mud pump preventive maintenance manufacturer

Distributor of engineered fluid handling pumps, packaged pumping systems, repairs, parts, & integrated pump control systems. Mud pumps, chiller/condenser pumps, plumbing pumps, boiler feed systems, in-line circulators, condensate systems, sump & sewage pumps, end suction pumps, submersible sump & sewage, non-clogs & grinders, self primers, packaged lift stations, variable speed pump systems, metering pumps, chemical injection systems, chemical mixing systems, peristaltic pumps for chemical feed, high viscous & shear sensitive fluids, self primers, stainless steel, trash pumps, hot oil pumps, vertical turbine pumps, sanitary pumps, marine pumps, industrial pumps, ANSI end suction, vertical cantilever, double suction, non-clogs, progressive cavity pumps, helical gear pumps, well pumps, lab pumps, hose pumps, control valves, check valves, air release valves, tanks, pressure vessels.

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.

Repairing your pumps quickly and efficiently to get your operations back up and running is GD Energy Products’ top priority. If your pump requires immediate attention, our field engineers and service technicians can be deployed to your job site or facility. Our experienced technicians are trained to identify and inspect your pumping issue and conduct as-needed service, repairs and preventative maintenance at your preferred location.

GDEP offers a full range of 24/7 on-site pump maintenance and repair offerings tailored to your individual needs. We offer comprehensive repairs for fracking pumps, drilling pumps, well service pumps, fluid ends and modules. Additionally, our customers have access to 24/7 service, ongoing parts support and product maintenance.

GDEP’s inspection program offers a comprehensive and proactive approach to solving your pump issues. Our field service technicians can utilize advanced troubleshooting procedures to uncover various underlining issues with the capability of performing onsite repairs using genuine, high-quality OEM replacement parts to guarantee maximum performance

If you have a large fleet or pumps that simply require more attention, we can provide you with a dedicated field service technician with either half-day or full 24/7 coverage.

Our state-of-the-art repair facilities operate in a constant state of readiness to provide your pumps with the most comprehensive and cutting-edge repair and maintenance services. With facilities strategically located in all major shale plays throughout the United States, we are able to provide our customers with efficient service on a local level.

If you have a large-scale repair that cannot be completed in the field, bring your pump to any one of our repair facilities and expect the same level of service and expertise. A highly trained and experienced team of field engineers, service technicians and repair mechanics possess all the necessary skills and insights required to overhaul any pump, all under one roof. Backed by our satisfaction guarantee, you can have the confidence your pumps will operate at peak performance after it leaves our facility.

Our team of experts is available 24/7 to service and repair any brand of pump. Whatever your repair needs, GDEP will bring the proper experience, tools and equipment needed to get the job done.

STH has been selling and servicing Booster, Fire and Sump/Sewage pumps in the Maryland, DC, & Northern VA market since 1973. We have Factory-Trained and Certified Service Technicians and we currently manage over 850 Preventative Maintenance (PM) Agreements for various property management companies and owners. Routine annual or bi-annual maintenance of your pumping system will help to minimize any “unbudgeted” emergencies and reduce costly downtime. Weekly, monthly and quarterly maintenance programs are also available. STH also offers extended warranty options.

Envirep provides excellent service before, during, and after the sale. To maintain and protect your Gorman-Rupp equipment, our Service Department offers Gorman-Rupp preventative maintenance agreements. Regular preventive maintenance will uncover emerging problems and help to avoid costly and inconvenient breakdowns while keeping your pumping system working at peak efficiency.

Our service staff is factory-trained in the operation, maintenance, and troubleshooting of Gorman-Rupp pumping equipment and electrical controls. They are equipped with proper tools and testing instruments and arrive at your site with common replacement parts enabling them to solve potential problems quickly and economically. We will work with you to keep your pumping equipment operating reliably and efficiently.

