stroke counter for mud pump in stock

Our pump stroke counter systems (CPS101 Series) measure the stroke rate and number of strokes on mud pumps. The oilfield pump stroke system is user-friendly and reliable and is configurable to measure up to three mud pumps at once. Our digital pump stroke counter systems are manufactured here in the U.S. by Crown Oilfield Instrumentation, and Crown’s Pump Stroke Counter provides easy monitoring of strokes per minute on multiple mud pumps. Each mud pumps’s stroke rate can be selected individually and the display is updated regularly for accurate monitoring. LCD displays indicate both pumps strokes per minute and the total number of strokes. Located at the bottom of the panel, push buttons provide easy operation and reseting of each pump. When you need to accurately monitor and maintain the amount of mud being pumped, you can trust Crown’s oilfield stroke counters.

Crown"s One Pump Stroke Counter System monitors and displays strokes per minute and total stokes and has everything you need to monitor one mud pump. Encased in a stainless steel box, the LCD screens are easy to view at a distance, and with buttons mounted on the face place, this system is easy to reset as needed. With a low power, low voltage lithium battery, this system is self-contained and intrinsically safe, with a operational life of 5 years. The Crown One Pump Stroke Counter system is designed to work in the harshest industry conditions and is waterproof and resistant to excessive rig vibrations. With everything ready-to-use right out of the box, this system will get you counting mud pump flow rate quickly and efficiently. Here"s what you"ll get in the one pump stroke counter system:

Made in the US, the Crown One Pump Stroke Counter system is powered by a 3.6 Type D lithium battery, with no external power supply needed. Because it is a self-contained system, the CPS101-2 is intrinsically safe. When the system is not in use it will go into a null state, saving battery power and the life of the LCD screens. Each Screen displays either strokes per minute (0-240 SPM) or total strokes (0-9999).

Crown"s limit switch assembly can be mounted near the mud pump piston with the easy-to-use c-clamp. The stainless steel rod can be bent to reach the piston easily,  making the CPS101-2 one pump stroke counter system mountable in optimal proximity to the pump piston. The cable connecting the limit switch assembly to the stroke counter is made of the most durable materials to give you the best possible stroke counter on the market.

Need more information about our stroke counter systems? Check out our Stroke Counter Page or our Blog. And, if you only need one of the components in this system, give us a call. We"re more than happy to get you exactly what you need.

This product contains lithium batteries and is classed UN3091, lithium batteries contained in equipment. It can only be shipped via ground in the US. If you would like to purchase a system outside the US, please contact us directly to arrange transport.  For international customers, if you"d like to ship this product without a lithium battery to save on shipping costs, we can provide you with the information needed to purchase the required battery and detailed instructions on how to install the battery. Just give us a call at 1-877-908-3790 or email sales@drillinginstruments.com, and we"ll set that up for you.

Explore a wide variety of mud pump stroke counter on Alibaba.com and enjoy exquisite deals. The machines help maintain drilling mud circulation throughout the project. There are many models and brands available, each with outstanding value. These mud pump stroke counter are efficient, durable, and completely waterproof. They are designed to lift water and mud with efficiency without using much energy or taking a lot of space.

The primary advantage of these mud pump stroke counter is that they can raise water from greater depths. With the fast-changing technology, purchase machines that come with the best technology for optimum results. They should be well adapted to the overall configuration of the installation to perform various operations. Hence, quality products are needed for more efficiency and enjoyment of the machines" full life expectancy.

Alibaba.com offers a wide selection of products with innovative features. The products are designed for a wide range of flow rates that differ by brand. They provide cost-effective options catering to different consumer needs. When choosing the right mud pump stroke counter for the drilling project, consider factors such as size, shape, and machine cost. More powerful tools are needed when dealing with large projects such as agriculture or irrigation.

Alibaba.com provides a wide range of mud pump stroke counter to suit different tastes and budgets. The site has a large assortment of products from major suppliers on the market. The products are made of durable materials to avoid corrosion and premature wear during operations. The range of products and brands on the site assures quality and good value for money.

