preventative maintenance for mud pump for sale

Pumps are often designed to operate at a single point known as the Best Efficiency Point (BEP). As components begin to wear, a pumps performance begins to decline, with operation away from this point leading to issues such as accelerated bearing or seal wear, vibration, excess temperature rise or cavitation. Quite often declining performance can start gradually, before quickly accelerating until failure if performance issues are not addressed in a timely fashion.

Corrective Maintenance is undertaken when failure has occurred. The unit may be leaking, efficiency reduced, pump stopped or motor tripped, leading to loss of production resulting in an urgent situation where parts must be sourced and fitted quicky.

Preventative Maintenance is inspection and repair scheduled at specific intervals (daily, weekly, monthly, yearly) or based on the number of hours run. Visual inspections are made externally and internally by dismantling the unit, replacing seals such as gaskets and mechanical seals, with pump parts checked for wear.

Differential Pressure:Check the operating pressure by calculating the difference between the inlet and outlet pressure of the pump ensuring it is operating on curve.

Mechanical Seal (barrier fluid) – Check for contamination such as changes in general colour or appearance, PH, presence of particles, viscosity, or if fluid is at excess temperature during operation.

The “6 to 1 Rule” discovered by John Day Jr, (Manager of Engineering & Maintenance at Alumax South Carolina stated that the ideal ratio of Proactive Maintenance (PM) to Corrective Maintenance (CM) should be 6 to 1 - 6 PM checks to 1 RM check. If your ratio is below this then according to his theory it is being inspected too infrequently, above and inspections are too frequent.

Although Proactive Maintenance can seem to avoid the urgent costs and downtime associated with reactive maintenance, PM maintenance costs can be high due to the cost of labour in dismantling of complicated designs such as Progressing Cavity, or Triplex Plunger pumps which are often time consuming to maintain with more than one person required to undertake work.

On dismantling units, some seals require replacing regardless of condition, and excess spares can be required in case of gasket entrapment during assembly. Rental of specialist lifting equipment may be required and there can be situations where when inspected, pump parts do not require replacement.

MonitoringThe ideal situation is to ensure components are replaced before failure but not so far in advance that they have experienced little wear with valuable time spent on inspecting components which are otherwise fine.

This can be achieved through a monitoring device, where when the right data is collected, pump failure can be anticipated between 3 and 12 months in advance with an 80-95% accuracy.

With the average lead time on DN100 pumps, and units over 5 years old being 3 months or more, it is essential that spares are either on the shelf or failure is anticipated through advance ordering.

Monitoring devices can vary significantly in capability, and should provide the following to ensure failure can be forecast with sufficient time to plan:

Sample Length – Long sample lengths ensure data is captured for sufficient time to detect issues. A long sample length for fast rotating equipment is 22 Seconds (at 48Khz) or 110 seconds for slowly rotating equipment ensuring a detailed overview is provided.

AI Forecasting –Forecasting data within trends enables machine health forecasting. This allows advance repair decisions to be made, budgets forecast, correct resource allocation and enable stress reduction within supporting teams.

There are hazards during any maintenance activity. Always ensure the correct PPE is worn before attempting repair, that sufficient expertise is on hand and chemical data sheets of any fluid being pumped are checked prior to undertaking work. A full risk assessment should be completed in advance.

Hazardous FluidsIrritation, Chemical burns, ignitionEnsure when pump is opened the unit is cool, not pressurized, ignition sources are not present, and any fluids spilt are contained.

If inspection has been neglected for some time, then additional parts may require replacing than had the unit been inspected earlier, with some pump parts becoming beyond economical repair.

Enables planned work to be undertaken during lower activity levels and at lowest cost & risk.Pump has to be crucial within a process or above a certain size for monitoring to be cost effective

Thread Sealant –The use of semi-permanent thread sealant will ensure vitality important threaded fasteners such as bolts or screws on shafts, couplings or pump casings do not self-loosen due to vibration and become disengaged.

Interchangeable Spares –Our range of pumps are modular in design utilizing interchangeable spares, meaning on site stock holding of parts can be reduced by up to 80% further reducing slow moving stock.

Repair & Replace –Choosing to repair an existing pump within a process of vital importance, as well as replace, is a strategy we recommend for maximizing plant efficiencies and reducing downtime. Should unexpected pump failure occur, your process can be restored quickly.