If you or your customer would be interested in receiving a proposal for a Gorman-Rupp preventative maintenance agreement, please send an email to JPPRICE@Envirep.com

Envirep distributes Gorman-Rupp’s extensive line of products including Self-Priming Pumps, Packaged Wastewater Pumping Systems, Water Booster Stations and Submersible Pumps for the Municipal market. Envirep is a factory-trained, stocking distributor for Gorman-Rupp and provides local support and inventory.

Gorman-Rupp is the industry leader and innovator in high-quality pump design. At Envirep/TLC, we will help you choose the best Gorman-Rupp® pump parts for your needs. Our goal is to provide you with easy to operate, low maintenance pump parts to ensure you are being as cost-effective as possible

Envirep/TLC is an authorized distributor of Gorman-Rupp pump products and we carry a huge inventory of spare parts so our customers receive the best service possible.

When repairing a Gorman-Rupp pump, it is always best to use genuine Gorman-Rupp parts. Gorman-Rupp builds their parts to exact tolerances and exact material specifications. Not having the right part can reduce the service life and affect the pump’s life and efficiency. Only genuine Gorman-Rupp parts can guarantee that your part will fit perfectly, and deliver reliable service for many years.

Envirep/TLC is a leading manufacturer’s representative and service provider for municipal and industrial water and wastewater treatment and pumping systems. We represent manufacturers of quality products, serving Eastern Pennsylvania, Maryland, New Jersey, Delaware, Washington D.C., Northern Virginia, and part of West Virginia.

Envirep’s staff of application engineers and field service technicians have decades of experience in equipment selection, design, and operation and maintenance. We are committed to providing our customers with prompt and professional service. We assist consulting engineers and end-users with technical support, from new plant design and plant upgrades to equipment replacements and service. Our experienced team is here for you, to recommend the right product, part, and service for your application.

Everyone agrees that reactive maintenance is probably the worst pump reliability strategy. Maintaining equipment only after it breaks can mean unexpected downtime, emergencies, rush charges, overtime, and replacement of expensive parts.

The best pump reliability strategy is not either preventive or predictive maintenance, it’s a combination of the two, strategically applied. In this post, we’ll discuss the differences between predictive and preventive maintenance and when it’s best to use them.

Many operators rely heavily on “reactive” maintenance rather than preventing and planning for future repairs. As discussed in our eBook, 36 Ways to Kill Your Pump, “reactive” maintenance accounts for unplanned equipment downtime and increased costs.

Preventive and predictive maintenance programs extend the overall life of the equipment and result in fewer unplanned breakdowns. The choice is not one or the other, it’s a combination of the two.

Preventative maintenance is any variety of scheduled maintenance to a pump or other piece of equipment. Generally, it includes scheduled routine maintenance, such as equipment calibration, greasing, oil change, and analysis.

One of the biggest ways to prevent failures is to make sure your equipment is properly aligned and balanced. Misalignment and pump unbalance are the two most common reliability problems for rotating equipment. Laser alignment also fits within this category since its a service completed upon installation, setting the pump up for success.

These programs are designed to keep your maintenance costs low by preventing costly failures before they happen. If you need a preventative maintenance checklist, you can download one here.

Up to 50% of damage to rotating machinery is directly related to misalignment. Misalignment can cause increased vibration, premature seal and bearing failure, and increased power consumption. An unbalanced pump causes similar issues, such as vibration, which can be easily avoided with the right preventative maintenance measures.

Predictive maintenance services are used to monitor the condition of equipment over time. Vibration analysis, for example, measures the vibration of the equipment while it is still in service. This allows the technician to see the change in vibrations over time to predict when a problem may occur, and why.

Predictive maintenance should be part of routine maintenance for pumps and rotating equipment that absolutely can NOT go down. Operators and maintenance managers get a glimpse into the future life of the pump as it"s running today. This allows them to plan for repairs and avoid unexpected downtime.

Not all pumps are equally important in a manufacturing process, so not all pumps should receive the same maintenance plan. It wouldn’t make sense to spend time and money on vibration analysis for a pump in a non-essential application.

