training and competencies

All personnel involved in equipment or wellsite operations must be trained and
maintain current certification as defined in Schlumberger QHSE Standard S005:
Training and Competency (InTouch content ID# 3254848) and the Schlumberger
QHSE S005, WS Appendix: Training and Competency Passport (InTouch
content ID# 4059433), have completed certifications or training required in
iLearn or your local competency program, and must be deemed competent to
perform their assigned tasks.
Installation of equipment represents a significant hazard to our employees and

third parties; to minimize the risks, all personnel involved should be deemed
competent to perform their assigned tasks.
2.2 Environment
All employees are responsible for protecting the environment and minimizing the
environmental impact.
Accidental Release
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2-2 JET Manual 02 / Service quality and HSE 2-2
Any spill, leak, or other loss (pumping, pouring, emitting, emptying, discharging,
injecting, escaping, leaching, dumping, or disposing) of hazardous substances,
chemical, lubricant, crude oil, or produced water into the environment shall
be cleaned up and reported according to local procedures and Schlumberger
QHSE Std S002 HSE: Event Reporting and Management (InTouch content ID#
3260257).
2.3 Location safety

We are involved with wellsite operations every day. These operations involve risk.
To reduce this risk, Well Services QHSE Std 05: Wellsite Operations (InTouch
content ID# 3313681) outlines basic rules and procedures that shall be
implemented at all locations that involve Well Services and Well Intervention
Services operations.
2.4 Service quality and maintenance

The services we provide our customers depend on the harmonious operation of
a large variety of complex tools and equipment used under difficult environmental
and logistical conditions. The maintenance organization and maintenance
processes within a facility shall be designed so that the staff is well trained
to perform the appropriate preventative maintenance and repairs on all Well
Services and Well Intervention Services equipment efficiently and safely. This
will ensure that within given operating specifications, the equipment will operate
safely, accurately, efficiently, and without failure.
2.4.1 STEM
Well Services and Well Intervention Services use the STEM (Standard
Equipment Maintenance) methodology to ensure a systematic, preventative
approach to maintain Schlumberger equipment.
2.4.2 Equipment modification requests

All Equipment Modification Requests (EMR) and Non-Standard Equipment
Requests (NSR) must be submitted to the Well Services Operations Support
InTouch helpdesk for approval before modifications can be made to equipment
or before purchase. The process is detailed in Well Services QHSE Std 04:
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2-3 JET Manual 02 / Service quality and HSE 2-3
Equipment, Guideline 03: Equipment Modification Request (InTouch content

ID# 3313678); you can access Guideline 03 by clicking the file attachment
WS_QHSE_S04_G03_EMR.pdf in the Attachments tab.
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3-i JET Manual 02 / About Reciprocating Pumps 3-i
3 About Reciprocating Pumps

3.1 Reciprocating Pump Main Components ________________________ 3-2

3.1.1 Power End __________________________________________________ 3-2
3.1.2 Fluid End ____________________________________________________ 3-5
3.1.3 Gear Box/Speed Reduction ___________________________________ 3-7
3.2 Hydraulic Horsepower, Rate, and Pressure _____________________ 3-9
3.2.1 Hydraulic Horsepower ________________________________________ 3-9
3.2.2 Pump Rate _________________________________________________ 3-10
3.2.3 Pressure Rating ____________________________________________ 3-11
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3 About Reciprocating Pumps

A reciprocating pump is a type of positive displacement pump, also called a
plunger pump. Positive displacement means there is no fluid slippage in the
pumping action. In other words, if the pump is turning, fluid inside the pump
will be pushed out of the discharge. This is important from a safety standpoint,
because if there is a closed valve downstream, the pump will continue to displace
fluid, building up pressure to potentially dangerous levels.
Reciprocating pumps are named for the reciprocating action of the plunger in the
fluid end (item 2 in Figure 3-1). This back-and-forth movement is created by the
power end (item 1 in Figure 3-1). Reciprocating pumps are used primarily where
high discharge pressures are required and flow is a precise function of pump
speed – both characteristics of positive displacement.
Figure 3-1: Reciprocating Pump.

1. Power End
2. Fluid End
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3-2 JET Manual 02 / About Reciprocating Pumps 3-2
3.1 Reciprocating Pump Main Components

Most types of pump assemblies have three main components:

• power end
• fluid end
• gear box/speed reduction.
3.1.1 Power End

The power end converts rotational power into reciprocating power. The power
end (item 1 in Figure 3-2) functions the same way as a crankshaft in an
automobile engine. Rotation at the input shaft at the pump is converted to
reciprocating motion by the crankshaft, connecting rod, and crosshead assembly.
The reciprocating motion is transferred to the plunger located inside the fluid end
(item 2 in Figure 3-2, described in the next section of this manual).
Figure 3-2: Reciprocating Pump Components.

1. Power End
2. Fluid End
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Figure 3-3 shows the internal components of the pump.

Figure 3-3: Reciprocating Pump (Internal Components).

1. Crosshead Assembly
2. Connecting Rod
3. Crankshaft
4. Input Shaft
Each power end will have a family of fluid ends (defined by plunger diameter)
associated with it. For example, the 2250 hp triplex pump used on the SPF-343
can be outfitted with fluid ends with plunger sizes from 3 3/4 inch to 6 1/2 inch.
Power ends are rated by maximum input horsepower, number of cylinders (e.g.,
triplex or quintuplex), stroke, and rod load.
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Stroke (shown in Figure 3-4) is the distance that the plungers travel. Rod load
(shown in Figure 3-5) is the maximum force that the plunger, under pressure, can
exert on the power end. This corresponds to the discharge pressure multiplied
by the area of the plunger.
Figure 3-4: Stroke
Figure 3-5: Rod Load
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3.1.2 Fluid End

In the fluid end, the mechanical power of the power end is converted to hydraulic
horsepower. Fluid enters at low pressure at the suction inlet (item 3 in Figure
3-6), and is boosted to final pumping pressure by the motion of the plungers
(item 1 in Figure 3-6).
The mechanical pumping action is similar to a conventional piston-type internal

combustion engine or a reciprocating piston-type air compressor.
Figure 3-6: Reciprocating Pump (Fluid End – Details).