The RIGCHINA Pump Stroke Counter/Rate Meter displays both the total number of strokes and the strokes per minute for 3 mud pumps up to 1,024 strokes per minute for each pump. Push buttons conveniently located on the front of the instrument make it easy for the operator to reset each pump count

The Two-pump Digital Stroke Rate Meter monitors and displays the Rate and Total Strokes of up to two individual pumps simultaneously. The unit continually displays, on large easy to read, low power LCD displays, RPM, TOTAL ACCUMULATED STROKES (0-9999 total strokes) and STROKE RATE (8-350 strokes per minute) for each pump. The unit is internally powered by a battery source having an operational life of 3 years.

At Matherne Instrumentation, we"re proud to provide both our two-pump and three-pump stroke counters to companies and oilfield operators across the states of Texas, Louisiana, North Dakota, and Pennsylvania. While our offices are based in Odessa, TX; Lafayette, LA; and Houma, LA, we"re proud to serve those across the cities of Midland, TX; Houston, TX; Williston, ND; and Pittsburgh, PA. To learn more or for a quote, please feel free to give us a call today!

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This application claims the benefit of Provisional U.S. Patent Application No. 62/655,927, filed Apr. 11, 2018, and entitled “SYSTEM AND METHODS FOR NON-INVASIVE PUMP STROKE, RPM AND PUMP HEALTH DETECTION” the entire content and disclosure of which, both express and implied, is incorporated herein by reference. FIELD OF THE INVENTION

The present invention relates to apparatus and methods for monitoring pumps, and in particular, positive displacement triplex pumps. BACKGROUND OF THE INVENTION

Positive displacement pumps are used in oil fields to circulate high volumes of drilling fluid/mud under high pressure down the drill string and back up the annulus. There are two common types of positive displacement pumps: duplex pumps and triplex pumps. Duplex pumps have two pistons while triplex pumps have three pistons that move back and forth in liners.

Triplex pumps have three intake valves and three discharge valves. The three pistons in triplex pumps can be moved back, also called back stroke, to pull in drilling mud through open intake valves on the same side of the piston. When the pistons are moved forward, also called forward or discharge stroke, the drilling fluid is pushed out through open discharge valves on the same side of the piston and down a discharge line. Due to this, the triplex pumps are also called “single acting”.

Triplex mud pumps produce pulsating flows which lead to pressure spikes. In order to accelerate the drilling fluid to maximum velocity, each piston stroke must overcome the inertia of the columns of fluid in the suction/intake and discharge pipe work. At the end of each stroke, this inertia must again be overcome to bring the fluid columns to rest. This cycle of alternate acceleration and deceleration is the primary cause of fluid pulsations or pressure spikes.

In order to avoid these pressure spikes, the drilling industry uses pulsation dampeners or dampers. For example, a triplex pump includes a pulsation dampener in the discharge line. The pulsation dampener smooths out surges or pulses created by the pistons as they discharge mud. A pulsation dampener creates an area of low pressure in the system with enough volume to absorb the pulsation. The pulsation dampener has a membrane with a “cushion” of compressible gas/air behind it that flexes to absorb the pulse, allowing a laminar flow downstream of the dampener.

Positive displacement pumps can produce the same flow at a given speed (RPM) irrespective of the discharge pressure. However, a slight increase in internal leakage as the pressure increases prevents a substantially constant or linear flow rate.

When a triplex mud pump is in operation, the driller requires information on the amount of mud flowing down hole in order to keep the operation running at peak efficiency. Many service companies provide services related to obtaining this information. Typically, this involves monitoring the pump strokes and then calculating the flow out from the pump using a standard formula involving the pump strokes per minute and the pump volume. Electronic pump stroke counters can also assist the driller by measuring the mud pump"s strokes per minute and total strokes.

Triplex mud pumps are basic pumps with minimal technology. Current techniques for monitoring the pump strokes involve physically altering the pump. Two conventional solutions involve a C-clamp pump stroke sensor and a proximity switch sensor. Both techniques require the installer to make mechanical modifications to the triplex pump in order to install the sensors so that they can detect the piston stroke rate inside the pump. In order to install these sensors, the operator either needs to drill holes in the pumps in order to run cables or may be required to leave the lids or covers off the pump after installation.