Before creating a maintenance plan, place the pumps into categories. This will help determine how much time and money to invest in each one. Use these categories to get started:

Regularly maintaining pumps will extend the life of your pump. When a pump is properly maintained, the parts that need replacing are usually the less expensive wear parts.

Check shaft alignment – believe it or not, shaft alignment can change! Thermal growth and machine movement due to load shifts can cause pumps to move out of alignment.

Up to 50% of damage to rotating machinery is directly related to misalignment. That’s huge. Machine vibration, bearing damage, premature seal wear, and coupling damage are all examples of issues pumps experience when misaligned.

For the most accurate alignment, we always recommend laser alignment. It’s the most accurate method available (to .0001), and once familiar, an operator can align a pump/motor very quickly. It is the most expensive method to get into if doing alignments in-house and can be difficult to learn at first. But when looking for long-term results, the laser align method is the better choice.

Precision rebuild or precision maintenance is the practice of rebuilding a pump as close to OEM specifications as possible. Attention to detail is required for precision rebuilds.

Precision rebuilds are proven to reduce failures and should be a central piece of a pump reliability strategy. If the team lacks capacity, tools, or expertise to rebuild pumps to OEM standards, look for a capable local shop.

Add taps with isolating ball valves into piping on the suction and discharge sides of the pump. Use these to mount pressure indicators to ensure the pump is performing properly.

Read the pump manual and follow each step in the procedure. The procedures therein give the best possible instruction for long and trouble-free life for the pump.

Upon start-up, record the pump performance baseline data – amps, suction pressure, discharge pressure. This is handy when troubleshooting issues, should they arise.

Vibration monitoring is a very helpful tool for predicting pump failures. Some manufacturing facilities have a vibration technician on staff to take readings on critical pumps. These technicians may read the results themselves or send them to a firm that can interpret the readings and provide a report.

Unfortunately, this is not a skill easily attained by a maintenance team. It requires expensive equipment and a great deal of training to be an effective vibration technician. Unless the facility has a large population of critical equipment, this is a service best hired out.

Arguably the most important piece of a preventative/predictive maintenance plan... The TRAINING! Training isn’t just for the maintenance team, it’s for everyone in contact with pumps, operators especially! Failure prevention is everyone’s responsibility.

The maintenance team is the keeper and protector of equipment in the facility. Train operators on the signs of failure so they can report it quickly. Show them how to properly start-up or shut down a pump and how their actions will affect other parts of the system.

If all these steps were do-able by a maintenance team alone, everyone’s reliability goals would be already met. Some of the steps we’ve laid out require specialized training, tools, or specialized training on tools to make them effective. It’s likely the team doesn’t possess all these as they’re expected to know how to fix every machine in the plant. Hire outside help where it makes sense.

Look to a preventative maintenance program and predictive maintenance measures to save on annual maintenance costs and unscheduled downtime. We recommend working with your local equipment supplier to schedule a preventative or predictive maintenance program for your pumps.

Need more information about our preventative and predictive maintenance services? We are happy to help businesses in Wisconsin and upper Michigan. Got a noisy, underperforming pump? Consider our FREE Bad Actor Pump Assessment!

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.

JL Offshore AS can support your drilling equipment needs in Repair and Refurbishment, Field Service, Inspections and Spare Parts for Mud Pumps, Drawworks, Rotary Tables, Travelling Blocks and Crown Blocks. We have experienced mechanics and technicians for field support that are highly respected in the industry and their technical expertise in inspecting and refurbishing drilling equipment meets or exceeds OEM standards.

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.

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.

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.

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.

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.

IMAGE 1: An example of a deployed solution for predictive monitoring and failure detection of critical mud pumps in the oil and gas industry. (Images courtesy of Predictronics)

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.

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.

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.

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

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.

High-pressure stand-alone mud pumps such as the SA400 are constantly tackling tough pipeline drilling projects alongside horizontal directional drills, or HDDs. Tough jobs mean operators should take extra steps when possible to maximize the life of the machine. These steps can vary from visual inspections of the machine to performing preventative maintenance tasks on schedule. Refer to your machines operator’s and maintenance manual for safety messages and further information. Now we will go over some operator best practices that can help extend the life of your mud pump.

