mud pump flow loop supplier

During drilling in Oil and Gas exploration, drilling mud or Bentonite is pumped into boreholes for multiple reasons. Pumping drill mud into boreholes cools the drill bit as well as bringing drill cuttings to the surface as the way in which mud is pumped into boreholes forms a closed loop system. The use of drilling mud also provides hydrostatic pressure to prevent liquids such as oil and gas rising to the surface, as drilling mud is thixotropic meaning when it is not agitated it stiffens forming a mud which is an effective liquid and gas barrier.

Our in-house testing cell includes the Flow Loop Testing Facility. Our Flow Loop Testing Facility plays a key role in estimating how to float equipment performs under various conditions in the field.

• The Flow Loop Tank is fitted with two agitators to ensure that fluid remains well mixed. These agitators also prevent the sagging of the weighting material in the drilling mud.

• Two flow meters are installed at different locations to ensure continuous measurement of the flow rate. The pump’s speed is adjusted to maintain the flow rate as per test requirements.

makes it possible to run the entire test from the computer reducing the operator’s impact on test results. This system is set to record readings every 20 seconds. Real-time readings of all the flow transducers and pressure transducers are displayed on the screen when the test is being conducted.

APT Full open valve and seat is designed designed for Maximum Flow Characteristics with the combination of strength of a forged alloy steel upper body with precision casting to minimize flow restriction and fluid turbulence.

APT Four-web valve and seat is designed for maximum flow characteristics by adopting premium forged steel with the performance of high strength and high hardness. The rubber is fixed on the valve body, the seats have high strength and resistance to impact, suitable for high pressure jet drilling.

APT Three-web valve and seat is designed to enable maximum flow charactristcs, offering additional bearing area for valve that minimize stress and promotes a long service life.

Rubbers are made with tough and durable Buna N Rubber for all pressures, ideally suited for either oil-base or water-base mud. The special processed fabric provides an unusual waterproof bond of seals to piston which assures a longer life with high tensile strength rated with resistance to chemicals, hydrocarbo for all drilling conditions.

The one-piece bonded comstructed piston is desiged and manufactured to handle the tough assignments encountered during ladn and offshore drilling. A spcecial processing of the fabric eliminates leakage points and resistance to abrasion. The fluid expanded lip is not damged by high presure and fast pump strokes. The Fail-Safe piston seals off to greater diameter as liner wears.

Piston rods are made with premium grade, heat treated alloy steel, offering excellent resistance to fatigue, corrosion and heavy loads. A full line of piston rods are available for various pumps.

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Closed loop pressurized freshwater liner wash system, complete with integral water cooling tank equipped with centrifugal pump and driven by explosion proof electric motor

Belt drive transmission: two each motor sheaves and QD mounted pump sheaves; banded Kevlar Vbelts; belt guards; for use with AC drive motors c/w 20HP blower assemblies

Mud Pump Pulsation Dampener is usually installed on the discharge line to reduce the fluctuation of pressure and displacement of the drilling mud pump.

Mud Pump Pulsation Dampener is a pneumatic device built into the outflow line of each UUD pump to dampen the pressure fluctuations resulting from the action of the pump. Although presented as a surge tank, this device is really a device that can be tuned to greatly diminish the output pulsations transmitted downstream from the mud pump. Unfortunately, the effectiveness of the pulsation dampener is a function of both output pump pressure and frequency of the pump pulsations.

Top-Co’s engineering team is focused on the R&D of new products, often in response to operating challenges encountered by customers. The engineering team, populated with professionals with experience in this sector, employs electronic design media and 3-D modeling to facilitate precise and quick designs. In-house testing validates new or improved products prior to field introduction. Upgraded state-of-the-art test loop equipment currently is being installed, ensuring that existing and modified float equipment consistently complies with API IIIC specifications.

Commissioned in 2009, Top-Co’s flow loop testing facility is designed to foster standard and creative testing for a number of its tools. In addition, a goal has been to close the cycle from identifying a product requirement to achieving complete customer satisfaction.

Top-Co’s facility features a tank with a storage capacity of 160 bbl and has two agitators used in combination with the tank’s shape to avoid sagging of the weighting material in the drilling mud. Mud is pumped with a centrifugal pump capable of delivering up to 22 bbl/minute at approximately 140 psi. Heat blankets in the pipes can be set to 600 ºF while circulating the mud to increase its temperature to the test requirements. (Images courtesy of Top-Co Primary Cementing Equipment)

The tank has a storage capacity of 160 bbl and has two agitators used in combination with the tank’s shape to avoid sagging of the weighting material in the drilling mud.

