8/9/2019 Hps 165958ecol Als

1/195

Horizontal Pump System

ColombiaECOPETROL S.A.

Reference: HPS-165958ECOL_ALS

Created: 15-JAN-2014

Owner: ColombiaEcopetrol S.A.

No. Of Unit: 2

8/9/2019 Hps 165958ecol Als

2/195

SchlumbergerPrivate

Intentionally Blank

8/9/2019 Hps 165958ecol Als

3/195

SchlumbergerPrivate

Legal Information

Copyright 2011 Schlumberger. All rights reserved.

This work contains the confidential and proprietary trade secrets of Schlumberger and may notbe copied or stored in an information retrieval system, transferred, used, distributed, translated orretransmitted in any form or by any means, electronic or mechanical, in whole or in part, withoutthe express written permission of the copyright owner.

Trademarks & Service marks

Schlumberger, the Schlumberger logotype, and other words or symbols used to identify theproducts and services described herein are either trademarks, trade names or service marks ofSchlumberger and its licensors, or are the property of their respective owners. These marks maynot be copied, imitated or used, in whole or in part, without the express prior written permissionof Schlumberger. In addition, covers, page headers, custom graphics, icons, and other designelements may be service marks, trademarks, and/or trade dress of Schlumberger, and may notbe copied, imitated, or used, in whole or in part, without the express prior written permission ofSchlumberger.

A complete list of Schlumberger marks may be viewed at the SchlumbergerOilfield Services Marks page: http://www.hub.slb.com/index.cfm?id=id32083

8/9/2019 Hps 165958ecol Als

4/195

SchlumbergerPrivate

Document Control

Owner: ColombiaEcopetrol S.A.

Reviewer: AL Engineering

Approver: AL Engineering

Contact Information

Name: ColombiaEcopetrol S.A.

LDAP Alias: ColombiaEcopetrol S.A.

Revision History

Rev Effective Date Description Prepared by

A 15-Jan-2014 HPS Unit Manual W. Ruiz

8/9/2019 Hps 165958ecol Als

5/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

6/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

7/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

8/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

9/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

10/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

11/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

12/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

13/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

14/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

15/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

16/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

17/195

SchlumbergerPrivate

8/9/2019 Hps 165958ecol Als

18/195

SchlumbergerPrivate

Intentionally Blank

8/9/2019 Hps 165958ecol Als

19/195

SchlumbergerPrivate

Table of Contents

1. Design

1.1. Technical Design Data _______________________________ 1-11.2. Pump Performance Data _______________________________ 1-2

2. Equipment Information

2.1. Quality Control Plan ___________________ 2-12.2. Manufacture Codes ___________________ 2-22.3. Checklist Assembly ___________________ 2-42.4. Material Specification Pump ___________________ 2-52.5. Motor Data/Information ___________________ 2-62.6. Seal Information ___________________ 2-72.7. Pressure Switchgage Information ___________________ 2-82.8. Vibration Switchgage Information ___________________ 2-92.9. Motor/Thrust Chamber Coupling Information _______ 2-122.10. Thrust Chamber Information _______ 2-132.11. Thrust Chamber Oil Switch Information _______ 2-142.10 Allowable Nozzle Loading _______ 2-15

3. Drawings and Bills of Materials

3.1. General Assembly Drawing and Bill of Materials ____________ 3-13.2. Thrust Chamber Serviceable Parts Drawing and Bill of Materials____ 3-23.3. Seal Drawing __________________ 3-33.4. Motor Drawing ___________________ 3-43.5. Electrical Drawing ___________________ 3-53.6. Pump Shaft Setting Procedure ___________________ 3-63.7. Pump Drawing and Bill of Materials ___________________ 3-73.8. Lube Oil Cooler Information ___________________ 3-8

4. Pump Performance Tests and Reports

4.1. Pump Test ____________ 4-14.2. Intake and Discharge Test ____________ 4-2

5. Recommended Spare Parts and Servicing Tools

6. Installation and Commissioning

6.1. Transport and Handling _______________________________ 6-16.2. Site Requirements _______________________________ 6-56.3. Piping Connections _______________________________ 6-7

8/9/2019 Hps 165958ecol Als

20/195

SchlumbergerPrivate

6.4. Commissioning _______________________________ 6-106.5. Vibration _______________________________ 6-156.6. HPS Storage _______________________________ 6-21

7. Maintenance

7.1. Lubrication Maintenance Summary _____________ 7-17.2. Recommended Maintenance Schedules _____________ 7-27.3. HPS Field Service Report _____________ 7-37.4. Decommissioning Procedures _____________ 7-77.5. Decommissioning Procedures _____________ 7-9

8. Troubleshooting

8.1. Troubleshooting Basics _____________ 8-18.2. Troubleshooting Electric Motors and Starters _____________ 8-28.3. Troubleshooting Thrust Chamber Vibrations _____________ 8-58.4. Troubleshooting Thrust Chamber Overheating (The HPS Unit Has a

Thrust Chamber Cooling and Filtration System) _____________ 8-78.5. Troubleshooting Thrust Chamber Overheating (The HPS Unit Does Not

