mud pump wikipedia in stock
A mud pump (sometimes referred to as a mud drilling pump or drilling mud pump), is a reciprocating piston/plunger pump designed to circulate drilling fluid under high pressure (up to 7,500 psi or 52,000 kPa) down the drill string and back up the annulus. A mud pump is an important part of the equipment used for oil well drilling.
Mud pumps can be divided into single-acting pump and double-acting pump according to the completion times of the suction and drainage acting in one cycle of the piston"s reciprocating motion.
Mud pumps come in a variety of sizes and configurations but for the typical petroleum drilling rig, the triplex (three piston/plunger) mud pump is used. Duplex mud pumps (two piston/plungers) have generally been replaced by the triplex pump, but are still common in developing countries. Two later developments are the hex pump with six vertical pistons/plungers, and various quintuplexes with five horizontal piston/plungers. The advantages that these new pumps have over convention triplex pumps is a lower mud noise which assists with better measurement while drilling (MWD) and logging while drilling (LWD) decoding.
The fluid end produces the pumping process with valves, pistons, and liners. Because these components are high-wear items, modern pumps are designed to allow quick replacement of these parts.
To reduce severe vibration caused by the pumping process, these pumps incorporate both a suction and discharge pulsation dampener. These are connected to the inlet and outlet of the fluid end.
The pressure of the pump depends on the depth of the drilling hole, the resistance of flushing fluid (drilling fluid) through the channel, as well as the nature of the conveying drilling fluid. The deeper the drilling hole and the greater the pipeline resistance, the higher the pressure needed.
With the changes of drilling hole diameter and depth, the displacement of the pump can be adjusted accordingly. In the mud pump mechanism, the gearbox or hydraulic motor is equipped to adjust its speed and displacement. In order to accurately measure the changes in pressure and displacement, a flow meter and pressure gauge are installed in the mud pump.
The construction department should have a special maintenance worker that is responsible for the maintenance and repair of the machine. Mud pumps and other mechanical equipment should be inspected and maintained on a scheduled and timely basis to find and address problems ahead of time, in order to avoid unscheduled shutdown. The worker should attend to the size of the sediment particles; if large particles are found, the mud pump parts should be checked frequently for wear, to see if they need to be repaired or replaced. The wearing parts for mud pumps include pump casing, bearings, impeller, piston, liner, etc. Advanced anti-wear measures should be adopted to increase the service life of the wearing parts, which can reduce the investment cost of the project, and improve production efficiency. At the same time, wearing parts and other mud pump parts should be repaired rather than replaced when possible.
A mud tank is an open-top container, typically made of square steel tube and steel plate, to store drilling fluid on a drilling rig. They are also called mud pits, as they were once simple pits in the earth.
The body of the tank is made by welding the steel plate and section, using the smooth cone-shape structure or the corrugated structure. The mud tank surface and passages are made of slip resistant steel plate and expanded steel plate. The mud tanks are made of the side steel pipe, all of the structure can be folded without barrier and pegged reliably. The surface of the tank is equipped with a water pipeline for cleaning the surface and equipment on the tank, it uses soaked zinc processing for the expanded steel plate. The ladder is made of channel steel to take responsibility the body, the foot board is made of expanded steel plate. The two-sided guard rails are installed the safe suspension hook. The mud tank is designed to be in a standard shanty to prevent the sand and the rain. The pipeline is installed in the tank to preserve the warm air heat.
The tanks are generally open-top and have walkways on top to allow a worker to traverse and inspect the level of fluids in the tanks. The walkways also allow access to other equipment that is mounted on the top. Recently, offshore drilling rigs have closed-in tanks for safety. The mud tank plays a critical role in mechanically removing destructive solids and sediment from costly land and offshore drilling systems.
