mud pump liner definition factory

Zirconia Ceramic Liners are the ultimate in liner performance and durability. The offshore industry has made Zirconia liners the new industry standard.

Acumen International Zirconia liners are a proprietary based matrix that have significantly improved and superior mechanical characteristics. This translates to cost savings, better performance and significantly longer service hours than those of the commonly used alumina ceramic liners.

These three advantages equate to lower operating costs. The improved wear characteristics directly extend the service life of liner sleeve, while improved impact strength cuts down on the cost of replacing cracked liners. Additionally, a smoother and finer surface finish means less friction between the liner and piston, ultimately reducing temperature and improving piston life.

A mud pump (sometimes referred to as a mud drilling pump or drilling mud pump), is a reciprocating piston/plunger pump designed to circulate drilling fluid under high pressure (up to 7,500 psi or 52,000 kPa) down the drill string and back up the annulus. A mud pump is an important part of the equipment used for oil well drilling.

Mud pumps can be divided into single-acting pump and double-acting pump according to the completion times of the suction and drainage acting in one cycle of the piston"s reciprocating motion.

Mud pumps come in a variety of sizes and configurations but for the typical petroleum drilling rig, the triplex (three piston/plunger) mud pump is used. Duplex mud pumps (two piston/plungers) have generally been replaced by the triplex pump, but are still common in developing countries. Two later developments are the hex pump with six vertical pistons/plungers, and various quintuplexes with five horizontal piston/plungers. The advantages that these new pumps have over convention triplex pumps is a lower mud noise which assists with better measurement while drilling (MWD) and logging while drilling (LWD) decoding.

The fluid end produces the pumping process with valves, pistons, and liners. Because these components are high-wear items, modern pumps are designed to allow quick replacement of these parts.

To reduce severe vibration caused by the pumping process, these pumps incorporate both a suction and discharge pulsation dampener. These are connected to the inlet and outlet of the fluid end.

The pressure of the pump depends on the depth of the drilling hole, the resistance of flushing fluid (drilling fluid) through the channel, as well as the nature of the conveying drilling fluid. The deeper the drilling hole and the greater the pipeline resistance, the higher the pressure needed.

With the changes of drilling hole diameter and depth, the displacement of the pump can be adjusted accordingly. In the mud pump mechanism, the gearbox or hydraulic motor is equipped to adjust its speed and displacement. In order to accurately measure the changes in pressure and displacement, a flow meter and pressure gauge are installed in the mud pump.

The construction department should have a special maintenance worker that is responsible for the maintenance and repair of the machine. Mud pumps and other mechanical equipment should be inspected and maintained on a scheduled and timely basis to find and address problems ahead of time, in order to avoid unscheduled shutdown. The worker should attend to the size of the sediment particles; if large particles are found, the mud pump parts should be checked frequently for wear, to see if they need to be repaired or replaced. The wearing parts for mud pumps include pump casing, bearings, impeller, piston, liner, etc. Advanced anti-wear measures should be adopted to increase the service life of the wearing parts, which can reduce the investment cost of the project, and improve production efficiency. At the same time, wearing parts and other mud pump parts should be repaired rather than replaced when possible.

The present invention relates to mud pumps of the triplex-type which are used in conjunction with a rotary oil well drilling operation to pump a mud mixture down through the drill pipe for removing drilled earth formations.

Pumps of this character have three cylinders in which each cylinder includes a piston reciprocated by a piston rod. The cylinder communicates with suction and discharge valve equipped chambers so that, as the piston is reciprocated by the piston rod, drilling fluid will be alternately drawn into and discharged from the working chambers. Since the material pumped is of an abrasive character, the wear on the piston and cylinder wall is quite severe and it has been common practice, in order to more easily repair a worn pump, to provide each cylinder with a replaceable steel liner which reciprocably supports the piston in the cylinder, however, as mentioned above, the abrasive drilling fluid results in a relatively short life for the liner and piston.

Prior patents generally relate to seals between the liner and cylinder walls and between the piston and liner in which the life of the seals is lengthened by forming fluid channels through the piston rod and piston between its end seals for conducting oil and/or water to lubricate the seals and reduce the abrasive action of the drilling mud particles.

This invention approaches the liner and piston wear problem from a different standpoint, namely, by washing drilling mud abrasive particles off the liner in the path of movement of the piston therein which is accomplished by providing conductors supported by the liner and applying streams of water to the bore of the liner and surface of the piston.

