maintenance of mud pump quotation

Many things go into getting the most life out of your mud pump and its components — all important to extend the usage of this vital piece of equipment on an HDD jobsite. Some of the most important key points are covered below.

The most important thing you can do is service your pump, per the manufacturer’s requirements. We get plenty of pumps in the shop for service work that look like they have been abused for years without having basic maintenance,  such as regular oil changes. You wouldn’t dream of treating your personal vehicle like that, so why would you treat your pump like that.

Check the oil daily and change the oil regularly. If you find water or drilling mud contamination in the oil, change the oil as soon as possible. Failure to do so will most likely leave you a substantial bill to rebuild the gear end, which could have been avoided if proper maintenance procedures would have been followed. Water in the oil does not allow the oil to perform correctly, which will burn up your gear end. Drilling mud in your gear end will act as a lapping compound and will wear out all of the bearing surfaces in your pump. Either way it will be costly. The main reasons for having water or drilling mud in the gear end of your pump is because your pony rod packing is failing and/or you have let your liners and pistons get severely worn. Indication of this is fluid that should be contained inside the fluid end of your pump is now moving past your piston and spraying into the cradle of the pump, which forces its way past the pony rod packing. Pony rod packing is meant to keep the oil in the gear end and the liner wash fluid out of the gear end. Even with brand new packing, you can have water or drilling fluid enter the gear end if it is sprayed with sufficient force, because a piston or liner is worn out.

There is also usually a valve on the inlet of the spray bar. This valve should be closed enough so that liner wash fluid does not spray all over the top of the pump and other components.

Liner wash fluid can be comprised of different fluids, but we recommend just using clean water. In extremely cold conditions, you can use RV antifreeze. The liner wash or rod wash system is usually a closed loop type of system, consisting of a tank, a small pump and a spray bar. The pump will move fluid from the tank through the spray bar, and onto the inside of the liner to cool the liner, preventing scorching. The fluid will then collect in the bottom of the cradle of the pump and drain back down into the collection tank below the cradle and repeat the cycle. It is important to have clean fluid no matter what fluid you use. If your liners are leaking and the tank is full of drilling fluid, you will not cool the liners properly — which will just make the situation worse. There is also usually a valve on the inlet of the spray bar. This valve should be closed enough so that liner wash fluid does not spray all over the top of the pump and other components. Ensure that the water is spraying inside the liner and that any overspray is not traveling out of the pump onto the ground or onto the pony rod packing where it could be pulled into the gear end. If the fluid is spraying out of the cradle area and falling onto the ground, it won’t be long before your liner wash tank is empty. It only takes a minute without the cooling fluid being sprayed before the liners become scorched. You will then need to replace the pistons and liners, which is an avoidable costly repair. Make a point to check the liner wash fluid level several times a day.

Liner wash fluid can be comprised of different fluids, but it is recommended to just using clean water. In extremely cold conditions, you can use RV antifreeze.

Drilling fluid — whether pumping drilling mud, straight water or some combination of fluid — needs to be clean. Clean meaning free of solids. If you are recycling your fluid, make sure you are using a quality mud recycling system and check the solids content often throughout the day to make sure the system is doing its job. A quality mud system being run correctly should be able to keep your solids content down to one quarter of 1 percent or lower. When filling your mud recycling system, be sure to screen the fluid coming into the tanks. If it is a mud recycling system, simply make sure the fluid is going over the scalping shaker with screens in the shaker. If using some other type of tank, use an inline filter or some other method of filtering. Pumping out of creeks, rivers, lakes and ponds can introduce plenty of solids into your tanks if you are not filtering this fluid. When obtaining water out of a fire hydrant, there can be a lot of sand in the line, so don’t assume it’s clean and ensure it’s filtered before use.

Cavitation is a whole other detailed discussion, but all triplex pumps have a minimum amount of suction pressure that is required to run properly. Make sure this suction pressure is maintained at all times or your pump may cavitate. If you run a pump that is cavitating, it will shorten the life of all fluid end expendables and, in severe cases, can lead to gear end and fluid end destruction. If the pump is experiencing cavitation issues, the problem must be identified and corrected immediately.

The long and the short of it is to use clean drilling fluid and you will extend the life of your pumps expendables and downhole tooling, and keep up with your maintenance on the gear end of your pump. Avoid pump cavitation at all times. Taking a few minutes a day to inspect and maintain your pump can save you downtime and costly repair bills.

The fluid end of a duplex or triplex pump offers hundreds of opportunities for error. The results of an error in such a high-pressure system can mean (1) expensive downtime on the pump and maybe the entire rig, (2) expensive repair-replacement, and (3) possible injury or death of a crewman or a company man. Under the laws of nature, pump pistons and liners will wear, and there will be some corrosion and metallurgical imperfections, but the majority of pump failures are manmade. Theoretically, thorough training and retraining should avoid most mud pump problems. Realistically, a critical failure analysis during repair will be necessary to determine how to correct the failure. Telltale signs of trouble are distortion of piston rods, frayed piston polymer, discoloration, odor, hard-to-remove piston, rod cracks, pitting, total fracture, valve seat wear, and unsuitable external appearance.

