mud pump condition monitoring supplier

Distributor of engineered fluid handling pumps, packaged pumping systems, repairs, parts, & integrated pump control systems. Mud pumps, chiller/condenser pumps, plumbing pumps, boiler feed systems, in-line circulators, condensate systems, sump & sewage pumps, end suction pumps, submersible sump & sewage, non-clogs & grinders, self primers, packaged lift stations, variable speed pump systems, metering pumps, chemical injection systems, chemical mixing systems, peristaltic pumps for chemical feed, high viscous & shear sensitive fluids, self primers, stainless steel, trash pumps, hot oil pumps, vertical turbine pumps, sanitary pumps, marine pumps, industrial pumps, ANSI end suction, vertical cantilever, double suction, non-clogs, progressive cavity pumps, helical gear pumps, well pumps, lab pumps, hose pumps, control valves, check valves, air release valves, tanks, pressure vessels.

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.

A comprehensive range of mud pumping, mixing, and processing equipment is designed to streamline many essential but time-consuming operational and maintenance procedures, improve operator safety and productivity, and reduce costly system downtime.

We keep your mud pumps running in first class condition – providing onsite inspections, repairs and complete overhaul as well as all associated parts.

Periodically we’ll inspect for wear, cracks and damage to critical components such as bearings, bull gear and pinion, conrods and crossheads. We’ll check the condition of your seals and other rubber goods and look for oil contamination. We’ll inspect your frame and ensure your pump is set up as per the manufacturer’s recommended tolerances, providing feedback and detailed reporting.

Where overhaul is required we’ll take care of complete disassembly, cleaning and NDT. Repairs will be made to machined components as necessary. Bearings, seals and other components will be replaced in line with our inspections. Motors will be overhauled, lube systems serviced and pulsation dampeners recertified. We’ll also check your fluid ends are in spec and can repair or replace. Your pump is then fully reassembled and commissioned.

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Any drilling operations site that wants to optimize its process and preserve its equipment is well aware of its mud. Drilling fluid (what the layperson calls mud) is a vital part of the drilling process. Drilling mud is important for downhole drilling; cooling and lubricating the bit, removing debris from the well, controlling formation pressures and maintaining wellbore stability.

If a project is going to succeed, the drilling fluid system must be monitored, maintained and maximized. Go to any drilling site and someone there is keeping an eye on the mud.

There is no shortage of equipment, instruments and technologies that are used to maintain the drilling fluid process. Depending on site needs, drilling professionals might opt for flow meters, shakers, additives, centrifuges, degassers and any number of other technologies to monitor mud movement. The process can be further maximized for efficiency by using process instrumentation in the different phases of the mud system.

Radiometric sensors are a popular choice for pipeline mud flow. Maintaining the correct density profile of the mud traveling through the pipeline and ending down hole is important in maintaining stability and controlling formation pressures. The fluid also needs to be the correct density to both travel back up the annulus and carry away drilling debris. As a well is drilled, underground land formations change. That is just one of many factors that may affect the internal well pressure.

Continuous monitoring of the conditions inside the wellbore and the characteristics of the drilling fluid must be maintained to ensure well integrity. For an accurate account of those characteristics, users often trust radiometric density detectors.

The chief advantage of radiometric systems is that they operate without contacting the measured product. In a pipeline application, a secure source holder is mounted on one side of the pipe, and a detector is mounted on the other. The detector measures radioactive energy; the more energy it reads, the lower the inferred mud density. This noncontact design prevents the wear suffered by contact instruments abused by pipeline fluid. Additionally, because the system measures energy and not mud, the instruments do not need recalibration or adjustment to measure changing product. Radiometric sensors also offer durability in extreme heat and other adverse conditions. These instruments are rugged.

Through-air radar is noncontact and free from damage inflicted by corrosive products. These instruments are durable in challenging conditions and many models are sensitive enough to measure products of any chemical composition. Dielectric constant does not matter anymore. These sensors can measure virtually anything. If users considered through-air radar for level measurement and passed, now is the time to reevaluate radar, since the technology has advanced significantly in the last two years.

Drilling mud has to go somewhere and the tank that collects the spent mud also needs accurate process instruments. Product density is important to monitor and maintain in the mud tank. It is imperative that users maintain the correct formula of the fluid for downhole drilling propulsion and wellbore integrity. The mixture of additives and other products complicates the measurement, but an accurate reading of mud tank density measurement is necessary to controlling operations.

Electronic differential pressure (EDP) is a popular choice for measuring mud tank density. An EDP system consists of two independent instruments that deliver a differential pressure measurement without capillaries or impulse lines. EDP systems can be configured to output a number of values including density. EDP instruments are invulnerable to temperature changes that distort traditional DP measurements and optional ceramic measuring cells are resistant to abrasion and drift. These instruments also offer overload resistance. Maintenance free and relatively easy to install, there is a lot to like about EDP. However, not all EDP systems are created equal. Some EDP systems do not tolerate extreme heat, and metallic measurement diaphragms are susceptible to damage.

Every drilling project has to account for mud. From the pipeline to the storage tank and beyond, mud measurements are vital to a project’s success. Accurate measurements can help users optimize operations and make the most of materials and equipment. Selecting the right process instruments for mud measurement comes down to the realities of the project at hand.

