Troubleshooting for Caterpillar Well Stimulation Pumps {5070} Caterpillar

Troubleshooting for Caterpillar Well Stimulation Pumps {5070}

Usage:

Well Pump: WSF223 (S/N: FNL1-UP); WSF223 SS (S/N: BM81-UP); WSF255 SS (S/N: BM91-UP); WSF255 XD (S/N: FNP1-UP)
Well Stimulation Pump: WS223 (S/N: SR31-UP); WS223 SS (S/N: BM31-UP); WS223 XD (S/N: SR41-UP); WS255 (S/N: SR51-UP); WS255 SS (S/N: BM51-UP); WS255 XD (S/N: SR61-UP); WS273 XD (S/N: DG21-UP); WS305 XD (S/N: EA21-UP); WSF255 XD (S/N: P231-UP)
Well Stimulation Pump Fluid End: WS255 SS (S/N: AE31-UP); WSF223 (S/N: FN41-UP); WSF223 SS (S/N: BM41-UP); WSF223 XD (S/N: FN31-UP; FNM1-UP); WSF243 SS (S/N: RX21-UP; RX31-UP; RX41-UP; RX51-UP); WSF243 XD (S/N: FN91-UP; FNC1-UP; FND1-UP; FNE1-UP); WSF253 SS (S/N: RWC1-UP; RWD1-UP); WSF253 XD (S/N: FN81-UP; FNT1-UP); WSF255 (S/N: AE51-UP; FN51-UP; FN61-UP; FN71-UP); WSF255 SS (S/N: AE41-UP; BM61-UP; BM71-UP); WSF255 XD (S/N: AE21-UP; FN21-UP); WSF273 XD (S/N: DG41-UP; DG51-UP; DG61-UP); WSF275 SS (S/N: RX61-UP; RX71-UP; RX81-UP; RX91-UP); WSF275 XD (S/N: FNB1-UP; FNF1-UP; FNG1-UP; FNH1-UP); WSF305 XD (S/N: EA41-UP; EA51-UP; EA61-UP; EA71-UP)
Well Stimulation Pump Power End: WSP223 (S/N: FNJ1-UP); WSP255 (S/N: FNK1-UP); WSP273 (S/N: DG31-UP); WSP305 (S/N: EA31-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and understand the information.

This Special Instruction covers the troubleshooting for the well stimulation pump.

Troubleshooting of the Caterpillar Well Stimulation Pumps

The following procedures cover the troubleshooting and repairs for the well stimulation pumps.

No Fluid Delivery to Pump

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Table 1
Symptom Description	Probable Cause	Suggested Action
No fluid delivery through the pump.	1. The pump is not primed for operation.	Repair : Prime the pump for proper operating conditions.
	2. An air or vapor pocket is in the suction line.	Repair : Relive the air or vapor pocket from the suction line.
	3. The suction line has become clogged.	Repair : Clean the suction of any obstacles that restrict flow.
	4. The suction and/or discharge valves are stuck open.	Repair : Remove any obstructions that do allow for proper operation of the discharges valves.

Low Fluid Discharge Pressure from the Pump

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Table 2
Symptom Description	Probable Cause	Suggested Action
Low fluid discharge from the pump.	1. A check valve has become worn or damaged.	Repair : Replace the valve assembly as necessary.
	2. A check valve is stuck open.	Repair : Remove any obstructions that do allow for proper operation of the discharges valves.
	3. Cavitation of the pump has occurred.	Repair : Refer to Special Instruction, REHS8177, "Cavitation".
	4. Fluid is leaking from the fluid end of the pump.	Repair : Replace the plungers, packing, and/or fluid end seals as necessary.

Low Suction Pressure

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Table 3
Symptom Description	Probable Cause	Suggested Action
Low suction side pressure.	1. Low head pressure.	Repair : Increase the level of fluid supply and/or install a charging pump.
	2. Inadequate charging pump pressure.	Repair : Increase the charging pump speed or size.
	3. Slow fluid flow through the suction side of the pump.	Repair : Remove any obstructions or restrictions from the suction line.

Cavitation of the Fluid End

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Table 4
Symptom Description	Probable Cause	Suggested Action
Cavitation of the fluid end has occurred.	1. Low suction system pressure.	Repair : Refer to Special Instruction, REHS8177, "Low Suction Pressure".
	2. Pulsation damper and stabilizer not used.	Repair :Install the pulsation damper and suction stabilizer.
	3. Defective pulsation damper and/or stabilizer.	Repair : Repair or replace the parts as necessary.
	4. High viscosity or temperature of discharge fluid.	Repair : Reduce the speed of the pump.
	5. High acceleration head	Repair : Increase the supply line size or decrease the supply line length.
	6. The suction valve spring is too stiff with the low net positive suction head.	Repair : Replace the spring with a weaker spring.
	7. There is air or gas in the supply fluid.	Repair : Allow for more settling time in the supply tank and reduce the pump speed.
	8. There is air entering the suction line of the pump.	Repair : Find any source allowing the air to enter and repair.
	9. There is air entering the charging pump.	Repair : Tighten or replace the shaft packing or seal.
	10. Air is entering, or charge gas is escaping from the suction stabilizer.	Repair : Repair and recharge the suction stabilizer as necessary.

