mud pump motor commissioning factory

Distributor of heavy duty submersible mud, sand, sludge & slurry pumps. Specifications of pumps include 5 hp to 30 hp motor, three phase, 208 V to 575 V, 6.8 A to 39 A, 3 in. to 6 in. NPT sizes, 38 ft. to 134 ft. head size & 475 gpm to 1,690 gpm flow rate. Features include impellers, wear plates & agitators made from abrasive resistant 28 percent chrome iron, process hardened ductile iron volutes casted with thick walls, class H motor insulation, double silicon carbide mechanical seals, heavy duty lip seal & stainless steel shaft & shaft sleeve. Sand, sludge & slurry pumps are used in mines, quarries, dredging, coal & ore slurries, sewage treatment plants & steel mills. UL listed. CSA approved. Meets OSHA standards.

Continental Emsco Drilling Products, Inc., which consisted of Emsco drilling machinery and Wilson mobile rigs, was purchased by National-Oilwell, Inc on July 7, 1999. To our knowledge, no pumps have been manufactured and sold under the Emsco brand name since National-Oilwell acquired them.

Fairbanks Morse pumps are currently manufactured in Kansas City, Kansas. Fairbanks Morse is a division of Pentair ever since August, 1997 when Pentair purchased the General Signal Pump Group.

Gaso pumps are manufactured by National Oilwell Varco. Gaso was acquired as "Wheatley Gaso" by National-Oilwell in the year 2000. At the time, Wheatley Gaso was owned by Halliburton.

Skytop Brewster pumps are no longer available as new pumps. Skytop Brewster(Cnsld Gold), a unit of Hansen PLC"s Consolidated Gold Fields subsidiary, was acquired while in bankruptcy by National-Oilwell, Inc. in November, 1999.

Because of a skilled manpower shortage, particularly at remote sites, the industry has given less attention to the technical details of pump commissioning. A high percentage of pumps are commissioned and then improperly started. This can result in damages or unit production interruptions. Pump maintenance and repair can be costly, which makes pump pre-commissioning, commissioning and startup crucial in today’s industry.

Good pump alignment can provide improved bearing and seal life, lower vibration, superior pump reliability and better overall pump performance. Improper pump alignment can cause excessive vibration, premature wear and early failure. Adequate clearance for each pump casing is important for proper alignment. The pump shaft interface alignment tolerance should be around 0.0005 times the shaft diameter (approximately 0.01 to 0.02 millimeter for typical 25 to 50 millimeters shaft diameters). Some textbooks recommend alignment tolerance around 0.01 millimeter overall, regardless of the shaft diameter. Special pump trains may need tighter alignment tolerances.

Pump trains with flexible couplings (which transmit the torque through elastomeric materials) could tolerate interface fits higher than those mentioned. The coupling spacer length is also important because parallel misalignment accommodation is directly proportional to the length.

An important criterion for pump alignment is the pump’s running vibration. If excessive, particularly at twice the running speed (or axially), a further alignment improvement is required. The analysis of failed pump components—such as bearings, couplings and seals—can also indicate the need for improved alignment.

The reverse-indicator method preferred for modern pump alignment. The accuracy of this method cannot be affected by the axial movement of the shafts in sleeve bearings (used in large pumps). Both shafts should turn together (generally both shafts should be rotatable and coupled together). This prevents the coupling eccentricity or the surface irregularities from reducing the accuracy of the alignment readings. The geometrical accuracy is usually better using this method. It is convenient and generally implemented without disconnecting the coupling.

For complex alignment situations in which thermal growth or multi-casing pump trains are involved, the reverse-indicator method could be used. Usually a single-axis leveling is sufficient for pumps using rolling element bearings (small- and medium-size pumps), and a two-axis leveling could suffice for pumps employing sleeve bearings.

Some limitations exist when using the reverse-indicator alignment method. If the coupling diameter exceeds the available axial measurement span (closely-packaged pumps), the geometric accuracy may be poor using the reverse-indicator alignment method (compared to other methods). The general trend is toward high-torsional-stiffness couplings (such as metallic, flexible, spacer-type couplings).

