mud pump flush procedure brands

Tired of changing mud pump pistons? We have your solution. The TD will work in all types of drilling mud including oil based, synthetic and water based. It was specifically designed to work in applications where water based mud is used or in situations where WBM is used on the top side & OBM is used on the bottom end. This eliminates the need for changing the piston midway through the drilling program. The “TD” or “Total Depth” name reflects our commitment to make a single piston that will last from “spud” to “TD”. This piston has been engineered with a unique friction reducing material bonded into the urethane of the sealing lip. Because the TD is built to withstand friction in the liner, wear on your parts is minimized and savings is maximized. The Patriot™ TD is also designed to meet pressures of 7500 psi as well as temperatures up to 220 degrees.

Pipe flushing is the process where pipework is flushed using a pump and a specific fluid to remove impurities, flush sludge or oil from extensive runs of pipework. Pipe flushing can also be performed on new pipework which has recently been installed to ensure contaminants are removed using freshwater and foam pigs or spherical cleaning balls which scrape the walls with foam removing any dirt or particles.

Drilling consumables such as mud pump systems and their components can drastically increase your uptime while reducing costs and health/safety/environmental (HSE) risks. To support your drilling needs, Forum’s patented P-Quip® mud pump system offers a single-source solution that integrates high-quality fluid end components for maximum longevity and performance.

With more than 20 years of successful operation in severe environments, P-Quip offers a proven track record for the lowest cost of ownership in the industry. As part of our commitment to quality, our mud pump parts use patented Banded Bore™ technology that significantly reduces stress concentrations and leads to longer module life.

Problem:Water activated chemical grouts and time sensitive epoxies can greatly shorten the life of the pump if not properly cleaned from the pump after each use. This can result in time consuming rebuilds of seals and packing’s as well as cleaning the internal components of the pump. Internal pressure control sensors can also be affected by deposits left behind from improper cleaning and can cause the pump to not shut off at the prescribed pressure.

Always use Prime Flex Eco-Flush. It’s formulation of powerful organic solvents and iso-neutralizers help insure any residual water activated materials left in the pump will be non-reactive.

Turn the pump to the “OFF POSITION,” make sure dispensing valves are in the “OFF” position. Set the pressure dial to the lowest pressure setting above “pulse clean” that will still run the pump.

Switch the pump into the “Primer Position” and turn the pump to the “ON POSITION,” allow the pump to run until the small siphon tube is completely clear of resin, and then turn the pump “OFF.”

Place the small siphon tube into the Eco-Flush pail, and turn the pump on to re-circulate. After one minute switch the pump into the “Spray Position.”

After the pump primes up, carefully open the dispensing valve into the resin pail to reclaim the material held in the hose. There will be an air pocket in the line that will signal you when to stop the purge. At that point dispense the remaining resin left in the line into your waste pail until a clear stream of Eco-Flush is dispensed from the gun.

Redirect the gun into the Eco-Flush pail to re-circulate flush through the pump. Add additional Eco-Flush at this point if necessary. Turn the pressure dial on the pump to “Pulse Clean.” Allow the pump to re-circulate for 2 minutes. Switch the pump from the “Primer” setting and back to the “Spray” setting several times during the re-circulation process.

This used Eco-Flush should be used for the “Initial Flush” sequence only. You should be able to get 3 – 5 reuses out of the Eco-Flush solvent. When the Eco-Flush is too dark to see through, dispose of per state, federal and local solvent disposal regulations.

Lift both siphon hoses from the Eco-Flush pail with the pump “ON” and allow flush purge from the pump. This will help prevent the flush from leaking out of the hose valve during transport or storage.

Pressure relief valves are generally positioned on your vacuum pump truck’s primary or secondary tank but can be retrofitted to go between the primary tank and the secondary scrubber. An adjustable pressure relief valve is often paired with a vacuum relief valve, and both can be monitored with a dual vacuum/pressure gauge as seen in Moro’s Pressure/Vacuum Relief Tree. A vacuum relief valve functions similarly to a pressure relief valve but is more concerned with keeping the vacuum pump safe and preventing tank implosion, rather than the larger issue of keeping personnel safe.