1. Plunger
2. Packing
3. Suction Inlet
4. Suction Valve
5. Discharge Valve
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As the plunger is drawn toward the power end during the suction stroke, it
reduces the pressure inside the chamber between the suction and discharge
valves. The reduction of pressure causes the suction valve to lift and allow the
fluid to flow into the suction manifold through the suction port, around the suction
valves, and into the chamber. Refer to item 1 in Figure 3-7.
When the plunger moves in the opposite direction toward the fluid end, the fluid
inside the chamber is forced out. This process is also called discharge stroke.
The suction valve closes immediately and the fluid lifts the discharge valve from
its seat and flows into the discharge chamber. Refer to item 2 in Figure 3-7.
Figure 3-7: Flow-Through Fluid End: Suction Stroke (Left) and Discharge Stroke (Right).
1. Discharge Valve
2. Suction Valve
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3.1.3 Gear Box/Speed Reduction

Reciprocating pumps are low-speed, high-torque devices, and typically operate

at 100 to 300 rpm. Prime movers (engines or electric motors) typically operate
up to 1,800 to 2,100 rpm. Therefore, speed reduction (a gear box) is required
to allow the pump to operate at the correct speed.
An additional function of the gear box is to create an offset between the prime
mover driveline and the power end crankshaft. This offset allows for more flexible
positioning of the pump on the unit.
Several arrangements are used to accomplish the speed reduction. They include
• Internal gear reduction – This is the most common arrangement. The
drivetrain is connected to the pinion shaft (item 1 in Figure 3-8), and the
pinion shaft bull gear combination (items 1 and 3 in Figure 3-8) accomplishes
the gear reduction.
Figure 3-8: Internal Gear Reduction.
1. Pinion Shaft
2. Offset
3. Bull Gears
4. Input
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• External gear box – An alternate arrangement uses an externally-mounted

gear box. Examples of externally-mounted gear boxes include the GD1250
(Figure 3-9) used on offshore cementing skids and the 600 compact pumps
(Figure 3-10) used on cementers.
Figure 3-9: GD1250 External Gear Box
Figure 3-10: 600 Compact Pump External Gear Box
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3.2 Hydraulic Horsepower, Rate, and Pressure

3.2.1 Hydraulic Horsepower

Hydraulic horsepower is a measure of the hydraulic power output of the pump
created in the mechanical-to-hydraulic power conversion. There are losses
in this conversion. The exact value depends on the details of the unit (prime
mover, transmission, and pump model), but typically the value is 10% to 15% of
the input horsepower. This is expressed as the “mechanical efficiency” of the
unit. A 15% loss would be described as 85% mechanical efficiency. Published
performance curves account for this efficiency.
Hydraulic horsepower (hhp) is directly proportional to flow rate and pressure and
inversely proportional to the efficiency of a system.
Hydraulic horsepower is the product of the flow rate and pumping pressure of
the pump:
P× Q
hhp =
C
where:
• P is the pumping pressure [psi (kPa)]
• Q is the flow rate [bbl/min (m3/min)]
• C is a constant, depending on the units used to measure pressure and flow
rate; when pressure is expressed in psi (kPa) and rate in bbl/min (m3/min),
C = 40.8.
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The relationship between rate and pressure (at an example of 1,000 hhp) is
shown in the Figure 3-11. As rate increases, the pressure must drop for constant
horsepower.
Figure 3-11: Hydraulic Horsepower, Rate, and Pressure (at 1,000 hhp)
3.2.2 Pump Rate

Pump rate is calculated by determining the volume swept by the plunger,
multiplying it by the number of plungers to obtain the volume per revolution, and
finally multiplying by the rpm of the pump.
Example
For the 2250 quintuplex pump used on an SPF-743 unit, for example, the bbl/rev
values for common plunger sizes are
Plunger Size (in) bbl/rev (m3/rev) , 97% VE

4 0.05026 (0.00799)
4 1/2 0.06360 (0.01011)
5 0.07852 (0.01248)
Therefore, an SPF-743 unit with 4-in plungers operating at 200 rpm will generate:
200 rpm x 0.05026 bbl/rev (0.00799 m3/rev) = 10.1 bbl/min (1.6 m3/min)
These bbl/rev (m3/rev) values are 97% of the theoretical number to match the
calibration of the pumper rate meter. The 97% factor accounts for volumetric
efficiency considerations.
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Note
The 97% value is used as a global average for all conditions and usually is
sufficient.
3.2.3 Pressure Rating

Each power end and fluid end plunger size combination has a maximum
pressure rating. This pressure rating is determined by the power end rod load
and plunger size.
Maximum pressure = rod load / plunger area
Example
The Gardner Denver® HD2250 power end on the SPF-343 has a rod load
of 237,000 lbf. If a 4 1/2-in plunger is used (area = 15.9 in2), the maximum
pressure is:
237,000 lbf / 15.9 in2 = 14,900 psi
The metric equivalent is:
107,503 kgf / 10,258 mm2 = 10.48 kgf/mm2 (102,770 kPa)
The actual pumping pressure is determined by the characteristics of the well

being serviced.
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4-i JET Manual 02 / Pump Types 4-i
4 Pump Types
4.1 Pumps Used in Cementing/Completion Services _______________ 4-1

4.1.1 5-in-Stroke PG Series Pump __________________________________ 4-1
4.1.2 6-in-Stroke 600 Compact/Shorty Pump ________________________ 4-3
4.1.3 8-in-Stroke GD1250 Pump ___________________________________ 4-6
4.1.4 MD1000 Pump ______________________________________________ 4-7
4.2 Pumps Used in Stimulation/Fracturing Services _______________ 4-10
4.2.1 Pump Types ________________________________________________ 4-10
4.2.1.1 8-in-Stroke HD2250, GD2250T, and SPM TWS2250 Triplex
Pumps __________________________________________________ 4-10
4.2.1.2 8-in-Stroke GD2500Q and SPM QWS2500 Quintuplex
Pump ___________________________________________________ 4-12
4.2.2 Fluid End Types ____________________________________________ 4-13
4.2.2.1 Monoblock ______________________________________________ 4-13
4.2.2.2 Split Fluid End __________________________________________ 4-14
4.2.2.3 Stainless Steel Fluid End ________________________________ 4-15
4.2.3 Special CO2 Considerations _________________________________ 4-15
4.3 Pumps Used in Coiled Tubing Services ________________________ 4-16
4.3.1 6-in-Stroke OPI600 Pump and 600 Compact/Shorty Pump _____ 4-16
4.3.2 Nitrogen Pump Unit _________________________________________ 4-17
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WS T&D, WIS T&D\Joe Hubenschmidt, Zhiming Rao\InTouch content ID# 4127825\2.2\Release Date:07-Aug-2015\EDMS UID: 1656100842\Produced: 16-Oct-2015 13:51:54 4-1 JET Manual 02 / Pump Types 4-1
4 Pump Types
The quintuplex and triplex pumps are mainly used in Well Services and Well
Intervention Services, such as
• cementing/completion services
• stimulation/fracturing services
• coiled tubing services.
Triplex reciprocating pumps are also mounted on nitrogen units.
4.1 Pumps Used in Cementing/Completion

