mud pump motor thermal imaging in stock

Cameron AC electric motors improve the performance of your mud pumps, drawworks, and rotary tables. Custom configuration is available, and ATEX, ABS, and DNV certification can be provided for new motors. Our flexible design offers you a choice between a tapered shaft or BullShaft to meet specific application requirements.

Cameron AC traction motors are designed and manufactured to handle deep drilling applications. Available in 400-hp, 550/600-hp, 1,150-hp, and 1,500/1,600-hp models, these inverter motors are designed specifically for 460-V to 690-V duty and deliver maximum efficiency. To meet varying installation requirements, our AC motors are available in vertical or horizontal designs.

Unlike conventional traction motors, Cameron AC motors have a unique design that meets the requirements of oil and gas applications. A key characteristic of the motor is the ability to provide a high level of torque at speeds ranging from 0 to 800 rpm (select motors can achieve a maximum speed up to 3,000 rpm). The torque generated at a wide range of speeds can enhance the performance of a broad array of drilling equipment driven by these motors.

Hydraulic systems are an integral part of many mobile and fixed machines. Because hydraulic components generate heat during normal operation, they are excellent subjects for thermal imaging. Quite often, failures in hydraulic systems are accompanied by a change in operating temperature. When hydraulic components are visually accessible, thermal imaging and non-contact thermometry can provide valuable data for system diagnostics. This paper will discuss the theory and operation of hydraulic systems, common system failures, and the proper application of thermal imaging for hydraulic system diagnostics.

Troubleshooting hydraulic systems requires knowledge in basic hydraulic theory, hydraulic systems and troubleshooting. So, how can Infrared (IR) Equipment (i.e. thermal imagers/cameras and spot radiometers/laser thermometers) be used to analyze and troubleshoot hydraulic systems?

During the course of this presentation, discussion and emphasis will be on using non- contact temperature (IR) readings to analyze an operating hydraulic system. The paper will also present some of the more common reasons for elevated operating temperatures. The use of IR equipment may and should be used in conjunction with your system’s thermal indicating systems and/or the instruments just noted.

It takes time for a hydraulic driven operation to occur. The time taken can be crucial in determining which pump, motor, or actuator is not performing properly.

The pump (1) is intended to provide a constant flow. The relief valve (pressure regulator) (2) is normally set to a level just above that produced within the operating system. The pressure gauge (3) observes operating system pressure. The control valve (4) provides operating pressurized fluid to the double acting cylinder (5). The heat exchanger (or oil cooler, radiator) (6) in conjunction with a reservoir (or oil tank) maintains a fluid temperature that is below component damaging and fluid damaging temperatures.

Consider a simple example. A technician uses a previously unopened can of oil to completely fill a system/tank that uses a 25 GPM pump that will be run continuously. The pump in this system will circulate around 3,500 pounds of dirt to the system’s components each year (Ref. 1). The source might be a teaspoon full of particulate found in the clean oil and then recirculated continuously. Elevated system temperatures will occur. This elevated temperature can be observed by the thermographer.

Gear and piston pumps will have seal clearances ranging from 0.5 to 10 microns, while a linear actuator might have clearances ranging from 50 to 250 microns. With component wear due to poor filtering of contaminants; you might find a defective component by its elevated heat in comparing components within your system.

Next a thermographer might view the hydraulic reservoir (oil tank). If oil tank levels are low, inlet line sizing is wrong or oil tank filtering is improper, cavitation of the pump in a previously working system can be expected and the pump (and oil) will run hotter. The oil tank is typically the hydraulic system’s primary heat sink. If sized or installed wrong (like locating it next to a wall), heat may not be dissipated in sufficient quantity to maintain a thermally balanced system, and the system will heat up beyond its fluids and components maximum temperature limits. This will result in increased particle contaminants and viscosity changes in the oil, with even greater heating of the system occurring as a consequence.

DC solenoids draw a fixed current. A DC coil failure is usually caused by coil aging, physical and/or thermal damage. Their heat signature can be previously known (i.e. recorded) and an open coil can be observed by the thermographer.

Another use of infrared equipment is in analyzing the circuit(s) driven by pump(s). If a system has been working for a while, plumbing, fluids and components will be warmed up, even hot. Some multiple systems share the hydraulics, but only when called upon to do so. The offline components in the intermittent circuit can be cold. When hit by the hot hydraulic oil, thermal shocking of those components can occur. This shock can result in seal leakage, shafts binding and shearing the shear key on hydraulic motors. A thermographer will be able to see and question offline parts of an operating hydraulic system.

Thermally view an operating hydraulic system globally, then by component and plumbing. IR imagers can allow the thermographer to get the “big picture,” before diving into a specific area.

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Mud Pump is one of the most critical equipment on the Rig; Powerful Mud Pumps pick up mud from the suction tank and circulate the mud down hole, out the bit and back to the surface.

In Rigs, two types of Mud Pumps are mostly used; namely, Triplex Pumps or Duplex Pumps, whereas Triplex Pumps have three pistons that move back-and-forth in liners. Duplex Pumps have two pistons move back and forth in liners.

Constant use of the Mud Pumps disturbs balancing of the Rotating components and the imbalance causes vibration, resulting in reduced Pump performance efficiency. To rectify such imbalanced Components and to retain the Pump performance efficiency, Dynamic Balancing is highly recommended.

Thermal cameras have evolved from a specialist-only device to an ideal tool for process equipment maintenance—from troubleshooting to scheduled maintenance. By using a thermal camera for troubleshooting, the technician can diagnose the root-cause more efficiently while also often identifying other potential problems during the same inspection.

Unlike regular digital cameras that capture images of the visible light reflected by objects, thermal cameras create pictures by measuring infrared energy or heat. The thermal camera then assigns colors based on the temperature differences it measures. In a “radiometric” imager, each pixel of color on screen represents an individual temperature.