Checklists & Logs –The use of checklists and logs ensures a fully repeatable process ensuring important maintenance intervals are not missed. Logs can provide valuable insight and reveal a pattern before failure occurs enabling easier troubleshooting.

indicates which areas should be checked, but note that a units maintenance routine is dependent on several factors such as hours of operation, duty, aggressiveness of pump medium, rpm of motor, temperature, inlet conditions and location of equipment.

As it is the case with most equipment, pumps require regular maintenance to keep within peak performance benchmarks. The benefits of preventive maintenance in the HVAC industry have proven to improve asset life cycle, boost CRM, cut excessive repair costs and reduce unplanned equipment downtime.

When talking about pump failure the best remedy is having a great schedule and maintenance checklist in place. In a pump’s life cycle, environmental conditions can often be a major factor in its performance. Some other important maintenance tasks and factors to consider include:

All of these issues can be detrimental to a pump’s performance and cause defects if not resolved with regular maintenance. When considering what to include in your regular maintenance checklist a great place to start is the warranty and manufacturer standards as per pump type. Pump manufacturers often set requirements to follow to ensure the best life cycle for your equipment.

Pump efficiency point is the result of hydraulic, mechanical and volumetric parts to ensure performance is within a desired level. The level of efficiency in a pump is drawn from the units of energy that is required for performance.

However in centrifugal pumps, the inner workings of the pump will drive the motor. Essentially this means the mechanical energy is transformed to hydraulic energy and electrical energy is transformed to mechanical energy. This means that for a centrifugal pump you will find your level of efficiency sits at either 75% or higher in larger pumps and around 60% in smaller pumps.

As a part of your work order management for your pump maintenance schedule, you need to do some research behind what factors you need to consider that will be most detrimental to your pump’s health. When you create your ultimate guide to maintenance, your aim is to reduce your unplanned downtime and improve your standard of service by keeping a regular schedule.

When trying to determine the frequency of your maintenance checklist, you need to consider the factors that will impact your pump listed in the beginning of this article. If you have a higher quality pump that is used every day and is largely impacted by elemental factors, you will need to have more regular services in place. The warranty and safety standards will also have an impact here, depending on your pump type and according to the manufacturer’s instructions.

The more thorough your maintenance is, the better service you can provide. While a large maintenance schedule can seem daunting to your maintenance team, the assistance of checklists can ensure no step is missed no matter how big or small. Having a checklist in place will also provide consistency across your team and ensure each pump may receive the correct care it needs.

The main area for concern in centrifugal pumps is the lubrication. As centrifugal pumps rely heavily on correct lubrication to work, maintenance is important to ensure pumps aren’t under or over lubricated, which can cause damage. When you have over lubrication your pump will create too much heat and can result in frothing the oil.

When considering your lubricant level and bearings you also need to consider what oils to use. Try to use non-detergent and non-foaming oilsfor the best performance. In your bearings you want to avoid using different variations and types of oils that can be varying in consistency and can affect performance.

Getting your maintenance plan right means you consider all these above factors and are able to incorporate them into your pump checklist and schedule.

For this checklist, you want to schedule a quick inspection of your pumps to avoid damage and wear. The main reason for having a daily checklist in your schedule is to catch those pesky issues that can turn into defects and pricey repairs if not caught early on.

Generally your quarterly maintenance will be done with the change of the season and can include varying tasks due to elemental factors. The severity of your pump environment will also affect the consistency and schedule of your pump maintenance program. Will your pump be exposed to extreme heat or extreme cold temperatures?

In your annual preventive plan, you will generally go into more detail and evaluate pump performance. Each year you should take a record of your annual operations and benchmarking data that might include:

For your routine maintenance schedule for your centrifugal pumps you need to make sure you have a solid system in place where you can reliably plan and train your team. Having a great software in place will also give you the ability to structure your maintenance program according to the manufacturer’s instructions and adhere to your customer contracts.

Job management software like FieldInsight gives you the ability to keep your centrifugal pump maintenance in perfect balance. With FieldInsight, you also gain access to the five primary automations in your business:

To reduce the stress in your scheduling system and improve your maintenance program, book a free demo today and find out what FieldInsight can do for your business.