Services
4.1.1 5-in-Stroke PG Series Pump

The PG Series pump was the main pump used for all cementing services
equipment a decade ago. This pump was available in a magnesium frame (truck
mounted) and steel frame (offshore). Power end gear reduction is internal, using
a bull gear and pinion shaft. The pump is usually coupled to a chain case to
provide additional reduction and driveline offset.
Figure 4-1 shows the 5-in-Stroke PG Series.
Figure 4-1: 5-in-Stroke PG Series
Refer to Table 4-1 for PG Series pump head capacities and Table 4-2 for general
specifications.
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4-2 JET Manual 02 / Pump Types 4-2
Table 4-1: PG Series Pump Head Capacities
5-in-Stroke PG Series Fluid End Plunger Max psi Max bbl/rev bbl/rev
Size (in) (kPa) bbl/min (m3/rev) (m3/rev)

(m3/min) Pinion Main
4.32 ratio, internal gears TSO 2.5 20,000 2.58 (0.41) 0.0017 0.00736
(137,900) (0.0003) (0.0012)
350 rpm max at main shaft
1,512 rpm max at pinion TRO 3 15,000 3.71 (0.59) 0.0025 0.01060
shaft (103,400) (0.0004) (0.0017)
Max rod load 110,000 lbf TGO 3.75 10,000 5.79 (0.92) 0.0038 0.01656
(68,900) (0.0006) (0.0026)
TLO 4.5 7,000 8.34 (1.33) 0.0055 0.02384

(48,300) (0.0009) (0.0038)
THO 5 5,500 10.3 (1.64) 0.0068 0.02943

(37,900) (0.0011) (0.0047)
Table 4-2: General Specifications for the PG Series Pump
GENERAL SPECIFICATIONS
Application Completion
Power end PG-03 – Magnesium
PG-05 – Steel case
Length 70 in (179 cm)
Width 43 in (109 cm)
Height 31 in (79 cm)
Weight – magnesium 4,132 lbm (1,878 kg)
Weight – steel case 4,765 lbm (2,161 kg)
Weight with chain reducer Add 485 lbm (2,161 kg)
Hydraulic horsepower 300 hhp
Main shaft 350 rpm (maximum)
Stroke 5 in (12.7 cm)
Internal gear reduction ratio 4.32:1
External chain reducer ratio 27:40
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4.1.2 6-in-Stroke 600 Compact/Shorty Pump

The 600 Shorty pump uses stuffing box construction in the fluid end. The plunger
size can be varied over a limited range. This can be done by changing only
the stuffing box. In addition, the 600 Shorty pump features a crankshaft-style
power end with a bolt-on gear reducer.
Note
Several years ago, this pump was introduced as a replacement for the PG series
pump. Recently built completion/cementing units use the 600 Shorty pump.
However, there are older units in the field that still use the PG Series pump.
The 600 Shorty pump is a much more compact design and is rated at 600 hp
input, compared with 250 hp for the PG series pump. This is also advantageous
for the new higher horsepower cementers being developed and is more suitable
for continuous pumping operations associated with coiled tubing services. Its
short length allows for back-to-back placement of two pumps on the unit.
The four major suppliers of the 600 Shorty pumps are SERVAgroup, Gardner
Denver®, Weir™ SPM, and MSI® Dixie. Specifically, MSI provides an upgraded
version of the 600 Shorty pump called the MSI Hybrid™. This hybrid pump
utilizes a power end plunger between the fluid end plunger and the crosshead.
The conventional (standard) pump has a common plunger that reciprocates
in both the fluid end and power end. The hybrid design uses a “power end
plunger” to isolate the power end from the fluid end and reduce the chance of
contamination of the power end by the pumped fluids.
Refer to Figure 4-2 for a visual comparison of the MSI 600 Hybrid pump and
the MSI 600 Standard pump.
Private
Figure 4-2: MSI 600 Hybrid (Top) and MSI 600 Standard (Bottom)
Typical units using the 600 Shorty pumps include both cementing skids and
trailers, such as the CPS-361, CPS-636, CPF-377, CPF-378, and CPF-577.
Figure 4-3 shows a picture of the 600 Shorty pump and Figure 4-4 shows the
600 Shorty pumps in the CPS-361. Refer to Table 4-3 for pump compatibility
information.
Figure 4-3: 600 Shorty Pump (SPM TWS 600S Pump)
Private
Figure 4-4: 600 Shorty Pumps on the CPS-636
Table 4-3: 6-in-Stroke SPM TWS 600S Pump Compatibility Table
6-in-Stroke SPM TWS 600S Fluid End Plunger Size MAX psi MAX bbl/min bbl/rev (m3/rev)
(in) (kPa) (m3/min) MAIN
4.6 ratio, external reduction TWS600 2 3/4 16,836 4.95 (0.787) 0.01095
(116,000) (0.00174)
450 rpm max at main shaft
2,070 rpm max at input TWS600 3 14,147 5.9 (0.938) 0.01310

(97,500) (0.00208)
max rod load 100,000 lbf
TWS600 3 1/2 10,400 8.0 (1.272) 0.01731
(71,700) (0.00275)
TWS600 4 8,000 10.4 (1.653) 0.22615

(55,200) (0.03596)
TWS600 4 1/2 6,288 13.3 (2.115) 0.02852

(43,400) (0.00453)
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4.1.3 8-in-Stroke GD1250 Pump

The GD1250 pump is a lightweight design offering high horsepower per pump
weight. It was originally used on the SCT-673 PumperPOD*, which is a frac pump
and blender combination. It is also used on high-horsepower offshore skids as
a replacement for the MD1000 pump, where the pump weight, footprint, and
reliability are important considerations. (Refer to Section 4.1.4: MD1000 Pump.)
Typical cementing skids using the GD1250 include the CPS-679, CPS-665,
CPS-763 and CPS-977. Furthermore, the GD1250 used in these skids are ABS,
DNV and CE-marking certified for the requirements of offshore placement.
There are three types of fluid end assemblies available: high pressure, medium
pressure, and low pressure. Refer to Table 4-4 for a list of the plunger sizes
associated with these fluid end assembly types.
Table 4-4: Fluid End Assembly Types
Type Plunger Size (in)
High Pressure 3.75
Medium Pressure 4.5, 5.0, or 5.5
Low Pressure 6.0 or 6.5
Figure 4-5 shows the GD1250 pumps on the CPS-679. Refer to Table 4-5 for
pump compatibility information.
Figure 4-5: GD1250 Pumps on the CPS-679
Private
Table 4-5: GD1250 Pump Compatibility Table
8-in-Stroke GD1250 Fluid End Plunger MAX psi MAX bbl/rev bbl/rev

