mud pump inspection checklist price

Created specifically for drilling equipment inspectors and others in the oil and gas industry, the Oil Rig Mud Pump Inspection app allows you to easily document the status and safety of your oil rigs using just a mobile device. Quickly resolve any damage or needed maintenance with photos and GPS locations and sync to the cloud for easy access. The app is completely customizable to fit your inspection needs and works even without an internet signal.Try Template

Fulcrum helps us improve our processes and make our work environment safer by streamlining inspections, surfacing inspection-related insights, and managing follow-up actions. Once you close the loop from action to insight to further action, the possibilities are limitless.

Instead of using paper checklists when out in the field, drilling contractors and rig inspection services can generate a new inspection form from anywhere and the results are saved electronically.

Specifically designed for drilling companies and others in the oil and gas industry, the easy to use drilling rig inspections app makes it easy to log information about the drill rigs, including details about the drill rigs operators, miles logged and well numbers. The inspection form app covers everything from the mud pump areas and mud mixing area to the mud tanks and pits, making it easy to identify areas where preventative maintenance is needed. The drilling rig equipment checklist also covers health and safety issues, including the availability of PPE equipment, emergency response and preparedness processes, and other critical elements of the drilling process and drill press equipment.

Cavitation is an undesirable condition that reduces pump efficiency and leads to excessive wear and damage to pump components. Factors that can contribute to cavitation, such as fluid velocity and pressure, can sometimes be attributed to an inadequate mud system design and/or the diminishing performance of the mud pump’s feed system.

Although cavitation is avoidable, without proper inspection of the feed system, it can accelerate the wear of fluid end parts. Over time, cavitation can also lead to expensive maintenance issues and a potentially catastrophic failure.

When a mud pump has entered full cavitation, rig crews and field service technicians will see the equipment shaking and hear the pump “knocking,” which typically sounds like marbles and stones being thrown around inside the equipment. However, the process of cavitation starts long before audible signs reveal themselves – hence the name “the silent killer.”

Mild cavitation begins to occur when the mud pump is starved for fluid. While the pump itself may not be making noise, damage is still being done to the internal components of the fluid end. In the early stages, cavitation can damage a pump’s module, piston and valve assembly.

The imperceptible but intense shock waves generated by cavitation travel directly from the fluid end to the pump’s power end, causing premature vibrational damage to the crosshead slides. The vibrations are then passed onto the shaft, bull gear and into the main bearings.

If not corrected, the vibrations caused by cavitation will work their way directly to critical power end components, which will result in the premature failure of the mud pump. A busted mud pump means expensive downtime and repair costs.

To stop cavitation before it starts, install and tune high-speed pressure sensors on the mud suction line set to sound an alarm if the pressure falls below 30 psi.

Although the pump may not be knocking loudly when cavitation first presents, regular inspections by a properly trained field technician may be able to detect moderate vibrations and slight knocking sounds.

Gardner Denver offers Pump University, a mobile classroom that travels to facilities and/or drilling rigs and trains rig crews on best practices for pumping equipment maintenance.

Severe cavitation will drastically decrease module life and will eventually lead to catastrophic pump failure. Along with downtime and repair costs, the failure of the drilling pump can also cause damage to the suction and discharge piping.

When a mud pump has entered full cavitation, rig crews and field service technicians will see the equipment shaking and hear the pump ‘knocking’… However, the process of cavitation starts long before audible signs reveal themselves – hence the name ‘the silent killer.’In 2017, a leading North American drilling contractor was encountering chronic mud system issues on multiple rigs. The contractor engaged in more than 25 premature module washes in one year and suffered a major power-end failure.

Gardner Denver’s engineering team spent time on the contractor’s rigs, observing the pumps during operation and surveying the mud system’s design and configuration.

The engineering team discovered that the suction systems were undersized, feed lines were too small and there was no dampening on the suction side of the pump.

Following the implementation of these recommendations, the contractor saw significant performance improvements from the drilling pumps. Consumables life was extended significantly, and module washes were reduced by nearly 85%.

Although pump age does not affect its susceptibility to cavitation, the age of the rig can. An older rig’s mud systems may not be equipped for the way pumps are run today – at maximum horsepower.

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.

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.