Not all process needs are the same, and not all mud is either. Users should seek the counsel of their process instrumentation providers to select the mud measurement instrument that best suits their operation.

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:

Optimizing production under dynamic well conditions requires flexible and adaptive electrical submersible pumping (ESP) solutions. ESP pumps from Baker Hughes incorporate innovative hydraulic designs to expand the application range of your ESP systems.

Our flexible pumps have the broadest operating range in the industry to deliver unsurpassed levels of efficiency, reliability, and speed to your production operations. You get customized pumping solutions to improve your operating economics, regardless of your field application.

ENSCO 71 is a Jack-Up drilling rig which was originally constructed at the Hitachi Zosen shipyard in 1982.  The original GE motor controls comprised five 1163 KVA generators and four 1800 ADC SCR units with associated auxiliary transformer feeders and jacking units. The SCRs were assignable to two 1600 HP twin-motor Mud Pumps, a twin motor 2000 HP Drawworks and a 1000 HP Rotary Table. A separate feeder drives a 1110 HP Top Drive. A fifth SCR was added by Hill Graham Controls in 1985 to power a third 1600 HP Mud Pump, which was cabled to the main busbars.

In early 2012, a decision was made to add a fifth 2500 KVA generator and an additional auxiliary transformer, to close-couple these to the main switchboard via a bus tie circuit breaker, and to include a dedicated feeder for the fifth SCR. A sixth SCR was also included in the switchboard extension to provide an alternative drive source for the third Mud Pump, effectively removing this load from the main switchboard. The switchboard extension, including full integration with the existing GE and Hill Graham equipment, was engineered and built by Zeefax.

The Power System Study was completed by gathering data about the existing switchboard arrangement and comparing this to the original, hand written, fault level calculations. The new calculations were performed using software modelling and verified to IEC 61363. The IEC 61363 Short Circuit study represents conditions that may affect typical marine or offshore installations more significantly than land-based systems, including more emphasis on generator and motor decay. This confirmed the original calculations were accurate.

Finally, the study also included calculating the strength and current-carrying capacity of the busbars under normal and fault conditions to establish the correct busbar sizes and bracing.

Industrial Internet of Things (IIoT) pump condition monitoring can be a solution to help understand pump issues and, better yet, reduce operating costs. If the pump is expensive to maintain or replace and is critical to the process, consider adding IIoT monitoring. There are many things that can be monitored on different pump styles. For instance, a progressive cavity pump should never run dry. Positive head and flow should always be on the suction side of the pump. If this type of pump runs dry for even a half a minute, the rotor and stator can be permanently damaged. Adding vibration sensors and flow meters can help diagnose and stop a pump before serious damage occurs. Main bearings, gear boxes and motors can be monitored so increasing vibration can be detected and an e-mail or text can be sent to relevant personnel to diagnose and fix a small problem before it becomes significant and costly.

Immense data can be captured from an integrated frequency drive. Any instrumentation that resides in the area of the pump that provides input to pump performance can be tapped into and monitored from a cloud based portal. Alarms will be displayed on the cloud-based portal but e-mails or text messages can be sent to relevant personnel for any alarm.

Any asset that has digital or analog instrumentation inputs can be monitored. Instrumentation has become much less expensive and easier to install. Some call this instrumentation “lick and stick.” It can be bolted on, use magnets or adhesives. Virtually any asset including pumps can use IIoT monitoring. Some areas or instances where IIoT condition monitoring can help are:

Roxia provided smart pumping solutions for a waste management company EKJH in Finland. The company had a remote unmanned pumping station where the control system was old and out of date. Personnel had to travel to the station several times a week to take readings and make adjustments to pumps and other assets. The smart valve and pump manufacturer provided an updated control system to replace the existing system for half the cost of a new control system. Now the owners of that remote pumping station can sit in offices 80 miles away to make system adjustments and all the readings are real time cloud-based. If there is an alarm, the owners get an e-mail, and they can log in and determine if a site visit is required.

The same wastewater management company contacted the manufacturer last year about an aeration system for its leveling pond. It had a problem with the pond freezing during winter and generally low oxygen content in the water, which resulted in foul odors. The manufacturer recommended that the aeration system should be fully automated and operated under the same platform as the remote pumping station. The goal was to supply the lowest total cost of ownership. Roxia partnered with a company that specializes in surface aerators because the project required compressors and energy efficient oxygen transfer while keeping the pond surface from freezing. Roxia was able to gather all the data from the aeration units and provide an automatically adjusted system that operates according to weather and water conditions, as well as incorporate the remote pumping station. The EKJH waste management company has been pleased with the solution.

Last year, the IIoT provider added vertical tower pressure filter monitoring on three pressure filters also in Finland. These machines are highly automated and have many instruments and inputs to monitor. However, the manufacturer did not add any additional instrumentation to these machines. It began to analyze the data and provide dashboards so the plant could better understand its issues.

Any plant can capture data, but if it does not have an effective way to analyze the data, then it is useless. IIoT monitoring is proving to be an analysis tool that is benefiting many customers.