(m3/min) PINION MAIN
Mixed cement/frac service EGD 3.75 18,100 8 (1.272) 0.00441 0.02649

(124,800) (0.00070) (0.00421)
9.13 ratio, external reduction
350 rpm max at main shaft EGD 4.5 12,500 12 (1.908) 0.00636 0.03814
(86,200) (0.00101) (0.00606)
3195 rpm max at input
HGD 5 10,200 15 (2.385) 0.00785 0.04709
Max rod load 200,000 lbf
(70,300) (0.00125) (0.00749)
IGD 5.5 8,400 18.5 (2.941) 0.00950 0.05698

(57,900) (0.00151) (0.00906)
6.5 6,030 25 (3.975) 0.01330 0.07958

(41,600) (0.00212) (0.01265)
4.1.4 MD1000 Pump

The MD1000 pump gets its name from its developer, Michel Drevet. Its maximum
hydraulic horsepower (hhp) output, is 1,000 hhp. Unlike the other two types of
triplex pumps, the MD1000 pump uses a single swashplate rather than separate
wheels to operate the three plungers.
The MD1000 pump consists of three 120° thrust rods connected to an oscillating
plate. Each thrust rod is, in turn, attached to a crosshead, which operates a
plunger. As power turns the gears of the power end, one thrust rod is at the
maximum forward position, while a second is in forward motion, and a third
is in backward motion.
The MD1000 pump has advantages over a traditional triplex pump in terms
of the efficiency, weight per horsepower, and horsepower per volume, but is
mainly used in offshore applications. This pump has been made obsolete by the
supplier, but is still being used in the field.
Private
Figure 4-6 shows the MD1000 pump. Refer to Table 4-6 for pump compatibility
information and Table 4-7 for general specifications.
Figure 4-6: MD1000 Pump
Table 4-6: MD1000 Pump Compatibility Table
6-in-Stroke MD1000 Fluid End Plunger MAX psi MAX bbl/rev bbl/rev
(m3/min) PINION MAIN
4.125 ratio internal gear M 3 20,000 7.08 (1.126) 0.0030 0.01271

(137,900) (0.00048) (0.00202)
557 rpm max at miain
shaft F 3.75 12,200 11.07 (1.760) 0.0048 0.01987
2,300 rpm max at input (84,100) (0.00076) (0.00316)
shaft E 4.5 8,500 15.93 (2.533) 0.0069 0.02861

(58,600) (0.00110) (0.00455)
D 5 6,800 19.67 (3.127) 0.0086 0.03532

(46,900) (0.00137) (0.00562)
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Table 4-7: General Specifications for the MD1000
GENERAL SPECIFICATIONS
OPTION MX MY
Application Completion and Stimulation Completion and Stimulation
In-Line Allows two pumps to be mounted side-by-side Allows two pumps to be mounted side-by-side
within 8 in within 8 in
Length 83 3/4 in (213 cm) 83 3/4 in (213 cm)
Width 41 in (104 cm) 41 in (104 cm)
Height 52 in (132 cm) 52 in (132 cm)
Weight — overall 7,930 lbm (3,600 kg) 7,930 lbm (3,600 kg)
Horsepower 1,100 hp Maximum Input 1,100 hp Maximum Input
Main shaft 557 rpm Maximum 420 rpm Maximum
Stroke 6 in (15.24 cm) 6 in (15.24 cm)
Internal Gear Reduction 4.125:1 Ratio 5.474:1 Ratio
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4.2 Pumps Used in Stimulation/Fracturing

Services
4.2.1 Pump Types
4.2.1.1 8-in-Stroke HD2250, GD2250T, and SPM TWS2250 Triplex

Pumps
The HD2250 triplex pump (Figure 4-7) is the standard pump for fracturing
services. Currently, it is placed behind a 2250 brake horsepower prime mover.
Older units may have an earlier version called the 1800 AWS pump. This pump
uses internal gear reduction. Each plunger size uses a different fluid end.
The GD2250T, an upgrade of the HD2250 pump, offers new fluid end and power
end technologies for enhanced service life expectations.
Figure 4-7: 8-in-Stroke HD2250/GD2250T Pump
Alternately, the TWS2250 from SPM can provide similar and comparable
performance. The SPM fluid end and GD fluid end are interchangeable, i.e., an
SPM TWS2250 fluid end can be installed in a GD2250T power end for service
and vice versa.
The typical fracturing unit using GD2250T and TWS2250T is the SPF-343 unit.
The GD2250T is also used in the SPS-343 stimulation skid as shown in Figure
4-8. Refer to Table 4-8 for HD2250, GD2250T, and SPM TWS2250 pump
compatibility information.
Private
Figure 4-8: GD2250T Pump in the SPS-343
Table 4-8: HD2250/GD2250T & SPM TWS2250 Pump Compatibility Table
FLUID END PLUNGER SIZE MAX psi (kPa) MAX bbl/min bbl/rev (m3/rev) bbl/rev (m3/rev)
(in) (m3/min) PINION MAIN
FOPI 3 3/4 20,000 (137,900) 8.7 (1.383) 0.00417 0.0265 (0.04213)

(0.00066)
EOPI 4 1/2 15,000 (103,400) 12.6 (2.003) 0.00600 0.0381 (0.00606)

(0.00095)
HOPI 5 12,000 (82,700) 15.5 (2.464) 0.00741 0.0471 (0.00749)

(0.00118)
IOPI 5 1/2 10,000 (68,900) 18.8 (2.989) 0.00897 0.0570 (0.00906)

(0.00143)
WOPI 6 1/2 7,000 (48,300) 26.3 (4.181) 0.01253 0.0796 (0.01266)

(0.00199)
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4.2.1.2 8-in-Stroke GD2500Q and SPM QWS2500 Quintuplex Pump