As it is the case with most equipment, pumps require regular maintenance to keep within peak performance benchmarks. The benefits of preventive maintenance in the HVAC industry have proven to improve asset life cycle, boost CRM, cut excessive repair costs and reduce unplanned equipment downtime.

When talking about pump failure the best remedy is having a great schedule and maintenance checklist in place. In a pump’s life cycle, environmental conditions can often be a major factor in its performance. Some other important maintenance tasks and factors to consider include:

All of these issues can be detrimental to a pump’s performance and cause defects if not resolved with regular maintenance. When considering what to include in your regular maintenance checklist a great place to start is the warranty and manufacturer standards as per pump type. Pump manufacturers often set requirements to follow to ensure the best life cycle for your equipment.

Pump efficiency point is the result of hydraulic, mechanical and volumetric parts to ensure performance is within a desired level. The level of efficiency in a pump is drawn from the units of energy that is required for performance.

However in centrifugal pumps, the inner workings of the pump will drive the motor. Essentially this means the mechanical energy is transformed to hydraulic energy and electrical energy is transformed to mechanical energy. This means that for a centrifugal pump you will find your level of efficiency sits at either 75% or higher in larger pumps and around 60% in smaller pumps.

As a part of your work order management for your pump maintenance schedule, you need to do some research behind what factors you need to consider that will be most detrimental to your pump’s health. When you create your ultimate guide to maintenance, your aim is to reduce your unplanned downtime and improve your standard of service by keeping a regular schedule.

When trying to determine the frequency of your maintenance checklist, you need to consider the factors that will impact your pump listed in the beginning of this article. If you have a higher quality pump that is used every day and is largely impacted by elemental factors, you will need to have more regular services in place. The warranty and safety standards will also have an impact here, depending on your pump type and according to the manufacturer’s instructions.

The more thorough your maintenance is, the better service you can provide. While a large maintenance schedule can seem daunting to your maintenance team, the assistance of checklists can ensure no step is missed no matter how big or small. Having a checklist in place will also provide consistency across your team and ensure each pump may receive the correct care it needs.

The main area for concern in centrifugal pumps is the lubrication. As centrifugal pumps rely heavily on correct lubrication to work, maintenance is important to ensure pumps aren’t under or over lubricated, which can cause damage. When you have over lubrication your pump will create too much heat and can result in frothing the oil.

Getting your maintenance plan right means you consider all these above factors and are able to incorporate them into your pump checklist and schedule.

For this checklist, you want to schedule a quick inspection of your pumps to avoid damage and wear. The main reason for having a daily checklist in your schedule is to catch those pesky issues that can turn into defects and pricey repairs if not caught early on.

Generally your quarterly maintenance will be done with the change of the season and can include varying tasks due to elemental factors. The severity of your pump environment will also affect the consistency and schedule of your pump maintenance program. Will your pump be exposed to extreme heat or extreme cold temperatures?

In your annual preventive plan, you will generally go into more detail and evaluate pump performance. Each year you should take a record of your annual operations and benchmarking data that might include:

For your routine maintenance schedule for your centrifugal pumps you need to make sure you have a solid system in place where you can reliably plan and train your team. Having a great software in place will also give you the ability to structure your maintenance program according to the manufacturer’s instructions and adhere to your customer contracts.

Job management software like FieldInsight gives you the ability to keep your centrifugal pump maintenance in perfect balance. With FieldInsight, you also gain access to the five primary automations in your business:

A pump that lets you down when you need it most causes obvious losses of time and money. Not so obvious, but every bit as costly, are losses you can incur with pumps that operate at less-than-peak efficiency. A pump laboring under the handicap of a suction line air leak, a corroded discharge line or a clogged impeller uses excessive energy, takes longer than necessary to do the job, and subjects parts to undue stress, causing premature failure.

A 6-inch gasoline-driven, self-priming centrifugal pump operating at 25% less than peak efficiency through an eight-hour day uses approximately 8.8 gallons more fuel than a pump operating efficiently. At $2.00 per gallon over a 40-hour week that’s $80.00 per week LOST! And that figure doesn’t include additional service costs!

Gorman-Rupp wants to keep your pump performance efficient. If you already own Gorman-Rupp pumps, you know how easy they are to service, so there is really no reason to let them deliver less than their best.