The face-and-rim method, a traditional alignment procedure, was popular decades ago. It can be used on large and heavy pumps, those with shafts that cannot be turned. However, some run out error may occur because of the shaft or coupling eccentricity. It may offer a better geometric accuracy compared to the reverse-indicator alignment method for couplings with short spans (a small span-to-diameter ratio). Generally, this method is easier to apply on short coupling spans or small, non-critical pumps.

If this method is used on a large pump with sleeve bearings, the axial float error could be significant, and a special procedure may be required. As a general rule, two-axis leveling or three-axis leveling could be required for rolling element bearings and sleeve bearings, respectively (the reverse-indicator method requires leveling in one less axis for each).

The face-face-distance alignment method is used for long spans (such as special pump trains that use a long-transmission shaft instead of a coupling).

Thermal growth (or pump contraction) can be significant for alignment purposes. The relative movement of one casing/machine compared to other(s) is a concern (absolute movements do not affect the alignment). Movements because of pipe loads, fluid forces and torque reactions have important effects. Pump vibration can indicate whether thermal movements and other operational effects are causing misalignment during startup or operation. Considering the thermal operational growth correction in the pump alignment may be required during commissioning. One of the best methods can be mechanical pump measurements during operation onsite with the final foundation and piping. Another recommendation is to make pump and piping adjustments during operation, using vibration as the primary reference.

Unbalance occurs for many reasons—including distortion, deflection, dimensional changes and other problems. An improper shipment and poor assembly, installation and/or commissioning could result in rotating assembly unbalance.

Often, field balancing is required onsite during pump commissioning or startup. If the danger of this unbalance vibration is not recognized quickly, costly damages can occur. This may result in the destruction of bearings, seal damage, cracks in different components, foundation damage, mounting system problems or other issues.

With a simply supported rotor assembly (bearing at both ends), vibration because of unbalance will occur mainly in the radial plane. In the case of an over-hung rotor, high axial vibrations may also occur (the axial vibration amplitude may equal those measured radially). Field balancing of the pump rotor could be necessary to increase safety and bearing and seal life. It may also be needed to minimize the vibration (and stresses), noise, fatigue and power losses.

Static unbalance exists when the principal axis of inertia is displaced parallel to the shaft axis. This type of unbalance is found primarily in narrow, disc-shaped rotating parts, such as a thin pump impeller. Static balance is satisfactory only for relatively slow-revolving disc-shaped components or for parts that are subsequently assembled onto a larger rotor that is then balanced dynamically as an assembly.

A field balancing package usually provides sensing and monitoring instrumentation for the balancing of a pump rotor, while the rotor runs inside the pump, onsite (in its own bearings and under its own power). Field balancing systems consist of a combination of proper transducers and measurement devices that provide an unbalance indication proportional to the vibration magnitude. A suitable calculation module is used to convert the readings—usually the vibration in several runs with the test masses—into the magnitude and phase angle of the required correction masses. Vibration measurements at one end of a pump could be affected by an unbalance vibration from the other end. To  accurately determine the size and phase angle of the needed correction masses, at least three runs are required. One is the current condition. The second uses a test mass in one plane. The third uses a test mass in another correction plane.

The cleanliness of a pump’s lubrication system is critical. The same oil as the specified operating lubrication oil should be used for the entire pump lubrication system flushing at the field. Any dirt or debris in a lubrication system should be collected in the lubrication filter (or additional strainers) during the flushing. Sufficient time is needed for the proper flushing of the lubrication circuits of a pump (usually one to two days).

During pump commissioning and startup, damages to mechanical seals often occur. Modern mechanical seals are usually supplied as a pre-mounted cartridge unit and often do not require adjustment during pump commissioning. Increased imperfections of concentricity and run-out in the pump shaft can lead to high vibrations, which significantly decrease the service life of the seal. The mechanical seal should be supplied with the required, clean seal fluid.

When all accessories and utilities are ready, the pump can be started. The alignment should be monitored as the temperature changes to the operating level. Alignment changes should be properly documented, and the alignment should be corrected, if required. The pump’s operating data should be recorded on the job with liquid and stable operating conditions to establish the base reference points.

For some pumps, tight manufacturing clearances and complex geometry make refurbishing difficult, especially when major damage occur or a catastrophic component fails (such as a bearing). The pump rotor may end up digging and melting into the casing. If bent, the rotor should be replaced. If not bent, it may be refurbished, which is usually a difficult process. For example, the rotor’s sealing edges can often be sprayed in case of damage. Repairing the pump casings could be both difficult and risky for machining and even more so for welding.

