mud pump condition monitoring quotation

Power and high pressure mud management system is a core function in any oil field operation. Consequential cost of any failure results in an exponential manner through out the chain of drilling activity. Under an open pay zone condition, the effect would compound leading to complications in oil recovery, where such far flung effects are involved in terms of cost of failure, the demand of availability and reliability is not the final requirement of a maintenance manager. Monitoring the trend of all the achievements and failure also becomes an important activity to device a means for all the time injection of dependability. In this trend analysis the diverse and concurrent behavior of different group of equipments are to be monitored in a manageable manner for setting up the hypothesis structures to derive fairly repeatable and accurate predictions.

The complexity of today’s drilling projects, especially the need for sufficient pressure and flow rate for wellbore cleaning, challenge mud pumps manufacturers. Their efforts focus on the improvement of pump running time and efficient maintenance management to reduce or eliminate nonproductive time and HSE risks. Drilling rigs rely on mud pumps to efficiently circulate the mud, and synchronized pumps are employed to minimize mud pulsation effects. The mud circulation system is of major interest…Expand

Unexpected failure of mud pumps during drilling operations can result in non-productive time (NPT) and increase well construction cost. Several prior studies and implementations of condition-based maintenance (CBM) systems for mud pumps have failed to provide a generalized solution for the variety of pump types encountered in the field, in particular by failing to detect damage early enough to mitigate NPT. Our research is aimed at improving upon this situation by developing a practical, generally-applicable CBM system for mud pumps.

In the study reported here, a laboratory test bed with a triplex mud pump was used to collect data to test a new approach to mud pump CBM. Artificial damage was introduced to the two most frequently replaced parts of the pump, i.e., the valve and piston. An accelerometer and an acoustic emission (AE) sensor were used to collect experimental data. Based on this data, an anomaly detection algorithm was constructed using a one-class support vector machine (OC-SVM) to pin-point the early onset of mud pump failure. The CBM methodology thus developed does not require prior knowledge (data) of the mud pump itself or of the failures of its components. This is key to it being more widely deployable.

The trained machine-learning algorithm in the test setup provided an accuracy greater than 90% in detecting the damaged state of the valve and piston. Only the characterization of the normal (i.e., non-damaged) state data was required to train the model. This is a very important result, because it implies that the sensors can be deployed directly onto mud pumps in the field – and additionally, that the first few hours of operation are sufficient to benchmark normal operating conditions. Also, it was observed that a multi-sensor approach improved the accuracy of detection of both the valve and piston damage. The system is able to detect early-stage damage by combining the cumulative sum control chart (CUSUM) with the damage index developed in this project.

This work is the first attempt at applying semi-supervised learning for CBM of mud pumps. The approach is applicable for field use with very little or no prior damage data, and in various working conditions. Additionally, the system can be universally deployed on any triplex pump and efficiently uses the data collected in the first few hours of operation as a baseline. Consequently, the practicality and scalability of the system are high. It is expected to enable the timely maintenance of critical rig equipment before catastrophic damage, failure and associated downtime occurs. The system has been deemed promising enough to be field-trialed, and is currently being trialed on rigs in North America.

Higher circulating pressures result in increased wear on mud pump parts, subsequently causing rig downtime for pump maintenance. The paper presents the field experience gained with mounting high-frequency mud pressure transducers and analyzing the pressure signatures of Triplex Mud Pumps to identify pump wear in time for running routine maintenance and service. By comparison with recorded drilling data, every operating condition can be allocated to pressure curves. The characteristics of typical pump wear as expressed in these signatures are discussed together with suggestions how to automate the monitoring system. In addition, mud pumps have been fitted with vibration sensors for supplemental information.

The HDI 2100 Pump Stroke Counter is an intrinsically safe, certified, solid-state electronic stroke counter primarily used for monitoring mud pumps. Found most commonly within the HDI 9000 Choke Console System, the HDI 2100 monitors and displays the total accumulated mud pump strokes and the stroke rate of up to 4 individual mud pumps simultaneously. The stroke rate for each mud pump can be individually selected for display and is updated every second. Once installed, there is virtually no maintenance or calibration required. The quartz crystal oscillator provides high precision counts with no drift. The stainless steel case is completely sealed and features stainless steel piezo switches for long life. The entire package is constructed to operate in harsh environments and high vibration conditions encountered in land and offshore drilling. All HDI Gauges provide safety, accuracy, reliability, and low maintenance for the user.

The matrix composed of relatively independent columns taken from the absolute continuous distribution has full k-rank. If all three matrices meet this condition, the sufficient condition for recognizability is shown in formula (10).

Simulation experiments can investigate the characteristic of the results of input signals with different parameters after parallel factor analysis for fault diagnosis. Therefore, the simulation signals are used to simulate the running state of the centrifugal pump to test the method proposed in this article. The simulation signal is shown in the following formula (23).

The vibration signals collected in engineering are generally mixed with various noise signals. In order to check on the effectiveness in complex conditions, we add the noise signal to the original simulation signal and perform parallel factor analysis on it. Figures 7 and 8, respectively, show the time-domain diagram of the original simulation signal after adding noise to the signal and the time-frequency diagram obtained through continuous wavelet transform. After adding the noise signal to the original simulation signal, it can be seen that the waveform of the noisy simulation signal is similar to the original simulation signal in Fig. 4 and the impact signal is almost covered by the noise signal. The waveform of the noisy simulation signal in Fig. 8 is steeper and more rapid, and there is a larger blurred signal at 10–20 Hz.

A mud pump is a reciprocating piston/plunger device designed to circulate drilling fluid under high pressure down the drill string and back up the annulus.

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 the pump of choice. Duplex mud pumps (two piston/plungers) have generally been replaced by the triplex pump, but are still common in developing countries. A later development is the hex pump with six pistons/plungers.

The normal mud pump consists of two main sub-assemblies—the fluid end and the power end. 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 for quick replacement.

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

The number of mud pumps varies per drilling rig depending on the size of the drilling rig. The larger the rig the more mud pumps that will be needed. The mud pumps are considered vital to the operation of the drilling rig. If the mud pumps fail it affects production and can be very costly to repair due to the downtime in production.

To avoid any failures of the pumps, an online monitoring system was selected to collect and transmit vibration data back to a software system for analysis. This online monitoring and diagnostic system can also be expanded by a series of program modules (MUXs) that are specific to the application:

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