mud pump pressure rating free sample

A well-placed suction stabilizer can also prevent pump chatter. Pump chatter occurs when energy is exchanged between the quick opening and closing of the reciprocating pump’s valves and the hammer effect from the centrifugal pump. Pump isolation with suction stabilizers is achieved when the charge pumps are isolated from reciprocating pumps and vice versa. The results are a smooth flow of pumped media devoid of agitating energies present in the pumped fluid.

Suction stabilizer units can mitigate most of the challenges related to pulsations or pressure surges, even in the most complex piping conditions. The resulting benefits prevent expensive unplanned downtime and decrease costs and inconvenience associated with system replacements and repairs.

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.

Pumps tend to be one of the biggest energy consumers in industrial operations. Pump motors, specifically, require a lot of energy. For instance, a 2500 HP triplex pump used for frac jobs can consume almost 2000 kW of power, meaning a full day of fracking can cost several thousand dollars in energy costs alone!

So, naturally, operators should want to maximize energy efficiency to get the most for their money. Even a 1% improvement in efficiency can decrease annual pumping costs by tens of thousands of dollars. The payoff is worth the effort. And if you want to remotely control your pumps, you want to keep efficiency in mind.

In this post, we’ll point you in the right direction and discuss all things related to pump efficiency. We’ll conclude with several tips for how you can maintain pumping efficiency and keep your energy costs down as much as possible.

In simple terms, pump efficiency refers to the ratio of power out to power in. It’s the mechanical power input at the pump shaft, measured in horsepower (HP), compared to the hydraulic power of the liquid output, also measured in HP. For instance, if a pump requires 1000 HP to operate and produces 800 HP of hydraulic power, it would have an efficiency of 80%.

Remember: pumps have to be driven by something, i.e., an electric or diesel motor. True pump system efficiency needs to factor in the efficiency of both the motor AND the pump.

Consequently, we need to think about how electrical power (when using electric motors) or heat power (when using combustion engines) converts into liquid power to really understand pump efficiency.

Good pump efficiency depends, of course, on pump type and size. High-quality pumps that are well-maintained can achieve efficiencies of 90% or higher, while smaller pumps tend to be less efficient. In general, if you take good care of your pumps, you should be able to achieve 70-90% pump efficiency.

AC motors can achieve 90%+ efficiency when converting electrical to mechanical energy. Combustion engines are much less efficient, with typical efficiency ratings coming in at ~20% for gasoline and ~40% for diesel. Your choice of engine or motor type will depend on the availability and cost of fuel or electricity in your area.

Now that we have a better understanding of the pump efficiency metric, let’s talk about how to calculate it. The mechanical power of the pump, or the input power, is a property of the pump itself and will be documented during the pump setup. The output power, or hydraulic power, is calculated as the liquid flow rate multiplied by the "total head" of the system.

IMPORTANT: to calculate true head, you also need to factor in the work the pump does to move fluid from the source. For example, if the source water is below the pump, you need to account for the extra work the pump puts in to draw source water upwards.

*Note - this calculation assumes the pump inlet is not pressurized and that friction losses are minimal. If the pump experiences a non-zero suction pressure, or if there is significant friction caused by the distance or material of the pipe, these should be factored in as well.

Every foot of water creates an additional 0.434 PSI of pressure, so we"ll find the elevation head by converting the change in elevation in feet to the suction pressure created by the water.

You"ll notice that the elevation head is minimal compared to the discharge pressure, and has minimal effect on the efficiency of the pump. As the elevation change increases or the discharge pressure decreases, however, elevation change will have a greater impact on total head.

Obviously, that’s a fair amount of math to get at the pump efficiency, considering all of the units conversions that need to be done. To avoid doing these calculations manually, feel free to use our simple pump efficiency calculator.

Our calculations use static variables (pump-rated horsepower and water source elevation) and dynamic variables (discharge flow and pressure). To determine pump efficiency, we need to measure the static variables only once, unless they change.

If you want to measure the true efficiency of your pump, taking energy consumption into account, you could add an electrical meter. Your meter should consist of a current transducer and voltage monitor (if using DC) for electrical motors or a fuel gauge for combustion. This would give you a true understanding of how pump efficiency affects energy consumption, and ultimately your bank account.