Have a Thrust Chamber Cooling and Filtration System.)___________ 8-88.6. Troubleshooting Instruments _____________ 8-108.7. Troubleshooting Gearbox Noise _____________ 8-118.8. Troubleshooting Gearbox Overheating ____________ _ 8-118.9. Troubleshooting Gearbox Vibration _____________ 8-11

List of Tables

7-1 Lubrication requirements for the motor, and thrust chamber _______ 7-17-2 Lubrication chart for standard systems _________________________ 7-17-3 Lubrication chart for flush-plan systems ___________________ 7-27-4 Client and Date of Report _______________________________ 7-37-5 General Information _______________________________ 7-37-6 Pump Data _______________________________ 7-4

7-7 Motor Data _______________________________7-4

7-8 Engine-Driven Units _______________________________ 7-47-9 Thrust Chamber and Intake Assembly _________________________ 7-57-10 Shutdown Switches _______________________________ 7-57-11 Observed Operating Parameters _________________________ 7-57-12 Motor Maintenance Check List _________________________ 7-67-13 Thrust Chamber Maintenance Checklist ___________________ 7-67-14 Falk Steel flex Coupling Maintenance Checklist__________________ 7-67-15 General Operation Checklist _________________________ 7-77-16 Vibration Measurements _________________________ 7-78-1 Troubleshooting electric motors and starters ___________________ 8-48-2 Troubleshooting Thrust Chamber Vibrations ___________________ 8-68-3 Troubleshooting Thrust Chamber Overheating Problems on HPS Units With

a Thrust Chamber Cooling and Filtration System _____________ 8-78-4 Troubleshooting Thrust Chamber Overheating Problems On HPS Units

8/9/2019 Hps 165958ecol Als

21/195

SchlumbergerPrivate

Without a Thrust Chamber Cooling and Filtration System _______ 8-98-5 Troubleshooting a Motor Starter That Does Not Engage _______ 8-10

8/9/2019 Hps 165958ecol Als

22/195

SchlumbergerPrivate

Intentionally Blank

8/9/2019 Hps 165958ecol Als

23/195

SchlumbergerPrivate

1. Design

1.1 Technical Design Data _______________________________ 1-11.2 Pump Performance Data _______________________________ 1-2

8/9/2019 Hps 165958ecol Als

24/195

SchlumbergerPrivate

Intentionally Blank

8/9/2019 Hps 165958ecol Als

25/195

SchlumbergerPrivate

REDA HPS

HORIZONTAL PUMPING SYSTEM

TECHNICAL DESIGN

Customer: ECOPETROL TIBU

Project: P-30 INYECCION TEMPORAL

Flow: 12000 STB/d

Boost Pressure: 2981.64 psi

Discharge Pressure: 3001.6 psig

Pump: J350N 79 stages

Motor: SIEMENS, 900 hp, 4000 Volts, 60 Hz

Date: 4/18/2013

8/9/2019 Hps 165958ecol Als

26/195

SchlumbergerPrivate

Input Values

System Input Data

Input Voltage

Area Classification Non HazardousAmbient Temperature 80 F

Liquid Temperature 80 F

Input Frequency 60

NOTES :

Results Summary

Pump Summary

Operating Frequency 59.1 Hz Pump Type J350N

Speed 3501.7 RPM Stages 79

Power Required (@ Duty) 770.1 hp Shaft Type INCONEL 625

Run out Power 923 hp Pressure Rating 3330 psig

Pump Efficiency 79.33 % Shut in Pressure 3805.3 psigBoost Generated 2981.64 psi TDH 6877.55 ft

Component Details

Thrust Chamber

TC Rating 8000 lbf

Peak Downthrust 5550.15 lbf

Operating Downthrust 5233 lbf

NOTES :

Skid Type

Model

Overall Unit Length 0 ftNOTES :

Discharge Flange

Size 4 inFlange Class 2500

Configuration RF

Material 410-13CR SS

Process Input Data

Liquid Type Injection Water

Specific Gravity 1Design Flow Rate 12000 STB/d

Design Suction Pressure 20 psig

Design Discharge Pressure 3020 psig

Design Boost Pressure 3000 psi

NOTES :

Motor

Classification Non Hazardous

Voltage 4000 Volts

Shaft Power 900 hp

Altitude Adjusted HP 900 hp

Enclosure WPII

Frame 5010SBearing Type SLEEVE

NOTES :

Seal

Seal Type 2

Cartridge Seal NCSeal Flush Type

NOTES :

Intake Flange

Size 6 inFlange Class 150

Configuration RF

Material 316L SS

Intake Orientation 0 deg. (Standard)

8/9/2019 Hps 165958ecol Als

27/195

SchlumbergerPrivate

Limits Summary

Process Input Data

Frequency 59.1 Hz Controller kW 707.56

Voltage 4000 Volts Controller kVA 792.34

Motor Amps 114.5 Amps PF at Controller 0.89Motor Rating 900 hpPump Power Draw 770.1 hp