The Gardner-Denver GD-2500Q quintuplex pump is specifically designed to meet

the high flow rate requirements in stimulation. It has five plungers in contrast with
the three plungers in the GD2250T triplex pump. This pump incorporates new
power frame fabrication technology and an upgraded crosshead liner with an
improved oil-grooved pattern. The crosshead liner is upgraded to high strength
aluminum bronze to minimize power end lube contamination. The typical plunger
sizes used in the units are 4 inch, 4.5 inch, and 5 inch.
SPM provides a pump, the QWS2250, with similar and comparable performance.
The SPM fluid end and GD fluid end are interchangeable, i.e., an SPM QWS2500
fluid end can be installed in a GD2500Q power end for service, and vice versa.
The GD2500Q and the SPM QWS2500 pumps are commonly used in the
SPF-743 as shown in Figure 4-9.
Figure 4-9: GD2500Q Quintuplex Pump in the SPF-743
Table 4-9: GD2500Q and SPM QWS2500 Pump Compatibility Table
8-in-Stroke PLUNGER SIZE MAX psi (kPa) MAX bbl/min bbl/rev (m3/rev) bbl/rev (m3/rev)
Max Input 2,500 bhp 4 15,600 (107,600) 17.2 (2.735) 0.00815 0.05177
(0.00130) (0.00823)
Max rpm 330 Gear
Ratio 6.353 4.5 12,400 (85,500) 21.6 (3.434) 0.01031 0.06547
(0.00164) (0.01041)
5 10,000 (68,900) 26.7 (4.245) 0.01274 0.08095

(0.00203) (0.01287)
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4.2.2 Fluid End Types

4.2.2.1 Monoblock
The monoblock fluid end (Figure 4-10) has been commonly used in both triplex
and quintuplex pumps. The monoblock fluid end is a one-piece design with
multiple plunger bores in the block. Conventionally, the fluid end is made of alloy
steel, which is easily available for manufacturing. However, in recent years,
there has been a trend to change to stainless steel for corrosion resistance
to improve the fluid end life.
Figure 4-10: Monoblock Quintuplex Fluid End
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4.2.2.2 Split Fluid End

The OPI split fluid end (Figure 4-11), developed by Schlumberger, is intended for
use with OPI-series well servicing pumps. Currently, the XOPI and HOPI split
fluid ends are designed for use in the applications for which the monoblock XOPI
and HOPI fluid end is utilized. The split fluid end consists of a separate block for
each plunger bore with the three blocks connected across a common discharge
bore. The three blocks are assembled together with an endplate on either end of
the fluid end and four stud rods providing the assembly tension.
The split fluid end design enables easy maintenance, interchangeability, and
manufacturing due to the smaller forging size. The fluid end is made of stainless
steel material, which significantly improves the fluid end life and provides greater
resistance to fatigue cracking.
Figure 4-11: OPI Split Fluid End
Refer to Table 4-10 for split fluid end configuration information.
Table 4-10: Split Fluid End Compatibility Table
FLUID END PLUNGER SIZE MAX psi (kPa) MAX bbl/min bbl/rev (m3/rev) bbl/rev (m3/rev)
XOPI 4 18,800 (129,600) 10 (1.590) 0.00475 0.03015

(0.00076) (0.00479)
HOPI 5 12,000 (82,700) 15.5 (2.464) 0.00741 0.04711

(0.00118) (0.00749)
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4.2.2.3 Stainless Steel Fluid End

Corrosion fatigue has been a common failure issue for the conventional alloy
steel fluid end block. To improve the fluid end life, stainless steel is also used
to make some fluid ends, resulting in increased corrosion resistance for Well
Services pumping. Both the XOPI and HOPI split fluid ends use the stainless
steel material, doubling the life compared to the alloy steel blocks.
4.2.3 Special CO2 Considerations

CO2 is sometimes used on fracturing jobs. For this service, a CO2-rated suction
manifold (Figure 4-12) capable of handling high suction pressure is required.
When pumping CO2, the suction stabilizer must be disconnected by blanking
off the suction header.
For CO2 service up to 5,000 psi (34,500 kPa), a standard header ring packing
and plunger lube can be used. However, CO2 service at pressures above 5,000
psi (34,500 kPa) requires the use of special header rings.
This is because at higher pressures, CO2 gas is entrained in the header ring
during pumping and released after the job. This causes the packing to fail when
a conventional job is performed after a CO2 job.
Figure 4-12: CO2 Suction Manifold
Private
4.3 Pumps Used in Coiled Tubing Services

With Coiled Tubing Services, different pump parameters are required. Due to the
high friction pressure through the coiled tubing, pump rates tend to be lower than
for other services. Therefore, dedicated coiled tubing triplex pumps have been
developed and should be used for this application.
4.3.1 6-in-Stroke OPI600 Pump and 600 Compact/Shorty

Pump
The OPI600 pump is rated at 600 bhp. It has the same gear ratio and input
horsepower as the 600 Shorty pump. (Refer to Section 4.1.2: 6-in-Stroke 600
Compact/Shorty Pump.) However, the distance between the power end and fluid
end is longer, leaving more space and, therefore, enabling easier access to the
packing set for maintenance. The OPI600 pump (Figure 4-13) is usually installed
in a single pumper skid due to its length.
Figure 4-13: 6-in-Stroke OPI600 Pump
Private
As mentioned in Section 4.1.2, the 600 Shorty pump is also widely used in Coiled
Tubing Services, because it is much more suitable for continuous pumping
operations associated with Coiled Tubing Services.
Table 4-11 lists the pump compatibility information.
Table 4-11: OPI600 Pump Compatibility Table
6-in-Stroke OPI600 PLUNGER MAX psi MAX bbl/min bbl/rev (m3/rev) bbl/rev (m3/rev)
SIZE (in) (kPa) (m3/min) PINION MAIN
4.6 ratio, external 2 3/4 16,800 4.9 (0.78) 0.002355 (0.000374) 0.01102 (0.00175)
reduction (115,800)
450 rpm max at main shaft 3 1/2 8,000 10.4 (1.65) 0.003810 (0.000606) 0.01783 (0.002835)
2,070 rpm max at input (55,200)
Max rod load 100,000 lbf
4.3.2 Nitrogen Pump Unit

Triplex reciprocating pumps are also mounted on nitrogen units.
The high-pressure cryogenic triplex pump has a power end and a fluid end. The
power end converts the input power from the power source to a reciprocating
action. This action drives each one of the cold end pistons through the
suction and discharge cycle. The cold ends are specifically designed and built
assemblies for pumping liquid nitrogen (LN2). The pressure-containing metal
components are made of stainless steel. Parts used to hold and compress seals
are made of brass. The seals and packing used in the cold end are made from
Teflon™ and other materials capable of withstanding the cold LN2.
Private
Refer to Figure 4-14 for a picture of the warm and cold ends components of
an LN2 triplex pump.
Figure 4-14: Warm and Cold Ends Components of an LN2 Triplex Pump.
1. Warm End Component
2. Cold End Component
Figure 4-15 shows the cold end pump in an NPF-374 unit.
Figure 4-15: Cold End Pump in an NPF-374
Private
Table 4-12 lists information about the available cold end sizes.
Table 4-12: Size of Cold Ends