Up until this point, we’ve covered the ins and outs of how to determine pump efficiency. We’re now ready for the exciting stuff - how to improve pump efficiency!

One of the easiest ways to improve pump efficiency is to actually monitor pumps for signs of efficiency loss! If you monitor flow rate and discharge (output power) along with motor current or fuel consumption, you’ll notice efficiency losses as soon as they occur. Simply having pump efficiency information on hand empowers you to take action.

Another way to increase efficiency is to keep pumps well-maintained. Efficiency losses mostly come from mechanical defects in pumps, e.g., friction, leakages, and component failures. You can mitigate these issues through regular maintenance that keeps parts in working order and reveals impending failures. Of course, if you are continuously monitoring your pumps for efficiency drops, you’ll know exactly when maintenance is due.

You can also improve pump efficiency by keeping pumps lubricated at all times. Lubrication is the enemy of friction, which is the enemy of efficiency (“the enemy of my enemy is my friend…”).

A fourth way to enhance pump efficiency is to ensure your pumps and piping are sized properly for your infrastructure. Although we’re bringing this up last, it’s really the first step in any pumping operation. If your pumps and piping don’t match, no amount of lubricant or maintenance will help.

Pipes have physical limits to how much fluid they can move at a particular pressure. If pipes aren’t sized properly, you’ll lose efficiency because your motor will have to work harder. It’s like air conditioning - if your ductwork isn’t sized appropriately for your home, you’ll end up paying more on your energy bill.

In this post, we’ve given you the full rundown when it comes to calculating and improving pump efficiency. You can now calculate, measure, and improve pump efficiency, potentially saving your business thousands of dollars annually on energy costs.

For those just getting started with pump optimization, we offer purpose-built, prepackaged solutions that will have you monitoring pump efficiency in minutes, even in hazardous environments.

Uses the real-life example of a highway system to introduce valves and manifolds on a drilling rig. Walks through the definition, function, and importance of the pump, standpipe, and choke manifolds through vibrant animations. Introduces the adjustable choke and briefly goes into its importance in well control operations.

Examines pressure through several different, real-life examples. Introduces students to pressure differentials and the concept of equilibrium; setting the stage for later discussion on pressure in the wellbore.

Offers a comprehensive look at Formation Pressure deep underground. First, introduces the concept of porosity- taking a look at formation rocks at a molecular level. Then, examines underground pressures both before and after drilling begins, taking a look at what pressures are removed during drilling operations. Lastly, examines the Formation Pressure Gradient and walks through how formation pressure can be mathematically calculated. Student must interact with and answer a question to complete lesson.

Examines the pressure exerted by a column of fluid, both in and out of the wellbore. Derives the generally accepted equation for hydrostatic pressure in a well and walks students through examples. Interactive, in-module questions require student to read, answer, and think about question while going through the lesson.

Introduces friction and examines how frictional losses act against any movement along a surface. Identifies Pump Pressure as the pressure needed to overcome the frictional losses throughout the entire system. Lastly, explains how Annular Friction Loss can contribute to bottomhole pressure.

Discusses how pressure differentials are relevant in balancing well pressures in a producing well. Specifically, introduces the concept of underbalance and overbalance and examines the consequences.

Explains the pressure felt on rig surface equipment and the consequences of exceeding the maximum surface pressure limits of well equipment. Creates an analogy to compare wellbore surface pressure with surface pressure felt on the cap of a shaken soda bottle.

Introduces the fundamental objectives of well production operations, including an animated and graphical look at the Christmas Tree, tubing hanger, and tubing and casing pressure gauges.

Uses powerful, downhole animation to let students visualize the suction effect of Swabbing and how it can pull formation fluid upwards into the well. Introduces Swab Pressure and explains how it acts against bottomhole pressure.

Uses powerful, downhole animation to let students visualize the water hammer effect of Surging and how it can create significant downward pressure that causes fracturing or lost circulation. Introduces Surge Pressure and explains how it acts against bottomhole pressure.