A tank is sectioned off into different compartments. A compartment may include a settling tank, sometimes called a sand trap, to allow sand and other solids in the drilling fluid to precipitate before it flows into the next compartment. Other compartments may have agitators on the top, which have long impellers below inserting into the tank and stirring the fluids to prevent its contents from precipitating. And mud guns are often equipped at the corners of the tanks" top, spraying high-pressed mud to prevent the drilling fluids in the corner of the compartment from precipitating, typically for the square tanks.
The piping linking the mud tanks/pits with the mud pumps is called the suction line. This may be gravity fed or charged by centrifugal pumps to provide additional volumetric efficiency to the mud pumps.
Mud tanks play an important role in a solids control system. It is the base of solids control equipment, and also the carrier of drilling fluids. Solids control equipment that are all mounted on the top of mud tanks include the following:
Drilling fluids flow into the shale shaker directly after it returns to the surface of the well, and the solids that are removed by the screen would be discharged out of the tank, and the drilling fluids with smaller solids would flow through the screen into mud tank for further purification. A centrifugal pump sucks the shaker-treated fluids up to the desilter or mud cleaner for further purification. And vertical slurry pump is used to pump the drilling fluids up to the centrifuge, and a mud pump would pump the drilling fluids from mud tank into the borehole after it is treated by centrifuge and the circulation system continues.
The number of the mud tanks that are needed on the drilling rig depends on the depth of the well, and also the mud demands of drilling. Normally the shale shaker and vacuum degasser and desander are mounted together on the same mud tank as the first tank at the oilfield, while desilter and centrifuge on the second tank. Also, the drilling rig has other different tanks such as a reserve tank, emergency tank, etc.
Mud tanks are an important part in the solids control system. Based on functions, mud tanks include metering tanks, circulating tanks, chemical tanks, aggravating tanks, precipitating tanks, storing tanks, etc.
A mud motor (or drilling motor) is a progressive cavity positive displacement pump (PCPD) placed in the drill string to provide additional power to the bit while drilling. The PCPD pump uses drilling fluid (commonly referred to as drilling mud, or just mud) to create eccentric motion in the power section of the motor which is transferred as concentric power to the drill bit. The mud motor uses different rotor and stator configurations to provide optimum performance for the desired drilling operation, typically increasing the number of lobes and length of power assembly for greater horsepower. In certain applications, compressed air, or other gas, can be used for mud motor input power. Normal rotation of the bit while using a mud motor can be from 60 rpm to over 100 rpm.
Normal mud motor construction consists of a top sub, which connects the mud motor to the drill string; the power section, which consists of the rotor and stator; the transmission section, where the eccentric power from the rotor is transmitted as concentric power to the bit using a constant-velocity joint; the bearing assembly which protects the tool from off bottom and on bottom pressures; and the bottom sub which connects the mud motor to the bit.
A mud motor is described in terms of its number of stages, lobe ratio and external diameter. Stages are the number of full twists that the stator makes from one end to the other and the lobe ratio is the number of lobes on the stator, to the number of lobes on the rotor (the stator always has one more lobe than the rotor). A higher number of stages indicates a more powerful motor. A higher number of lobes indicates a higher torque output (for a given differential pressure), a lower number of lobes indicates a reduction in the torque produced but a faster bit rotation speed.
The use of mud motors is greatly dependent on financial efficiency. In straight vertical holes, the mud motor may be used solely for increased rate of penetration (ROP), or to minimize erosion and wear on the drill string, since the drill string does not need to be turned as fast.
The majority of mud motor use is in the drilling of directional holes. Although other methods may be used to steer the bit to the desired target zone, they are more time-consuming, which adds to the cost of the well. Mud motors can be configured to have a bend in them using different settings on the motor itself. Typical mud motors can be modified from 0 degrees to 4 degrees with approximately six increments in deviation per degree of bend. The amount of bend is determined by rate of climb needed to reach the target zone. By using a measurement while drilling (MWD) tool, a directional driller can steer the bit to the desired target zone.
