mud pump preventive maintenance made in china

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.

F 500 mud pump for oil drilling have features of solid and compact structure, small volume, good and reliable performance. It can meet the drilling requirements such as high pressure and big displacements whether in land drilling or off-shore drilling.

F 500 mud pumps have a longer stroke and can be operated at a lower stroke, thus improved the water supplying performance effectively and extended the lifetime of mud pump fluid end parts greatly.

Contaminants are detrimental to the safety, yield, reliability and sustainability of your vacuum pump system, which makes it critical to commit to an ongoing system maintenance plan. As each vacuum pump is different and depends on the application it’s used for, your maintenance plan will be unique to the system it’s intended for. High and extremely-high vacuum pumps such as turbomolecular or ion getter pumps will require completely different maintenance treatments to their rough and medium pump counterparts. That said, there are two maintenance mainstays that apply across the board:

Higher temperatures can hinder your pump"s ability to pull its full vacuum, so make sure to keep it cool. If the pump is enclosed, use fan cooling; if not, fresh air will suffice. But never pump vapours while pump is still cold.

The below checklist will expand on the specific components and areas of a vacuum pump that should be checked and maintained regularly. For supplementary information on effective maintenance and safety plans, read our Ultimate Guide to Vacuum System Maintenance & Safety.

Mud pump and slurry pump are both a kind of impurity pump. What are the differences between these two pumps that make it difficult for users to choose?

Mud pump, as the earliest pump type, is generally made of cast iron. Its wear resistance is low. As an important part of drilling machinery, it can only be used to transport mud or slurry that contains suspended particles. Slurry pumps are mainly used in the mining industry to transport slag-containing slurry, they can also be used to transport slurry.

When mud pumps work, they often need to be used in conjunction with high-pressure clean water pumps. High-pressure pumps can deliver clean water that exceeds the pressure of the mud pumps to the leak-proof packing to protect the packing, otherwise, it is easy to wear the sealing part; while the wear-resisting slurry pump can complete the conveying work alone, without help from other auxiliary equipment.

The working principle of the mud pump is that the motor drives the piston through the link mechanism, which causes the change of the enclosed volume in the mud pump, and forms the change of the pressure difference between the inside and outside of the pump, thereby completing the water absorption and drainage process; while the working principle of the wear-resisting slurry pump is that the motor drives the impeller to rotate, that is, the impeller works on the slurry to increase the kinetic energy of the slurry.

Due to the different application mediums of the two pumps, the application fields will also vary. Slurry pumps are mainly used in metallurgy, electric power, mining, coal, and other industrial sectors to transport slurry with solid particles; while mud pumps are mainly used to transport suspended slurry in drilling, pharmaceutical, brewing, papermaking, and other industries.

This example models a triplex pump with a predictive maintenance algorithm that can detect which parts of the pump are failing simply by monitoring the pump output pressure.

The Simscape model of the pump can be configured to model degraded behavior due to seal leakage, blocked inlets, bearing wear, and broken motor windings. MATLAB code shows how to accelerate testing by reusing results from previous simulations. The model can be used to generate training data for the machine learning algorithm and can be used to test the deployed algorithm. MATLAB Live Scripts show you how to develop the algorithm.

Mechanical, hydraulic, and electrical parameters are all defined in MATLAB which lets you easily resize the pump. The pump housing is imported from CAD.

Read the e-book “Predictive Maintenance with MATLAB”https://www.mathworks.com/content/dam/mathworks/tag-team/Objects/p/93060v00_Predictive_Maintenance_e-book_v04.pdf

Backed by the industry"s best delivery, customer service, and technical support, Cat Pumps products and service parts are readily available when you need them. A worldwide network of highly qualified distributors provides sales and service support for pumps, parts and accessories when servicing is required.

Predictive maintenance systems can help oil and gas companies turbocharge their performance, optimize costs, and grow revenues. For instance, oil and gas giant Repsol is using predictive maintenance to improve equipment health and productivity. As a result, the company has reduced unplanned maintenance by 15%, leading to $200 million in annual savings in its operational expenses. So, let’s look at some of the most significant benefits.