When a new oil and gas plant is built or remodeled, new pumping systems for industrial process water and waste are inevitable. This was the case at one company in Port Arthur, Texas, and St. Charles, Louisiana. The requirement was two identical above-grade, skid-mounted systems that need to deliver 540 gallons per minute (gpm) against 80 feet of total dynamic head (TDH) in existing force mains.

Pumping into a high-pressure existing force main required an above-grade, self-priming end suction centrifugal pump for several reasons. First, there are more motor/pump combinations to select from for a given duty point. Additionally, how the pump is coupled to the motor will dictate the speed at which the impeller rotates. High impeller speeds (to a point) help to overcome large duty points (gpm at TDH). An above-grade pumping skid is also ideal for pumping into a high-pressure existing force main because it keeps the pumps out of the process fluid and allows for easy maintenance as all aspects of the pump are accessible.

The design criteria must be considered, along with the larger system, before designing the best pumping system to meet the application. These criteria must be considered instead of just providing a model that is expected to fit into the application of the facility. This is also in addition to using the staff’s preferred equipment, since they will be owning and maintaining the pumping system.

After the design is complete, the sump (wet well) is prefabricated along with the pumping skid, the valve vault and the controls. This allows for an easy installation on-site. This is critical at an oil and gas facility as space can be limited and precise construction is needed. All aspects of the system also need to be easily maintained to ensure the facility can maintain production.

To ensure the installation and startup are handled correctly, pump station design and supply personnel are sent to the construction site. A refined commissioning process is followed, working through all aspects of the system (controls, structural/mechanical, electrical, etc.) while adhering to safety policies at the facility. Before leaving, the responsible personnel is trained to guarantee the long-term success of the system.

Pump station controllers are selected by the user’s standards and requirements, which in this case was an ultrasonic transducer to be used for the primary level sensor. Ultrasonic transducers are common within industrial applications and provide many advantages versus other forms of level sensing such as floats and pressure transducers. One of the primary advantages of an ultrasonic transducer is that it is a noncontact level sensing device. In other words, the transducer does not come into direct contact with the media that is being pumped. In an environment where fluids with extreme pH and temperatures are being pumped, this can prove to be useful in the life span of the unit.

ENSCO 71 is a Jack-Up drilling rig which was originally constructed at the Hitachi Zosen shipyard in 1982.  The original GE motor controls comprised five 1163 KVA generators and four 1800 ADC SCR units with associated auxiliary transformer feeders and jacking units. The SCRs were assignable to two 1600 HP twin-motor Mud Pumps, a twin motor 2000 HP Drawworks and a 1000 HP Rotary Table. A separate feeder drives a 1110 HP Top Drive. A fifth SCR was added by Hill Graham Controls in 1985 to power a third 1600 HP Mud Pump, which was cabled to the main busbars.

In early 2012, a decision was made to add a fifth 2500 KVA generator and an additional auxiliary transformer, to close-couple these to the main switchboard via a bus tie circuit breaker, and to include a dedicated feeder for the fifth SCR. A sixth SCR was also included in the switchboard extension to provide an alternative drive source for the third Mud Pump, effectively removing this load from the main switchboard. The switchboard extension, including full integration with the existing GE and Hill Graham equipment, was engineered and built by Zeefax.

The Power System Study was completed by gathering data about the existing switchboard arrangement and comparing this to the original, hand written, fault level calculations. The new calculations were performed using software modelling and verified to IEC 61363. The IEC 61363 Short Circuit study represents conditions that may affect typical marine or offshore installations more significantly than land-based systems, including more emphasis on generator and motor decay. This confirmed the original calculations were accurate.

Industrial pumps are essential devices required in every phase of oil and gas operations. Basically, they help transfer process fluids from one point to another.

For example, a pump can be used to transfer crude oil from a storage tank to a pipeline and mud pumps are used to circulate drilling mud into the annulus of a drill bit and back to a storage tank for re-purification.

In oil and gas operations, process fluids can range from easy to difficult.  Depending on the nature of the substance you want to transfer and your required flow rate, you’ll need a suitable pump for your needs.