The PCPD stator, which is a major component of the pump, is usually lined with an elastomer. Most of PCPD pump failures are due to this elastomer part. However, the operating conditions
The mud motor may be sensitive to fouling agents. This means that certain types of drilling fluids or additives may ruin the motor or lower its performance. One particular example, as mentioned above, would be the use of oil based mud with the mud motor. Over time the oil degrades the elastomers and the seals in the motor.
Electronic Pump Stroke Counters are a vital part to any drilling rig operation. When a mud pump is in operation, the driller must know how much mud is flowing down hole in order to keep the operation running at peak efficiency. Pump stroke counters assist the driller by measuring the mud pump’s strokes per minute and total strokes. So, how does a pump stroke counter tally the mud pump’s strokes
Electronic Pump Stroke Counters are a vital part to any drilling rig operation. When a mud pump is in operation, the driller must know how much mud is flowing down hole in order to keep the operation running at peak efficiency. Pump stroke counters assist the driller by measuring the mud pump’s strokes per minute and total strokes. So, how does a pump stroke counter tally the mud pump’s strokes, and why it is important? In order to understand that, you’ll need to know some basic information about mud pumps.
Knowing how a mud pump functions is important in understanding the role a pump stroke counter plays in rig operations. Mud pumps act as the heart of the drilling rig, similar to how our heart works. Just as our heart circulates blood throughout our bodies, a mud pump circulates essential drilling mud down the hole and back up to the surface. Mud tanks house drilling mud, and a mud pump draws the fluid from the mud pump. A piston draws mud in on the backstroke through the open intake valve and pushes mud through the discharge valve and sends it towards the rig. By circulating fluid, the mud pump ensures that the drill bit is cool and lubricated and that cuttings are flushed from the hole. The two main kinds of pumps used are duplex and triplex pumps, where the duplex pump has two pistons and the triplex pump has three. Whether the rig is using a duplex or triplex pump, it is important to know how many strokes per second the pistons are moving. The driller monitors strokes per minute to determine how much costly, yet essential, mud is being pumped into the system with the use of a mud pump stroke counter system. Now, that you know about mud pumps, you’ll need to know what’s in a stroke counter system.
Stroke Counter — The stroke counter stainless steel box is mounted on the driller’s console and is either square or rectangular in shape, depending on the number of pumps it is monitoring. Stroke counters will show strokes per minute and total strokes, and when a particular mud pump is operating the strokes/minute and total strokes will be displayed. Power is supplied by a 3.6 volt lithium battery, and the counter contains a crystal-controlled real time clock with 100 parts per million accuracy or better. Each counter is mounted to the console with 1/4” stainless steel hex head bolts, lock washers and nuts.
Micro Limit Switch — The micro switch is connected to a c clamp near the mud pump piston. The micro switch stainless steel rod (sometimes called a whisker) sticks out in the piston housing near the piston. As the piston passes the rod, it moves the rod and the switch sends an electronic signal back to the counter. The counter increases by one each time the piston moves the rod, counting the mud pump’s strokes. The switch’s signal is then transmitted to the stroke counter. These micro switches are built to stand up to demanding outdoor conditions. They can withstand shock, equipment vibration, extreme temperatures, water and dust.
Cable and Junction Box – A cable is connected to the back of the pump stroke counter and then to the junction box. From the junction box, the cables travel to the limit switches.
Pump Stroke Counters are like a blood pressure machine. Each time our heart pumps, a blood pressure machine reads our systolic and diastolic blood pressure by way of our pulse. A mud pump stroke counter functions in much the same way. Just as a blood pressure machine detects our pulse so too does a limit switch rod detect the movement of the piston. When the stainless steel rod is moved, the micro limit switch detects the movement. The signal is sensed as a contact closure, and it is transmitted to the stroke counter where the contact closure is converted to a logic pulse. The pulse feeds two separate circuits. The total strokes circuit reads and displays the closures one at a time, totaling them up to reveal the total strokes in the LED window. The second pulse is sent along a separate circuit which is a rate circuit. This rate circuit will average the closures against the real time clock. The result is displayed as the total strokes per minute.