Motor Load Factor 85.57 %

System Summary at Maximum Condition

Pump

MAWP Rating 3330 psig

Shutoff Pressure 3805.3 psig

Pressure Load Factor 114.27 %

Shaft Rating 1019.5 hpPeak Required Power 923 hp

Shaft Load Factor 90.54 %NPSHr 23 ft

Thrust Chamber

TC Rating 8000 lbf

TC Load Factor 69.38 %

Flanges

Intake Rating 230 psig

Load Factor 8.7 %

Discharge Rating 6000 psig

Discharge Load Factor 63.42 %

System Summary at Design Point

Pump

MAWP Rating 3330 psig

Discharge Pressure 3001.6 psig

Pressure Load Factor 90.14 %

Shaft Rating 1019.5 hpRequired Power 770.1 hp

Shaft Load Factor 75.54 %NPSHr 23 ft

Thrust Chamber

TC Rating 8000 lbf

TC Load Factor 65.41 %

Flanges

Intake Rating 230 psig

Load Factor 8.7 %

Discharge Rating 6000 psig

Discharge Load Factor 50.03 %

8/9/2019 Hps 165958ecol Als

28/195

Actual Pump Curve

8/9/2019 Hps 165958ecol Als

29/195

NPSHr Actual Pump Curve

8/9/2019 Hps 165958ecol Als

30/195

VSD Curves Plot

8/9/2019 Hps 165958ecol Als

31/195

8/9/2019 Hps 165958ecol Als

32/195

Intentionally Blank

8/9/2019 Hps 165958ecol Als

33/195

.1 Quality Control Plan

8/9/2019 Hps 165958ecol Als

34/195

8/9/2019 Hps 165958ecol Als

35/195

8/9/2019 Hps 165958ecol Als

36/195

8/9/2019 Hps 165958ecol Als

37/195

.2 Manufacture Codes

COMPONENT CODES/NORMSKID AWS D 1.1

MOTOR IEEE 841NEMA

OTHER INTERNATIONALSPECIFICATIONS

PUMP API-RP-11S11S211S311S8

SEAL API-610API-862

ACOPLE API-610API-671

FLANGE SUCTION & DISCHARGE ASME B-16.5

TESTPRESSURE COMPONENT ASME BPV

INTRUMENTATION API-670ELCETRICAL COMPONENT NEC/IEC

8/9/2019 Hps 165958ecol Als

38/195

.3 Checklist Assembly

Date:28-03-2014 P/N: HPS-165958E COL_ALC W/O #: 33595 CADDY:

Customer:ECOPETROLTIBU S/N: 5FP4 C 3 359 5

Skid PN: 101033979 SkisSN: INDEIN 18720-1

HP: 900 Volts:4000 Amps:112 Serial#: 3003798208-30

Motor Alignment:

Motor Soft Foot

0.225F1

0.020F2

0.225

F3

0.020

F4

SleeveBearing: Yes No X Alignmentby: JSILVA - JVASQUEZ

Coupling Sizeand Type used:METASTREAMSPACE 7

Thrust Chamber:100448447

SerialNumber:XDP4C 33594

Thrust Chamber ModelNumber: G3A2 BRG

Thrust Chamber Verified to BOM and Installedby: JSILVA

Coupling Guard installedby: JSILVA

Verified Oil in Thrust Chamberby: JSILVA - UARIZA

Pump SealVerifiedby: JSILVA - UARIZA

Pump SealInstalledby: JSILVA

Intake:PN 3909508 6 x 150

SerialNumber:JPB2D 04993

Intake verified to BOM and installedby: JSILVA - UARIZA

Cooler Package:3908812

SerialNumber: FBB2K 2168495

Correct Oil installed Verifiedby: UARIZA/JVASQUEZ

ElectricalWiring Verifiedby: UARIZA

Oil & Fan correct rotation Verified by: UARIZA/JVASQUEZ

8/9/2019 Hps 165958ecol Als

39/195

8/9/2019 Hps 165958ecol Als

40/195

Date:8-04-2014 P/N: HPS-165958E COL_ALC W/O #: 33965 CADDY:

Customer:ECOPETROLTIBU S/N: 5FP4D 33965

Skid PN: 101033979 SkisSN: INDEIN 18720-2

HP: 900 Volts:4000 Amps:112 Serial#: 3003893096-10

Motor Alignment:

Motor Soft Foot

0.215

F10.20

F2

0.0215

F3

0.020

F4SleeveBearing: Yes No X Alignmentby: NSuarez

Coupling Sizeand Type used:METASTREAMSPACE 7

Thrust Chamber:100448447

SerialNumber:XDP3E 28506

Thrust Chamber ModelNumber: G3A2 BRG

Thrust Chamber Verified to BOM and Installedby: NSUAREZ/JVASQUEZ

Coupling Guard installedby: JVASQUEZ

Verified Oil in Thrust Chamberby: JVASQUEZ - UARIZA

Pump SealVerifiedby: NSUAREZ

Pump SealInstalledby: NSUAREZ

Intake:PN 3909508 6 x 150

SerialNumber:JPB2L 2175031

Intake verified to BOM and installedby: NSUAREZ/JVASQUEZ

Cooler Package:3908812

SerialNumber: FBB2F 39288

Correct Oil installed Verifiedby: UARIZA/JVASQUEZ

ElectricalWiring Verifiedby: UARIZA

Oil & Fan correct rotation Verified by: UARIZA/JVASQUEZ

8/9/2019 Hps 165958ecol Als

41/195

Pump Alignment: JVASQUEZ PN: 100367159 PUMP #1

SerialNumber: 2NP4C 33549 Stages:35 Stages, J350N C-CT Serie 675/675

Pump O-ring verified and installedby: JVASQUEZ

Pump Alignment: JVASQUEZ PN: 100498656 PUMP #2

SerialNumber: 2NP4B 33387 Stages:44 Stages, J350N C-CT Serie 675/675

Pump O-ring verified and installedby: JVASQUEZ

DischargeHead Assembly: 100055281 4 2500

SerialNumber: JDB3B 2167760 Fittings installed by: UARIZA

Dischargeverified to BOM and installed by: NSUAREZ

Flush Plan: 2

Tubing installed by: UARIZA

Type of Plan: 2

Electrical: UARIZA

Instruments verified and installedby: UARIZA/JVASQUEZ

Wiring Installed and verified by: UARIZA

Wiring Diagramposted insidecover of Junction box: Pendiente

QA Final Check:UARIZA

Verifiedjackpad boltswith locknuts: UARIZA

Verified all nuts and boltsfor tightnessby: JVASQUEZ

Verified all flangecovers inplaceby: UARIZA

Is information showing placement of decalsand nameplatesprovided? Yes X No

Verified nameplateinformation and placement: WRUIZ

Verified decalinformation and placement:

8/9/2019 Hps 165958ecol Als

42/195

.4 Material Specification Pump

8/9/2019 Hps 165958ecol Als

43/195

8/9/2019 Hps 165958ecol Als

44/195

8/9/2019 Hps 165958ecol Als

45/195

8/9/2019 Hps 165958ecol Als

46/195

8/9/2019 Hps 165958ecol Als

47/195

8/9/2019 Hps 165958ecol Als

48/195

8/9/2019 Hps 165958ecol Als

49/195

8/9/2019 Hps 165958ecol Als

50/195

8/9/2019 Hps 165958ecol Als

51/195

8/9/2019 Hps 165958ecol Als

52/195

8/9/2019 Hps 165958ecol Als

53/195

8/9/2019 Hps 165958ecol Als

54/195

8/9/2019 Hps 165958ecol Als

55/195

8/9/2019 Hps 165958ecol Als

56/195

8/9/2019 Hps 165958ecol Als

57/195

8/9/2019 Hps 165958ecol Als

58/195

8/9/2019 Hps 165958ecol Als

59/195

8/9/2019 Hps 165958ecol Als

60/195

8/9/2019 Hps 165958ecol Als

61/195

8/9/2019 Hps 165958ecol Als

62/195

8/9/2019 Hps 165958ecol Als

63/195

8/9/2019 Hps 165958ecol Als

64/195

8/9/2019 Hps 165958ecol Als

65/195

8/9/2019 Hps 165958ecol Als

66/195

8/9/2019 Hps 165958ecol Als

67/195

8/9/2019 Hps 165958ecol Als

68/195

8/9/2019 Hps 165958ecol Als

69/195

8/9/2019 Hps 165958ecol Als

70/195

8/9/2019 Hps 165958ecol Als

71/195

8/9/2019 Hps 165958ecol Als

72/195

8/9/2019 Hps 165958ecol Als

73/195

8/9/2019 Hps 165958ecol Als

74/195

8/9/2019 Hps 165958ecol Als

75/195

8/9/2019 Hps 165958ecol Als

76/195

8/9/2019 Hps 165958ecol Als

77/195

8/9/2019 Hps 165958ecol Als

78/195

8/9/2019 Hps 165958ecol Als

79/195

8/9/2019 Hps 165958ecol Als

80/195

8/9/2019 Hps 165958ecol Als

81/195

8/9/2019 Hps 165958ecol Als

82/195

8/9/2019 Hps 165958ecol Als

83/195

8/9/2019 Hps 165958ecol Als

84/195

8/9/2019 Hps 165958ecol Als

85/195

8/9/2019 Hps 165958ecol Als

86/195

8/9/2019 Hps 165958ecol Als

87/195

8/9/2019 Hps 165958ecol Als

88/195

8/9/2019 Hps 165958ecol Als

89/195

8/9/2019 Hps 165958ecol Als

90/195

8/9/2019 Hps 165958ecol Als

91/195

8/9/2019 Hps 165958ecol Als

92/195

8/9/2019 Hps 165958ecol Als

93/195

8/9/2019 Hps 165958ecol Als

94/195

8/9/2019 Hps 165958ecol Als

95/195

8/9/2019 Hps 165958ecol Als

96/195

8/9/2019 Hps 165958ecol Als

97/195

8/9/2019 Hps 165958ecol Als

98/195

8/9/2019 Hps 165958ecol Als

99/195

8/9/2019 Hps 165958ecol Als

100/195

8/9/2019 Hps 165958ecol Als

101/195

8/9/2019 Hps 165958ecol Als

102/195

8/9/2019 Hps 165958ecol Als

103/195

8/9/2019 Hps 165958ecol Als

104/195

8/9/2019 Hps 165958ecol Als

105/195

8/9/2019 Hps 165958ecol Als

106/195

8/9/2019 Hps 165958ecol Als

107/195

8/9/2019 Hps 165958ecol Als

108/195

8/9/2019 Hps 165958ecol Als

109/195

8/9/2019 Hps 165958ecol Als

110/195

8/9/2019 Hps 165958ecol Als

111/195

8/9/2019 Hps 165958ecol Als

112/195

8/9/2019 Hps 165958ecol Als

113/195

8/9/2019 Hps 165958ecol Als

114/195

8/9/2019 Hps 165958ecol Als

115/195

8/9/2019 Hps 165958ecol Als

116/195

8/9/2019 Hps 165958ecol Als

117/195

8/9/2019 Hps 165958ecol Als

118/195

8/9/2019 Hps 165958ecol Als

119/195

8/9/2019 Hps 165958ecol Als

120/195

8/9/2019 Hps 165958ecol Als

121/195

NOZZLE LOADING ALLOWABLES

US COSTOMARY UNIT

NOZZLE SIZES OF FLANGE (INYAKE 6 IN)

FORCE (Lbs) MOMENTS (Lbs)

Fx Fy Fz Mx My Mz

1120 1400 920 3400 1740 2600

X: Pump Centerline

Y: Horizontal

Z: Vertical

8/9/2019 Hps 165958ecol Als

122/195

NOZZLE LOADING ALLOWABLES

US COSTOMARY UNIT

NOZZLE SIZES OF FLANGE (DISCHARGE 4 IN)

FORCE (Lbs) MOMENTS (Lbs)

Fx Fy Fz Mx My Mz

800 640 520 1960 1000 1480

X: Pump Centerline

Y: Horizontal

Z: Vertical

8/9/2019 Hps 165958ecol Als

123/195

Schlumberger

REDA Production Systems

HORIZONTAL UNIT MAINTENANCE AND REPAIR

G3 THRUST SECTION

The thrust chamber reservoir is filled with the recommended lubricant prior to shipment. The fluid level wilbe at or near the center of the sight glass located on the side of the reservoir. As long as fluid is visible inthe sight glass, it is not necessary to add oil.

MODEL G3-A THRUST CHAMBER

A lubricant change is recommended every six months of continuous operation. A plug for draining thelubricant can be removed from the bottom of the reservoir. This plug is a 1 pipe plug and can be removedwith an adjustable wrench. Fill the chamber through the vent cap located on top of the reservoir.

Caution should be taken not to fill the reservoir to a level above the center of the sight glass. The capacityis 1.0 gallon (3.79 liters). Do not overfill as overfilling causes excess heat buildup in the thrust chamber.

It is not unusual to have a small amount of oil seepage from the front and rear seal of the bearingchamber. The leakage is minimal and replenishing of the oil level should not be required more than oncein a six-month period.

Use only Reda recommended thrust chamber lubricant, Royal Purple, Synfilm 46 GT Part Number100179556 (five gallon).

Cartridge & Non-Cartridge Seal

The Cartridge type (or Non-Cartridge type) mechanical seal isolates the fluid from the thrust section. If thisseal should leak, the fluid will be visible in the area between the intake and thrust section. When the seal

requires changing out, the spacer coupling between the motor and the thrust chamber is removed. AnySS tubing connected to the seal cartridge needs to be removed (make sure the intake and dischargevalves for the pump are closed and the pressure in the pump is bleed down). Provision should be made toprevent spillage of the oil. The thrust chamber and seal section is now ready to remove as a unit. Theassembly must be supported during removal; the assembly weight is approx. 275 lbs. The ring of bolts onthe seal-retaining bracket is removed. The assembly moves toward the motor until the O-ring hascleared. The assembly should move freely toward the motor. The thrust chamber shaft is coupled to pumpshaft with a splined coupling. Inside the coupling is a set of shim washers.

Cartridge & Non-Cartridge Seal( cont)

The shims are critical to the operation of the pump and must be installed when the unit is assembledOnce the assembly is moved back and the thrust chamber shaft has cleared the intake housing removethe splined coupling.

Cartridge Seal Removal

The seal and seal chamber is removed by first unscrewing four 7/16 Allen head bolts located on the fluidside of the adapter spool. The bolts are located on the same lip as the O-ring. The setscrews on theseal-driving sleeve are loosened. The shaft has to be cleaned of any foreign material. After the shaft isclean the seal and seal chamber is removed by use of two jacking bolts (use the 7/16 Allen head bolts).

8/9/2019 Hps 165958ecol Als

124/195

Once the seal chamber has cleared its mounting plate slide it down the shaft. The seal is removed fromthe seal chamber by removing the four bolts and separating the two pieces. The throat bushing located inthe seal chamber should be inspected and replaced if damaged or worn.

Non-Cartridge Seal Removal

Thoroughly clean the shaft and primary ring surface area. Reverse the dismantle process to install theseal. O-Ring lubricant should be used when replacing the mating ring to facilitate installation. The use oftool Part Number 3900672 will also facilitate this installation. Use a quality non-detergent oil on the shaft

to install the primary mating assembly.

All O-rings should be lubricated with silicon grease before assembly. The new seal is installed in the seachamber and tighten. The rest of the components are assembled in the reverse order to disassembly.

Replacement of Thrust Chamber Bearing Sub-Assembly

The procedure for replacing the subassembly is basically the same as replacing the seal down to the pointwhere the seal chamber is to be removed from the shaft. The eight bolts located at the junction of thebearing sub-assembly and the adapter spool is removed. This will separate the bearing sub-assembly andthe adapter spool.

The new sub-assembly is attached to the adapter spool and then the seal chamber is installed asinstructed above. Upon completion, it will be necessary to re-set or check the shaft setting. See ShaftSetting procedure.

Pump Replacement

The upper half of the pump clamps need to be loosened or removed the entire length of the skid. Thebase of the pump at the intake end is to be unbolted from the intake adapter. A section of the dischargepiping, i.e., dropout spool, will have to be removed to allow the pump to be moved toward the dischargeend of the skid 10 to 12 inches. The pump jacks need to be placed on the main beam accordingly to allowthe entire pump to be lifted slightly by the jacks. Slide the pump away from the intake. If possible, leavethe coupling between the intake and pump on the pump shaft.

Pump Replacement (cont)This coupling has been shimmed on the pump side. To avoid losing the shims, do not remove them fromthe coupling. The pump should be free. Using a two-point sling lift the pump out of the saddles and setaside. In the case of multiple pumps lift the pumps out in sections starting with the pump farthest from themotor. Install the new pumps in the reverse manner shimming the pumps as described in the attachedshimming procedure.

Since the top half of the pump support saddles have been removed from the skid, they must be replacedin the same manner as they were removed. The top and bottom half of each saddle has a numberstenciled on one side only of each half. These numbers must match and be on the same side.

BOLTING TORQUE SPECIFICATIONS3/8 bolts1/2 heads20 ft-lbs.If using a torque wrench (Part Number 1156926) with adapter (Part Number 0047225), set at 17 ft-lbs.

7/16 bolts5/8 heads30 ft-lbs.If using a torque wrench (Part Number 1156926) with adapter (Part Number 0047225), set at 26 ft-lbs.

8/9/2019 Hps 165958ecol Als

125/195

1/2 bolts3/4 heads50 ft-lbs.If using a torque wrench (Part Number 1156926) with adapter (Part Number 0047233), set at 43 ft. lbs.

9/16 bolts13/16 heads80 ft-lbs.If using a torque wrench (Part Number 1156926) with adapter (Part Number 0047225), set at 70 ft-lbs.

1 bolts1-1/4 heads100 ft-lbs.If using a torque wrench (Part Number 1156926) with adapter (Part Number 0047225), set at 87 ft-lbs.

8/9/2019 Hps 165958ecol Als

126/195

2. Drawings and Bills of Materials

2.1. General Assembly Drawing and Bill of Materials ________________ 3-12.2. Thrust Chamber Serviceable Parts Drawing and Bill of Materials____ 3-12.3. Seal Drawing ______________________ 3-12.4. Motor Drawing ________________ 3-12.5.

Electrical Drawing ______________________3-1

2.6. Pump Shaft Setting Procedure ______________________ 3-12.7. Pump Drawing and Bill of Materials ______________________ 3-12.8. Lube Oil Cooler Information ______________________ 3-1

8/9/2019 Hps 165958ecol Als

127/195

Intentionally Blank

8/9/2019 Hps 165958ecol Als

128/195

8/9/2019 Hps 165958ecol Als

129/195

Part SLB HPS 165958ECOL_ALC Engineering Bill of Materials

Usage Type Name Rev

Last

Rev Description State

U

ofM

Qty

Item

Num

UsedPartSLB

100367159 AA AAPUMP: J 350N/J 12000N C-CT 35 STG 675/675 120 RLOYBTHD, 1.18 INC, M-TRM, HSN, ARZ-ZS, HPS, BLUE PAINT

Released EA 1.0 001

UsedPart

SLB100487696 E E

MOTOR: SIEMENS, 900HP 2300/4000V 114.5A 60HZ,

5010S, WPII, BALL BRG, 1.15 SF, STATOR RTDSReleased EA 1.0 002

UsedPart

SLB101033979 AB AB

WELDMENT ASSY, G3, MD, TANDEM, 4 CLAMP WITH 5

CLAMP EXTENSION, 12.5 INCH HEIGHT, 210.37 AND

260.25 PUMP LENGTHS, STD GRAY

Released EA 1.0 003

UsedPart

SLB100163819 AB AB

ASSEMBLY: COUPLING, METASTREAM, TSCS/TSKS 0230,

W/7 IN SPACER, 2.375-2.625 BOREReleased EA 1.0 004

UsedPart

SLB100571777 AD AD GUARD: ASSY, HPS, CPLG, 16-22 INCHES Released EA 1.0 005

UsedPart

SLB100448447 AN AN

THRUST CHAMBER: ASSEMBLY, 2 BEARING, HPS, G3A,

1.50-6B SPLINE, STD BLUEReleased EA 1.0 006

UsedPartSLB

7004534 AA AASEAL: SHAFT, 1.50, AFL, TYPE 2, EXTENDED TRAVEL, JCM50442

Released EA 1.0 007

UsedPart

SLB100212120 AD AD SEAL HOUSING: ASSY, G3, SINGLE CART, SINGLE SEAL Released EA 1.0 008

UsedPartSLB

3909508 AD ADASSEMBLY: INTAKE, 6 IN, 150, RFWN, 316L SS, MAWP-230 PSI

Released EA 1.0 009

UsedPart

SLB3909571 AC AC ADAPTER:INTAKE,PMP 675,SS,12 HOLES Released EA 1.0 010

UsedPart

SLB100352555 A A

COUPLING: ASSY, 1.50-6B X 1.18-6B SPLINE, 3.50 IN.,

303/304 SSReleased EA 1.0 011

UsedPartSLB

100005721 AA AACLAMP: PUMP, HPS, 675 SERIES PUMP (6-3/4 IN), STDGRAY

Released EA 9.0 012

Used

Part

SLB 100055281 C C

HEAD ASSY: DISCHARGE, 4 IN., 2500, RF, 675 SERIES, 410-

13CR SS, MAWP-6000 PSI Released EA 1.0 013

UsedPart

SLB3920098KIT AF AF

BOX: JUNCTION, NON-EXP,10 X 8 X 4, NEMA 4X, W/PANEL

HOFFMAN A1008CHNFSS, PANEL A10P8, SS,

W/INSTALLATION COMPONENTS

Released EA 1.0 014

UsedPart

SLB100144733 AL AL KIT: SWITCH, MURPHY, 45APE-S-200 Released EA 1.0 015

UsedPart

SLB100301754 AL AL KIT: SWITCH, MURPHY, 45APE-S-5000 Released EA 1.0 016

UsedPartSLB

100288082 AL AL KIT: SWITCH, VIBRATION, MURPHY VS2 Released EA 1.0 017

UsedPart

SLB100498656 AW AW

PUMP: J350N C-CT 44 STG 675/675 150 RLOY BTHD, 1.18

INC, M-TRM, AFL, ARZ-ZS, HPS, BLUE PAINTReleased EA 1.0 018

UsedPart

SLB100166584 AH AH

CP: HPS-G3, MD, 9 CLAMP, CLASS 900/2500 INTAKE,

COMPONENT HARDWARE DETAILS, TANDEM SKIDReleased EA 1.0 019

UsedPartSLB

100155123 AB AB KIT, MOTOR MOUNTING,0.875 BOLTS Released EA 1.0 020

UsedPartSLB

100304570 AA AA KIT, HPS, O-RING SET, HSN, 675 SERIES TANDEM Released EA 1.0 021

UsedPart

SLB100428379 AB AB

KIT, DISCHARGE MOUNTING,675-XH SERIES PUMPS,

MONELReleased EA 1.0 022

UsedPart

SLB0207480 B B

COUPLING: ASSY, 1.18-6B X 1.18-6B SPLINE, 3.63 IN.,

MONELReleased EA 1.0 023

UsedPart

SLB3908812 B B

ASSEMBLY: COOLER, OIL, BH, STANDARD, 60HZ,

115/230V, 1PH, WITH INTERCONNECT KITReleased EA 1.0 024

8/9/2019 Hps 165958ecol Als

130/195

8/9/2019 Hps 165958ecol Als

131/195

8/9/2019 Hps 165958ecol Als

132/195

8/9/2019 Hps 165958ecol Als

133/195

8/9/2019 Hps 165958ecol Als

134/195

8/9/2019 Hps 165958ecol Als

135/195

4 Pump Performance Tests and Reports4.1 Pump Test

8/9/2019 Hps 165958ecol Als

136/195

8/9/2019 Hps 165958ecol Als

137/195

8/9/2019 Hps 165958ecol Als

138/195

8/9/2019 Hps 165958ecol Als

139/195

8/9/2019 Hps 165958ecol Als

140/195

8/9/2019 Hps 165958ecol Als

141/195

8/9/2019 Hps 165958ecol Als

142/195

8/9/2019 Hps 165958ecol Als

143/195

8/9/2019 Hps 165958ecol Als

144/195

5. Recommended Spare Parts and Servicing Tools

8/9/2019 Hps 165958ecol Als

145/195

SchlumbergerHORIZONTAL PUMPING SYSTEM

RECOMMENDED SPARE PARTS AND SERVICING TOOLSQUANTITIES RECOMMENDED ARE FOR 1 UNIT(S) FOR 3 YEARS

SPARE PART

ITEM QTY DESCRIPTION PN WT/LBS1 1 THRUST CHAMBER: ASSEMBLY, 2 BEARING, HPS, G3A, 1.50-6B SPLINE,

INC, STD BLUE

100448447 275

2 2 SEAL: SHAFT, 1.50, AFL, TYPE 2, EXTENDED TRAVEL, JC M50442 7004534 1

3 3 KIT, HPS, O-RING SET, HSN, 675 SERIES TANDEM 100304570 1

4 4 OIL:LUBE,ROYAL PURPLE,THRUST CHAMBER,SYNFILM,GRADE 46 GT,5

GALLON

100179556 12

6 4 GREASE, LUBRICANT: DOW CORNING 4, 5.3 OZ TUBE 0553420 12

8/9/2019 Hps 165958ecol Als

146/195

8/9/2019 Hps 165958ecol Als

147/195

6 Installation and Commissioning

6.1 Transport and Handling _________________________ 6-16.1.1 Lifting _____________________________________ 6-26.1.1.1 Forklifts _____________________________________ 6-26.1.1.2 Cranes _____________________________________ 6-26.1.2