Mud is pumped with a centrifugal pump capable of delivering up to 22 bbl/minute at approximately 140 psi. Heat blankets in the pipes can be set to 600 ºF (316ºC) while circulating the mud to increase its temperature to the test requirements.

The flow rate is measured continuously by a flowmeter installed at the exit of the test bench and is controlled by varying the speed of the centrifugal pump. The flow loop has three thermometers measuring mud temperature. One is installed in the tank and is used mainly during mud warmup prior to starting a test. The other two are installed in the inlet and outlet of the test bench and allow for full compliance with test temperature requirements by API RP 10F, independently of heat loss due to a lower ambient temperature.

The flow rate is measured continuously by a flowmeter installed at the exit of the test bench and is controlled by varying the speed of the centrifugal pump. The pump’s motor speed is, in turn, controlled by a variable frequency drive that reacts to the flowmeter’s measurement, adjusting the pump speed as required to maintain the specified flow rate. This setup allows for a stable constant flow rate to be maintained during testing.

The flow loop has three thermometers measuring mud temperature. One is installed in the tank and is used mainly during mud warmup prior to starting a test. The other two are installed in the inlet and outlet of the test bench and allow for full compliance with test temperature requirements by API RP 10F, independently of heat loss due to a lower ambient temperature. This is of importance during tests conducted in winter.

A parameter in the testing of float equipment is what API calls “volume required to achieve valve closure,” which the facility can accurately measure by collecting backflow in graduated buckets sitting on calibrated weight scales. The weight measurement is used in combination with the latest rheological properties to calculate the volume. The combination of leak weight and visual observation allows the operator to identify minimum amounts of backflow (dripping). In a real application, a valve leaking a very small amount could go undetected for days or weeks when the plug is found higher than expected.

The flow loop is equipped with 22 pressure measurement locations connected to a data acquisition system capable of recording up to 100 readings/second. A benefit of this system is the flexibility in the types of tests it allows, in addition to standard API tests. All instruments in the facility are subject to a strict calibration schedule that also is part of the plant’s quality management system.

The facility’s pumps and valves are actuated from the control software, allowing for a complete test to be run entirely from the computer. To minimize operator impact on the test results, an investment was made to build subroutines into the software that guide the operator through the test procedure. This improves the speed at which tests are conducted and increases the repeatability of results.

In anticipation of the longer reach and deeper wells in the coming years, Top-Co also has initiated tests under more demanding conditions such as higher flow rates and longer circulating times. This is most relevant in extended-reach wells, where fluid particle velocities required for appropriate hole cleaning may be as high as three to five times those of vertical wells and take longer to clean. For deeper wells, higher differential pressure capabilities may be expected and, therefore, testing above 5,000 psi also is required. Top-Co is using this capability in testing on destruction and development of new high-pressure products.

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.

Mud is circulated through a wellbore to bring the cuttings to the surface. Here cuttings are separated out so that clean mud can be reinserted into the well.

A typical circulation system is presented in Figure 1 as an example from a fixed drilling platform, while Figure 2 presents the circulation system from another view; on a floating drilling unit. Here mud is mixed and prepared in the mud pits consisting of several large tanks, each typically 60 m³ large. One or two of the mud tanks are in active use for mud circulation, while the others are for transfer and storing. One reserve pit is for kill mud, where density is kept typically at 0.25 kg/l above the density in the active pits.

Both density and rheology are maintained in the active mud pits. Typical total volume of a mud pit is 200 m³, with a surface area of typically 50 m². A vertical height of two cm corresponds to a volume of 1000 liters! In the surface mud system in Figure 1, we see two pumps in parallel. On offshore rigs it is more common with three.

From the pumps, a high-pressure output line leads up to the drill floor, where, on the standpipe, a multy purpose junction is made, called the standpipe manifold. Here the driller can read the standpipe pressure, which as almost identical with the pump pressure, reduced only by pipe friction in the short distance between the pump and the standpipe manifold.

On its return to the surface, the mud is directed through a wide settling tank, where the largest particles are allowed to settle out: On other rigs this tank is called the sand trap, positioned in front of the shale shakers as an over flow tank.

Low gravity solids (LGS) enter the mud through dispersed or disintegrated cuttings and has a density of 1.8–2.8 kg/l. If its content (LGSC) is increasing above a certain limit, solids control must be intensified.

Pumping drilling fluids through kilometre long pipe systems will result in large hydraulic friction, and correspondingly powerful mud pumps are required. One typical pump is shown in Figure 4.

The mud pump characteristics are divided into two different operating ranges: Range 1 is defined through the pump’s smallest liner, and range 2 includes the rest of the liners. Table 3 presents a typical pump characteristic for large sized mud pumps.