These installation techniques have inherent risks and problems. For example, leaving the lids off can potentially cause drilling fluids to spill over or other similar safety hazards. If the spills exceed certain pre-determined limits, the operator may be required to report it to regulatory bodies, such as the United States Environmental Protection Agency. Modifying or drilling holes into existing pumps can also cause safety issues. Additionally, there is an associated cost with stopping drilling operations during such an installation. This may expose the environment and personnel to danger and can create liability for the drilling contractor as well as the operator of the oil and gas field.

Accordingly, there is a need for a non-invasive solution to measure desired pump characteristics, such as, piston strokes in triplex pumps. Ideally, such a solution should also monitor the speed (PRM) and health of the pump and valves. SUMMARY OF THE INVENTION

According to an embodiment, an apparatus for detecting a characteristic of a pump includes: a housing having a first planar surface and a second planar surface opposite the first planar surface, a mount structure located on the second planar surface, wherein the mount structure is configured to facilitate attachment of the apparatus on an external surface of the triplex pump, and wherein the mount structure avoids penetrating an inside surface of the triplex pump. The housing is configured to enclose one or more sensors, such as, an accelerometer for detecting the pump characteristic. In one or more embodiments, the pump is a triplex pump having three cylinders. The mount structure can be a magnet or a similar coupling device for affixing the apparatus to a metal pump. The magnet facilitates a non-intrusive detection of the pump characteristic. The non-intrusive detection of the pump characteristic substantially eliminates production downtime at an oil rig. The housing has a third planar surface, wherein the third planar surface comprises a plurality of LED lights. At least one LED light is configured to provide an indicator of a pump characteristic, such as, the speed of rotation of the pump.

In another embodiment, a method for determining health of a triplex pump involves the steps of: providing the magnetic-base apparatus discussed above, wherein the apparatus is configured to be mounted on a pump head. The apparatus is configured to detect a first signal waveform indicative of at least one of a valve signature and a pump speed. The detected signal is input into a signal shaper circuit and a comparator circuit. The first signal is filtered to generate a second signal waveform having one or more defined peak forms. Each peak is representative of a valve signature. The method further involves putting the second signal waveform through a relay circuit to generate a third signal waveform. The relay is configured to divide the frequency of the second signal waveform by three to generate a single signal pulse representative of the speed of the pump. Each of the three waveforms is digitally transmitted to a display terminal and displayed in a single graph. The method further comprises flagging the pump for inspect when a deviance from a baseline speed is observed.

In another embodiment, a method for determining health of a triplex pump involves: providing the magnetic-base apparatus discussed above, wherein the apparatus is configured to detect one or more pump stroke signal waves, and wherein the apparatus includes a microprocessor running an algorithm for sampling detected pump stroke signal waves over a period of time or space and dividing it into one or more frequencies. This is followed by generating a graphical display of the frequencies. A first peak frequency is selected and its data is obtained from the graph. The pump stroke data can be obtained by converting the first peak frequency data into revolutions per minute (RPM). The method further comprises flagging the pump for inspect when a deviance from a predetermined baseline RPM is observed. BRIEF DESCRIPTION OF THE DRAWINGS

As shown in FIGS. 1A and 1B, an apparatus 100 is provided for detecting pump strokes. The apparatus 100 can be configured to detect pump valve and cylinder sealing health by monitoring valve noise and “valve signatures”. A set of valve positions and the corresponding signals is known as a valve signature. The apparatus 100 is also configured to non-intrusively detect pump speed in revolutions per minute (RPM). The apparatus 100 is configured as a compact and portable device that can be mounted at any location on the exterior of a pump.

The apparatus 100 includes a housing 110 having a first planar surface 120A and an opposing planar surface 120B. The housing 110 can include a metallic aluminum enclosure. The housing 110 includes a mount structure 130 located on its base or second planar surface 120B. The mount structure 130 allows for fast mounting to the exterior of metal pumps. In an exemplary embodiment, the mount structure 130 is a magnet.

A third planar surface 120C of the housing includes two LED indicators 150A, 150B. A first LED indicator 150A is configured to be illuminated when the apparatus 100 is synchronized with the signature of a pump cylinder while a second LED indicator 150B is configured to be illuminated when the apparatus 100 detects the RPM of the pump.

The housing 110 is configured to enclose one or more sensors, such as, accelerometers, vibration sensors, pressure sensors, displacement sensors and/or other sensors. The housing 110 can further include electronic circuitry, microprocessors which are configured to improve digital signal processing and firmware to process the valve signature data and pump stroke data and digitally transmit it a display unit. The housing 110 can further enclose a pulse shaper circuit and a comparator circuit to shape the raw signal detected by the apparatus 100. In some embodiments, the housing 110 can further include a divide by three relay circuit. As shown, the housing 110 can be substantially square in shape. However, in other embodiments, the housing 110 can be circular, elliptical, ovoid or any other desired shape.

In certain embodiments, the magnet 130 may include a suitable cover 135. The cover 135 is removed before the magnet 130 can be mounted or attached to metallic pumps. As shown in FIG. 1C, the apparatus 100 can be mounted on any desired location on an exterior housing of a triplex pump 140.

Conveniently, since the apparatus 100 is installed on the outside of the pump 140, it does not require the opening of the pump or any modifications to the inside or surface of the pump. Therefore, this advantageously avoids the risks and issues associated with current techniques for installing pump sensors. For instance, it avoids the need for opening or modifying or removing the pump covers which could potentially lead to spills of potentially hazardous fluids. The apparatus 100 does not have to be bonded to the pump. The apparatus 100 is installed on an exterior surface of the pump using the magnet 130 located at the base of the housing. As such, it does not affect or stop the drilling process which, advantageously, does not impact rig productivity. The apparatus 100 is, therefore, easy and convenient to install. The apparatus 100 is environmentally friendly in comparison to current techniques. Thus, there is also no requirement to comply with cumbersome EPA regulations since it significantly reduces or eliminates any potential spills of hazardous material.

The apparatus 100 provides a non-intrusive magnetic mounting means for quickly installing it on pumps. The magnetic-base apparatus 100 is configured to determine the speed or RPM of a triplex, multi-cylinder pump by producing a digital output signal which facilitates precise calculations of the RPM. In certain embodiments, the signatures of each cylinder can be used to derive the speed.

In one embodiment, a method for determining pump and valve health is disclosed. The method involves providing the apparatus 100 having one or more accelerometers mounted inside its housing. The method involves attaching the apparatus 100 on an external surface of the triplex pump to detect movements of the pump surface, and therefore, the pump strokes. For instance, the apparatus 100 can attached to the pump head using the magnet at the base of its housing. As the pistons in the triplex pump are actuated, the accelerometers sense the actuation of the valves and detect the forces generated by the actuator to measure the motion of the valves. In the case of triplex pump having three cylinders, three valve signals are detected per revolution. The apparatus 100 can then subject the detected raw signal to pulse shaping. With reference to FIG. 1C, pulse shaping involves inputting the raw signal in its signal shaper circuit 105 to filter it and trace an upper profile or peak of the signal waveform. The signal shaper circuit can include a diode that charges a capacitor to track/trace an upper profile of the waveform. The method can further include adding a bleeder resistor on the capacitor. This can allow the capacitor charge to trace the upper shape of the waveform. The method further involves inputting the waveform into the built-in comparator circuit 107 which can be adjusted to track the higher peaks of the signal which represent each valve signature. The shaped signal is then put through the built-in divide by three relay circuit 108 (for triplex pumps) to divide the frequency of the shaped signal by three in order to generate a single signal pulse representative of the speed or “RPM” of the pump. These signals can be digitally transmitted to a display terminal.

FIG. 2 illustrates an exemplary signal plot of the raw, shaped and single pulses. The output signal or “raw” signal from the accelerometers is shown on the first row. The shaped signal is shown in the second row while the single pulse signal is illustrated on the third row of FIG. 2. The plot provides a convenient mechanism for a user/pump operator to track and detect any problems with the pump.

In the oilfield, the inflow to the well is critical. The inflow to the well is the product of the speed of the pump and pump volume. Historically, pump rate was monitored for standard drilling purposes, so the pumps were typically running at a pump stroke rate of 30 RPM or higher. Newer techniques, such as under balanced drilling, may necessitate monitoring at much lower pumping rates—which could be as low as 3 RPM. In the traditional 1 pulse per RPM sensor devices, most computer counter calculations would detect the pumps during periods and not pumping if they were expecting a pulse every few seconds as a minimum. In certain embodiments, the method can involve inputting either one pulse per valve (three pulses per RPM) to obtain a better rotational resolution. Additionally, to get better resolutions, advanced techniques may be employed to observe the phase of the signature to get better than three positions per revolution emulating a resolver type output. Thus, the apparatus 100 facilitates improved pump position by monitoring multiple cylinders to derive the speed of slow moving pumps for applications like under balanced drilling.

In certain embodiments, the method further involves locating a drive motor of the pump to install a resolver on its shaft. In certain other embodiments, the method can involve monitoring the drive motor drive gear sprocket teeth to detect extreme low pump RPM based on drive gear movement or position in order to capture higher resolutions.

The method further involves plotting the pulse in a graphical format for user convenience. The method involves comparing the pump strokes detected by the apparatus 100 against a baseline at the time of install to track changes. Changes can be flagged for inspection after a defined deviation from expected profiles. The method further involves alerting a user to any predetermined material deviances from the baseline. This allows the user to rectify any issues and conduct preventive maintenance of the pump and its components before the problems worsen. In lieu of the apparatus 100, other pressure detection devices can also be used such as, a pressure strap (disclosed in U.S. Pat. No. 9,746,386), strain gauges, or pressure sensors can be used for monitoring pressure changes inside the pump cylinder head.

In another embodiment, a method for monitoring pump health involves measuring pump strokes with a microprocessor 106 circuit using digital signal processing. The method involves providing the apparatus 100 having one or more accelerometers mounted inside its housing. The method involves attaching the apparatus 100 on an external surface of the triplex pump to detect movements of the pump surface, and therefore, the pump strokes. The method involves using a microprocessor running a “fast Fourier transform” (FFT) algorithm that samples detected pump stroke signals over a period of time (or space) and divides it into its frequency components. These components are single sinusoidal oscillations at distinct frequencies each with their own amplitude and phase. This process optimizes accuracy of the corrected data and eliminates erroneous data points. The corrected signal can be digitally communicated to a display terminal.

The method involves converting complex signals into a frequency spectrum. The frequency spectrum of the signals can be displayed at the bottom of a plot. As shown in FIG. 3, the results can be plotted in an Accelerometer X FFT plot and displayed on the display terminal. The method further involves selecting a correct frequency peak. This selection involves utilizing predetermined information on the pump and its mechanics. In some embodiments, a first peak frequency may be the correct frequency peak. However, in other pump set ups, it could be different. After the digital microprocessor has converted the signal, the useable data can be communicated either wirelessly or in a customer desired format.

The method further involves using the frequency data to extract the pump strokes per minute, RPM or other usable measurements that may be needed for the pumps/drilling operation. For instance, as shown in FIG. 3, the first peak is approximately 1 HZ. The user can convert the 1 HZ (1 cycle per second) to RPM by multiplying it by 60 (seconds). This is converted to approximately 60 RPM. Thus, the user can determine the pump rotation data from the detected pump strokes.

In another embodiment, a method for monitoring pump health involves monitoring waveforms and frequency spectrums to determine the performance of a cylinder. The method involves providing a plurality of the magnetic-base apparatus 100, wherein the apparatus includes a vibration sensor mounted within. A first apparatus 100 can be affixed proximal to a first cylinder of a three cylinder triplex pump. A second apparatus 100 can be affixed proximal to an intake or discharge valve. The apparatus 100 is configured to detect signatures of the first valve and first cylinder and determine their corresponding waveforms and frequencies. A leaking valve has more signals between its openings and it may have a typical smaller valve “opening” signature. A good valve/cylinder combination will, on the other hand, have a strong pressure response when the valve opens and is quieter between the openings of the valve because of proper valve and cylinder sealing. The method involves comparing the signatures of the waves detected by the apparatus 100 against a baseline at the time of install to track changes. Changes can be flagged for inspection after a defined deviation from expected profiles. For example, the changes could indicate pump valve wear or cylinder leaks. Problems in this category can then be planned for maintenance before catastrophic failures occur resulting in non-productive downtime.

In another embodiment, a method for monitoring a pulsation dampener is disclosed. The method involves providing the apparatus 100, wherein the apparatus includes one or more pressure sensors mounted inside its housing. Pulsation dampeners are commonly used wherever a triplex pump discharges flow in an unsteady manner, and where the pulse is not desired for the optimal operation of the pump system. The method involves affixing the magnetic-base apparatus 100 on a top pressure port of the pulsation dampener. The apparatus 100 detects the pressure changes and generates an output signal. The output signal can be converted into a pulse stream using a conditioning circuit. The pulse stream can be configured to be representative of the working movements of the pulsation dampener. By monitoring the pulsation dampener, the pulses and therefore, the pump strokes can be detected. In lieu of the apparatus 100, other pressure detection devices can also be used such as, a pressure strap (disclosed in U.S. Pat. No. 9,746,386), strain gauges, or pressure sensors can be used to monitor pressure changes inside the pulsation damper.

The embodiments of the invention utilize acoustic, displacement and pressure measurements to monitor pump characteristics. The apparatus and methods disclosed herein do not require any interruption to production operations and there is no undue exposure to hazardous fluids. The apparatus can be conveniently mounted using its magnetic base at any desired location on the pump housing surface.

Although the embodiments are discussed with reference to monitoring pumps for the oil and gas industry, a person skilled in the art can understand that these embodiments be used in any industry that employs pumps and require the monitoring of valve and cylinder health. For example, the embodiments may also be used in refineries, chemical plants, water and waste water treatment plants, pulp and paper plants, etc.

The data from the one or more embodiments disclosed herein may be stored as computer program instructions. These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks. The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing one or more functions.

Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a non-transitory computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.

Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wired, optical fiber cable, RF, etc., or any suitable combination of the foregoing. Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages.

As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.

The Two-pump Digital Stroke Rate Meter monitors and displays the Rate and Total Strokes of up to two individual pumps simultaneously. The unit continually displays, on large easy to read, low power LCD displays, RPM, TOTAL ACCUMULATED STROKES (0-9999 total strokes) and STROKE RATE (8-350 strokes per minute) for each pump. The unit is internally powered by a battery source having an operational life of 3 years.

At Matherne Instrumentation, we"re proud to provide both our two-pump and three-pump stroke counters to companies and oilfield operators across the states of Texas, Louisiana, North Dakota, and Pennsylvania. While our offices are based in Odessa, TX; Lafayette, LA; and Houma, LA, we"re proud to serve those across the cities of Midland, TX; Houston, TX; Williston, ND; and Pittsburgh, PA. To learn more or for a quote, please feel free to give us a call today!

The pump stroke counter is used for measuring the number of pump strokes and per minute number of pump strokes (i.e. the frequency of pump strokes) of a reciprocation mud pump so to provide for the drill operators an accurate adding amount and speed of the mud to be grouted into a well shaft. It is a necessary meter in drilling process. Model BC-200A pump stroke counter comes out from improving the model BC 100 pump stroke counter, being a kind of updating and upgrading product of BC-100 pump stroke counter. Compared with BC-100, it increases a signal input channel and increases the functions of the count and accumulation of the pump strokes of a single channel, the total accumulation of the number of pump strokes, data memory when the machine is turned off, etc. Also its operation is even more convenient, simple and reliable. The totally enclosed structure, water-proof signal connectors and keys endow the BC-200A pump stroke counter with good moisture-proof and water-proof performance. After being subjected to a water-proof test for 12 hours under water with a depth of 1m, the BC-200A pump stroke counter shows so good water-proof performance that no water is found entering in. furthermore, with its overall power consumption being around 150uA, its sensor signal current around 5uA, the BC-200A pump stroke counter is actually explosion-proof, that is, it is intrinsically safe.

Rig pump output, normally in volume per stroke, of mud pumps on the rig is  one of important figures that we really need to know because we will use pump out put figures to calculate many parameters such as bottom up strokes,  wash out depth, tracking drilling fluid, etc. In this post, you will learn how to calculate pump out put for triplex pump and duplex pump in bothOilfield and Metric Unit.

Mud pump is one of the most critical equipment on the rig; therefore personnel on the rig must have good understanding about it. We’ve tried to find the good training about it but it is very difficult to find until we’ve seen this VDO training and it is a fantastic VDO training about the basic of mud pumps used in the oilfield. Total length of this VDO is about thirteen minutes and it is worth to watch it. You will learn about it so quickly. Additionally, we also add the full detailed transcripts which will acceleate the learning curve of learners.

Powerful mud pumps pick up mud from the suction tank and circulate the mud down hole, out the bit and back to the surface. Although rigs usually have two mud pumps and sometimes three or four, normally they use only one at a time. The others are mainly used as backup just in case one fails. Sometimes however the rig crew may compound the pumps, that is, they may use three or four pumps at the same time to move large volumes of mud when required.

Rigs use one of two types of mud pumps, Triplex pumps or Duplex pumps. Triplex pumps have three pistons that move back-and-forth in liners. Duplex pumps have two pistons move back and forth in liners.

Triplex pumps have many advantages they weight 30% less than a duplex of equal horsepower or kilowatts. The lighter weight parts are easier to handle and therefore easier to maintain. The other advantages include;

• One of the more important advantages of triplex over duplex pumps, is that they can move large volumes of mud at the higher pressure is required for modern deep hole drilling.

Triplex pumps are gradually phasing out duplex units. In a triplex pump, the pistons discharge mud only when they move forward in the liner. Then, when they moved back they draw in mud on the same side of the piston. Because of this, they are also called “single acting.” Single acting triplex pumps, pump mud at a relatively high speeds. Input horsepower ranges from 220 to 2200 or 164 to 1641 kW. Large pumps can pump over 1100 gallons per minute, over 4000 L per minute. Some big pumps have a maximum rated pressure of over 7000 psi over 50,000 kPa with 5 inch/127 mm liners.

Here is a schematic of a triplex pump. It has three pistons each moving in its own liner. It also has three intake valves and three discharge valves. It also has a pulsation dampener in the discharge line.

Look at the piston at left, it has just completed pushing mud out of the liner through the open discharge valve. The piston is at its maximum point of forward travel. The other two pistons are at other positions in their travel and are also pumping mud. But for now, concentrate on the left one to understand how the pump works. The left piston has completed its backstroke drawing in mud through the open intake valve. As the piston moved back it instead of the intake valve off its seat and drew mud in. A strong spring holds the discharge above closed. The left piston has moved forward pushing mud through the now open discharge valve. A strong spring holds the intake valve closed. They left piston has completed its forward stroke they form the length of the liner completely discharging the mud from it. All three pistons work together to keep a continuous flow of mud coming into and out of the pump.

Crewmembers can change the liners and pistons. Not only can they replace worn out ones, they can also install different sizes. Generally they use large liners and pistons when the pump needs to move large volumes of mud at relatively low pressure. They use a small liners and pistons when the pump needs to move smaller volumes of mud at a relatively high pressure.

In a duplex pump, pistons discharge mud on one side of the piston and at the same time, take in mud on the other side. Notice the top piston and the liner. As the piston moves forward, it discharges mud on one side as it draws in mud on the other then as it moves back, it discharges mud on the other side and draws in mud on the side it at had earlier discharge it. Duplex pumps are therefore double acting.

Double acting pumps move more mud on a single stroke than a triplex. However, because of they are double acting they have a seal around the piston rod. This seal keeps them from moving as fast as a triplex. Input horsepower ranges from 190 to 1790 hp or from 142 to 1335 kW. The largest pumps maximum rated working pressure is about 5000 psi, almost 35,000 kPa with 6 inch/152 mm linings.

A mud pump has a fluid end, our end and intake and the discharge valves. The fluid end of the pump contains the pistons with liners which take in or discharge the fluid or mud. The pump pistons draw in mud through the intake valves and push mud out through the discharge valves.

The power end houses the large crankshaft and gear assembly that moves the piston assemblies on the fluid end. Pumps are powered by a pump motor. Large modern diesel/electric rigs use powerful electric motors to drive the pump. Mechanical rigs use chain drives or power bands (belts) from the rig’s engines and compounds to drive the pump.

A pulsation dampener connected to the pump’s discharge line smooths out surges created by the pistons as they discharge mud. This is a standard bladder type dampener. The bladder and the dampener body, separates pressurized nitrogen gas above from mud below. The bladder is made from synthetic rubber and is flexible. When mud discharge pressure presses against the bottom of the bladder, nitrogen pressure above the bladder resists it. This resistance smoothes out the surges of mud leaving the pump.

Here is the latest type of pulsation dampener, it does not have a bladder. It is a sphere about 4 feet or 1.2 m in diameter. It is built into the mud pump’s discharge line. The large chamber is form of mud. It has no moving parts so it does not need maintenance. The mud in the large volume sphere, absorbs this surges of mud leaving the pump.

A suction dampener smooths out the flow of mud entering into the pump. Crewmembers mount it on the triplex mud pump’s suction line. Inside the steel chamber is a air charged rubber bladder or diaphragm. The crew charges of the bladder about 10 to 15 psi/50 to 100 kPa. The suction dampener absorbs surges in the mud pump’s suction line caused by the fast-moving pump pistons. The pistons, constantly starts and stops the mud’s flow through the pump. At the other end of the charging line a suction pumps sends a smooth flow of mud to the pump’s intake. When the smooth flow meets the surging flow, the impact is absorbed by the dampener.

Workers always install a discharge pressure relief valve. They install it on the pump’s discharge side in or near the discharge line. If for some reason too much pressure builds up in the discharge line, perhaps the drill bit or annulus gets plugged, the relief valve opens. That opened above protects the mud pump and system damage from over pressure.

Some rig owners install a suction line relief valve. They install it on top of the suction line near the suction dampener. They mount it on top so that it won’t clog up with mud when the system is shut down. A suction relief valve protects the charging pump and the suction line dampener. A suction relief valve usually has a 2 inch or 50 mm seat opening. The installer normally adjusts it to 70 psi or 500 kPa relieving pressure. If both the suction and the discharged valves failed on the same side of the pump, high back flow or a pressure surge would occur. The high backflow could damage the charging pump or the suction line dampener. The discharge line is a high-pressure line through which the pump moves mud. From the discharge line, the mud goes through the stand pipe and rotary hose to the drill string equipment.

The 2,200-hp mud pump for offshore applications is a single-acting reciprocating triplex mud pump designed for high fluid flow rates, even at low operating speeds, and with a long stroke design. These features reduce the number of load reversals in critical components and increase the life of fluid end parts.

The pump’s critical components are strategically placed to make maintenance and inspection far easier and safer. The two-piece, quick-release piston rod lets you remove the piston without disturbing the liner, minimizing downtime when you’re replacing fluid parts.

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Pump Output per Stroke (PO): The calculator returns the pump output per stroke in barrels (bbl).  However this can be automatically converted to other volume units (e.g. gallons or liters) via the pull-down menu.

A triplex mud (or slush) pump has three horizontal plungers (cylinders) driven off of one crankshaft. Triplex mud pumps are often used for oil drilling.

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