With the jobsites that these mud pumps encounter, it is no surprise that some parts of the machine can experience considerable wear. High sand content and mud weight on a jobsite will affect the life span of fluid-end components on your pump. Parts on the mud pump that may experience heavy wear include, but are not limited to:

Another area of the mud pump operators should diligently monitor are the intermediate rod seals. If a leakage occurs, these seals will need to be adjusted periodically by following the steps outlined in your machines operator’s manual.

Performing preventative maintenance is a game-changer when it comes to helping extend the life of your mud pump. It is recommended to check lubrication levels daily and inspect the transmission, gear reducer and drive motor. After a job is complete, flush the pump so that it is ready to head to the next jobsite. If the pump will not be used for an extended period of time between jobs, it is recommended to lubricate liners, pistons and valve seats. Doing this will help prevent the liners and seats from becoming pitted due to condensation.

When temps begin to drop, operators will want to remove all drilling fluids from the pump, hoses and any exposed drill string. After that is complete, fill the end of the mud pump with antifreeze, which will offer protection from freezing temperatures beyond what is anticipated. Planning and performing this maintenance before temperatures drop is key to optimizing machine performance.

These pumps are typically used on large-diameter projects, which means going at a slower rpm can maximize machine longevity and productivity. While the pump is processing heavy material, if it is run too quickly, it could affect machine performance. Keeping an eye on the rpm and adjusting when needed can help avoid plugging the pump with heavy material.

When setting up at the jobsite, remember to set the mud pump onto a level area of ground. Inside the pump many internal components only receive splash lubrication and if the pump is working on uneven ground, it is more difficult for those components to receive the adequate amount of lubrication.

Developing a consistent routine to check fluid levels and the condition of highly wearable parts will go a long way when it comes to maximizing the life of your mud pump. It is essential that operators take the time to inspect the pump between jobs and utilize the operator’s and maintenance manual for further instructions and safety messages.

Prior to performing service or maintenance on Vermeer equipment, always refer to the product’s operator’s and/or maintenance manual for safety messages and further instructions. Vermeer Corporation reserves the right to make changes in product engineering, design and specifications; add improvements; or discontinue manufacturing or distribution at any time without notice or obligation. Equipment shown is for illustrative purposes only and may display optional accessories or components specific to their global region. Please contact your local Vermeer dealer for more information on machine specifications.

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

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.

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

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

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

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

Pump maintenance is the process of keeping your pumps in good working condition. A thorough checklist that guides the maintenance engineer for pump maintenance can be very beneficial as pump maintenance is essential to keep your pumps running smoothly and prevent them from breaking down. This includes regularly checking and cleaning your pumps and replacing any parts that are worn out.

Modern pumps are essential equipment in the industrial and manufacturing sectors. These devices allow companies to move liquids and gases from one place to another, which can be crucial to operations. While modern pumps are reliable and rarely need maintenance, they require some attention over time.

The ideal way of classifying pump maintenance is through the method used for drawing out the maintenance plan. Based on this, the following are the four significant types of pump maintenance:

Corrective maintenance is the most reactive type of pump maintenance, and it involves repairing or replacing parts as needed to keep a pump functioning properly. While this approach may be necessary for some situations, it is often not ideal due to its high cost and disruption of operations.

Preventive maintenance is another common approach to pump maintenance that focuses on proactive measures such as regular inspections and adjustments. This can help avoid potential problems and keep pumps operating at peak efficiency. Using a reliable checklist for pump maintenance, engineers conduct a thorough checking and carry out the needful maintenance as and when needed. This approach is widely used in industries.

Predictive maintenance uses advanced sensors and equipment to monitor the condition of pumps and other components in real-time. This enables users to detect potential problems before they become serious issues that require extensive repairs or replacements. However, this type of maintenance is cost-intensive and unsuitable for small-scale pump systems.