A split tubular ring, having closed ends, forms a fluid reservoir substantially surrounding the end portion of a pump liner projecting outwardly of the cylinder housing in the direction of the piston rod connected with the piston, the split ring being secured to the liner by set screws. A pump supplying a source of water is connected with the perimeter of the fluid reservoir. A plurality of tubes are connected in radially spaced relation at one end to the tubular ring with the other end of the tubes being open and turned inwardly toward the inner wall surface of the liner to direct a like plurality of streams of water impinging on the inner surface of the liner during operation of the piston.

The principal object of the invention is to provide a device for connection with a mud pump liner for directing streams of fluid against the inner surface of the liner for removing abrasive material clinging thereto and lengthen the life of the liner and its contained piston.

The reference numeral 10 indicates a fragment of a triplex mud pump having a cylinder 12 communicating with valve equipped intake and exhaust chambers 14 in turn connected with mud supply lines, not shown. The cylinder is equipped with a sleeve-like liner 16 projecting at one open end outwardly of the cylinder in the direction of a piston rod 18 connected with a piston 20 for reciprocation in the liner 16 and pumping mud from a mud circulating pit to a drill string, neither of which are shown.

The numeral 22 indicates the device which is substantially coaxially mounted on the outwardly projecting end of the liner 16 adjacent its outwardly projecting end. The device 22 comprises a closed end length of tubing 24 of selected diameter forming a fluid reservoir 25. The tube 24 is arcuately curved in split ring fashion on a diameter slightly greater than the outside diameter of the liner 16 and having its respective closed ends 26 spacedapart a distance at least greater than the diameter of the piston rod 18. The inner perimeter of the tube 24 is rigidly secured, as by welding, indicated at 28, to a coextensive similarly arcuately curved section of strap metal 30.

A pair of set screws 32, each extending through a threaded sleeve 34 adjacent the closed ends of the tube 24, bear against the outer surface of the liner 16 to maintain the reservoir inner periphery substantially concentric with the liner.

An inlet line 36 is connected at one end by a collar 37 welded to the tube 24 for communication with the reservoir 25 and is connected at its other end with a pump P in turn connected with a source of water, not shown. A plurality, three in the example shown, of relatively small diameter tubes 38 are connected, at one end by fittings 39, and communicate with the reservoir 25 in circumferentially spaced relation. Each of the tubes 38 are arcuately curved toward the axis of the reservoir with their open ends 40 turned inwardly and directed toward the inner surface of the liner to apply a like plurality of streams of water under greater than atmospheric pressure, in the direction of the arrows 42, which wash abrasive particles off the inner surface of the liner.

Internal cavities of metal objects frequently require a cladding, or a coating, that is more corrosion, oxidation and/or wear resistant than the metal object itself. This need may arise in some cases due to high temperatures created within the cavity, exposure to a corrosive or abrasive liquid, and/or to rubbing action of an internal machine member such as a piston. An example of such a metal object is the liners in mud pumps used in oil field drilling. A mud pump is a part of the oil or gas well drilling fluid circulating system, one of five major components of a rotary drilling operation. The other components are the drill string and bit, the hoisting system, the power plant and the blowout prevention system.

Drilling fluid, usually called the "mud", in most cases consists of a mixture of water, various special chemicals including corrosion inhibitors and solid particles such as Barite to increase its density. Such fluid is continuously circulated down the inside of the drill pipe, through the bottom of the bit and back up the annular space between the drill pipe and the hole. The driving force is provided by a mud pump.

A mud pump liner is basically a heavy wall pipe section with one or two retaining rings at its outer diameter. It is the wear resistance of the inner surface that determines the liner service life. Consequently, the internal surface of the liner is desirably clad with a wear resistant material. The internal cladding layer is subjected to sliding wear by the rubber piston which can wear and cause metallic structure supporting the rubber to contact the liner cladding, thus accelerating the wear process. The cladding material is also subjected to corrosion from the drilling fluid, and metal fatigue caused by cyclic loading, especially at areas where the direction of the piston motion suddenly changes, Further, micro regions of cladding may experience sudden pressurization and depressurization. These operating conditions impose stringent metallurgical requirements on the cladding materials. An ideal cladding material should, therefore, possess high hardness and high resistance to corrosion, impact and metal fatiuge. Such properties are desirably achieved by a uniform, fine grained microstructure, which has been the goal of pump liner makers of many years.