Book a Demo. You’ll be in touch with an automation expert who has worked in this space for over 5 years, and knows the optimal workflow to address your needs.

The maintenance checklist, implemented a few months ago, covers equipment to monitor on a daily, weekly, and monthly basis. An area is devoted to tracking service truck miles, rig miles and hours, as well as welder hours to know when an oil change is needed. The goal is to not let any maintenance task fall by the wayside.

“It’s kind of brought about them (drilling crews) thinking of other things, recognizing other things, and having a mindset towards maintaining their equipment,” says Baker, owner of Apex Drilling LLC in Burley, Idaho, “and that’s the most important thing—having that mindset towards maintenance.”

Baker, president of the Idaho Ground Water Association, worked as a maintenance mechanic for nearly nine years at a potato processing plant before entering the water well industry. He worked at the plant under the supervision of a 20-year Air Force veteran who previously was a maintenance manager of intercontinental ballistic missile sites in the Midwest. Baker credits those years for helping him get keyed in on being proactive with equipment maintenance.

“I learned a lot about preventative maintenance and things you start looking for,” Baker says. “If you know about some of these small things before they become big things, then you don’t have downtime on the jobsites.”

Months into implementing the maintenance checklist, Baker is seeing his drill crews take ownership by noticing minor issues on their four drill rigs and making note of them. The crews then look at the list and fix the issues during half a day in the shop while they’re in between jobs, or at a jobsite when time allows for it.

Factoring into the maintenance of his equipment is the fact that Baker is using a higher-grade oil and additives package rather than what the manufacturer recommends. Also, every 200 to 300 hours of use, he has equipment oil samples (engine, hydraulic, and compressor oils) sent and analyzed by a lab in Salt Lake City, Utah. The lab runs an International Organization for Standardization (ISO) cleanliness analysis and designates a code to how clean the oil is and the results dictate when Baker needs to change the oil in his equipment.

The lab analysis, Baker says, provides a clear indication as to whether filtration is working properly, and if therefore, the oil is clean. Conversely, it indicates when a change might be necessary.

“Hydraulics, pumps, and motors have an ISO cleanliness code on the oil,” Baker explains. “If you run that hydraulic system within that cleanliness code at 70 degrees in a controlled environment, you’re going to get 10,000 hours out of your pumps.

“When putting the pumps on mobile equipment, it cuts it in half, so you get 5000 hours on pumps because they’re working in the extreme heat, cold, and dirt. As long as you maintain that cleanliness code in your oil, you can expect 5000 hours, but as soon as you go one code dirtier in your oil, you cut that in half. If you can operate one code cleanlier you can double it, and so we’re trying to operate in a manner that is not necessarily normal in an effort to try and get our equipment to last longer. Ultimately, it reduces our cost of maintenance.”

“When you put new bearings in and you’re running it, you’re going to see zinc in your oil, just a little bit all along and then you’ll see copper,” he says. “When you see copper, you know you’ve worn through the zinc. Then you watch it, and when it wears through the copper and starts showing up with brass in the oil, you know you’re ready for an engine overhaul.”

“The biggest thing—yes, it pushes out the engine overhaul timewise,” Baker says, “but it’s that it gives you a heads-up that it needs an overhaul before you’re on a well and you’ve got tooling 300, 400 feet down in the ground and all sudden you have an engine breakdown. If I know my engine needs rebuilt and is still running, after this job, we’re going to bring it in and do an engine overhaul. It’s on scheduled downtime and the other rigs are filling in the gaps.”

Beinhower Bros. Drilling Co. in Johnstown, Ohio, began using an oil sampling system when it purchased its 2018 GEFCO 40K. The company initially conducted oil sampling for warranty purposes, but it has continued to sample and monitor its equipment fluids.

“Typically before, the service interval would be based on hourly usage,” explains Nic Sprowls of Beinhower Bros. Drilling, “whereas with sampling, I have a better idea on how to gauge when to perform service. I feel it maximizes the life you get out of each fluid and doesn’t allow you to change too early or wait too long.

“Where I would’ve normally gone by footage drilled before doing this simple task, I’ve since changed to every use,” Sprowls says. “That simple change because of sampling saved a costly repair down the road. Every rig is different to where the sampling will give you an idea of what your rig needs.”