US refineries lose $6.6 billion because of unplanned downtime and poor equipment maintenance. Additionally, unwarranted yet routine inspections, which are standard in reactive maintenance, are also costly.

That’s where predictive maintenance can provide significant cost savings since it operates on the premise that maintenance should only be performed when the performance has decreased or there’s a chance of impending equipment failure.

Predictive maintenance systems make maintenance more efficient, as technicians can use a single, centralized dashboard to track and monitor all the performance of all assets in real-time, regardless of the location. This boosts the overall operational efficiency of oil and gas operations.

As mentioned earlier, even four days of unplanned downtime can cost millions. However, using predictive maintenance, oil and gas companies can develop machine learning algorithms that, for instance, predict failures in gas compressor trains with over 70% accuracy, making these systems more reliable and less prone to unplanned downtime.

Oil and gas companies can reduce the risks of such hazards and conduct safer operations using predictive maintenance. Moreover, they can tap into predictive analytics to identify potential natural gas sources with greater accuracy.

Accurate predictions and forecasting warrant high-quality, useful, and actionable data. That’s why the success of any predictive maintenance strategy relies on an organization’s master data management and governance frameworks. At the same time, oil and gas companies must establish a robust analytics infrastructure capable of processing and storing large volumes of big data.

The next step is to get buy-in from the senior leadership by demonstrating the value of predictive maintenanceand decision-making driven by analytics. That’s where tying the outcomes of predictive maintenance initiatives with the overall strategic initiatives comes in handy.

This should be followed by substantial investments in hiring the right experts — data scientists and analysts — and the relevant predictive maintenance technologies to build analytics models that generate real value.

Predictive maintenance has the potential to generate substantial cost savings for the oil and gas industry. For example, IoT solutions can increase production by 25%. Additionally, they can reduce maintenance costs by 30% and equipment downtime by 45%. That’s why oil and gas giants such as Shell, ExxonMobil, BP, Chevron are already tapping into technologies powered by AI and IoT, such as predictive maintenance, to cut costs and boost efficiency. However, while predictive maintenance looks promising for the oil and gas industry, it’s just one aspect on the path to complete digital transformation in the oil and gas world.

Producing oil and gas calls for working with sound equipment that can handle big jobs, and the centrifugal pump is one of the most integral components in the oil and gas industry. Maintenance plays a considerable part in the durability of these pumps. Exercising pump preventive maintenance and following established centrifugal pump repair procedure is essential to extend the life of your centrifugal pumps.

From interior pump corrosion to leakage problems, centrifugal pumps can experience several issues over time if not properly maintained. Maintenance issues can have adverse impacts over time and can even halt the function of the pumps, slowing down or even stopping production. That’s why it’s vital to ensure you’re not missing important steps.

Pump maintenance is challenging without a plan in place to guide you through mandatory centrifugal pump maintenance procedures. Thus, it’s vital to have a centrifugal pump maintenance checklist for guidance during the process. Read on to learn more about the preventative measures and maintenance to implement for your centrifugal pump.

Centrifugal pump preventive maintenance is an essential step in ensuring pumps last for as long as they possibly can. You achieve this by establishing a presentation plan for your pump. Make sure to include centrifugal pump troubleshooting maintenance steps to ensure everyone who uses the procedure not only identifies issues, but also knows what to do to solve the problem.

Include preventative measures that outline checkpoints based on frequency and date. For example, annual checkups can be performed for the pump’s pressure while verifying bolt tightness is essential to conduct every quarter.

Regular maintenance of pumps also calls for frequent monitoring. Thus, your pump maintenance procedures should cover essential process parameters. Some typical parameters include:

Monitoring and designing a preventative centrifugal pump maintenance plan is important, but it’s not enough to solve the issue. You must put your plan into motion and implement the centrifugal pump maintenance schedule.

Monitoring for the performance of your centrifugal pump should be a reoccurring event that happens promptly with a centrifugal pump alignment procedure. It helps you to verify that each component of the pump is functioning correctly.