Thermal cameras read the surface temperature of objects. The trick is that surfaces don’t all emit thermal energy equally well. Emissivity is the material property that describes the efficiency with which an object radiates or emits heat.

Infrared imaging shows a partial blockage in a process liquid waste drainage line. Failure to recognize a deteriorating situation could result in serious problems.

Objects with low-emissivity are—at the same time—highly reflective of their thermal surroundings. Because of this, the reflected energy a thermal camera sees may be different than actual temperature. To compensate (and improve temperature accuracy), follow these tips:

Think about how the equipment in question works and what its heat-related failure signatures are. It is important to understand the base line thermal pattern of the equipment you are thermally scanning.

Note: While thermal imaging is non-contact, if you measure live electricity with the enclosure doors removed, NFAP 70E safety standards still apply. Wear appropriate personal protective equipment and minimize time spent in the arc-flash zone.

Belts – Sheaves that are hotter around circumference could indicate slipping belts – Belts that do not cool between the motor and blower sheaves could indicate slipping belts – Belts with unequal thermal

Thermal signatures are often associated with machine health. Normal operation has a verifiable signature and problems often show up as differentials. To understand these, however, requires knowledge of the machine and how it fails.

With the help of your troubleshooting thermal camera, it pays to quickly check the overall motor temperature every so often, especially for smaller motors that may not get the kind of maintenance they should. Often these motors overheat before anyone notices otherwise. Use the motor temperature rating on the nameplate as a guide. Exterior motor temperatures are generally about 36 °F cooler than the interior temperatures.

For a routine or preventive maintenance program, it’s ideal to start with a newly commissioned and freshly lubricated motor and take a snap shot of the key inspection points, while the motor is running. Use these images as baselines.

Tip: On new motors, watch the initial motor start up through your thermal camera. A wiring problem, alignment or lubrication issue will show up thermally before permanent damage is incurred.

As a motor ages, components become worn, and heat-producing friction develops, the housings will begin to heat up. If possible, take additional thermal images at regular intervals, comparing them to the baseline to analyze the motor’s condition. When the thermal images indicate overheating, generate a maintenance order.

While most large process tanks have built-in visual or electronic indicators for tracking product levels, they are not always reliable. Thermal inspections can reveal the interface between the liquid and the gas (usually air) in a vessel, indicating how full it is and whether the contents have settled or separated inappropriately. Knowing the correct levels avoids overfilling when a level sensor is faulty and ensures reliable inventory figures for raw materials and/or finished products.

When a tank or silo is changing temperature, it’s often possible to see the thermal patterns associated with the various levels inside. Knowing the sludge level, for instance, is invaluable when it comes to operating a continuous process or preparing to clean out a tank. Thermography can also reveal floating materials such as wax and foam as well as layers of different liquids, gases and even solids, such as the layer of paraffin that sometimes forms between the oil and water layers in separators, hindering their normal operation.

Most leaks develop in or around a gasket or seal. Less often, corrosion will cause a weakness to develop and rupture the vessel. To find a leaky gasket or seal, scan the imager along the seal looking for thermal eccentricities. A large change in temperature along the seal or gasket indicates a loss of either heat or cold—the signature of a failure.

A thermal camera can monitor process control valves for leakage, stiction (sticking) or excess friction. Also, a valve’s excitation coil may overheat from working too hard, pointing to a problem such as current leakage or valve size mismatch. When thermography indicates a problem, technicians can follow up by calibrating the valve or the valve’s positioner.

Thermal cameras can quickly see the trap and line temperatures into and out of steam traps. Check all transmission lines and follow pipe temperatures to the source of problems.

A trap that has failed to open can go undetected for weeks or months and can be very costly. To a thermal camera, these traps will appear warm on both sides. If you find a trap like this, make sure it has not just cycled. If, after a few minutes, it remains hot on both sides, it is probably not working properly.

Thermal inspection of heat exchangers can quickly and safely identify areas of corrosion, mineral deposits, and sludge build-up, as well as a lack of heat transfer due to external damage like hail, abuse, or lack of maintenance. It is important to remember however, that mechanical heat transfer is one area in which clear, sharp lines of temperature difference rarely exist. Unlike the typical “hot spots” one is able to see in overheating or malfunctioning equipment, heat exchangers are constructed to facilitate a diffuse and monolithic temperature exchange. Higher resolution cameras with on-camera level-and-span adjustments typically help with capturing lower thermal differences (called Delta T) often exhibited by blocked passages or clogged strainers of plate-type exchangers. Inversely, shell-type heat exchangers often times show clear and definitive areas of blockage caused by solid buildup of materials. In these cases, infrared inspection will allow you to diagnose specific areas of trouble.

The missing ingredient in all of the above is personal experience. Troubleshooting by nature is scenario specific. The more time spent using thermal cameras, the better the user becomes at identifying anomalies. That thermal skill, blended into existing knowledge of line and equipment functionality, can make for a formidable troubleshooter and better, longterm maintenance.

Since most tanks are located outside, their contents heat up during the day due to solar loading, and cool off at night. This temperature difference between the product and the headspace can usually be observed through most tank walls. This technique can work any time during the day but keep in mind that there will be times when the air and liquid or solid will be the same temperature and no apparent level will be visible. The level will start to become visible as the air gains or looses thermal energy.

A thermal image of a tank that is completely empty or completely full, or that has a shiny reflective skin, will appear uniform and no product level will be apparent. Otherwise, the product level will appear as an obvious thermal separation between the headspace and the product.

Water holds on to heat far longer than air. That means that after a hot day, the liquid inside a tank will stay warm long after the air has cooled, giving you the greatest thermal differentiation to detect tank levels with.