Sprowls, president of the Ohio Water Well Association, also shared how hydraulic oil in the GEFCO 40K came back with elevated metal content. He says nothing indicated that the hydraulics were acting up, but the oil sample prompted further investigation which revealed a hydraulic pump failed prematurely.

“I’ve heard most of them will do oil sampling,” he says. “If their rig manufacturer or rig mechanic knows of a place to get this done, it works well for us to have results go to them also. If they get this far with it, definitely consult the operator on their thoughts. It’s only as effective as the person taking the sample.

Sprowls stresses that maintenance needs to be intentional where time is made for it. He makes a point that being proactive is less stressful than reacting to an engine replacement in a customer’s front yard. After all, it’s much easier to work on the machines in a climate-controlled shop or gravel lot with no mud.

“What I’ve done for routine items is put a value on them that is relevant to our industry,” he shares. “Most drilling is accounted for by the foot, so I will analyze what kind of drilling I’m doing and put a footage on it. For example, I grease the rig every so many feet of overall drilling. If I’m mud drilling, the mud pump and swivel get greased very well, no matter the footage. Air drilling may be more frequent on the swivel due to the temperatures.

“Some items I track are hydraulic pressures, oil changes, and even if the design of a pipe wrench gets changed,” he says, because “the more you write down the better. Time gets away from us so fast, you’d be surprised at what gets written down and forgotten about.”

“The main reason Layne is dedicated to a robust equipment inspection/maintenance program is the safety of our employees,” Snelten says. “If we can keep our equipment safe to operate, it reduces the hazards to our employees and helps prevent injuries. They go home to their families at the end of the day in the same condition they came to work.

“We’ve made incredible strides in our safety performance over the past four years, and we see equipment maintenance as a required component to our continued safety evolution to not just maintain industry leading safety performance, but achieve true world-class safety.”

Beyond improved safety, Layne sees additional benefits of an aggressive maintenance and repair program achieving increased employee engagement, client appreciation and recognition, decreased maintenance costs, decreased downtime, increased productivity and profitability, and differentiation from the competition.

Layne rolled out a new maintenance program in 2021 for its several thousand pieces of equipment—drill rigs, pump rigs, trucks, trailers, and support equipment—and for the roughly 350 field staff who operate them.

“We’re showing our crews that we care about their safety by caring for our equipment. We’re showing our clients that we care about our equipment and our people and making sure that their projects are completed in a safe and efficient manner,” says Snelten, chair of the NGWA Government Affairs

The program consists of daily, monthly, and annual inspections of the drill rigs, pump rigs, and service trucks. Inspection items include fluid levels, wire ropes, sheaves, frame welds, controls, emergency stops, etc. A copy of the inspection goes to the field superintendent and mechanic and repairs

The program also presents Layne with information to determine action steps for a piece of equipment. If a piece of equipment continues to have persistent maintenance issues, and its records show maintenance costs are excessive, the question becomes: Is it better to perform a mid-life rebuild where another seven to 10 years can be gained, or is it better to replace it?

“Find what works for your business and your equipment and keep working at it. Will it take money? You bet it will. But at the end of the day, it’s the right thing to do for employees to provide them with safely operating equipment. Your customers will thank you also when you don’t leave an oil bloom on their driveway or yard.”

The best safeguard against unplanned shut-down or system failure is a good preventive maintenance plan. Cat Pumps triplex pump design offers easy maintenance without the use of special tools, making routine maintenance achievable without difficulty. Every installation differs, so a unique maintenance schedule may be required.

The service life of pumps and wear parts vary by application based on duty-cycle, pumped liquid, temperature, inlet conditions, location of installation and system accessories. It is important to monitor the system carefully. At the first sign of low pressure, make a thorough system examination. Low pressure may be caused by system components other than the pump, such as:

Please consult the pump Data Sheet, Service Manual or Service Video to verify service procedures. If no problems are found with the system components, shut the system down and inspect the pump. Check for contamination in valves. Change seals and record hours for your preventive maintenance schedule. Typically valves should be replaced at every other seal replacement.

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We don"t stop once we sell our equipment... Fischer Process Industries offers full-service repair and reliability programs for pumps and related rotating equipment, valves, and instrumentation. Our degreed Reliaibility Engineers will work with your plant to design a comprehensive program using the most up-to-date software to monitor and support your rotating equipment and other equipment assets to ensure 100% uptime, zero percent unplanned downtime, and eliminate rework and lost time.