Size (in) Manufacturer Used with Warm Max Rate Max Pressure Max Pressure
End (scf/min) (psi) (kPa)†
1 1/4 Airco GMPD 1,500 10,000 68,900
1 5/6 Airco GUPD 4,800 10,000 68,900
2 Airco LMPD 5,000 10,000 68,900
2 1/2 Airco LMPD 7,500 6,500 44,800
2 7/8 Airco LMPD 10,000 4,900 33,800
2 Airco SLS 5,600 10,000 68,900
2 1/2 Airco SLS 8,500 10,000 68,900
2 7/8 Airco SLS 11,500 8,900 61,400
3 1/4 Airco SLS 15,000 6,900 47,600
1 1/4 Cryomec SG 1,500 10,000 68,900
1 5/6 Cryomec SG 10,000 68,900
2 Cryomec SL 5,000 10,000 68,900
2 1/2 Cryomec SL 8,500 6,500 44,800
2 7/8 Cryomec SL 11,500 5,000 34,500
2 Cryomec SLS 5,600 10,000 68,900
2 1/2 Cryomec SLS 8,500 10,000 68,900
2 7/8 Cryomec SLS 11,500 8,900 61,400
3 1/4 Cryomec SLS 15,000 6,900 47,600
† Maximum pressure is set by working pressure of the tube bundle of the vaporizer.
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5-i JET Manual 02 / Maintenance 5-i
5 Maintenance
5.1 Service and Maintenance Manuals from the Pump Vendor ______ 5-1
5.2 Well Services and Well Intervention Services Requirements ____ 5-1
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5 Maintenance
Like any equipment, maintaining the triplex pump and quintuplex pump ensures
many years of trouble-free service. This section provides guidelines and
references to specific information of pump maintenance.
In general, pump maintenance consists of maintaining and servicing the power

end, fluid end, and gear box.
The power end maintenance includes the lubrication system, lube pumps, etc.
The major components for maintaining the fluid end assembly are the plunger
lubrication system, the packing assembly, suction and discharge valves and
seats, and fluid end cover retainers.
5.1 Service and Maintenance Manuals from the

Pump Vendor
For the most commonly used pump models described in Section 4, the Service
and Maintenance manuals from the pump vendor can be found in InTouch
(http://intouchsupport.com/). The vendor manuals detail safety concerns,
preparation, maintenance and service procedures, troubleshooting guidelines,
etc.
5.2 Well Services and Well Intervention Services

Requirements
Besides the vendors’ Service and Maintenance manuals for the specific pumps,
Schlumberger also has requirements for the operation of pumps in Well Services
(WS) and Well Intervention Services (WIS). Refer to the WS Quality Management
System — QHSE Standards Reference Page for pumping (InTouch content
ID# 4055049) and the Coiled Tubing Reference Pages List — Navigation Page
(InTouch content ID# 5162992). In addition, refer to the Positive Displacement
Pumps Reference Page (InTouch content ID# 6183695) for detailed information
about recommended valves and seats for use with any Well Services positive
displacement pump.
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5-2 JET Manual 02 / Maintenance 5-2
Some of the typical requirements on the pump components are as follows:

• Burst disc valves
As per WS QHSE Std 05: Wellsite Operations (InTouch content ID#

3313681), all Well Services positive displacement pumps must have burst
disc valves installed in the suction of the pump as per the parameters stated
in Table 5-1.
Table 5-1: Burst Disc Pressure Ratings
Maximum Pump Pressure Rating Burst Disc Pressure Rating
Up to 7,499 psi (51,704 kPa) 10,000 psi (69,000 kPa)

7,500 to 12,499 psi (15,705 kPa to 86,180 kPa) 15,000 psi (103,500 kPa)
12,500 psi and above (86,181 kPa) 22,500 psi (155,250 (kPa)
• Flanged connections using studs or bolts

Some pump fluid end discharge ports use a flanged connection. To comply
with WS QHSE Std 05: Wellsite Operations (InTouch content ID# 3313681),
use only studs and bolts that meet or exceed ASTM A320 Grade L7. Use
only nuts that meet or exceed ASTM A194 Grade 7L. If there is any doubt
as to the quality of the studs, bolts, or nuts, replace them with new ones.
Destroy all studs, bolts, and nuts that are removed from service.
• Frac pump tie rod
The tie rod is used to connect the fluid end to the pump power end. Poor
maintenance may result in premature failure of tie rods or in extreme cases
pumping off of fluid ends. Therefore, it is very important to inspect the tie rods
on the fluid ends used in frac operations on a regular basis. For information
about the guidelines for inspection, installation, and selection of correct parts
and tools, refer to the best practice, Inspection and Maintenance of Frac
Pump Tie Rods, InTouch content ID# 5699827.
• Fluid end maintenance tool
To address safety and equipment damage and, thereby, improve service
quality, the pump tools currently supplied by the pump manufacturer, or
locally made, are being replaced with a new standard fluid end tool kit.
The tool kit standardizes the fluid end tools, making it easier to train personnel
on fluid end maintenance. For more information about this tool kit, refer to
Fluid End Tool Kit, InTouch content ID# 5640202.
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6-i JET Manual 02 / Operational Guidelines 6-i
6 Operational Guidelines
6.1 Pumping at High Rate/High Pressure ___________________________ 6-1

6.2 Duty Cycle and Pump Life ______________________________________ 6-1
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6 Operational Guidelines
6.1 Pumping at High Rate/High Pressure

All pumps have maximum ratings for both speed (rate) and pressure. For
information about maximum pressure ratings, refer to Section 3.2.3: Pressure
Rating.
In general, the manufacturer’s maximum speed and rate limits usually exceed
practical field limits. Actual maximum rates in a field application are most likely
limited by suction hook-up, suction pressure and fluid properties (viscosity,
density, etc.).
Table 6-1 summarizes manufacturer maximum ratings and suggested maximum

practical limits for field conditions. These are guidelines. The details of your job
will determine the actual limits.
Table 6-1: Maximum Speed Ratings (Manufacturer Versus Field Conditions)
Manufacturer Maximum Recommended Maximum

Speed Rating Speed for Field Conditions
GD and SPM 2250 triplex 330 250
GD and SPM 2250 quintuplex 330 250
GD, SPM, Serva, and MSI 600 450 350
No restrictions apply to pumping at the maximum pressure rating of the pump,

but most pumps and plunger sizes are selected so that is avoided. When pumps
are operated at high pressures, component life will be shortened. The duty cycle
discussion in the following section goes into more detail.
6.2 Duty Cycle and Pump Life

Understanding how job characteristics (rate, pressure, and horsepower) affect
pump life can help to make informed decisions on equipment deployment and
utilization.
For the purposes of this discussion, consider the power end and fluid end as
major components, and routinely replaced items like valves, seats, plungers,
and packing as expendables.
Private
6-2 JET Manual 02 / Operational Guidelines 6-2
Section 3.2.1: Hydraulic Horsepower introduced the basic pump equation:
P ×Q
HHP =
C
• For a given treating pressure, increasing horsepower increases rate.