The outer, heavy wall portions of the commercially available mud pump liners typically consist of either a carbon steel, or a low alloy steel; and the liner cladding is, in most cases, a cast sleeve of iron--28% chromium alloy. The sleeve can be centrifugally cast into the steel pipe section or cast separately as a pipe, and shrink fitted into the outer pipe section, then machined to a smooth finish. These manufacturing procedures are lengthy and costly, while providing only a cast metal microstructure which is known to be chemically nonuniform, since in castings the solidification process results in natural segregation of the elemental species contained in the alloy. Furthermore, the cladding thicknesses are kept undesirably large to allow casting processes to be used. The claddings within metallic objects other than pump liners can be similarly characterized and most likely be prone to the same deficiencies.

It is a major object of the invention to provide a powder metal cladding method and apparatus for cladding the internal cavity surface of metal liners and objects, overcoming the above problem and deficiencies. In addition, the invention provides various material combinations for the production of pump liners and internally clad pipe segments for use with oilfield mud pump fluids. There are many other products that can benefit from this processing technique.

As will appear, pressurization of the grain is typically carried out by transmitting force to the grain along a primary axis, the layer extending about that axis and spaced therefrom, whereby force is transmitted by the grain away from the axis and against said layer. To this end, the method contemplates providing a die having a first chamber receiving said object, the die having a second chamber containing grain communicating with grain in the cavity, pressurizing of the grain in the cavity being carried out by pressurizing the grain in the second chamber, as for example by transmitting pressure from the grain in the second chamber to only a medial portion of the grain in the first chamber everywhere spaced from said layer. Further, the metal object is typically cylindrical, the layer being applied on an internal cylindrical surface of said object, the latter for example comprising a mud pump liner.

Referring first to FIG. 1, and alloy steel mud pump liner 10 comprises an elongated tube 11 having an outer flange 12 on one end portion. The tube axis appears at 13, and the tube inner cylindrical surface at 14. Tube 11 may be considered to represent other metal objects having interior surfaces (as at 14) facing internal cavities 15.

Referring to FIG. 2, the next step in the process is to place the liner containing the green now lightly sintered layer 11a within a step die 19 where the liner fits into the large cavity (i.e. first chamber 19) in the die as shown in the figure, and having inner cylindrical walls 19a and 19b. The die second chamber 20 throat diameter D1 should be equal to or smaller than the "green" internal diameter D2 of the mud pump liner 11a. This assures relatively shearless pressing of the green powder metal cladding 11a under largely lateral pressure during the pressurizing step. Chamber 20 has a bore 20a.

As seen in FIG. 3, pressurization takes place in a press 21 after filling both the die and the pump liner cavities with a refractory powder 22 already at a temperature near or above the consolidation temperature of the cladding powder. The pressure from ram 23 is transmitted to the liner by the horizontal forces created within the refractory powder grains. In this regard, the second chamber 20 is in axial alignment with the first chamber 19, the second chamber having a cross section less than the cross section of the first chamber, whereby pressure is transmitted from the grain 22a in the second chamber to only a medial portion of the grain 22b in the first chamber which is everywhere spaced from layer 11a. Therefore, lateral pressurizing of the grain in the cavity 19 is affected by grain pressurized longitudinally in the second chamber, and no destructive shear is transmitted to layer 11a.

The process, while remaining basically the same, may have some variations. For example, there may be an insulating material positioned between the part (the pump liner in FIG. 2) and the die to reduce heat loss before pressing.

Lake Petro provides high quality Mud Pump Parts including Mud Pump Liners, Mud Pump Fluid End Module, piston, Valve and Seat etc. With more than 10 years of experience in the oil and gas industry, we are dedicated to help and support our loyal clients with the most cost-effective and quality Liners and Pistons. We also provide mud pump price and mud pump for sale.

We offer Liners with Ceramic (Zirconia and Aluminium oxide) and Steel (Metal and Bi-metal) materials for all common brands of the mud pump and triplex mud pump.