Assess performance and durability of the oil drain plug, pump casing, discharge flanges and suction, and the bolts for motor alignment for leakage and damage, including air leaks.

Ensuring your centrifugal pump works is essential to its durability. With a centrifugal pump preventive maintenance checklist, you can optimize your industrial pump maintenance to extend the life of your pumps, keep every part functioning correctly, and enhance the reliability and performance of the machine over time.

The mud pump piston is a key part for providing mud circulation, but its sealing performance often fails under complex working conditions, which shorten its service life. Inspired by the ring segment structure of earthworms, the bionic striped structure on surfaces of the mud pump piston (BW-160) was designed and machined, and the sealing performances of the bionic striped piston and the standard piston were tested on a sealing performance testing bench. It was found the bionic striped structure efficiently enhanced the sealing performance of the mud pump piston, while the stripe depth and the angle between the stripes and lateral of the piston both significantly affected the sealing performance. The structure with a stripe depth of 2 mm and angle of 90° showed the best sealing performance, which was 90.79% higher than the standard piston. The sealing mechanism showed the striped structure increased the breadth and area of contact sealing between the piston and the cylinder liner. Meanwhile, the striped structure significantly intercepted the early leaked liquid and led to the refluxing rotation of the leaked liquid at the striped structure, reducing the leakage rate.

Mud pumps are key facilities to compress low-pressure mud into high-pressure mud and are widely used in industrial manufacture, geological exploration, and energy power owing to their generality [1–4]. Mud pumps are the most important power machinery of the hydraulic pond-digging set during reclamation [5] and are major facilities to transport dense mud during river dredging [6]. During oil drilling, mud pumps are the core of the drilling liquid circulation system and the drilling facilities, as they transport the drilling wash fluids (e.g., mud and water) downhole to wash the drills and discharge the drilling liquids [7–9]. The key part of a mud pump that ensures mud circulation is the piston [10, 11]. However, the sealing of the piston will fail very easily under complex and harsh working conditions, and consequently, the abrasive mud easily enters the kinematic pair of the cylinder liner, abrading the piston surfaces and reducing its service life and drilling efficiency. Thus, it is necessary to improve the contact sealing performance of the mud pump piston.

As reported, nonsmooth surface structures can improve the mechanical sealing performance, while structures with radial labyrinth-like or honeycomb-like surfaces can effectively enhance the performance of gap sealing [12–14]. The use of nonsmooth structures into the cylinder liner friction pair of the engine piston can effectively prolong the service life and improve work efficiency of the cylinder liner [15–17]. The application of nonsmooth grooved structures into the plunger can improve the performance of the sealing parts [18, 19]. The nonsmooth structures and sizes considerably affect the sealing performance [20]. Machining a groove-shaped multilevel structure on the magnetic pole would intercept the magnetic fluid step-by-step and slow down the passing velocity, thus generating the sealing effect [21–23]. Sealed structures with two levels or above have also been confirmed to protect the sealing parts from hard damage [24]. The sealing performance of the high-pressure centrifugal pump can be improved by adding groove structures onto the joint mouth circumference [25]. The convex, pitted, and grooved structures of dung beetles, lizards, and shells are responsible for the high wear-resistance, resistance reduction, and sealing performance [26–28]. Earthworms are endowed by wavy nonsmooth surface structures with high resistance reduction and wear-resistance ability [29]. The movement of earthworms in the living environment is very similar to the working mode of the mud pump piston. The groove-shaped bionic piston was designed, and the effects of groove breadth and groove spacing on the endurance and wear-resistance of the piston were investigated [30]. Thus, in this study, based on the nonsmooth surface of earthworms, we designed and processed a nonsmooth striped structure on the surface of the mud pump piston and tested the sealing performance and mechanism. This study offers a novel method for prolonging the service life of the mud pump piston from the perspective of piston sealing performance.

The BW-160 mud pump with long-range flow and pressure, small volume, low weight, and long-service life was used here. The dimensions and parameters of its piston are shown in Figure 1.

