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When choosing a size and type of mud pump for your drilling project, there are several factors to consider. These would include not only cost and size of pump that best fits your drilling rig, but also the diameter, depth and hole conditions you are drilling through. I know that this sounds like a lot to consider, but if you are set up the right way before the job starts, you will thank me later.

Recommended practice is to maintain a minimum of 100 to 150 feet per minute of uphole velocity for drill cuttings. Larger diameter wells for irrigation, agriculture or municipalities may violate this rule, because it may not be economically feasible to pump this much mud for the job. Uphole velocity is determined by the flow rate of the mud system, diameter of the borehole and the diameter of the drill pipe. There are many tools, including handbooks, rule of thumb, slide rule calculators and now apps on your handheld device, to calculate velocity. It is always good to remember the time it takes to get the cuttings off the bottom of the well. If you are drilling at 200 feet, then a 100-foot-per-minute velocity means that it would take two minutes to get the cuttings out of the hole. This is always a good reminder of what you are drilling through and how long ago it was that you drilled it. Ground conditions and rock formations are ever changing as you go deeper. Wouldn’t it be nice if they all remained the same?

Centrifugal-style mud pumps are very popular in our industry due to their size and weight, as well as flow rate capacity for an affordable price. There are many models and brands out there, and most of them are very good value. How does a centrifugal mud pump work? The rotation of the impeller accelerates the fluid into the volute or diffuser chamber. The added energy from the acceleration increases the velocity and pressure of the fluid. These pumps are known to be very inefficient. This means that it takes more energy to increase the flow and pressure of the fluid when compared to a piston-style pump. However, you have a significant advantage in flow rates from a centrifugal pump versus a piston pump. If you are drilling deeper wells with heavier cuttings, you will be forced at some point to use a piston-style mud pump. They have much higher efficiencies in transferring the input energy into flow and pressure, therefore resulting in much higher pressure capabilities.

Piston-style mud pumps utilize a piston or plunger that travels back and forth in a chamber known as a cylinder. These pumps are also called “positive displacement” pumps because they literally push the fluid forward. This fluid builds up pressure and forces a spring-loaded valve to open and allow the fluid to escape into the discharge piping of the pump and then down the borehole. Since the expansion process is much smaller (almost insignificant) compared to a centrifugal pump, there is much lower energy loss. Plunger-style pumps can develop upwards of 15,000 psi for well treatments and hydraulic fracturing. Centrifugal pumps, in comparison, usually operate below 300 psi. If you are comparing most drilling pumps, centrifugal pumps operate from 60 to 125 psi and piston pumps operate around 150 to 300 psi. There are many exceptions and special applications for drilling, but these numbers should cover 80 percent of all equipment operating out there.

The restriction of putting a piston-style mud pump onto drilling rigs has always been the physical size and weight to provide adequate flow and pressure to your drilling fluid. Because of this, the industry needed a new solution to this age-old issue.

As the senior design engineer for Ingersoll-Rand’s Deephole Drilling Business Unit, I had the distinct pleasure of working with him and incorporating his Centerline Mud Pump into our drilling rig platforms.

In the late ’90s — and perhaps even earlier —  Ingersoll-Rand had tried several times to develop a hydraulic-driven mud pump that would last an acceptable life- and duty-cycle for a well drilling contractor. With all of our resources and design wisdom, we were unable to solve this problem. Not only did Miller provide a solution, thus saving the size and weight of a typical gear-driven mud pump, he also provided a new offering — a mono-cylinder mud pump. This double-acting piston pump provided as much mud flow and pressure as a standard 5 X 6 duplex pump with incredible size and weight savings.

The true innovation was providing the well driller a solution for their mud pump requirements that was the right size and weight to integrate into both existing and new drilling rigs. Regardless of drill rig manufacturer and hydraulic system design, Centerline has provided a mud pump integration on hundreds of customer’s drilling rigs. Both mono-cylinder and duplex-cylinder pumps can fit nicely on the deck, across the frame or even be configured for under-deck mounting. This would not be possible with conventional mud pump designs.

The second generation design for the Centerline Mud Pump is expected later this year, and I believe it will be a true game changer for this industry. It also will open up the application to many other industries that require a heavier-duty cycle for a piston pump application.

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Created specifically for drilling equipment inspectors and others in the oil and gas industry, the Oil Rig Mud Pump Inspection app allows you to easily document the status and safety of your oil rigs using just a mobile device. Quickly resolve any damage or needed maintenance with photos and GPS locations and sync to the cloud for easy access. The app is completely customizable to fit your inspection needs and works even without an internet signal.Try Template

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I’ve run into several instances of insufficient suction stabilization on rigs where a “standpipe” is installed off the suction manifold. The thought behind this design was to create a gas-over-fluid column for the reciprocating pump and eliminate cavitation.