Fischer"s well-trained and certified technicians are experienced in pump and process equipment service repair and fabrication. We offer 24 hour emergency field repair services as well as on-site repair of pumps and rotating equipment, valves, instrumentation, and general process equipment. We specialize in the repair of any brand of centrifugal pumps, gear pumps, rotary lobe pumps, air operated diaphragm pumps, small triplex piston pumps, mechanical seals, centrifugal blowers, and vertical turbines. In addition, we are a factory authorized repair shop for Carver, Fybroc, Gorman-Rupp, Nikkiso, Kontro, Liquiflo, Sundyne, Sunflo, Versamatic, Waukesha, and Yamada pumps.

Certified as valve assemblers of Dynatec, Flowserve (Worcester, McCanna), Jarecki, and Kace equipment, we also offer complete rebuilding and refurbishment of existing equipment or redesign of equipment and systems to increase performance or efficiency. Our in-house services include high quality OEM or equivalent replacement parts, pump upgrades, retrofitting, machining, milling, turning, drilling, pressing, duty certification, testing, sand blasting, epoxy coating, and technical support. Our comprehensive field services include emergency response, performance evaluations, mechanical repairs, total asset management, preventative maintenance, extended warranties, and pick-up and delivery.

Most industrial facilities have hundreds if not thousands of pieces of critical equipment. Much of this equipment runs reliably for many years between overhauls and some equipment fails often and repeatedly. The key to reducing lifecycle cost is to understand equipment by:

With this information, we can pinpoint the most unreliable plant equipment, justify improving based on cost and eliminate its underlying root causes of failure to extend its life between overhauls.

Many things go into getting the most life out of your mud pump and its components — all important to extend the usage of this vital piece of equipment on an HDD jobsite. Some of the most important key points are covered below.

The most important thing you can do is service your pump, per the manufacturer’s requirements. We get plenty of pumps in the shop for service work that look like they have been abused for years without having basic maintenance,  such as regular oil changes. You wouldn’t dream of treating your personal vehicle like that, so why would you treat your pump like that.

Check the oil daily and change the oil regularly. If you find water or drilling mud contamination in the oil, change the oil as soon as possible. Failure to do so will most likely leave you a substantial bill to rebuild the gear end, which could have been avoided if proper maintenance procedures would have been followed. Water in the oil does not allow the oil to perform correctly, which will burn up your gear end. Drilling mud in your gear end will act as a lapping compound and will wear out all of the bearing surfaces in your pump. Either way it will be costly. The main reasons for having water or drilling mud in the gear end of your pump is because your pony rod packing is failing and/or you have let your liners and pistons get severely worn. Indication of this is fluid that should be contained inside the fluid end of your pump is now moving past your piston and spraying into the cradle of the pump, which forces its way past the pony rod packing. Pony rod packing is meant to keep the oil in the gear end and the liner wash fluid out of the gear end. Even with brand new packing, you can have water or drilling fluid enter the gear end if it is sprayed with sufficient force, because a piston or liner is worn out.

There is also usually a valve on the inlet of the spray bar. This valve should be closed enough so that liner wash fluid does not spray all over the top of the pump and other components.

Liner wash fluid can be comprised of different fluids, but we recommend just using clean water. In extremely cold conditions, you can use RV antifreeze. The liner wash or rod wash system is usually a closed loop type of system, consisting of a tank, a small pump and a spray bar. The pump will move fluid from the tank through the spray bar, and onto the inside of the liner to cool the liner, preventing scorching. The fluid will then collect in the bottom of the cradle of the pump and drain back down into the collection tank below the cradle and repeat the cycle. It is important to have clean fluid no matter what fluid you use. If your liners are leaking and the tank is full of drilling fluid, you will not cool the liners properly — which will just make the situation worse. There is also usually a valve on the inlet of the spray bar. This valve should be closed enough so that liner wash fluid does not spray all over the top of the pump and other components. Ensure that the water is spraying inside the liner and that any overspray is not traveling out of the pump onto the ground or onto the pony rod packing where it could be pulled into the gear end. If the fluid is spraying out of the cradle area and falling onto the ground, it won’t be long before your liner wash tank is empty. It only takes a minute without the cooling fluid being sprayed before the liners become scorched. You will then need to replace the pistons and liners, which is an avoidable costly repair. Make a point to check the liner wash fluid level several times a day.