This type of pump maintenance is a newer type of pump maintenance that uses data collected from sensors to assess the condition of pumps and other equipment. This information is then used to develop a customized maintenance plan tailored to the equipment’s specific needs. This approach can be more effective than traditional pump preventive maintenance plans and can help to reduce downtime and costs. But setting up a CBM system can prove to be a costly affair.

Whether you are using one of these approaches or a combination of them, it is essential to ensure that your pump maintenance program is adequately designed and implemented to optimize the performance and longevity of your pumps. Pump maintenance plans are also created based on the system they target, including mechanical, electrical, and hydraulic. Mechanical maintenance typically involves replacing parts that have worn out or broken down due to normal wear and tear. Electrical pump maintenance requires checking the wiring for any signs of damage and replacing fuses if necessary. And hydraulic pump maintenance may involve changing fluid levels or upgrading the oil viscosity depending on the level of use.

The strength and effectiveness of your pump preventive maintenance plan depending on how robust your checklist is. While you would want to include all possible checks in the plan, it is impractical and inadvisable for all routine checks. Therefore the checklist is divided based on the frequency of checks making it more sustainable and effective:

Please note that the pump preventive maintenance schedule for each pump would depend on its design and application, and hence you should always consult the pump manufacturer for the same. However, the above checklist is a general checklist that can guide the process of pump preventive maintenance. A well-maintained pump will last longer and perform better than one not correctly cared for.

Check the manufacturer’s recommendation for service interval schedules. Depending on the type of pump, different servicing may be required at different intervals.

Maintain the proper records for all pump maintenance activity. Good data collection will give you the correct information about the pump’s health and operational condition.

Based on the checklist, pump maintenance may seem a simple task that needs to be done regularly. However, this is not true. Understanding the pump behaviour and performing suitable maintenance activities requires years of experience. Therefore, it is always advisable to hire a qualified expert to carry out pump maintenance due to the following reasons:

Safety – Pump maintenance through a qualified expert, ensures that all safety hazards are identified and eliminated. This keeps you, your equipment, and your employees safe from harm.

Efficiency – Qualified experts know how to service and maintain pumps to operate at peak efficiency. This can save you money on your energy bills and help prolong the life of your pump.

Peace of Mind – Pump maintenance can be a complex task. By entrusting it to a qualified expert, you can rest assured that the job will be done correctly and on time.

Avoid Downtime – Downtime is costly, both in terms of lost productivity and repair costs. Pump maintenance through a qualified expert can help minimize the risk of unexpected downtime.

Compliance – Pump maintenance through a qualified expert can help ensure that your pump complies with all relevant safety and environmental regulations. This can save you from costly fines or penalties.

The majority of reliable pump manufacturers offer pump maintenance as a part of their service. Therefore, it is always a good practice to hire them to execute the pump maintenance of your site. They will also be able to create an effective schedule and an exhaustive checklist that your site engineers can follow for pump inspection. Ensuring that pump preventive maintenance is done at the right time in the right way will make your overall system more reliable and efficient.

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.

Centrifugal pumps are one of the most popular pumping solutions in the world due to their highly efficient and simple design. However, just like any other pump, they can also suffer from pump failure and damage if preventive maintenance is neglected. So if you have invested in a centrifugal pump for your site, you need to ensure that you have a maintenance schedule in place, that will not only extend your system"s life but also reduce operating costs.

Even if you have invested in a high-quality centrifugal pump like Azcue, which means that you have a great pump solution in place, preventive maintenance is essential to keep your process running smoothly and prevent any unexpected downtime and costs. Centrifugal water pumps have hundreds of components that keep them running smoothly and are integral to providing effective pump operation. Therefore, consistent maintenance can not only prevent pump failures but also help your engineers to identify the source of the problem faster, as they will have enough maintenance history recorded to refer back to. To help you put together your centrifugal pump maintenance schedule, we asked our technical sales engineer for a good preventive maintenance strategy…

Don"t have time to read the whole article. Download our helpful infographic that you can use to implement a centrifugal pump maintenance schedule.Click here

If you have a centrifugal pump on-site and don"t already have a maintenance programme in place, then you are probably asking yourself all of these questions: How often do you need to perform routine maintenance or replace parts? Which pump components must be checked more often, and when should you schedule the pump maintenance? What spare parts do you need to stock to prevent any pump downtime?