A mud pump piston sealing performance test bench was designed and built (Figure 3). This bench mainly consisted of a compaction part and a dynamic detection part. The compaction part was mainly functioned to exert pressure, which was recorded by a pressure gauge, to the piston sealed cavity. This part was designed based on a vertical compaction method: after the tested piston and the sealing liquid were installed, the compaction piston was pushed to the cavity by revolving the handle. Moreover, the dynamic detection part monitored the real-time sealing situation and was designed based on the pressure difference method for quantifying the sealing performance. This part was compacted in advance to the initial pressure P0 (0.1 MPa). After compaction, the driving motor was opened, and the tested piston was pushed to drive the testing mud to reciprocate slowly. After 1 hour of running, the pressure P on the gauge was read, and the pressure difference was calculated as , which was used to measure the sealing performance of the piston.

To more actually simulate the working conditions of the mud pump, we prepared a mud mixture of water, bentonite (in accordance with API Spec 13A: viscometer dial reading at 600 r/min ≥ 30, yield point/plastic viscosity radio ≤ 3, filtrate volume ≤ 15.0 ml, and residue of diameter greater than 75 μm (mass fraction) ≤ 4.0%), and quartz sand (diameter 0.3–0.5 mm) under complete stirring, and its density was 1.306 g/cm³ and contained 2.13% sand.

Figure 4 shows the effects of stripe depth and angle on the sealing performance of mud pump pistons. Clearly, the stripe depth should be never too shallow or deep, while a larger angle would increase the sealing performance more (Figure 4).

The standard piston and the bionic piston were numerically simulated using the academic version of ANSYS® Workbench V17.0. Hexahedral mesh generation method was used to divide the grid, and the size of grids was set as 2.5 mm. The piston grid division is shown in Figure 8, and the grid nodes and elements are shown in Table 3. The piston cup was made of rubber, which was a hyperelastic material. A two-parameter Mooney–Rivlin model was selected, with C10 = 2.5 MPa, C01 = 0.625 MPa, D1 = 0.3 MPa−1, and density = 1120 kg/m3 [32, 33]. The loads and contact conditions related to the piston of the mud pump were set. The surface pressure of the piston cup was set as 1.5 MPa, and the displacement of the piston along the axial direction was set as 30 mm. The two end faces of the cylinder liner were set as “fixed support,” and the piston and cylinder liner were under the frictional interfacial contact, with the friction coefficient of 0.2.

To better validate the sealing mechanism of the bionic striped pistons, a piston’s performance testing platform was independently built and the sealed contact of the pistons was observed. A transparent toughened glass cylinder liner was designed and machined. The inner diameter and the assembly dimensions of the cylinder liner were set according to the standard BW-160 mud pump cylinder liners. The sealing contact surfaces of the pistons were observed and recorded using a video recorder camera.

(1)The bionic striped structure significantly enhanced the sealing performance of the mud pump pistons. The stripe depth and the angle between the stripes and the piston were two important factors affecting the sealing performance of the BW-160 mud pump pistons. The sealing performance was enhanced the most when the stripe depth was 2 mm and the angle was 90°.(2)The bionic striped structure can effectively enhance the contact pressure at the piston lips, enlarge the mutual extrusion between the piston and the cylinder liner, reduce the damage to the piston and cylinder liner caused by the repeated movement of sands, and alleviate the abrasion of abrasive grains between the piston and the cylinder liner, thereby largely improving the sealing performance.(3)The bionic striped structure significantly intercepted the leaked liquid, reduced the leakage rate of pistons, and effectively stored the leaked liquid, thereby reducing leakage and improving the sealing performance.(4)The bionic striped structure led to deformation of the piston, enlarged the width and area of the sealed contact, the stored lubricating oils, and formed uniform oil films after repeated movement, which improved the lubrication conditions and the sealing performance.

The bionic striped structure can improve the sealing performance and prolong the service life of pistons. We would study the pump resistance in order to investigate whether the bionic striped structure could decrease the wear of the piston surface.