Drilling fluid — whether pumping drilling mud, straight water or some combination of fluid — needs to be clean. Clean meaning free of solids. If you are recycling your fluid, make sure you are using a quality mud recycling system and check the solids content often throughout the day to make sure the system is doing its job. A quality mud system being run correctly should be able to keep your solids content down to one quarter of 1 percent or lower. When filling your mud recycling system, be sure to screen the fluid coming into the tanks. If it is a mud recycling system, simply make sure the fluid is going over the scalping shaker with screens in the shaker. If using some other type of tank, use an inline filter or some other method of filtering. Pumping out of creeks, rivers, lakes and ponds can introduce plenty of solids into your tanks if you are not filtering this fluid. When obtaining water out of a fire hydrant, there can be a lot of sand in the line, so don’t assume it’s clean and ensure it’s filtered before use.

Cavitation is a whole other detailed discussion, but all triplex pumps have a minimum amount of suction pressure that is required to run properly. Make sure this suction pressure is maintained at all times or your pump may cavitate. If you run a pump that is cavitating, it will shorten the life of all fluid end expendables and, in severe cases, can lead to gear end and fluid end destruction. If the pump is experiencing cavitation issues, the problem must be identified and corrected immediately.

The long and the short of it is to use clean drilling fluid and you will extend the life of your pumps expendables and downhole tooling, and keep up with your maintenance on the gear end of your pump. Avoid pump cavitation at all times. Taking a few minutes a day to inspect and maintain your pump can save you downtime and costly repair bills.

Our preventive maintenance program assists the rig in preventing costly downtime. Our technicians utilize custom checklists based on the OEM’s original maintenance and inspection recommendations. Each grease point, oil check or change, filter replacement or other regular maintenance activity is inspected on a monthly basis. The execution of these activities by the crew is evaluated to identify possible training needs or hands on assistance by Premium. Percentage scores are generated by the Premium checklist to rate the rig on preventive maintenance performance.

Our technicians visit each rig twice per month. During these visits, technicians will complete checks according to the checklist. Recommendations are made for the rig and maintained in a Corrective Action Register to assist the rig with integrating these tasks into period of planned maintenance. The program is customized to promote recordkeeping of preventive maintenance activities and to collect performance data on the top drive. These top drive variables can be converted into visual graphs that provide trend monitoring capability. Customers receive a monthly summary report of all rig visits, including rig scores, corrective actions, and trend monitoring charts, as applicable.

Premium Oilfield Technologies has a team of highly-trained mud pump, handling tool, and valve experts in all of the major U.S. shale areas and the Middle East. In the U.S., these professionals visit each rig every two weeks and help our customers choose the right parts for the drilling conditions and mud mixtures that they are encountering. They know which pistons and valves to recommend for water-based mud versus oil-based mud, or which parts to use in high temperature and high pressure applications. Additives to the drilling mud, such as LCM and acids, will also impact the choice of the ideal piston, liner, or valve.

Our field mechanics and technicians are trained to perform all types of pump and valve maintenance including, but not limited to, pump alignment, periodic maintenance, and equipment change-outs. If a pump is using an unusual amount of spares and expendables, often our technicians can identify adjustments to the pumps that can fix the problem. These experts are available to fly/travel anywhere in the world at short notice.

Premium Oilfield Technologies leads the industry in technology for precise alignment of the power end section of the mud pump and the fluid end section. We use a specially designed laser system for determining alignment, a method far superior and accurate than the traditional method of using uncalibrated wooden rods. Proper alignment of the pump’s crosshead to the fluid end liner is a requirement for maximizing piston and liner life. Our laser alignment inspection system takes the guesswork out of the alignment process by providing results indicating horizontal and vertical offset as well as angular misalignment – down to 0.0001".

One of the key elements to avoiding unplanned downtime is a strong preventative maintenance program supported by thorough inspections. Our Technical Services group offers inspection services as well as assistance with field and shop repairs and upgrades.