Explains the second part of Kick Theory; the consequences of letting Bottomhole Pressure become too much larger than Formation Pressure. Through animation, demonstrates how Lost Circulation can cause True Vertical Depth to fall and cause a kick to occur.

Defines the blowout and introduces the terrible consequences of an uncontrolled blowout on causing injury to personnel, loss of rig, and harm to the environment. Then, introduces the kick and examines how a kick is caused by pressure differentials and how a kick can turn into a blowout.

Explains the importance of fluid measurement in detecting problems in the wellbore. Introduces the Pit Level Indicator, used to measure the amount of fluid returning to the mud tanks, the Mud Return Indicator, used to measure the speed of fluid returning to the mud tanks, and the Mud Pump Stroke counter, used to count how many strokes of fluid have been pumped into the well.

Provides a detailed, step-by-step conceptual understanding of the impact of well shut-in on underground pressures. Using the example of a bottle cap, explains how shutting-in the well makes bottomhole pressure automatically equal to formation pressure.

Explains the three most important parameters that need to be recorded after shut-in: Shut in Tubing Pressure (SITP), Shut in Casing Pressure (SICP), and Estimated Pit Gain. Walks through the importance of SITP and SICP in understanding Formation Pressure and explains why SITP is generally lower than SICP. Also introduces the procedure involved in recording slow pump rates or slow circulating rates.

Visualizes the different locations where trapped pressure can become trapped in a completed well and looks at some of the methods of trapped pressure resolution.

Mud pressure gauges are extremely accurate pressure measuring devices, designed to operate in harsh working environments. Mud pressure gauges operates even at a high temperature of 120°C and a vibration range up to 15 Hz. They are mostly used in the drilling, mining, petroleum and chemical industries. The mud pressure gauge are used for the measurement of static mud pressure.

Mud pressure gauges are of critical importance to the drilling process. They allow the driller to observe the pressure while drilling on land or offshore drilling rigs. At the time of drilling, it is the pressure that indicates the problems downhole, such as if the pressure is too low, it may indicate worn pump packing or liners, broken drill strings or loose joints, washed-out pipe orbit nozzles or lost returns due to formation breakdown and if the pressure is too high, it may indicate an increase in mud density or viscosity or a plugged drill bit.

Reliable pressure information from mud pressure gauges provides an early warning of the upcoming problems, enabling the driller to make corrections and thus avoid major problems.

Mud pressure gauges can withstand high vibration and high-pressure pulsations. The built-in dampening in mud pressure gauges minimizes the gauge fluctuations and their liquid-filled gauge arrangement minimizes vibration and wear to gauge movement so that even minor pressures can be seen and recorded accurately.

The demand for mud pressure gauges is influenced by various factors such as the energy necessity across the globe, especially in developing countries such as China, Brazil and India. The energy demand in these countries is constantly rising, owing to the improving standard of living among the general population. Natural gas and crude oil are essential to the energy supply chain and play a critical role in the overall economic development of a region.

In recent years, several developing nations have been stepping towards self-reliability in oil and gas by investing in the development of new onshore as well as offshore oil reserves, which is boosting the mud pressure gauges market. Moreover, oil and gas refineries are increasing their production capacities to cater to the growing demand. This increased demand and production capacity is surging the demand for mud pressure gauges.

On the other hand, the unpredictability of the oil and gas industry and tumbling global crude oil prices have led to a reduction in exploration, drilling and production activities. Hence, these factors can hamper the growth of the global mud pressure gauges market over the forecast period.

North America is the largest market for mud pressure gauges, followed by the Asia Pacific and the Middle East. The market for mud pressure gauges in North America is expected to register a high growth rate, owing to the recent development of oil sands, shale assets and then Gulf of Mexico"s deep-water resources in this region.

The Middle East region is also a major market for mud pressure gauges, where the market is exhibiting significant growth, owing to the increase production capacity of oil and gas processing plants in this region. The mud pressure gauges market is growing at a moderate rate in Asia Pacific, mainly owing to increased production capacity in China and India. The rest of the world is estimated to account for a relatively small share of the mud pressure gauges market.