When the standpipe is installed on the suction manifold’s deadhead side, there’s little opportunity to get fluid into all the cylinders to prevent cavitation. Also, the reciprocating pump and charge pump are not isolated.

The suction stabilizer’s compressible feature is designed to absorb the negative energies and promote smooth fluid flow. As a result, pump isolation is achieved between the charge pump and the reciprocating pump.

The isolation eliminates pump chatter, and because the reciprocating pump’s negative energies never reach the charge pump, the pump’s expendable life is extended.

Investing in suction stabilizers will ensure your pumps operate consistently and efficiently. They can also prevent most challenges related to pressure surges or pulsations in the most difficult piping environments.

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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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A comprehensive range of mud pumping, mixing, and processing equipment is designed to streamline many essential but time-consuming operational and maintenance procedures, improve operator safety and productivity, and reduce costly system downtime.

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Discharge Head: This is the vertical distance that you are able to pump liquid. For example, if your pump is rated for a maximum head of 18 feet, this does not mean that you are restricted to 18 feet of pipe. You can use 300 feet, so long as the final discharge point is not higher than 18 feet above the liquid being pumped.

Suction Lift: This is the vertical distance that the pump can be above the liquid source. Typically, atmospheric pressure limits vertical suction lift of pumps to 25 feet at sea level. This does not mean that you are limited to 25 feet of pipe. You could use upwards of 300 feet of suction pipe, so long as the liquid source is not lower than 25 feet below the pump center line.

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A contractor is on the pre-qualified list to bid a project. Before the bid, he contacts a mud engineer for consultation. The geo-technical information is forwarded to and examined by the mud engineer. Together, the contractor and mud engineer put together a drilling fluids plan. The plan encompasses the entire job from rig selection, cleaning equipment, pumps, ream passes, fluid properties and pump volume targets. This plan is specific to the contractor and the proposed work.

Drilling fluid selection criteria is based upon rheological properties of the mud instead of products. The desired properties of the drilling mud — viscosity, fluid loss, gel strengths, yield point, plastic viscosity, density and sand content — are geared to the expected soil conditions. Calculations are made regarding volumes of fluid required for the project and the amounts of products needed to build the volume. Desired rheological characteristics are used in the calculations. This allows the contractor to have a firm handle on fluid costs and equipment selection for the bid.

Often, the impartial view of the mud engineer has an impact on the equipment selected. Sometimes smaller drill rigs can successfully be used to complete jobs usually done by much larger rigs, when the hole is properly developed and cared for. Schedule — an important part of any job — is reviewed by the mud engineer who has substantial field experience. He or she does not dictate anything but gives an important viewpoint for consideration. Excessive optimism, while a good character trait, does not always fit a large HDD project.

Once they are awarded the contract, another phase of work begins. Timelines and proposed scheduling drive mobilization, rigging up, drilling, reaming, pullback, rigging down and de-mobilization. An effective mud engineer will work with the project manager to set up a delivery schedule for the bentonite and polymers selected. The planned delivery schedule must be flexible and account for problems with logistics often encountered (border crossing, barging, remote location etc.). This minimizes downtime and keeps rush transportation costs to a minimum.

During the rig up, it is a great time for the mud engineer to inspect the recycling plant. Screen sizes and availability are noted, along with general observations about the recycling plant. The working knowledge of the plant allows anticipation of future problems and formulation of appropriate contingency plans. After mud up, the mud engineer performs a check on the virgin fluid. This allows a baseline to be established. A typical mud check consists of recording the Marsh Funnel viscosity, density using a mud balance, pH using test strips, hardness and chlorides using titrates, fluid loss using a filter press, 600 and 300 reading from a calibrated viscometer, yield point and plastic viscosity using the 600 and 300 readings, 10 second and 10 minute gels using a viscometer and finally sand content using a sand content kit. The values are recorded in a form useful for both the contractor and engineer.

After establishing the baseline, mud samples are checked once per hour. Sampling from the same locations provides consistent data. Cleaned fluid from the recycler and returns from the hole are tested on alternate hours. Should an area of concern or problem develop, constant monitoring between the hourly tests assist in evaluating both the cause and the solution. The hourly tests must be maintained when possible. The finished mud report is given to the project superintendent and anyone else the contractor specifies at the end of each shift. Keeping a copy of all the previous mud reports allows the mud engineer to observe previous trends and assists in predicting future developments of the drilling fluids.