Rate corresponds to rpm, or revolutions per minute, and each revolution
corresponds to a load cycle or stroke.
• For a given pressure (load), the pump will have a characteristic life (measured
in cycles).
Note
Horsepower does NOT enter directly into this – horsepower just determines how
quickly the cycles are accumulated.
If you consider two identical pumps operating at the same discharge pressure,
but at different horsepower (therefore, different rates), the life of the major
components will be the same (measured in strokes). However, on a calendar
basis, the higher horsepower unit will accumulate strokes faster and will fail
sooner.
Example
Two identical pumps operating at 200 and 400 horsepower with the same
discharge pressure will experience the same life in terms of strokes, but the 400
hp pumps will last half as long on a calendar basis.
On the other hand, if pumps are operating at the same horsepower, but at
different pressures, the lives, measured as strokes, will vary much more. This is
because the life of pump components is very sensitive to load (pressure).
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6-3 JET Manual 02 / Operational Guidelines 6-3
The chart in Figure 6-1 shows the decay in life when increasing rate and pressure.
Figure 6-1: Relative Life Versus Increase in Rate or Pressure
• The rate versus life relationship is inverse – doubling the horsepower reduces
the life in half.
• However, the pressure relationship is exponential. Doubling the pressure
reduces the life (when expressed in cycles) much more than half of the
original value.
The chart shows that increasing the rate (for a constant pressure) by a factor of
two (horizontal axis) decreases the pump life by a factor of 0.5 (blue curve, read
on vertical axis). Increasing the pressure by a factor of two, however, decreases
life by a factor of 0.125 (red curve).
This discussion is theoretical and the chart shows only general trends. Actual
major component life estimation is difficult, because it includes several
operational factors not discussed in this training manual. Although this concept
also applies to expendables, life estimation is more variable.
Keep these points in mind when considering jobs that require pumping at higher
pressures for extended periods of time. The life of major components, especially
fluid ends, will drop considerably in terms of strokes.
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7-i JET Manual 02 / References 7-i
7 References
7.1 InTouch ________________________________________________________ 7-1

7.2 Books __________________________________________________________ 7-1
7.3 High-Pressure Pumping SIG ____________________________________ 7-1
7.4 WS QHSE Std 05: Wellsite Operations __________________________ 7-1
7.5 WS QHSE Std11: Pumping Nitrogen ____________________________ 7-2
7.6 Positive Displacement Pumps Reference Page _________________ 7-2
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7 References
7.1 InTouch
InTouch (www.InTouchSupport.com) is a good source of maintenance,
performance curve, and operational information for units. You can search by
unit model designation (e.g., SPF-743).
It is also a good source for operating and maintenance manuals. You can search
by manufacturer model (e.g., GD1250).
In addition, InTouch has bulletins and best practices on key pump topics, such as
tie rods, valves and seats, and cover seals.
7.2 Books
You may also refer to the following books for more information:
• Karassik, I.J., Messina, J.P., Cooper, P., Heald, C.C.: Pump Handbook (4th
ed.), U.S.A., McGraw-Hill Publishing Company (2007).
• Miller, J.E.: The Reciprocating Pump: Theory, Design, and Use (2nd ed.),
Melbourne, FL, Krieger Publishing Company (1995).
7.3 High-Pressure Pumping SIG

The High-Pressure Pumping SIG (sourcing interest group) is an additional source
of information. Visit http://www.eureka.slb.com/Room.cfm?Room=4065.
7.4 WS QHSE Std 05: Wellsite Operations

WS QHSE Std 5: Wellsite Operations (InTouch content ID# 3313681) is a
primary source of safety, rig-up, and pumping guidelines, including prime-up,
pressure testing, bleed-off and flow back.
Private
7-2 JET Manual 02 / References 7-2
7.5 WS QHSE Std11: Pumping Nitrogen

The WS QHSE Std 11: Pumping Nitrogen (InTouch content ID# 3313684) is a
primary source of safety, rig-up, and pumping guidelines for pumping nitrogen.
7.6 Positive Displacement Pumps Reference

Page
The Positive Displacement Pumps Reference Page (InTouch content ID#
6183695) provides links to best practices, lessons learned, maintenance
information, technical alerts, and additional reference documentation. Additional
documentation includes information about recommended valves and seats for
use with any type of Wells Services positive displacement pump.
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Glossary
JET Manual 02 / Glossary

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8 Glossary
Table 8-1: Glossary
Term Definition
centrifugal pump A low-pressure pump
fluid end One of the three main components of a reciprocating pump.
In the fluid end, the mechanical power of the power end is
converted to hydraulic horsepower. Low pressure fluid enters
at the suction, and is boosted to final pumping pressure by
the motion of the plungers. The mechanical pumping action
is similar to a conventional piston-type internal combustion
engine or a reciprocating piston-type air compressor.
gear box One of the three main components of a reciprocating pump.
It is used for speed reduction, so the pump can operate at
the correct speed. An additional function of the gear box is
to create an offset between the prime mover driveline and
the power end crankshaft. The offset allows for more flexible
positioning of the pump on the unit.
hydraulic horsepower A measure of the hydraulic power output of the pump created
in the mechanical-to-hydraulic power conversion. Hydraulic
horsepower is the product of the flow rate and pumping
pressure of the pump. Refer to Section 3.2.1 for more
information.
mechanical efficiency Measurement of the efficiency of the conversion of brake
horsepower to hydraulic horsepower expressed as a ratio of
hydraulic horsepower to brake horsepower.
power end One of three main components of a reciprocating pump. The
power end converts rotational power into reciprocating power.
It functions the same way as a crankshaft in an automobile
engine.
reciprocating pump A mechanical device consisting of single-acting,
positive-displacement elements, such as pistons or plungers
and used to impart a pulsating flow to a liquid. The reciprocating
pumps used by Well Services/Well Intervention Services
are single-acting triplex (three plungers) and quintuplex (five
plungers) units.
rod load The maximum force the plunger, under pressure, can exert
on the power end.
stroke The distance the plungers travel.
volumetric efficiency Measurement of ratio of actual flow to theoretical flow, because
the fluids being pumped are slightly compressible at high
pressure.
Other factors that may influence volumetric efficiency include
the ratios of swept and unswept volumes internal valve slippage
associated with increasing pump speed.
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JET Manual 02 / Check Your Understanding
Check Your Understanding