The RIV 1-1/2” Pressure Relief Valve also features a convenient hose shank connection to divert air and overflow liquids away from the vacuum pump to an appropriate vessel. This keeps your pump cleaner, reduces maintenance for you and your staff, and extends the overall life of the pump.

Under normal circumstances, your system – the pipes, fittings, tanks, pumps, and other equipment – operates at or around a certain PSI. At this point, the pressure relief valve is not engaged and remains closed. Inside the relief valve there is a large, adjustable spring that is set to a specific pressure higher than that of the fluids in the system. When the pressure in the system is greater than that of the spring, it will force a small poppet inside to lift, compressing the spring, and opening the valve. Excess pressure is discharged, and PSI is reduced. Once it has returned to the desired operating pressure, the spring’s force will again be greater than that of the process fluid and will release, pushing the poppet back down into its seat, closing the valve, and returning the system to the appropriate pressure.

The Liberty Process LL8 Progressive Cavity Pump is ideal for abrasive pumping applications such as drilling fluids with sand and grit common in fracking operations. As a Mud Pump, the LL8 Series is a popular model on many mobile pumping rigs in use today. Replacement mud pump parts are available as well from our stock and work on other popular manufacturers models.

The Liberty LL8 is a standard flanged pump design manufactured with cast iron or 316 stainless steel pump casings designed in 1, 2, and 3 stages for 75, 150 and 225 psi discharge pressures and a flow rate of 18 up to 100 GPM.

The LL8 is a modular design with simple hardened pinned joint drive assembly. LL8 Rotors are typically hardened tool steel or 316 stainless steel with a hard chrome plating for long life in abrasive pumping applications.

All other wetted parts are either carbon steel or 316 stainless steel. Stators are available in many elastomer materials such as Buna Nitrile, Natural Rubber, EPDM and Viton. The standard seal design is a set of gland packing with a lantern ring set and flush connections. Mechanical seal options for this progressive cavity pump are readily available.

The LL8 represents one of the most popular progressive cavity pumps available for the transport of drilling mud with easily replaceable in-stock parts.

Gearboxes and bearing housings periodically need a thorough flushing rather than a simple drain and fill. Several signs point to this requirement, such as overheating of the sump, gross liquid or solid contamination, and development of a severe wear pattern.

Material evidence in the form of sludge, rust, moisture, wear metals, gel or other viscous residue that is present at the beginning of the drain should confirm to the technician that a flush is in order. A thorough flush is also useful for removing construction and assembly contaminants from equipment sumps prior to commissioning.

With these factors in mind, what constitutes a thorough sump flush? Are there any particular problems that the operator should be careful to avoid? What equipment can or should be used for this purpose? Finally, what items should be included in a detailed flushing procedure?

Flushing is a clean fluid circulation process designed to remove water, chemical contaminants, air and particulate matter (not fixed to surface) resulting from construction, normal ingression, internal generation or component wear.

For in-service machinery after an oil change due to heavy fluid contamination, component failure, extremely degraded lubricant (oxidation), or if a system flushing has not been performed in the past three years.

For gearboxes and bearing housings that are not fitted with filtration, flushing is required to remove contamination and sediment. Water, rust, excessive wear debris, sludge, varnish or lacquer, and hard-to-open drain ports suggest system contamination and indicate the need for a thorough flush.

Soils may be mechanically or chemically removed. Flushing is a type of high-pressure, high-flow fluid circulation used to generate physical movement of contaminants. As the pressures/flow is used for flushing, circulating clean fluid in the system cannot clean rust and scale from the piping, deburr machined elements or remove flux or weld slag.

Three levels of system flushing are practiced, depending on the machinery internal conditions and type of contaminants compromising the system. Figure 1 provides a summary of different flushing approaches that may be used and various circumstances and criteria associated with each method.

Power flushing - A variation of recirculation, where the oil level in the sump is reduced and a high-velocity fluid is applied to mechanically dislodge, lift and entrain particulate debris. Power flushing suspends and transports particles; absorbs air, chemical products and water from the system; and releases the contaminants to a filter.

Wand flushing - A wand attached to one of the cart hoses is used to discharge at high pressure (kicking up adherent debris). The flow is then reversed and the wand vacuums the sediments.

Regardless of the flushing compound/fluid selected, unless it is identical to the lubricant used following the flush, it is important that all of the flushing fluid be removed from the sump prior to final fill. Some petroleum solvents with a concentration of five percent can create an appreciable thinning effect on the lubricant viscosity.

Fluid Properties. Fluid solubility and hygroscopic characteristics influence removal efficiency of water, air and chemical contaminants. Most oil companies supply special flushing fluids (rust-inhibited oils with good solvency power) that demonstrate the following desirable properties:

Fluid Turbulence. To remove particles, the flushing process depends on the lift forces, drag forces and the depth of the laminar sublayer in the stagnant fluid next to the conduit wall.

As seen in Figure 1, turbulence can have a significant influence on loosely attached solid debris lingering in crevices or in the sidewall perimeter low-flow area. Turbulence in the system shortens the time and improves the quality of the flushing activity.

There is some risk associated with the high-velocity flush. Circulation of a fluid at high velocity with particulate contaminants can damage sensitive components (pumps, heat exchangers and valves). Also, such high pressures and flow can affect system filters. It is necessary to bypass flow- or contaminant- sensitive components.

Filter housings can be left in place if filter elements are removed. Components that restrict the flow rate, and thereby increase the pressure drop, should be isolated from the flushing circuit and cleaned individually.

The flushing equipment required depends on the size, location and installed devices on the machinery. A mobile filtration unit is helpful if the pumps are capable of providing a flow rate at least twice that normally used in the fluid system or the flow requirements for the proper Reynolds number. An air breather is required to prevent dirt ingression during flushing.

Use large duplex filters (Beta 3= 200 or higher) with differential pressure indicator to allow filter changing without interrupting flushing. If water removal is desired, include a filter with water-absorbing capabilities.

A heater should be required in case of low ambient temperature to maintain or reduce fluid viscosity and achieve the flow requirements. Permanently installed quick-connectors are beneficial for flushing or filtration if the connector and piping are large enough to facilitate flow. In some cases, a reservoir other than the machinery sump is needed to contain the high volume of fluid required for the appropriate flushing.

The flushing procedure depends on the specifics of machinery, plant conditions and flushing equipment. To obtain the best results, follow these guidelines:

If drain port is not located at the lower point, heavy solid particles, water and/or emulsions will stick to the bottom of the reservoir. Wand flush is required.

For gearboxes and bearings, the target cleanliness level for flushing should be at least one number below the cleanliness level for the operating fluid. A maximum of 16/14/12 (ISO 4406.99) is recommended for critical gearboxes and element bearings.

The flushing process may be perceived to be an expensive, complicated and time-consuming extra task for an oil change. However, some conditions justify the effort. Highly contaminated reservoirs on critical systems warrant additional attention to assure a high state of reliability.

Flushing is justified for new and rebuilt equipment prior to commissioning to sustain high levels of reliability. A proactive maintenance approach of deploying flushing for in-service bearings and gearboxes helps to increase lubricant life and equipment durability. Generally, the flushing efforts and costs are well compensated with increased reliability related to system cleanliness.

Piston Of JA-3 Relief Valve, Manual Reset Relief Valve is mainly used as mud pump relief valve, with the same function as shear relief valve; but Reset Relief Valve can automatically snap to a full open position when the preset pressure is exceed. Once the pressure released, the reset was done to recover to work within several minutes when to operate the reset handle.

JA-3 Shear Relief Valve 3”-5000psi, which is popular used in BOMCO Mud Pump F1300/1600, HHF1300/1600 and 3NB1300/1600. There is Threaded and Flanged connection, union is available upon request.

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.

Flushing is the process of using the scouring action of moving water to help rid a water supply of contaminants, and it is an essential part of the disinfection process. Flushing normally takes place several times during the disinfection process.

Install the pump as close to the bottom of the well as possible during the flushing stage. For fractured or very porous rock formations, it may be necessary to move the pump up and down the length of the exposed borehole to assure water movement into the entire well bore.

Generally, the longer the flushing time, the better. A suggested minimum is to pump until at least 20 casing volumes have discharged from the well. For example: A 100-foot deep 5-inch well has a casing volume of 100 gallons. A minimum of 2,000 gallons of water (20 casing volumes times 100 gallons) should be flushed from the well.