Once drilling begins, the mud engineer can also assist in training the person working the recycling plant. Often it seems that inexperienced people are in charge of operating the recycling plant; assisting them with training is beneficial to the mud engineer, the contractor and the project. They can also run some of the simple tests in order to solve a problem.

Mud data is useful for things other than building and maintaining drilling fluid. As an example, if we found that the sand content on the clean fluid had been under .75 percent and it suddenly rises to 5 percent while maintaining similar characteristics of the returns, it is safe to assume we have a mechanical issue with the recycling plant. A quick check of the screens to look for a hole or pass through would be appropriate. The problem can be fixed quickly without interruption of the drilling process and loss of time.

Not fixing or knowing about the problem will lead to other problems. We start to pump more and more sand through the high-pressure pump and induce wear. We decrease the ability of the clean fluid to efficiently suspend and carry out the drilled solids. The hole is not developed properly and we risk an increase in rotary torque or drag on the drill string. As mud weight increases, the efficiency of our recycling plant will decrease unless compensations are made. This small, preventable problem cascades into a major one with significant costs attached.

Comparative data from the report gives us a snapshot about how well we are cleaning the hole during drilling and ream passes. If the yp/pv ratio is out of range and the density and sand content are high, we can slow down or increase the pump rate. The changes are made before it becomes a significant issue. Decisions about the hole are made on good scientific information. If we are drilling sand or gravel, fluid loss becomes important. Keeping the fluid loss within an acceptable range will stop us from water wetting the formation and decreasing the annular space available to flow out drilled solids.

These are just a few examples. Every single fluid characteristic described above can have an impact on your job. The craftsman you select as your mud engineer is very valuable in manipulating and controlling the relevant characteristics.

What about costs? Most of the mud engineers do charge a day rate. Prudent contractors will have an open dialogue with their chosen mud engineer. Ask questions about issues that are not clear.  Challenge the use of expensive polymers and drilling systems. If they are required, your engineer will be able to justify their use. Successful completion of the project, in a cost-effective manor, should be a priority for all parties involved. Contrast this to the what ever it costs attitude when you are stuck. Meeting or beating schedule and reducing downtime also compensate for the cost incurred. Overall, the professional mud engineer will more than pay for himself. There is no substitute for horsepower but running an efficient operation with smaller equipment can allow us to be more competitive in this environment of low dollar footage.

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Pump systems play a critical role in keeping our world in motion. However, specifying parties can often overlook opportunities to improve pump system reliability and efficiency. This can happen when designers or engineers fail to consider new demands placed on the system since installation or understand the benefits of available options. Often, the most significant opportunities missed stem from neglecting to see the big picture savings and efficiencies to be gained. When specifying a pump, whether for a new system or replacing an old one, there is certain criteria to consider. The usual checklist includes process liquid, flow, pressure, size and power, efficiency, space capacity, reliability, and cost. But there are many nuances to pump selection that can make big differences in performance, reliability, and cost-saving energy efficiencies. Here are five factors to always keep front of mind in pump selection:

No matter the application, approach the process with the notion that a pump is selected to meet system requirements, and not the other way around. Defaulting to the traditional tried-and-tested solutions may not always yield the most effective option to improve performance, efficiency, and reliability. By designing for excellence across a complete system instead of addressing challenges in silos, engineers will be better positioned to maximize the impact of any improvements.

Space availability and the pump system’s footprint are an important factor in the selection process. Given the accessible space, a frame-mounted (pump has its own bearing frame), close-coupled (motor bearings carry pump loads), or inline pump may be appropriate based on the power and speed requirements. However, these options will not have an interchangeable footprint.

Compared to frame-mounted pumps, commercial close-coupled pumps may be limited to 100 to 150 hp but offer space savings of around 20 percent. Alternatively, the use of inline pumps where applicable can dramatically reduce footprint. Similar to valves, inline pumps are designed so the flow enters and exits on a single axis, requiring minimal floorspace. As a result, inline pumps can occupy a third of the floorspace a typical frame-mounted pump occupies. So, know if space is at a premium, which pumps can help maximize it, and how those choices can impact other criteria. And remember that it’s not just about horizontal space — suitable vertical space is required, which is more important for the inline pumps that typically have a vertical motor above the pump.

Often, there is opportunity to improve performance, efficiency, and reliability of a system. For example, utilizing smart pumps that integrate a variable frequency drive (VFD) that has the pump performance programmed in from the factory, instead of retrofitting

Fouling, corrosion, and erosion of pumps and pipes over time can be attributed to biological, chemical, and abrasive factors, so understanding fluid properties can be critical to avoid failure or the need for continuous and costly maintenance. Additionally, fluid viscosity and temperature are also critical considerations in the pump selection process.