Preventative maintenance kit for the Model 1000D / SyriXus 1000x Syringe Pumps.  Includes: O-Ring - 3.109 I.D., 0.139 Cross Section (2 each) Standard replacement seal (lower) Standard replacement seal (upper)...

Both the EMP40™ and PITPUMP™ feature advanced telematics for active health monitoring in support of proactive preventative maintenance programs. The variable pump speed of PITPUMP™ allows it to work seamlessly with the smart generator architecture of the EMPOWER™ line. Current job site use has resulted in decreased fuel consumption of over 40% when the EMP40™ is used in tandem with PITPUMP™ across both entry- and exit-side operations.

Instead of using paper checklists when out in the field, drilling contractors and rig inspection services can generate a new inspection form from anywhere and the results are saved electronically.

Specifically designed for drilling companies and others in the oil and gas industry, the easy to use drilling rig inspections app makes it easy to log information about the drill rigs, including details about the drill rigs operators, miles logged and well numbers. The inspection form app covers everything from the mud pump areas and mud mixing area to the mud tanks and pits, making it easy to identify areas where preventative maintenance is needed. The drilling rig equipment checklist also covers health and safety issues, including the availability of PPE equipment, emergency response and preparedness processes, and other critical elements of the drilling process and drill press equipment.

Pumps are vital to industries including water treatment and wastewater facilities, power generation, oil and gas, food processing and more. In the oil and gas industry, the uptime of industrial pumps is especially critical. The total world consumption of global petroleum and other liquid fuels averaged 92.30 million barrels per day in 2020, according to the U.S. Energy Information Administration. That total has risen by approximately 5 million in 2021 and will continue to grow in 2022. Any unplanned downtime can impact the ability to meet this growth.

There are three basic types of pumps, and they are classified by how they transport fluid: positive-displacement, centrifugal and axial-flow. Pumps can experience several different types of failures, including cavitation, bearing failures and seal failures, among others. In oil and gas, conditions in which pumps operate are often challenging, dirty and hazardous, resulting in wear and tear. Failure of these pumps not only results in unexpected operation delays and increased costs, but it can lead to dangerous oil and gas leaks, impacting labor safety and the environment. To avoid these unexpected failures, many companies increase preventative maintenance and create aggressive inspection schedules. These practices, however, can sometimes lead to unnecessary part replacement, maintenance costs and labor.

Others may rely on condition-based maintenance, which focuses on maintenance performed after monitoring real-time data and detecting unacceptable condition levels. However, this may not come with the advanced warning needed to prevent impending failure events or avoid downtime. By taking a predictive approach, past maintenance data and current sensor measurements can be used to determine early signs of failure, allowing companies to perform maintenance only at the exact time it is needed.

Developing and deploying a predictive maintenance solution for pumps is challenging. It requires a combination of sensing and instrumentation expertise, domain knowledge, and a practical perspective on applying machine learning and analytics for predictive monitoring. The instrumentation aspect is crucial since this data will be analyzed and will serve as the foundation of the actionable information. The decisions made from this information include what maintenance actions are needed and when they should be taken given the current pump health, as well as any trends or patterns that could emerge.

Vibration is typically the most crucial signal to use for monitoring the condition of a pump, but information on the rotating or reciprocating motion is also useful, especially for performing the more advanced signal processing methods. In addition, pressure and flow rate measurements are important for understanding pump operation and providing context for understanding the vibration data. A balance must be struck between the benefit of including these important measurements versus the hardware and implementation costs of doing so. This challenge is especially true for vibration sensors. Domain expertise is needed to place a minimal set of sensors to keep the hardware cost down and monitor the pump properly and accurately.

When handling the analytics, it is challenging to apply machine learning for this application without any domain-specific preprocessing and signal processing steps. Typically, pump failures are rare, so using a supervised machine learning model is not typically practical. Instead, a combination of domain-specific feature extraction methods for the vibration signals coupled with a baseline-based anomaly index machine learning algorithm is a more reasonable approach. The deployment and user interface should be closely aligned with the industrial use case and expected user, as well as the problem being solved. For some applications, it is not feasible to transmit the data to a remote monitoring center or central server, requiring the analytics and deployment to be performed closer to the data source.

Additionally, the frequency of data collection and the speed of both the data analytics processing and the reporting of asset health information would vary based on the industrial application and use case. These aspects should be evaluated during a preproject phase. By following requirements and best practices, solution developers can formulate the appropriate approach and the solution that should be considered and ultimately implemented.