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9 Check Your Understanding

1. Reciprocating pumps are positive displacement. This means
__________________.
a. the plunger goes back and forth.
b. there is no slippage in the pumping action.
c. the discharge valve can safely be closed while pumping.
d. the pump always runs at the same speed.
2. Reciprocating pumps are used primarily __________________.
a. to pump slurries.
b. where high discharge pressures are required and flow is a precise
function of pump speed.
c. for jobs requiring high pump rates.
d. where the size and weight of the pump are critical.
3. Select the main components of a reciprocating pump.
a. Engine
b. Fluid end
c. Transmission
d. Power end
e. Gear box
f. Plunger
4. The function of the power end is to _____________________.
a. convert power from the diesel engine or electric motor into hydraulic
power.
b. limit the maximum speed of the pump.
c. convert rotational power into reciprocating power
d. attach the pump to the engine.
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9-2 JET Manual 02 / Check Your Understanding 9-2
5. Which items are used to rate power ends? Select four:

a. Stroke
b. Rod load
c. Weight
d. Input horsepower
e. Number of cylinders
f. Maximum pressure
6. Is the maximum pressure rating of a pump determined by dividing the rod
load by the plunger area?
a. True
b. False
7. Hydraulic horsepower is proportional to ___________________.
a. pressure divided by rate
b. pump RPM
c. rate multiplied by pressure.
d. rate divided by pressure
8. Pump rate calculations assume a volumetric efficiency of
__________________.
a. 92%
b. 97%
c. 99%
d. 100%
9. The manufacturer’s maximum speed rating can always be used to determine
the pump maximum rate for job design.
a. True
b. False
10. Assuming all other pumping parameters are equal, increasing discharge
pressure reduces pump life more than an equal increase horsepower.
a. True
b. False
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9-3 JET Manual 02 / Check Your Understanding 9-3
11. The 600 Shorty pump is primarily used for ___________________.

a. Fracturing services
b. CO2 services
c. Cementing, Completion, and Coiled Tubing services
d. Mixed Cement/Frac services
12. Which of the following pump models is ABS, DNV, and CE/PED certified?
a. 600 Shorty
b. GD1250
c. GD2500Q
d. SPM QWS2500
13. GD2250T and SPM TWS2250 triplex pumps are typically used for fracturing
services.
a. True
b. False
14. An SPM QWS2500 fluid end cannot be installed in a GD2500Q power end
for service or vice versa.
a. True
b. False
15. For a pump with a 10,000 psi (68,900 kPa) maximum working pressure fluid
end, what should the burst disc pressure rating be for the suction valve of the
fluid end per Well Services QHSE Std 05: Wellsite Operations?
a. 5,000 psi (34,500 kPa)
b. 10,000 psi (68,900 kPa)
c. 15,000 psi (103,400 kPa)
d. 22,500 psi (155,100 kPa)
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JET Manual 02 – Reciprocating

Copyright © 2015 Schlumberger, Unpublished Work. All rights reserved.

Copyright © 2015 Schlumberger, Unpublished Work. All rights reserved.

Trademarks & Service marks

Schlumberger, the Schlumberger logotype, and other words or symbols used

A complete list of Schlumberger marks may be viewed at the Schlumberger

Author: Joe Hubenschmidt, Zhiming Rao

Approver: Shri Kelkar

2.2 07-Aug-2015 Updated Figure 4-4. Author: Andre Simanjuntak;

1.1 31-Jul-2006 Minor update Author: WS T&D

1.0 19-May-2006 Initial release Author: WS T&D

Well Ser vices, PPCG, PPC, for eword

This document is OBSOLETE when printed.

Regulatory Compliance __________________________________________ iv

1 Introduction ____________________________________________________ 1-1

2 Service quality and HSE ________________________________________ 2-1

3 About Reciprocating Pumps ___________________________________ 3-1

4 Pump Types ____________________________________________________ 4-1

5 Maintenance ___________________________________________________ 5-1

6 Operational Guidelines _________________________________________ 6-1

7 References _____________________________________________________ 7-1

8 Glossary _______________________________________________________ 8-1

9 Check Your Understanding _____________________________________ 9-1

3-1 Reciprocating Pump _______________________________________________ 3-1

4-1 PG Series Pump Head Capacities __________________________________ 4-2

1.1 Learning Objectives ____________________________________________ 1-1

1.1 Learning Objectives

1.2 Deﬁnition of Terms

2 Service quality and HSE

2.1 Training and competencies _____________________________________ 2-1

2 Service quality and HSE Well Services

To ensure optimum health, safety, and environmental (HSE)

2.1 Training and competencies

Installation of equipment represents a signiﬁcant hazard to our employees and

2.3 Location safety

2.4 Service quality and maintenance

2.4.2 Equipment modiﬁcation requests

Equipment, Guideline 03: Equipment Modification Request (InTouch content

WS_QHSE_S04_G03_EMR.pdf in the Attachments tab.

3 About Reciprocating Pumps

3.1 Reciprocating Pump Main Components ________________________ 3-2

3 About Reciprocating Pumps

Figure 3-1: Reciprocating Pump.

3.1 Reciprocating Pump Main Components

Most types of pump assemblies have three main components:

3.1.1 Power End

Figure 3-2: Reciprocating Pump Components.

Figure 3-3 shows the internal components of the pump.

Figure 3-3: Reciprocating Pump (Internal Components).

Figure 3-4: Stroke

Figure 3-5: Rod Load

3.1.2 Fluid End

The mechanical pumping action is similar to a conventional piston-type internal

Figure 3-6: Reciprocating Pump (Fluid End – Details).

3.1.3 Gear Box/Speed Reduction

Reciprocating pumps are low-speed, high-torque devices, and typically operate

Figure 3-8: Internal Gear Reduction.

• External gear box – An alternate arrangement uses an externally-mounted

Figure 3-9: GD1250 External Gear Box

Figure 3-10: 600 Compact Pump External Gear Box

3.2 Hydraulic Horsepower, Rate, and Pressure

3.2.1 Hydraulic Horsepower

3.2.2 Pump Rate

Plunger Size (in) bbl/rev (m3/rev) , 97% VE