If you don’t own Gorman-Rupp pumps, you’ll find our 9-point checklist helpful because today every penny of profit counts, and we want your pumps to work as efficiently as possible.

Indications that your pump isn’t operating at peak efficiency may not be dramatic, but they’re easily recognized. Look for these signs of inefficiency:

There is a noticeable difference in pump flow. Has the discharge flow visibly decreased? Is it taking your pump longer to do the same job than it used to? The slow-up might be caused by a collapsed suction hose lining, a leaking gasket, a plugged suction line, or a damaged or worn impeller or wear plate.

Your pump isn’t re-priming as rapidly as it once did. Most commonly, slower re-prime can be attributed to excessive face clearance. If this is not the cause of your slowdown, check the following: Is the seal leaking? Are all hardware at gaskets tight? Is the suction check valve sealing properly? Is the cutwater section of the volute badly worn? Is the recirculating port clogged?

Your pump is making excessive noise. Does it sound like a bunch of marbles rattling in a can? This may be an indication of cavitation and could be caused by a suction lift that’s too high, a suction hose that’s too long or plugged or that has a collapsed lining, a clogged strainer, a combination of any of these, or perhaps a problem on the discharge side of the pump. Failing bearings can also cause excessive noise.

Your pump is clogging frequently. The suction check valve may be clogged, the strainer may be too large or too small, face clearance could be too wide, or the strainer may be stuck in mud, plugging the suction side.

Your pump is overheating. Very likely the flow of liquid into or out of the pump is being restricted. Improper impeller clearance could be slowing re-priming, or the suction strainer may be clogged.

Although this list is not a complete guide to pump inspection and service, it does cover the more common conditions that can impair pump efficiency. Keep in mind that excessive wear could also be the cause of any of the problems in the above paragraphs.

Check for air leaks. Using a vacuum gauge, make sure that the suction line, fittings and pipe plugs are airtight. Most Gorman-Rupp pumps have a tapped hole for easy connection of a vacuum gauge. Use pipe dope to seal gauge threads and pipe plugs. Replace leaky seals and badly worn hoses.

Check the suction hose lining. The rubber lining in a suction hose can pull away from the fabric, causing partial blockage of the line. If the pump develops a high vacuum but low discharge pressure, the hose lining may be blocking suction flow. Replace the hose.

Check the suction strainer. Frequent inspection and cleaning of the suction strainer is particularly important when pumping liquids containing solids. Always use the proper size strainer to prevent the pump from clogging.

Check the impeller vanes, wear plate or wear rings. The removable cover plate on many Gorman-Rupp pumps provides quick, easy inspection of the impeller and wear plate. These components should be inspected every six months or sooner, depending on pump application. They are subject to faster wear when pumping abrasive liquids and slurries. Gorman-Rupp wear plates and wear rings can be replaced without replacing expensive castings.

Check the impeller clearance. Pumping efficiency will be reduced if the clearance between impeller and wear plate or wear rings is beyond the recommended limits. If the clearance is less than recommended, components will wear by rubbing, causing excess work for the engine or motor. Check the impeller clearance against the pump manual specifications and adjust it if necessary.

Check the seal. Many Gorman-Rupp pumps are equipped with a double seal which is lubricated under pressure by a spring-loaded grease cup, or an oil-lubricated seal for long, trouble-free service. Some pumps are equipped with a single seal that is lubricated by the liquid being pumped. Sand or other solids can cause rapid wear of the seal faces. Check and replace the seal if worn. Replace the seal liner or shaft sleeve if they have scratches.

Check the bearings. Worn bearings can cause the shaft to wobble. Eventually the pump will overheat, and sooner or later it will freeze up and stop. Replace bearings at the first sign of wear.

Check the engine or motor. The pump may not be getting the power it needs to operate efficiently. The engine may need a tune-up, or the motor may need service.

If your submersible pump is operating at a reduced capacity, it could be caused by a worn impeller, excessive impeller clearance, low or incorrect voltage, or it could be running backward. A discharge head that’s too high, a clogged or kinked hose, or a clogged strainer could also be responsible for reduced flow. Use an amp meter and volt meter to determine if the pump is getting the proper power it needs to operate efficiently. Normal amp readings are provided in the manual accompanying your pump.