Bi-metal liners (double metal liners) are made of forged steel shell and wear-resistant sleeve of high chromium iron. In the production process, the size accuracy should be strictly controlled, which can ensure that they can be easily and stably installed. The inner sleeve with high finish and hardness is wear-resistant, corrosion-resistant and has a long service life. The bi-metal liners are suitable for a lot of bad working conditions. Its service life is more than 800 hours.

Ceramic Liners are made of a ceramic inner sleeve and a forged steel outer shell. The service life of ceramic liners is about 4000 to 10000 hours, the minimum time is at least 2000 hours, which is a lot more than bi-metal liners. Because of the phase transformation toughen technology, the ceramic liners have the features of wear-resistance, erosion-resistance, high-pressure-resistance, high hardness and strength. Zirconia type and Alumina type are common type of ceramic sleeve. Compared with Alumina type, Zirconia type liners have better toughness properties and a much longer service life. Piston wear and water consumption for lubrication can be reduced as well.

Seal Rings for Liner packing are also important. Liner Seal Rings is designed and made with hard corner which is an integral part of seal rings and soft nitrile element rubber center. We could provide reliable liner Seal Rings for our customers could order them at the same time.

All Lake Petro liner products are interchangeable with O.E.M. products. Meanwhile, we provide customized Liners according to drawings. Our liners, also with our other mud pump spares, are supplied for use in Honghua, F-Series, Bomco, Emsco and National lines of triplex drilling pumps. Let Lake Petro be your one-stop shop for your whole fleet of pumps. Please refer to “Suitable Pump Models” Lable for more details.

Function: Mud Pump Liner also called the cylinder liner. The cylinder liner is the core accessory of the mud pump, which has the functions of storing mud, bearing pressure and completing the suction and discharge of mud. Because the cylinder liner is in direct contact with the mud, it is easy to be worn and corroded by the tiny sand particles, acid and alkali liquid in the mud during work. As a result, the inner diameter of the cylinder liner becomes larger, leakage occurs in the seal between the cylinder liner and the piston, and the pressure is reduced. The cylinder liner is scrapped eventually. Cylinder liner is a one-time wearable part that cannot be reused, and its life span directly affects the normal operation and cost of the drilling operation.

Bimetal Liners are also known as double metal liners. Forged steel pipe 45# (ASTM1045) is used for the outer sleeve, the normalizing hardness: 160BHN (HB180-200); elongation: 17%; tensile strength is not less than 85000PSI; yield strength is not less than 60000 PSI; The inner sleeve material is high chromium wear-resistant cast iron, with chromium content of 26-28%; thickness is 0.25 to 0.35 inches (6.35-8.89 mm), and the standard thickness is 7 mm. Usually, the service life is 800 hours under normal drilling conditions.

The inner liner is made of zirconia or aluminium oxide, and the outer sleeve is made of 45# (ASTM1045) forged steel. It has the advantages of more wear resistance, corrosion resistance, high-pressure resistance, high-temperature resistance, high strength and high hardness than metal cylinder liners. The service life is more than 4000 hours under normal drilling conditions.

The piston assembly is one of the main parts of the hydraulic end system of the mud pump, and it is also one of the vulnerable parts of the drilling work. The discharge pressure of the mud pump is generated by the reciprocating linear movement of the piston assembly in the piston.

Polyurethane rubber has excellent oil resistance and wear resistance. The working temperature is not higher than 120℃, which is suitable for oil-based mud with working pressure below 35Mpa and working environment with high sand content.

Lake Petro has over 10 years of experience in Liners and Pistons, we export a large amount of mud pump parts to many countries and regions in the world. If you are interested in any of our products, please contact sales@lakepetro.com.

As usual, winter — or the slow season — is the time most drillers take the time to maintain their equipment in order to get ready for the peak season. One of the main parts that usually needs attention is the mud pump. Sometimes, it is just a set of swabs to bring it up to snuff, but often, tearing it down and inspecting the parts may reveal that other things need attention. For instance, liners. I can usually run three sets of swabs before it is time to change the liner. New liners and swabs last a good long time. The second set of swabs lasts less, and by the time you put in your third set of swabs, it’s time to order new liners. Probably rods too. It’s not always necessary to change pistons when you change swabs. Sometimes just the rubber needs to be changed, saving money. How do you tell? There is a small groove around the outside of the piston. As it wears, the groove will disappear and it’s time for a new piston.