Pump stroke counters are essential to drilling rig operations because they measure the efficiency of mud pumps. Knowing strokes per minute and total strokes of the pistons helps the driller to determine if the correct amount of mud is going down hole. Having this information aids in running a drilling rig at peak efficiency, assists in extending drill bit life, and avoids costly overuse of drilling rig mud. Unsure which pump stroke counter is right for your application? Give our friendly, knowledgeable staff a call or email. We’ll keep you turning right.
An artificial lift system that is powered by injected fluid (usually water), that powers a pump similar to the rotating pump used in electrical submersible ...
FET manufactures a full range of valves and seats for every drilling and well-servicing application as part of our full line of Osprey® mud pump system solutions. All of our valves and seats can be used in water, water base, oil base and synthetic base mud applications. FET offers additional valves and seats not listed below, including drilling valves, frac valves and well service valves. FET’s QC standards for the dimensional and material specs are extremely rigid in comparison to other manufacturers. Contact your FET representative to learn more.
In 1845, the French engineer Pierre-Pascal Fauvelle (1797-1867) drilled successfully a water well in Perpignan, France, depth 718ft by using for 54 days a water-flushed set of tools, and this is credited as to have been the first likely predecessor (a hydraulic drill, patented in 1845 in France, and in 1846 in Spain) of all our modern rigs as far as the utilization of drilling fluids is concerned. In 1833, Fauvelle matured first the idea while was observing a well being bored by the percussion method of the time; the tool struck water, which spouted with great force up around the drill, and Fauvelle noticed the gusher of water bringing cuttings to the surface. He designed a set of tools, possibly aided by some designs developed by the British Robert Bear who patented a similar system but never put it into practice. His equipment consisted of a hollow boring rod, formed of wrought iron tubes screwed end to end; the lower end of the hollow rod is armed with a perforating tool; the diameter of the tool is larger than the diameter of the tubular rod, in order to form around it an annular space through which the water and excavated material may rise up. The upper end of the hollow rod is connected with a force-pump by jointed or flexible tubes. This boring tube may be either worked by a rotary movement with a turning handle or by percussion with a jumper. Fauvelle used his equipment to drill water wells, and it was not until many years later that it was used to drill oil wells. The only fluid used was plain water, no one thought at the time of mixing clay or other substances with the water to make a muddy fluid; but, undoubtedly, Fauvelle proofed and popularized the basic principles for the development of the drilling fluid technology. After him, drilling fluids were used around 1850 in the percussion drilling technique in order to suspend the cuttings.
In the United States, in 1857 a patent was issued to an inventor named Bowles for a drilling system which employed reverse or jetty circulation. This method employed a hollow drill stem, but instead of pumping the water down the inside of the hollow stem and allowing it to return to the surface outside the stem, the principle was reversed: the water was pumped down the borehole and came back up through the hollow stem. After Bowles, the reverse circulation drilling
Afterwards, almost nothing was done in the petroleum drilling concerning fluid applied to boreholes. On the other hand, the concept was applied success in the mining industry - from which came many of the petroleum industry best professionals. For example, the diamond drill system developed by Rodolphe Leschot, French engineer, in 1863 was receiving increased attention during the 1870"s. According to the patent (July 14, 1863 US Patent 38235), his device included a small water pump to remove the rock cuttings and dust, as well as to cool the core barrel. The fluid used was water. This machine used a tubular boring rod with a water-swivel attachment at its upper end and a diamond studded bit on the lower end; a constant stream of water was forced down the boring rod and came up outside the rod to the surface.