Lifting Device Load Calculations ___________________6-3

6.2 Site Requirements _______________________________ 6-56.3 Piping Connections _______________________________ 6-76.4 Commissioning _____________________________________ 6-106.5 Vibration ___________________________________________ 6-156.6 HPS Storage _____________________________________ 6-216.6.1 Preventive Maintenance _________________________ 6-216.6.2 Motor and Pump _______________________________ 6-216.6.2.1 Ball Bearing Motors _______________________________ 6-226.6.2.2 Sleeve Bearing Motors _________________________ 6-226.6.3 Thrust Chamber _______________________________ 6-226.6.4 Units with a Plan 52 or Plan 53 Seal Flush System _______ 6-22

8/9/2019 Hps 165958ecol Als

148/195

8/9/2019 Hps 165958ecol Als

149/195

8/9/2019 Hps 165958ecol Als

150/195

8/9/2019 Hps 165958ecol Als

151/195

8/9/2019 Hps 165958ecol Als

152/195

8/9/2019 Hps 165958ecol Als

153/195

8/9/2019 Hps 165958ecol Als

154/195

8/9/2019 Hps 165958ecol Als

155/195

8/9/2019 Hps 165958ecol Als

156/195

8/9/2019 Hps 165958ecol Als

157/195

8/9/2019 Hps 165958ecol Als

158/195

8/9/2019 Hps 165958ecol Als

159/195

8/9/2019 Hps 165958ecol Als

160/195

8/9/2019 Hps 165958ecol Als

161/195

8/9/2019 Hps 165958ecol Als

162/195

8/9/2019 Hps 165958ecol Als

163/195

8/9/2019 Hps 165958ecol Als

164/195

8/9/2019 Hps 165958ecol Als

165/195

8/9/2019 Hps 165958ecol Als

166/195

8/9/2019 Hps 165958ecol Als

167/195

8/9/2019 Hps 165958ecol Als

168/195

8/9/2019 Hps 165958ecol Als

169/195

8/9/2019 Hps 165958ecol Als

170/195

7 Maintenance

7.1 Lubrication Maintenance Summary ______________________ 7-17.2 Recommended Maintenance Schedules ________________ 7-27.3 HPS Field Service Report ____________________________ 7-37.4 Decommissioning Procedures ____________________________ 7-77.4.1

Short-Term Decommissioning Procedures ________________7-7

7.4.2 Long-Term Decommissioning Procedures ________________ 7-87.5 Recommissioning Procedures ____________________________ 7-9

8/9/2019 Hps 165958ecol Als

171/195

8/9/2019 Hps 165958ecol Als

172/195

8/9/2019 Hps 165958ecol Als

173/195

8/9/2019 Hps 165958ecol Als

174/195

8/9/2019 Hps 165958ecol Als

175/195

8/9/2019 Hps 165958ecol Als

176/195

8/9/2019 Hps 165958ecol Als

177/195

8/9/2019 Hps 165958ecol Als

178/195

8/9/2019 Hps 165958ecol Als

179/195

8/9/2019 Hps 165958ecol Als

180/195

8/9/2019 Hps 165958ecol Als

181/195

8/9/2019 Hps 165958ecol Als

182/195

8 Troubleshooting

8.1 Troubleshooting Basics ______________________________ 8-18.2 Troubleshooting Electric Motors and Starters ______ 8-28.3 Troubleshooting Thrust Chamber Vibrations ____________ 8-58.4 Troubleshooting Thrust Chamber Overheating (The HPS Unit Has a

Thrust Chamber Cooling and Filtration System) ____________8-7

8.5 Troubleshooting Thrust Chamber Overheating (The HPS Unit Does NotHave a Thrust Chamber Cooling and Filtration System.) ______ 8-88.6 Troubleshooting Instruments ________________________ 8-108.7 Troubleshooting Gearbox Noise __________________ 8-118.8 Troubleshooting Gearbox Overheating ____________ 8-118.9 Troubleshooting Gearbox Vibration __________________ 8-118.9.1 Linear Vibration ______________________________ 8-128.9.2 Torsional Vibration ______________________________ 8-12

8/9/2019 Hps 165958ecol Als

183/195

8/9/2019 Hps 165958ecol Als

184/195

8/9/2019 Hps 165958ecol Als

185/195

8/9/2019 Hps 165958ecol Als

186/195

8/9/2019 Hps 165958ecol Als

187/195

8/9/2019 Hps 165958ecol Als

188/195

8/9/2019 Hps 165958ecol Als

189/195

8/9/2019 Hps 165958ecol Als

190/195

8/9/2019 Hps 165958ecol Als

191/195

8/9/2019 Hps 165958ecol Als

192/195

8/9/2019 Hps 165958ecol Als

193/195

8/9/2019 Hps 165958ecol Als

194/195

8/9/2019 Hps 165958ecol Als

195/195