If your diaphragm pump isn’t pumping as it should, check the diaphragm, suction and discharge check valve flappers and seats, and replace any worn parts. Check suction hose fittings for leaks, and check the plunger rod for proper adjustment.

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.

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.

The PZ 2400 features a Y-shaped module design, meaning less stress is placed on the pumps internal components and higher flow rates can be achieved with improved fatigue life.

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The maintenance checklist, implemented a few months ago, covers equipment to monitor on a daily, weekly, and monthly basis. An area is devoted to tracking service truck miles, rig miles and hours, as well as welder hours to know when an oil change is needed. The goal is to not let any maintenance task fall by the wayside.

Months into implementing the maintenance checklist, Baker is seeing his drill crews take ownership by noticing minor issues on their four drill rigs and making note of them. The crews then look at the list and fix the issues during half a day in the shop while they’re in between jobs, or at a jobsite when time allows for it.

“Hydraulics, pumps, and motors have an ISO cleanliness code on the oil,” Baker explains. “If you run that hydraulic system within that cleanliness code at 70 degrees in a controlled environment, you’re going to get 10,000 hours out of your pumps.

“When putting the pumps on mobile equipment, it cuts it in half, so you get 5000 hours on pumps because they’re working in the extreme heat, cold, and dirt. As long as you maintain that cleanliness code in your oil, you can expect 5000 hours, but as soon as you go one code dirtier in your oil, you cut that in half. If you can operate one code cleanlier you can double it, and so we’re trying to operate in a manner that is not necessarily normal in an effort to try and get our equipment to last longer. Ultimately, it reduces our cost of maintenance.”

Sprowls, president of the Ohio Water Well Association, also shared how hydraulic oil in the GEFCO 40K came back with elevated metal content. He says nothing indicated that the hydraulics were acting up, but the oil sample prompted further investigation which revealed a hydraulic pump failed prematurely.

Sprowls stresses that maintenance needs to be intentional where time is made for it. He makes a point that being proactive is less stressful than reacting to an engine replacement in a customer’s front yard. After all, it’s much easier to work on the machines in a climate-controlled shop or gravel lot with no mud.

“What I’ve done for routine items is put a value on them that is relevant to our industry,” he shares. “Most drilling is accounted for by the foot, so I will analyze what kind of drilling I’m doing and put a footage on it. For example, I grease the rig every so many feet of overall drilling. If I’m mud drilling, the mud pump and swivel get greased very well, no matter the footage. Air drilling may be more frequent on the swivel due to the temperatures.

“The main reason Layne is dedicated to a robust equipment inspection/maintenance program is the safety of our employees,” Snelten says. “If we can keep our equipment safe to operate, it reduces the hazards to our employees and helps prevent injuries. They go home to their families at the end of the day in the same condition they came to work.

Layne rolled out a new maintenance program in 2021 for its several thousand pieces of equipment—drill rigs, pump rigs, trucks, trailers, and support equipment—and for the roughly 350 field staff who operate them.

The program consists of daily, monthly, and annual inspections of the drill rigs, pump rigs, and service trucks. Inspection items include fluid levels, wire ropes, sheaves, frame welds, controls, emergency stops, etc. A copy of the inspection goes to the field superintendent and mechanic and repairs

Since the NOV A1700-PT Triplex Mud Pump was built approximately 60 years ago, the industry has widely accepted the three cylinder or triplex style pump. Triplex mud pumps are manufactured worldwide, and many companies have emulated the original design and developed an improved form of the triplex pump in the past decade.

NOV A1700-PT Triplex Mud Pumps have many advantages they weight 30% less than a duplex of equal horsepower or kilowatts. The lighter weight parts are easier to handle and therefore easier to maintain. The other advantages include;They cost less to operate

One of the more important advantages of triplex over duplex pumps, is that they can move large volumes of mud at the higher pressure is required for modern deep hole drilling.

NOV A1700-PT Triplex Mud Pump is gradually phasing out duplex units. In a triplex pump, the pistons discharge mud only when they move forward in the liner. Then, when they moved back they draw in mud on the same side of the piston. Because of this, they are also called “single acting.” Single acting triplex pumps, pump mud at a relatively high speeds. NOV A1700-PT Triplex Mud Pump has three pistons each moving in its own liner. It also has three intake valves and three discharge valves. It also has a pulsation dampener in the discharge line.