Planning preventive maintenance of centrifugal pumps can be confusing, especially if you don"t know where to start. So we asked our technical sales engineers to give us their recommendations for a centrifugal pump maintenance schedule. Here is their advice and an example of a maintenance plan…

Best practice is to carry out a visual inspection of the pump installation on a daily basis. Spotting an issue early is one of the best troubleshooting methods and can preventing pump breakdowns. Here are some of the things to look out for:

Just like the daily inspection, you should look for any abnormalities but this time, pay close attention to the following centrifugal water pump components:

Carry out a visual inspection for any signs of leakage from the pump or pipework. If standby pumps are installed, turn on and run for at least 5 minutes to ensure operation.

Check for a sudden decrease in the efficiency of your centrifugal pump. This may be due to a broken shaft seal. Inspect the shaft seals for any physical signs of damage/leakage and replace the seal where necessary.

Following our centrifugal pump maintenance schedule, you will need to check the following pump components once a month to ensure that your pump is running efficiently and prevent any potential failure or damage:

Check coupling alignment. If significant misalignment is found, check seals and bearings for wear. Clean the pump and motor, so it"s free of oil and debris to allow ventilation and prevent overheating.

Less often but very important is to thoroughly inspect the whole centrifugal pump and consider changing some of the spare parts to ensure that the pump operates in optimal conditions. Here are our recommendations:

Dismantle the pump, inspect the wearing parts and replace them if necessary. Typical parts include: mechanical seal, wear rings, impeller, o-ring, gasket, shaft. Remove all auxiliary parts, including gauges and valves, clean and inspect.

Replace certain components such as the mechanical seals and impellers to prevent leaking and other issues. The best practice is to hold stock of typical wearing parts on-site to prevent any delay in maintaining your pump if any components fail.

Always make sure to create a maintenance schedule that is consistent with the manufacturer"s guidelines and keep in mind that certain components need to be maintained based on their service intervals:

Lubricate the bearing as per the service intervals (usually in operating hours) found in the pump manual. This may be required more regularly in high-temperature or dusty environments.

Industrial plants, factories and vessels rely heavily on the reliability of their equipment and machinery; pumps being a core part of this. Downtime of a pump can costly in terms of loss of output and the cost of repairs. Imagine your pump plays a critical role in your production line; it is responsible for dosing a specific quantity of ingredient into a mix. If the pump unexpectedly fails, then the production of the mix comes to a halt. A pump failing on board a ship out at sea can have even worse implications, especially if it one required for the safety or operation of the vessel. Pump maintenance is therefore an integral operation within any plant to limit this costly downtime…

Maintenance is commonly split into two classifications; corrective and preventive maintenance. Corrective maintenance is essentially maintenance that is undertaken to cope with a pump failure that has already occurred. It has to be undertaken as quickly and efficiently as possible to get the installation up and running again with as little impact on operation as possible.

Relying on corrective maintenance however is an issue. It means that maintenance is only carried out once a problem has already arisen rather than preventing the problem from happening in the first place. To avoid downtime caused by unexpected problems with the pump, it is important to introduce a preventive maintenance schedule.

If you have a pump on site and you don’t already have a maintenance programme in place, then your first step should be to make someone responsible for this, maybe your inhouse engineer or operations team. Most pump engineers offer servicing contracts and can carry out any required maintenance then and there. However, it’s good practice to be able to inspect your pump yourself more regularly to catch any issues in between your services.

A pump maintenance programme would generally involve a periodic check of the pump performance, an inspection of the wearing parts and lubrication of bearings and joints. It is good practice to carry out a visual inspection of the pump installation on a daily basis. Spotting an issue early is one of the best methods of trouble shooting and preventing pump breakdown. Most of the things to look out for should be easily visible, these include:Leaks - Check the pump and pipework for any leaks that ne