A global oil and gas contractor with a specialty in automated drilling equipment and rig components wanted to develop a health monitoring solution for its mud pumps in the field. The contractor wanted to reduce unplanned downtime and unexpected failures. Not only did the company want to prevent these failure events, but they also wanted to distinguish between anomalies caused by maintenance issues and anomalies due to sensor issues.

By working with a predictive analytics company, this client sought to differentiate these anomalies, address the pump failures, and validate the solution by utilizing the induced fault data collected on its test rig.

The user provided the analytics company with a year’s worth of historical data from test bed data sets and sensors on the piston, suction and discharge mechanisms on two pumps in the field. The team of analytics experts was able to pull crucial features from the data by considering vibration patterns in the frequency and time-frequency domain. These features were integral to the development of health assessment models. The models then helped determine key indicators of pump seal failure, as well as establish the accuracy and necessity of the sensors.

By using advanced signal processing and vibration-based pattern recognition, the health monitoring system was able to detect and diagnose pump failures. This solution provided a baseline health assessment, failure identification and pattern recognition diagnosis capabilities.

The predictive analytics company was able to identify potential issues, as well as establish the best locations for sensor placement. The final solution predicted mud pump failure at least one day in advance, providing the data needed to take action and proactively perform maintenance. This approach helped reduce downtime, increase productivity, improve safety and prevent leaks.

1.Criticality analysis is essential in order to select the pumps for which predictive maintenance solutions can best be applied and to choose a solution that can provide the most value.

2.After determining the target pumps, the most critical failure modes should be identified, along with any relevant maintenance records for unplanned and planned downtime.

4.Based on the data and common failure modes, determine sensor placement and what, if any, additional sensors need to be added to the monitored pumps for the predictive solution.

These initial steps are essential when partnering with a technology provider and can help companies develop and adopt a predictive maintenance solution for their pumps that is robust and accurate.

David Siegel is the chief technology officer at Predictronics. He may be reached at contact@predictronics.com. For more information, visit predictronics.com.

Completed Maintenance DatabaseOnce the repair is competed the item is moved to the Completed Maintenance Database is the complete history of repairs carried out on the rig and this is the one that the client will want to see to verify the rig maintenance is up to date.

To edit or add additional checks to any of the checklists n Rig Maintenance, editing is done in the edit section and linked to the checklist. You can add to or edit any checklist in the editor.

If you have installed the PM Schedule all the rig equipment listed details will be linked in the Schedule which can be edited to reference any equipment due for scheduled checks as Daily, Weekly, Monthly Due or Completed maintenance

Set up the recommended service hours in the editor. Add the recommended service hours for each piece of equipment This section is linked to the monthly hours and the service hours. A visual warning shows if any equipment has exceeded the recommended hours At the end of the month the month hours are transferred to the monthly service hours which lists the total running hours for the month any equipment over service hours is indicated in RED Click on the cell to indicate the service has been carried out to zero the hours and start a new month’s running hours.

HENDERSON employs a highly-knowledgeable team of technicians who specialize in field services for a variety of drilling equipment. Best of all, they can perform across the board electrical and mechanical troubleshooting and repairs right there on the drill floor. In addition to providing preventative maintenance and repair services, technicians are also available for onsite installation and equipment operation training in East, West, South and Central Texas and Canada.To help you get up and running quicker, HENDERSON offers onsite support and 24/7 on-call technicians.

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

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

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

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

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

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

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

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

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

Misalignment can be detected by uneven wear on the pony (extension) rods. Premature liner wear will also be a result. Refer to the mud pump fluid end log book for signs of premature liner wear.

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

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

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

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

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

0.008 - 0.010 Okay to run untill the next annual inspection 0.011 - 0.013 Replace at the next scheduled maintenance. 0.014 - 0.016 Replace at first opportunity. 0.017 and greater Stop Pump and replace immediately.

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

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

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

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

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

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

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

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

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

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

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

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

Heavy Machinery is the most expensive construction equipment you own. It’s also the costliest to repair or replace. This guide will show you how to save money and extend the life cycle of your equipment with regular maintenance best practices.

We’ll identify commonly overlooked areas