The wear groove on a piston can be a good indicator of the general health of your pump. If the wear is pretty even all around, chances are the pump is in pretty good shape. But if you see wear on one side only, that is a clue to dig deeper. Uneven wear is a sign that the rods are not stroking at the exact angle that they were designed to, which is parallel to the liner. So, it’s time to look at the gear end. Or as some folks call it, “the expensive end.”

The wear groove on a piston can be a good indicator of the general health of your pump. If the wear is pretty even all around, chances are the pump is in pretty good shape. But if you see wear on one side only, that is a clue to dig deeper.

After you get the cover off the gear end, the first thing to look at will be the oil. It needs to be fairly clean, with no drill mud in it. Also look for metal. Some brass is to be expected, but if you put a magnet in the oil and come back later and it has more than a little metal on it, it gets more serious. The brass in the big end of the connecting rod is a wearable part. It is made to be replaced at intervals — usually years. The most common source of metal is from the bull and pinion gears. They transmit the power to the mud. If you look at the pinion gear closely, you will find that it wears faster than the bull gear. This is for two reasons. First, it is at the top of the pump and may not receive adequate lubrication. The second reason is wear. All the teeth on both the bull and pinion gears receive the same amount of wear, but the bull gear has many more teeth to spread the wear. That is why, with a well maintained pump, the bull gear will outlast the pinion gear three, four or even five times. Pinion gears aren’t too expensive and are fairly easy to change.

This process is fairly straightforward machine work, but over the years, I have discovered a trick that will bring a rebuild up to “better than new.” When you tear a pump down, did you ever notice that there is about 1-inch of liner on each end that has no wear? This is because the swab never gets to it. If it has wear closer to one end than the other, your rods are out of adjustment. The trick is to offset grind the journals. I usually offset mine about ¼-inch. This gives me a ½-inch increase in the stroke without weakening the gear end. This turns a 5x6 pump into a 5½x6 pump. More fluid equals better holes. I adjust the rods to the right length to keep from running out the end of the liner, and enjoy the benefits.

Other than age, the problem I have seen with journal wear is improper lubrication. Smaller pumps rely on splash lubrication. This means that as the crank strokes, the rods pick up oil and it lubricates the crank journals. If your gear end is full of drill mud due to bad packing, it’s going to eat your pump. If the oil is clean, but still shows crank wear, you need to look at the oil you are using.

Oil that is too thick will not be very well picked up and won’t find its way into the oil holes in the brass to lubricate the journals. I’ve seen drillers that, when their pump starts knocking, they switch to a heavier weight oil. This actually makes the problem worse. In my experience, factory specified gear end oil is designed for warmer climates. As you move north, it needs to be lighter to do its job. Several drillers I know in the Northern Tier and Canada run 30 weight in their pumps. In Georgia, I run 40W90. Seems to work well.

For the successful execution of your projects, it is important to find an appropriate company with a good track record. We help you in connecting with the top mud pump manufacturers and companies and get the best quotation.

The most widely used mud pumps across the industry are Triplex Reciprocating Pumps. Their application has gained immense popularity with time because they are 30% lighter than duplex reciprocating pumps with relatively less operational cost. Moreover, through these pumps the discharge of mud is smooth and they are capable of moving large volume of mud at higher pressure.

Yes. We help you find the best mud pumps irrespective of your location. We simplify your search by connecting you with top mud pump manufacturers and mud pump companies in your location, according to your budget and business requirement.

The most widely used mud pumps across the industry are Triplex Reciprocating Pumps. Their application has gained immense popularity with time because they are 30% lighter than duplex reciprocating pumps with relatively less operational cost. Moreover, through these pumps the discharge of mud is smooth and they are capable of moving large volume of mud at higher pressure.

The different parts of a mud pump are Housing itself, Liner with packing, Cover plus packing, Piston and piston rod, Suction valve and discharge valve with their seats, Stuffing box (only in double-acting pumps), Gland (only in double-acting pumps), and Pulsation dampener. A mud pump also includes mud pump liner, mud pump piston, modules, hydraulic seat pullers along with other parts.

The wearing parts of a mud pump should be checked frequently for repairing needs or replacement. The wearing parts include pump casing, bearings, impeller, piston, liner, etc. Advanced anti-wear measures should be taken up to enhance the service life of the wearing parts. This can effectively bring down the project costs and improve production efficiency.