Meanwhile, Fauvelle"s early success had remained almost forgotten in the literature of engineering by petroleum drillers. Development of these devices continued throughout the late 1800s that were capable of drilling to around 6000 feet. However, most of this mud assisted drilling was used in mining operations, not for petroleum. In the 1870s-1880s few European drillers were experimenting improved versions of the Fauvelle technique in the petroleum fields. The first known successful use of the water-flush system in drilling for oil was that of a well drilled in Pechelbronn, Alsace, in 1881. About this same time, the Nobel brothers used the Fauvelle method while drilling in the Russian petroleum fields at Baku, Absheron Peninsula (modern-day Azerbaijan). Prior to 1876, when steel drill-stem pipe was introduced, drillers had difficulties with their drill-stem bursting under the continued pressure required to inject the waters. The pumps supplying water did not operate continuously, and it was necessary to stop the drilling every two feet of depth and started the pumps to let the circulating water wash away the cuttings.
It was during the 1880s that well drillers apparently first became aware of the value of mud as a drilling fluid. One of the first records is the 1887-1890 work developed and eventually patented by M. T. Chapman who mentioned the use of a "stream of water and a quantity of plastic material, whereby the core formed in the casing will be washed out and an impervious wall be formed along the outside." This concept represents the beginning of the modern science of drilling mud engineering. Fauvelle and the diamond drill system concerned the use of water to flush cuttings to the surface. Chapman also discussed use of several additives to sustain the building of a lining for the walls of the hole like clay, bran, grain, and cement.
In 1889, the Austrian-born engineer Albert Fauck (his name is known in the U.S. drilling sector with numerous inventions since the 1870s) was introducing his improved type of percussion drill which use used a master flush method. The bit was built in two sections, on a telescoping principle: water was pumped down the hollow drill-stem and returned bearing the cuttings to the surface. Its principal advantage was its speed of action since it could operate at the speed of 250 stokes per minute - it was called the Fauck Express.
In the 1890s the ground was ready to bring the fluid-flushed rotary drilling system to its climax. In June, 1899, Anthony Francis Lucas (1855-1921), a mechanical engineer born Antun Lučić in Split, Austria-Hungary (modern-day Croatia), arrived in Beaumont, TX and leased land on which he proposed to drill for oil. His crew, composed by veteran drillers experts, a rotary system and was already acquainted with the utilization of drilling fluids to bore for water. On October 1900, they started drilling and soon hit quicksand, and thickened the fluid with clay (high ground plasticity Pretty difficult the stabilization of the borehole). The site produced muddy fluid which promptly lined the hole, sealed off the quicksand, and solved the problem. At the start of drilling, the circulating fluid was used intermittently: the crew stopped the rotary drill at regular intervals to allow the pumps to send down fluid to bring up the cuttings. As they went deeper and struck gas pressures, they put the pumps on continuous service. On January 10, 1901, with the drill down 1,040ft (317m), oil was found. This is acknowledged to be the first massive oil discovery (pivotal for the beginning of the modern petroleum industry of Texas) achieved applying mud fluids to rotary drilling – the system than along the 20 years to come would have made the about 80% of the petroleum drilling in the world.
Rotary applications soon confirmed that drilling mud density improved the borehole stability and was fundamental for the hydraulic control of the well. In the 1920s the use of regulating mud density by barite became standard, and in the 1930s bentonite was identified as the most convenient viscosizing material. The first additives to control viscosity (phosphates, tannin, etc.) came into use in the same years, together with the standardization of both field and laboratory rheological measurement. Oil-based mud was also developed, and in 1938 a well was drilled by means of air as drilling fluid; however, this technology did not come into regular use until the 1950s, together with foam or aerated mud applications. In rotary drilling - a nearly continuous process - cuttings are removed as drilling fluids circulate through the bit and up the wellbore to the surface. Along the years, the expression drilling fluid was assimilated in the one drilling muds, since the fluids utilized were increasingly - then, totally - semiliquid-plastic compound of water mixed with sands, clays, cements, and/or several other substances. Today, muds
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