For example, positive displacement pumps are often used in the industrial and petrochemical sectors and in many applications with viscous product. These pumps come in many designs, but generally deliver consistent volume with every rotation of the shaft, efficiently handling viscous liquids and delivering a nearly consistent flow against low or very high pressures. A benefit is that adding a variable speed drive allows these pumps to be dialed into a very precise flow rate, or possibly have their flow extended to meet future system demands.

A variety of factors for different settings can affect energy savings resulting in long-term potential for significant cost savings. Upfront costs can often deter specifiers from considering overall savings throughout a pump’s lifecycle.

For a typical pumping system, 65 percent of the total cost of ownership (TCO) is related to energy and maintenance, while the initial cost only accounts for 10 percent. For example, a double-casing between bearing multistage pump (BB5) will cost more than an axially split multistage pump (BB3), but the BB5 is designed for high reliability in high pressure and temperature applications. Trying to reduce cost upfront by extending the pressure and temperature range of the BB3 pump could result in a much higher TCO due to maintenance costs. Enhancing the energy efficiency of pumps can also go a long way to save on utilities. To help identify the most efficient pump for the system requirements, the Hydraulic Institute (HI) offers an Energy Rating Program for select pump types below 200 hp. Further details can be found at pumps.org/energyefficiency.

The Hydraulic Institute (HI) centers the pump industry around excellence and efficiency to power everyday life. HI’s mission is to advance the pump manufacturing industry by becoming the world’s resource for pumping solutions and advancements in the industry by: Addressing Pump Systems, Developing Standards, Expanding Knowledge and Resources, Educating the Marketplace, and Advocating for the Industry.

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Knowing the liquid that you are pumping is vital as it allows us to ensure that we offer a pump constructed from compatible materials; thus avoiding potential corrosion and abrasion issues. What is the chemical make up? Are there any solids present, if so what is the maximum particle size and concentration?

The pressure at the inlet and outlet of the pump will determine the type and often the size of pump required. Knowing the pressure you are pumping against allows us to select the most suitable pump technology. If you are unsure of your differential pressure; we can help to calculate it

There are many units of measurement for viscosity however we tend to work in centipoise cP or centistokes cSt. Viscosity is a measure of a liquid’s resistance to deformation caused by stress, or more plainly; the ‘thickness’ of a liquid. Viscosity is typically higher for thicker liquids, for example; water has a viscosity of 1 cp at 20 degC whereas honey has a viscosity of approximately 10000 cp. Viscosity affects the type and size of the pump required, with higher viscosities usually requiring positive displacement units running at lower speeds rather than centrifugal pump solutions.

The density or specific gravity of the pumping liquid at the operating temperature will affect how much power is required to achieve the required duty. This in turn will help us size a suitable drive or motor to operate the pump without a problem.

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Slurry is one of the most challenging fluids to move. It"s highly abrasive, thick, sometimes corrosive, and contains a high concentration of solids. No doubt about it, slurry is tough on pumps. But selecting the right centrifugal pump for these abrasive applications can make all the difference in the long-term performance.

Slurries generally behave the same way as thick, viscous fluids, flowing under gravity, but also pumped as needed. Slurries are divided into two general categories: non-settling or settling.

Non-settling slurries consist of very fine particles, which give the illusion of increased apparent viscosity. These slurries usually have low wearing properties, but do require very careful consideration when selecting the right pump because they do not behave in the same manner as a normal liquid does.

Settling slurries are formed by coarse particles that tend to form an unstable mixture. Particular attention should be given to flow and power calculations when selecting a pump. The majority of slurry applications are made up of coarse particles and because of this, have higher wear properties.

Many types of pumps are used for pumping slurries, but the most common slurry pump is the centrifugal pump. The centrifugal slurry pump uses the centrifugal force generated by a rotating impeller to impact kinetic energy to the slurry, similar to how a water-like liquid would move through a standard centrifugal pump.

Slurry applications greatly reduce the expected wear life of pumping components. It’s critical that pumps designed for these heavy-duty applications are selected from the start. Consider the following when making selections:

To ensure the pump will hold up against abrasive wear, the impeller size/design, material of construction, and discharge configurations must be properly selected.

Open impellers are the most common on slurry pumps because they’re the least likely to clog. Closed impellers on the other hand are the most likely to clog and the most difficult to clean if they clog.

Slurry pumps are generally larger in size when compared to low-viscosity liquid pumps and usually require more horsepower to operate because they"re less efficient. Bearings and shafts must be more rugged and rigid as well.