Suction or Discharge Line Vibrations

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Table 5
Symptom Description	Probable Cause	Suggested Action
Suction or discharge lines vibrate excessively.	1. The pump has cavitation.	Repair : Refer to Special Instruction, REHS8177, "Cavitation of the Pump".
	2. The discharge pressure is low.	Repair : Refer to Special Instruction, REHS8177, "Low Fluid Discharge Pressure from the Pump".
	3. The suction pressure is low.	Repair : Refer to Special Instruction, REHS8177, "Low Suction Pressure".

There is a Knocking Noise in the Power End

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Table 6
Symptom Description	Probable Cause	Suggested Action
There is a knocking noise in the power end of the pump.	1. Improper main bearing clearances.	Repair : Check and adjust the main bearing clearances as necessary.
	2. The pump is operating in incorrect rotation.	Repair : Correct or reverse the rotation of the pump.
	3. Loose bearing housings and/or covers.	Repair : Check and tighten the housings as needed. Replace the housing if damaged.
	4. Worn crosshead bushings	Repair : Inspect and replace the bushings as necessary.
	5. Worn connecting rod bearings.	Repair : Inspect and replace the connecting rod bearing as necessary.
	6. Worn crankshaft	Repair : Inspect and replace the crankshaft as necessary.
	7. Worn main bearings	Repair : Inspect and replace the main bearings as necessary.
	8. Valve noise being transmitted to the power end	Repair : Refer to Special Instruction, REHS8177, "Excessive Valve Noise".
	9. Cavitation noise transmitted or causing shock load in the power end	Repair : Refer to Special Instruction, REHS8177, "Cavitation of the Fluid End".

Excessive Valve Noise

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Table 7
Symptom Description	Probable Cause	Suggested Action
Excessive valve noise is coming from the fluid end.	1. There is cavitation in the fluid end.	Repair : Refer to Special Instruction, REHS8177, "Cavitation of the Fluid End".
	2. A seal on a valve is damaged or a valve is missing.	Repair : Repair or replace the valve components as necessary.
	3. The valve springs are broke or weak.	Repair : Inspect and replace the springs as necessary.

Leaking Pony Rod Seal

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Table 8
Symptom Description	Probable Cause	Suggested Action
Oil is leaking from the oil seal of the rod.	1. Worn lip on the oil seal.	Repair : Inspect and replace the seal.
	2. The oil seal lip is damaged.	Repair : Inspect and replace the seal.
	3.The outside diameter of the seal is not sealing.	Repair : Clean and polish the bore of the oil seal housing.
	4. Too much pressure in the power end.	Repair : Clean and/or replace the air breather.

Fluid End Leaks

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Table 9
Symptom Description	Probable Cause	Suggested Action
The fluid end is leaking.	1. Short plunger and packing life	Repair : Refer to Special Instruction, REHS8177, "Short Plunger/Packing Life".
	2. Worn packing seals	Repair : Inspect and replace the packing seals and brass seals as necessary.
	3. Seal is worn or damaged in the fluid end.	Repair : Inspect and replace the fluid end seals as necessary.
	4. Corrosion due to wrong packing for supplied fluid.	Repair : Check and replace the packing with the appropriate packing for the supplied fluid.

Short Valve Life

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Table 10
Symptom Description	Probable Cause	Suggested Action
The valve life is shortened.	1. Check valves are not seating.	Repair : Inspect and replace any of the valve components as necessary.
	2. There is cavitation in the pump.	Repair : Refer to Special Instruction, REHS8177, "Cavitation of the Pump".
	3. There is corrosion of the valves and seals.	Repair : Treat the pumped fluid and choose the appropriate seals and packing for the fluid.

Short Packing/Plunger Life

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Table 11
Symptom Description	Probable Cause	Suggested Action
The packing/plunger life has been shortened.	1. There are abrasives in the plunger lube	Repair : Contact the local Caterpillar dealer for filtration and packing recommendations.
	2. Excessive packing and/or plunger friction	Repair :Do not overtighten packing nut and use Caterpillar plungers.
	3. Metal parts and/or particles are wearing on the plunger	Repair : Inspect the packing and seals for foreign debris. Inspect and correct gland or plunger alignment.
	4. Wrong packing and/or plunger chosen for pumped fluid	Repair : Contact the local Caterpillar dealer for appropriate packing and/or plunger for the pumped fluid.
	5. Wrong packing size used in fluid end	Repair : Install the correct packing size.
	6. Improper packing installation	Repair : Disassembly and Assembly, UENR3290, "Plunger - Remove and Install".
	7. Excessive crosshead wear	Repair : Replace the crosshead.
	8. Cavitation of the pump	Repair : Refer to Special Instruction, REHS8177, "Cavitation of the Pump".

Rod Assembly Failures

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Table 12
Symptom Description	Probable Cause	Suggested Action
There are failures caused by incorrect stay rod assembly.	1. Improper torque or procedure for rod nut.	Repair : Check the torque specifications and torque to correct value.
	2. Corrosion on the rods	Repair :Use corrosion protection on rods.
	3. Stay rods are wrong length	Repair : Use Caterpillar rod assemblies.

High Oil Temperature

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Table 13
Symptom Description	Probable Cause	Suggested Action
The oil temperature is high.	1. High ambient air temperature	Repair : Use and oil heat exchanger with a circulating pump.
	2. Improper oil used in the pump	Repair : Use the recommended oil from the OEM manual.
	3. The pump is overloaded	Repair : Reduce the pump speed and/or pressure.
	4. Improper clearances for main roller, rod , and/or crosshead thrust bearings	Repair : Inspect and adjust the clearance as necessary. Replace the related components as necessary.