In some cases, flushing without further chlorination has been effective in correcting contamination problems. Some local health departments have found that allowing water to discharge from a garden hose continuously for a period of at least 24 hours or more has corrected the contamination problem without the need to treat with chlorine. The hose is discharged into a roadside ditch or into the yard away from any on-site sewage disposal system. Open the sill cock valve all the way during the flushing stage.

A water sample should be collected from the water supply after the flushing period to determine if the flushing process has corrected the bacterial contamination problem. If coliform bacteria are not present in the water sample analyzed, the flushing may have successfully disinfected the water supply. However, a second water sample is recommended approximately one week later to verify that the bacterial contamination problem has been corrected.

The initial discharge of water from a recently chlorinated well may contain elevated levels of chlorine and chlorination byproducts. Do not run the water into a surface water body. Avoid flushing for long periods if discharge water will flow onto neighboring property or roadways, or otherwise create a nuisance condition.

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.

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.

It may be impractical to flush system piping during drilling operations. However, strainer screens should be checked daily to remove any debris or other flow restrictions.

Water waste is often deemed an unwanted, but inevitable by-product of mining processes. Yet modern pump sealing technology exists which can virtually eliminate this waste while conserving energy, improving pump reliability and achieving long term operational savings.

However, it is also one of the most unnecessarily squandered resources in mining operations. And while the industry has begun to embrace efficiency and sustainability-led advances such as automation and renewable energy, it remains steadfastly set in its ways when it comes to slurry pump technology.

Three approaches are routinely specified by pump manufacturers to seal slurry pumps: mechanical packing, expellers (also known as ‘dynamic’ seals’) and single mechanical seals. All come with significant limitations, including poor reliability, reduced mean times between failure (MTBF), intensive maintenance requirements and higher operational costs.

These factors alone should give mine managers cause for a re-evaluation of the sealing methods used on slurry pumps. However, any company with a commitment to the International Standards Organisation ISO-14001 Standard for environmental management systems and ISO-50001 Standard for energy management systems should pay attention to the excessive water waste and high energy consumption that results from opting for these traditional sealing methods.

Inefficient sealing When used to seal the process pumps in a mine’s scrubber and floatation circuits, gland packing, single mechanical seals and expeller seals all demand one of the most wasteful aspects of slurry processing which is seal flush water injection.

On gland packed pumps it’s essential that packing is flushed with clean water to keep it cool and lubricated, while both single slurry seals and expellers require a supply of cool, clean flush water to be injected into the process at high pressure, maintaining a stable fluid film between the delicate seal faces to keep them cool and lubricated, while forcing the damaging slurry away.

The flush water required in all three sealing approaches is supplied from an external source and injected into the process at a higher pressure than the stuffing box pressure, in line with the industry standard American Petroleum Institute (API) Piping Plan 32. Water which doesn’t leak onto the ground or into the process is sent to the tailings dam. This also has an effect on the water balance of the plant.

This approach constitutes a loss of clean water amounting to billions of gallons a year globally. One large, conventional slurry pump typically consumes 10 US gallons (37.8 litres) per minute, amounting to 5.2 million US gallons (19.6 million litres) of water every year – a shocking statistic by any measure.

As the mechanical seals generate heat, the hot water in the barrier space rises to the tank and is radiated to the atmosphere, allowing the cooler, denser water to sink back down to provide cool lubrication to the seal faces. Most importantly, the flush water is constantly recycled, flowing across the seal faces in a continuous loop and reducing leakage to the absolute minimum, roughly a teaspoonful a day.

While API Plan 32 is unsuitable for servicing multiple slurry pumps in a ‘series train’ without the need to install special pump systems, pressurised barrier tanks offer ratings up to 435 psi (30 bar), making them ideal for these applications. Self-topping and self-pressurising, they are also almost maintenance-free.

Wide-ranging benefits The benefits of upgrading to modern sealing solutions and support systems were felt by a coal mine in Poland using a slurry pump to supply coal mud at 9 bar (135 psi) to filter press. Flushed packing resulted in huge dilution of product, resulting in greatly increased filtration times and costs. The pump was sealed with a double mechanical seal designed to meet the arduous requirements of the process.

The mining industry must deal with a tough and costly challenge when it comes to maintaining rotating equipment. But the planning, processing and disposal of flush water constitutes an operational and financial burden which is entirely avoidable.