To protect the pump’s casing from abrasion, slurry pumps are oftentimes lined with metal or rubber. Goulds Pumps, for example, lines their XHD (Extra Heavy Duty) slurry pump with rubber.

The casings are selected to suit the needs of the application. For instance, pumps used in cement production handle fine particles at low pressures. Therefore, a light construction casing is acceptable. If the pump is handling rocks, the pump casing and impeller will need a thicker and stronger casing.

Those with experience pumping slurries know it"s not an easy task. Slurries are heavy and difficult to pump. They cause excessive wear on pumps, their components, and are known to clog suction and discharge lines if not moving fast enough.

It’s a challenge to make slurry centrifugal pumps last for a reasonable amount of time. But, there are a few things you can do to extend the life of your slurry pump and make pumping slurry less of a challenge.

Find the sweet spot that allows the pump to run as slow as possible (to reduce wear), but fast enough to keep solids from settling and clogging the lines

Pumping slurries poses several challenges and problems, but with proper engineering and equipment selection, you can experience many years of worry-free operation. It"s important to work with a qualified engineer when selecting a slurry pump because slurries can wreak havoc on a pump if not properly selected.

Check out the Must-Have Handbook for Centrifugal Pumps for more information on centrifugal pumps, including details about pumps specifically designed for slurry applications!

Engineers and experts rely on Crane Engineering for insight and help with centrifugal pumps to pump slurry. Our in-house team of engineers can answer questions related to not only pumps but valves and skid systems. We provide a complete service and repair team who will fix pumps back to OEM standards. We are ready to assist you, contact us, today whether you"re in Wisconsin, Minnesota, or Michigan

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There are many different ways to drill a domestic water well. One is what we call the “mud rotary” method. Whether or not this is the desired and/or best method for drilling your well is something more fully explained in this brief summary.

One advantage of drilling with compressed air is that it can tell you when you have encountered groundwater and gives you an indication how much water the borehole is producing. When drilling with water using the mud rotary method, the driller must rely on his interpretation of the borehole cuttings and any changes he can observe in the recirculating fluid. Mud rotary drillers can also use borehole geophysical tools to interpret which zones might be productive enough for your water well.

The mud rotary well drilling method is considered a closed-loop system. That is, the mud is cleaned of its cuttings and then is recirculated back down the borehole. Referring to this drilling method as “mud” is a misnomer, but it is one that has stuck with the industry for many years and most people understand what the term actually means.

The water is carefully mixed with a product that should not be called mud because it is a highly refined and formulated clay product—bentonite. It is added, mixed, and carefully monitored throughout the well drilling process.

The purpose of using a bentonite additive to the water is to form a thin film on the walls of the borehole to seal it and prevent water losses while drilling. This film also helps support the borehole wall from sluffing or caving in because of the hydraulic pressure of the bentonite mixture pressing against it. The objective of the fluid mixture is to carry cuttings from the bottom of the borehole up to the surface, where they drop out or are filtered out of the fluid, so it can be pumped back down the borehole again.

When using the mud rotary method, the driller must have a sump, a tank, or a small pond to hold a few thousand gallons of recirculating fluid. If they can’t dig sumps or small ponds, they must have a mud processing piece of equipment that mechanically screens and removes the sands and gravels from the mixture. This device is called a “shale shaker.”

The driller does not want to pump fine sand through the pump and back down the borehole. To avoid that, the shale shaker uses vibrating screens of various sizes and desanding cones to drop the sand out of the fluid as it flows through the shaker—so that the fluid can be used again.

Some drillers use compressed air to blow off the well, starting at the first screened interval and slowly working their way to the bottom—blowing off all the water standing above the drill pipe and allowing it to recover, and repeating this until the water blown from the well is free of sand and relatively clean. If after repeated cycles of airlift pumping and recovery the driller cannot find any sand in the water, it is time to install a well development pump.

Additional development of the well can be done with a development pump that may be of a higher capacity than what the final installation pump will be. Just as with cycles of airlift pumping of the well, the development pump will be cycled at different flow rates until the maximum capacity of the well can be determined. If the development pump can be operated briefly at a flow rate 50% greater than the permanent pump, the well should not pump sand.

Mud rotary well drillers for decades have found ways to make this particular system work to drill and construct domestic water wells. In some areas, it’s the ideal method to use because of the geologic formations there, while other areas of the country favor air rotary methods.

To learn more about the difference between mud rotary drilling and air rotary drilling, click the video below. The video is part of our “NGWA: Industry Connected” YouTube series: