mud pump design calculation quotation

Rig pump output, normally in volume per stroke, of mud pumps on the rig is  one of important figures that we really need to know because we will use pump out put figures to calculate many parameters such as bottom up strokes,  wash out depth, tracking drilling fluid, etc. In this post, you will learn how to calculate pump out put for triplex pump and duplex pump in bothOilfield and Metric Unit.

Το work with title Full design of a drilling mud pump and flow program by Balac Srdan is licensed under Creative Commons Attribution 4.0 International

Srdan Balac, "Full design of a drilling mud pump and flow program", Master Thesis, School of Mineral Resources Engineering, Technical University of Crete, Chania, Greece, 2019

Drilling projects must be planned carefully as they need to be a balance of both efficiency of drilling and the project expenditure; that is, the goal is to drill the well reaching target depth with highest performance at the lowest cost.When it comes to reducing the cost of a project, mud hydraulics are one of the most important factors. By minimizing pressure loss, due to friction in drilling string and annulus, maximum efficiency of the drilling bit and the maximum usage of pump pressure is achieved.Knowing the rheology of the mud and the flow regime we can calculate pressure loss in the system. Rheology studies the flow, or rather deformation of matter, described in terms of shear rate and shear stress. Shear rate is defined as the flow velocity gradient in the direction perpendicular to the flow direction. Hence, the higher the shear rate, the higher the friction between the flowing particles. On the other hand, Fluids are described as Newtonian or non-Newtonian depending on their response to shear stress.Flow regime that appear in drilling are laminar flow, turbulent flow, and transitional flow. Pressure loss in the system can be expressed by calculating fluid velocity and Reynolds number for flow regimes. Circulating fluid must overcome friction between the fluid layers and the drill pipe, hole walls or casing walls, as well as the friction between solid particles and fluid. The major pressure loss occurs on the drilling bit nozzles. Therefore, pressure on the pump must be high enough to compensate for it; and it is equal to sum of all these forces.When it comes to the required hole cleaning and high rate of penetration, mud pumps are the most important equipment for providing the bit hydraulics. Drilling hydraulics can always be optimized by altering the pump liner, flow rate, and size of the nozzles; in accordance to the depth of drilling.In making an effective design, it is essential to have an understanding of hydraulics problems, as well as all their possible causes; in order to prepare adequate solutions to overcome delays, reduce operation costs, and reach the target.This thesis studies hydraulics as a means of assisting the design of full flow programs, that will in return give us the necessary mud pump specification for optimal drilling. Through modeling this problem, the goal is to avoid potential drilling problems in order to ensure further efficient drilling; especially in complex and inclined wells, where the hydraulic are usually more complex because of well path and geometry.

Recent wellsite disasters have led to an increased emphasis on properly sized mud/gas separators. This paper reviews and analyzes existing mud/gas separator technology and recommends separator configuration, components, design considerations, and a sizing procedure. A simple method of evaluating mud/gas separation within the separator vessel has been developed as a basis for the sizing procedure. A mud/gas separator sizing worksheet will assist drilling personnel with the sizing calculations. The worksheet provides a quick and easy evaluation of most mud/gas separators for a specific well application. A brief discussion of other mud/gas separator considerations is provided, including separator components, testing, materials, and oil-based-mud considerations.

Progressive cavity pumps, also known as PC pumps, progressing cavity pumps, eccentric screw pump and mono pumps are a type of rotary positive displacement pump designed for the conveying of liquids and sludges from 1cst to 1Million. They handle not only viscous fluids and solids but also gassing or multiphase liquids containing gas slugs typical during crude oil extraction.

The volume of liquid pumped is proportional to speed providing a linear predictable pumping rate across a range of pressures. This technology delivers one of the highest flow and pressures available from a positive displacement pump being up to 600M³H and 48bar, with efficiency ranging from 55% to 75%. This technology is most suited for fluids more viscous than 5cst.

The design consists of a motor at the drive end which is connected to a gearbox as pc pumps operate at low rpm compared to centrifugal pumps. The output shaft from the gearbox connects to a rotor via a universal pin joint which rotates a metallic rotor within a rubber stator. Stators contain cavities, and the rotor pushes fluids through the cavities in a slow rotating fashion.

A pumps pressure generating ability will depend on the number of cavities within the pump, with high pressure designs often consisting of more than one stator and rotor. Each rotor will typically produce 6 bar enabling pressures up to 48 bar to be achieved through its modular design.

This design of pump is better suited for viscous lubricating fluids, which can contain solids. Short stator life can be experienced with abrasive slurries at which point a peristaltic pump can be a preferred option. Eccentric Screw Pumps viscosity handing is unrivalled, and they are usually specified when there are no other suitable options.

Stator designs consist of two types - equal and non-equal walled. Equal walled stators ensure a lower starting and running torque, lower pulsations and reduced power consumption, high volumetric pumping efficiency, and lower replacement costs. Materials are usually types of rubber being NBR, FKM but not PTFE meaning solvents cannot be handled.

·Oil & Gas – Cutting Transfer, Drilling Mud transfer and recovery, Separator Feed, Crude Oil Transfer, MOL (Main Oil line Pump), Multiphase transfer and injection in remote areas.

Low pulsating flow -Due to its rotary motion at low rpm, flow pulsation is limited with low amounts of acceleration head produced. Coupled with even wall design of stators and long pitch rotor design reduce pulsations further.

Low shear -Ensures gentle handling of the most difficult to pump fluids such as resins, viscous foods, oil and water emulsions without change in consistency to the liquid. They are often use in oily water separators as the design ensures oil droplets remain intact and was rated by SPE (Society of Petroleum Engineers) in Paper SPE18204 as the preferred pump to use for oil droplets which were disturbed the least during handling and a comparison of lobe, vane and screw technology.

Reversible – Units are reversible with reduced output pressure as standard meaning hoses can be emptied, or if blockages are encountered pump can be reversed to assist with clearing. It also enable the pump to be versatile for situations such as tanker loading and offloading.

Wide fluid handling capabilities –Designs can handle viscous liquids, large solids, abrasive materials, fibrous solids and gas slugs without issue making it one of the most versatile pumps available. This design has Unparalleled Viscosity handling viscosities from 1cst to 1Million means there are no comparable pumping technologies.

Self Priming –Due to the tight tolerances in its construction, it has high suction capabilities priming up to 8M, with a corresponding low NPSH. Designs are available which can withstand gas slugs for up to 30 minutes.

High Accuracy –Due to flow being directly proportional to pump speed, and due to its cavity design, it enables flows to be very predictable enabling it to be used in metering and dosing applications

Hopper Pump –A pump is fitted with a hopper of various designs, designed for viscous liquids, materials containing high amounts of dry matter, large solids requiring breaking up and materials which plasticise

Vertical Immersion –Designed to be immersed in the fluid such as in tanks eliminating NPSH issues, as units can be accepting of an NPSH as little as 0.5M (canned design) making them ideal for open or closed drain applications.

Multiphase Design -Baseplate mounted unit for multiphase boosting, with accessories allowing pump to handle viscous oil, gas slugs, sand and water, with automatic remote operation.

Bridge Breaker –For the breaking up of large solids within dehydrated sludge. Motorised paddles rotate within the hopper ensuring particles are broken into sizes which can be accommodated by the pump preventing blockages

Motorised wheel – Feeding of liquids with high dry solid content and materials which plasticize into the main pump. When materials such as liquid mortar, resins, mud, blocks of fat, or butter are pumped they can plasticise meaning they change shape rather than break up. To ensure they are fed into the rotor and stator, a motorised wheel ensures materials are broken up when other technologies may mean materials clog.

Liquid injection port –Typically used for the biogas sector, this unit has a separate injection port for accepting liquid manure which is combined with materials in the inlet containing high dry solids content (such as digestate, straw, corn, grass, rye, vegetable and food waste ) ensuring pumpability.

PC Pump curves are different to a centrifugal curve as it is linear demonstrating the units ability to handle liquids of varying viscosities with little impact on pump performance, with the bottom axis being speed rather than flow as flow is proportional to speed. Unit speed is much lower than centrifugal, operating from as little as 50rpm

Not suitable for solventsAll metal parts means solvents can be transferred, although some designs may have bearings within liquids and should be avoidedAll metal parts means solvents can be pumped.

Pump curves are calculated based on water which has an SG of 1. If a fluid has a higher specific gravity than water, then the head will show the same, but the pressure will increase since Pressure is a function relative to fluid calculated by multiplying Head x Specific Gravity.

The pressure supplied by a pump for each application is fluid dependent and relative to fluid density thus pressure will change according to the fluid’s specific gravity

Care must be taken where a pump curve shows a high NPSH is required. A fluid with a low specific gravity, must be checked against the NPSH required carefully.

Cavitation can occur if the inlet pressure is below that required by the pump, which can arise when the SG of the fluid is not accounted for correctly, when determining the NPSH available.

Positive Displacement Pump CurveA PD Pump curve will not be affected in the same way as a centrifugal pump curve by the specific gravity of a fluid, as flow rate will remain constant. However, the absorbed power will increase, with the pressure produced remaining fluid dependent.

The mud pump piston is a key part for providing mud circulation, but its sealing performance often fails under complex working conditions, which shorten its service life. Inspired by the ring segment structure of earthworms, the bionic striped structure on surfaces of the mud pump piston (BW-160) was designed and machined, and the sealing performances of the bionic striped piston and the standard piston were tested on a sealing performance testing bench. It was found the bionic striped structure efficiently enhanced the sealing performance of the mud pump piston, while the stripe depth and the angle between the stripes and lateral of the piston both significantly affected the sealing performance. The structure with a stripe depth of 2 mm and angle of 90° showed the best sealing performance, which was 90.79% higher than the standard piston. The sealing mechanism showed the striped structure increased the breadth and area of contact sealing between the piston and the cylinder liner. Meanwhile, the striped structure significantly intercepted the early leaked liquid and led to the refluxing rotation of the leaked liquid at the striped structure, reducing the leakage rate.

Mud pumps are key facilities to compress low-pressure mud into high-pressure mud and are widely used in industrial manufacture, geological exploration, and energy power owing to their generality [1–4]. Mud pumps are the most important power machinery of the hydraulic pond-digging set during reclamation [5] and are major facilities to transport dense mud during river dredging [6]. During oil drilling, mud pumps are the core of the drilling liquid circulation system and the drilling facilities, as they transport the drilling wash fluids (e.g., mud and water) downhole to wash the drills and discharge the drilling liquids [7–9]. The key part of a mud pump that ensures mud circulation is the piston [10, 11]. However, the sealing of the piston will fail very easily under complex and harsh working conditions, and consequently, the abrasive mud easily enters the kinematic pair of the cylinder liner, abrading the piston surfaces and reducing its service life and drilling efficiency. Thus, it is necessary to improve the contact sealing performance of the mud pump piston.

As reported, nonsmooth surface structures can improve the mechanical sealing performance, while structures with radial labyrinth-like or honeycomb-like surfaces can effectively enhance the performance of gap sealing [12–14]. The use of nonsmooth structures into the cylinder liner friction pair of the engine piston can effectively prolong the service life and improve work efficiency of the cylinder liner [15–17]. The application of nonsmooth grooved structures into the plunger can improve the performance of the sealing parts [18, 19]. The nonsmooth structures and sizes considerably affect the sealing performance [20]. Machining a groove-shaped multilevel structure on the magnetic pole would intercept the magnetic fluid step-by-step and slow down the passing velocity, thus generating the sealing effect [21–23]. Sealed structures with two levels or above have also been confirmed to protect the sealing parts from hard damage [24]. The sealing performance of the high-pressure centrifugal pump can be improved by adding groove structures onto the joint mouth circumference [25]. The convex, pitted, and grooved structures of dung beetles, lizards, and shells are responsible for the high wear-resistance, resistance reduction, and sealing performance [26–28]. Earthworms are endowed by wavy nonsmooth surface structures with high resistance reduction and wear-resistance ability [29]. The movement of earthworms in the living environment is very similar to the working mode of the mud pump piston. The groove-shaped bionic piston was designed, and the effects of groove breadth and groove spacing on the endurance and wear-resistance of the piston were investigated [30]. Thus, in this study, based on the nonsmooth surface of earthworms, we designed and processed a nonsmooth striped structure on the surface of the mud pump piston and tested the sealing performance and mechanism. This study offers a novel method for prolonging the service life of the mud pump piston from the perspective of piston sealing performance.

The BW-160 mud pump with long-range flow and pressure, small volume, low weight, and long-service life was used here. The dimensions and parameters of its piston are shown in Figure 1.

A striped structure was designed and processed on the contact surface between the piston cup and the cylinder liner. The striped structure was 5 mm away from the outermost part of the lip, which ensured the lip could contact effectively with the cylinder liner. Based on the structural dimensions of the piston cup, we designed a 2-stripe structure, and the very little stripe space affected the service life of the piston [30]. Thus, the stripe space of our bionic piston was set at 5 mm. According to the machining technology, two parameters of stripe depth h and the angle between the stripes and lateral of the piston α were selected (Figure 2).

A mud pump piston sealing performance test bench was designed and built (Figure 3). This bench mainly consisted of a compaction part and a dynamic detection part. The compaction part was mainly functioned to exert pressure, which was recorded by a pressure gauge, to the piston sealed cavity. This part was designed based on a vertical compaction method: after the tested piston and the sealing liquid were installed, the compaction piston was pushed to the cavity by revolving the handle. Moreover, the dynamic detection part monitored the real-time sealing situation and was designed based on the pressure difference method for quantifying the sealing performance. This part was compacted in advance to the initial pressure P0 (0.1 MPa). After compaction, the driving motor was opened, and the tested piston was pushed to drive the testing mud to reciprocate slowly. After 1 hour of running, the pressure P on the gauge was read, and the pressure difference was calculated as , which was used to measure the sealing performance of the piston.

To more actually simulate the working conditions of the mud pump, we prepared a mud mixture of water, bentonite (in accordance with API Spec 13A: viscometer dial reading at 600 r/min ≥ 30, yield point/plastic viscosity radio ≤ 3, filtrate volume ≤ 15.0 ml, and residue of diameter greater than 75 μm (mass fraction) ≤ 4.0%), and quartz sand (diameter 0.3–0.5 mm) under complete stirring, and its density was 1.306 g/cm³ and contained 2.13% sand.

The orthogonal experimental design method was used to study the effect of factors and the best combination of factor levels [31]. Stripe depth h and angle α were selected as the factors and were both set at three levels in the sealing performance tests (Table 1).

Figure 4 shows the effects of stripe depth and angle on the sealing performance of mud pump pistons. Clearly, the stripe depth should be never too shallow or deep, while a larger angle would increase the sealing performance more (Figure 4).

The standard piston and the bionic piston were numerically simulated using the academic version of ANSYS® Workbench V17.0. Hexahedral mesh generation method was used to divide the grid, and the size of grids was set as 2.5 mm. The piston grid division is shown in Figure 8, and the grid nodes and elements are shown in Table 3. The piston cup was made of rubber, which was a hyperelastic material. A two-parameter Mooney–Rivlin model was selected, with C10 = 2.5 MPa, C01 = 0.625 MPa, D1 = 0.3 MPa−1, and density = 1120 kg/m3 [32, 33]. The loads and contact conditions related to the piston of the mud pump were set. The surface pressure of the piston cup was set as 1.5 MPa, and the displacement of the piston along the axial direction was set as 30 mm. The two end faces of the cylinder liner were set as “fixed support,” and the piston and cylinder liner were under the frictional interfacial contact, with the friction coefficient of 0.2.

To better validate the sealing mechanism of the bionic striped pistons, a piston’s performance testing platform was independently built and the sealed contact of the pistons was observed. A transparent toughened glass cylinder liner was designed and machined. The inner diameter and the assembly dimensions of the cylinder liner were set according to the standard BW-160 mud pump cylinder liners. The sealing contact surfaces of the pistons were observed and recorded using a video recorder camera.

(1)The bionic striped structure significantly enhanced the sealing performance of the mud pump pistons. The stripe depth and the angle between the stripes and the piston were two important factors affecting the sealing performance of the BW-160 mud pump pistons. The sealing performance was enhanced the most when the stripe depth was 2 mm and the angle was 90°.(2)The bionic striped structure can effectively enhance the contact pressure at the piston lips, enlarge the mutual extrusion between the piston and the cylinder liner, reduce the damage to the piston and cylinder liner caused by the repeated movement of sands, and alleviate the abrasion of abrasive grains between the piston and the cylinder liner, thereby largely improving the sealing performance.(3)The bionic striped structure significantly intercepted the leaked liquid, reduced the leakage rate of pistons, and effectively stored the leaked liquid, thereby reducing leakage and improving the sealing performance.(4)The bionic striped structure led to deformation of the piston, enlarged the width and area of the sealed contact, the stored lubricating oils, and formed uniform oil films after repeated movement, which improved the lubrication conditions and the sealing performance.

The bionic striped structure can improve the sealing performance and prolong the service life of pistons. We would study the pump resistance in order to investigate whether the bionic striped structure could decrease the wear of the piston surface.

Mud Pump Valve & Seat are made of premium alloy steel through one-piece forging and carburizing treatment processes, thereby ensuring high intensity. In addition, the precise calculation is performed and CNC machining is conducted for the dimensional matching of the valve seat and valve body working angles to enhance the service life of the valve body and valve seat. Our valve products are able to work smoothly in normal mining and digging conditions for over 400 hours.

When two (or more) pumps are arranged in serial their resulting pump performance curve is obtained by adding theirheads at the same flow rate as indicated in the figure below.

Centrifugal pumps in series are used to overcome larger system head loss than one pump can handle alone. for two identical pumps in series the head will be twice the head of a single pump at the same flow rate - as indicated with point 2.

With a constant flowrate the combined head moves from 1 to 2 - BUTin practice the combined head and flow rate moves along the system curve to point 3. point 3 is where the system operates with both pumps running

When two or more pumps are arranged in parallel their resulting performance curve is obtained by adding the pumps flow rates at the same head as indicated in the figure below.

Centrifugal pumps in parallel are used to overcome larger volume flows than one pump can handle alone. for two identical pumps in parallel and the head kept constant - the flow rate doubles compared to a single pump as indicated with point 2

Note! In practice the combined head and volume flow moves along the system curve as indicated from 1 to 3. point 3 is where the system operates with both pumps running

In practice, if one of the pumps in parallel or series stops, the operation point moves along the system resistance curve from point 3 to point 1 - the head and flow rate are decreased.

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