Various types of industrial pumps are utilized for fluid transfer in the oil and gas industry. Pumps used in O&G can be classified based on their design and construction and generally fall into 6 major categories:

Centrifugal pumps are the most common types of pumps used in the oil and gas industry. Centrifugal pumps use centrifugal force through the rotation of the pump impeller to draw fluid into the intake of the pump and force it through the discharge section via centrifugal force. The flow through the pump is controlled by discharge flow control valves.

Single stage centrifugal pumps are primarily used for transferring low-viscosity fluids that require high flow rates. They are typically used as part of a larger pump network comprising other centrifugal pumps like horizontal multistage pump units for crude oil shipping or water injection pumps used in secondary oil and gas recovery.

Plunger pumps are some of the most ubiquitous industrial pumps in the oil and gas industry. Plunger pumps use the reciprocating motion of plungers and pistons to pressurize fluid in an enclosed cylinder to a piping system. Plunger pumps are considered constant flow pumps since at a given speed, the flow rate is constant despite the system pressure. A relief valve is an essential part of any plunger pump discharge piping system to prevent overpressuring of the pump and piping system.

Plunger pumps require more frequent maintenance than centrifugal pumps due to the design of the moving parts. They also have a noisier operation than centrifugal pumps.

A progressive cavity pump is a type of positive displacement pump and is also known as an eccentric screw pump or cavity pump. It transfers fluid by means of the progress, through the pump, of a sequence of small, fixed shape, discrete cavities, as its rotor is turned. Progressive cavity pumps are used in high viscosity applications or if blending the of the pumped fluid is not desired.

Progressive cavity pumps are also considered constant flow pumps since at a given speed, the flow rate is relatively constant despite the system pressure. Flow slippage is normal at higher pressures. A relief valve is an essential part of any progressive cavity pump discharge piping system to prevent overpressuring of the pump and piping system.

Diaphragm pumps are one of the most versatile types of oil and gas pumps in the industry and transfer fluid through positive displacement with a valve and diaphragm. The working principle of this pump is that a decrease in volume causes an increase in pressure in a vacuum and vice versa.

Diaphragm pumps are suitable for high-volume fluid transfer operations in oil refineries. They also require much less maintenance than positive displacement pumps due to their fewer moving parts and less friction during operation and are available in compact designs.

On the downside, diaphragm pumps are susceptible to ‘winks’ – low-pressure conditions inside the system that slow down pumping operations. Fortunately, winks can be rectified by using a back-pressure regulator. For the same reason, they are not suitable for continuous or long-distance pumping operations as they generally don’t meet the high-pressure conditions required.

A gear pump uses the meshing of gears to pump fluid by displacement. Gear pumps are one of the most common types of positive displacement pumps for transferring industrial fluids.

Gear pumps are also widely used for chemical transfer applications for high viscosity fluids. There are two main variations: external gear pumps which use two external spur gears or timing gears that drive the internal gear set. The internal gears do not touch, so non-lubricating fluids can be pumped with external gear pumps. Internal gear pumps use a shaft driven drive gear to drive the internal mating gear. Gear pumps are positive displacement (or fixed displacement), meaning they pump a constant amount of fluid for each revolution.

Since the pumped fluid passes between the close gear tolerances, gear pumps are normally used for clean fluids. A relief valve is an essential component in the discharge piping system to protect the pump and piping from over pressurizing.

A metering pump moves a precise volume of liquid in a specified time period providing an accurate flow rate. Delivery of fluids in precise adjustable flow rates is sometimes called metering. The term “metering pump” is based on the application or use rather than the exact kind of pump used. Most metering pumps are simplex reciprocating pumps with a packed plunger or diaphragm liquid end. The diaphragm liquid end is preferred since the pumped fluid is sealed inside the diaphragm. No pumped liquid leaks to the atmosphere.

Optimizing production under dynamic well conditions requires flexible and adaptive electrical submersible pumping (ESP) solutions. ESP pumps from Baker Hughes incorporate innovative hydraulic designs to expand the application range of your ESP systems.

Our flexible pumps have the broadest operating range in the industry to deliver unsurpassed levels of efficiency, reliability, and speed to your production operations. You get customized pumping solutions to improve your operating economics, regardless of your field application.