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.

Pumps are often designed to operate at a single point known as the Best Efficiency Point (BEP). As components begin to wear, a pumps performance begins to decline, with operation away from this point leading to issues such as accelerated bearing or seal wear, vibration, excess temperature rise or cavitation. Quite often declining performance can start gradually, before quickly accelerating until failure if performance issues are not addressed in a timely fashion.

Corrective Maintenance is undertaken when failure has occurred. The unit may be leaking, efficiency reduced, pump stopped or motor tripped, leading to loss of production resulting in an urgent situation where parts must be sourced and fitted quicky.

At times specialist labour may be required but also specialist lifting equipment. The average cost of downtime is £12K per incident, takes on average 8 hours to resolve and occurs 4 times a year. This is without considering customer dissatisfaction, and product wastage, so ideally this situation is one to be avoided.

Preventative Maintenance is inspection and repair scheduled at specific intervals (daily, weekly, monthly, yearly) or based on the number of hours run. Visual inspections are made externally and internally by dismantling the unit, replacing seals such as gaskets and mechanical seals, with pump parts checked for wear.

Differential Pressure:Check the operating pressure by calculating the difference between the inlet and outlet pressure of the pump ensuring it is operating on curve.

Wearing Part Tolerance – Check parts are within design tolerance through use of a vernier. Measure Shaft OD and condition, Impeller Diameter, bearing tautness around the shaft and casing thickness.

Mechanical Seal (barrier fluid) – Check for contamination such as changes in general colour or appearance, PH, presence of particles, viscosity, or if fluid is at excess temperature during operation.

The “6 to 1 Rule” discovered by John Day Jr, (Manager of Engineering & Maintenance at Alumax South Carolina stated that the ideal ratio of Proactive Maintenance (PM) to Corrective Maintenance (CM) should be 6 to 1 - 6 PM checks to 1 RM check. If your ratio is below this then according to his theory it is being inspected too infrequently, above and inspections are too frequent.

Although Proactive Maintenance can seem to avoid the urgent costs and downtime associated with reactive maintenance, PM maintenance costs can be high due to the cost of labour in dismantling of complicated designs such as Progressing Cavity, or Triplex Plunger pumps which are often time consuming to maintain with more than one person required to undertake work.

On dismantling units, some seals require replacing regardless of condition, and excess spares can be required in case of gasket entrapment during assembly. Rental of specialist lifting equipment may be required and there can be situations where when inspected, pump parts do not require replacement.

This can be achieved through a monitoring device, where when the right data is collected, pump failure can be anticipated between 3 and 12 months in advance with an 80-95% accuracy.

With the average lead time on DN100 pumps, and units over 5 years old being 3 months or more, it is essential that spares are either on the shelf or failure is anticipated through advance ordering.

High Frequency Data – Data is collected across a broad spectrum detecting the first stages of abnormality. Cheaper units typically collect data across a 1000Khz spectrum which will provide very little time to react. Our Overwatch device monitors over a 65,000Khz spectrum.

There are hazards during any maintenance activity. Always ensure the correct PPE is worn before attempting repair, that sufficient expertise is on hand and chemical data sheets of any fluid being pumped are checked prior to undertaking work. A full risk assessment should be completed in advance.

Hazardous FluidsIrritation, Chemical burns, ignitionEnsure when pump is opened the unit is cool, not pressurized, ignition sources are not present, and any fluids spilt are contained.

If inspection has been neglected for some time, then additional parts may require replacing than had the unit been inspected earlier, with some pump parts becoming beyond economical repair.

Enables planned work to be undertaken during lower activity levels and at lowest cost & risk.Pump has to be crucial within a process or above a certain size for monitoring to be cost effective

Thread Sealant –The use of semi-permanent thread sealant will ensure vitality important threaded fasteners such as bolts or screws on shafts, couplings or pump casings do not self-loosen due to vibration and become disengaged.

Interchangeable Spares –Our range of pumps are modular in design utilizing interchangeable spares, meaning on site stock holding of parts can be reduced by up to 80% further reducing slow moving stock.

Repair & Replace –Choosing to repair an existing pump within a process of vital importance, as well as replace, is a strategy we recommend for maximizing plant efficiencies and reducing downtime. Should unexpected pump failure occur, your process can be restored quickly.

Checklists & Logs –The use of checklists and logs ensures a fully repeatable process ensuring important maintenance intervals are not missed. Logs can provide valuable insight and reveal a pattern before failure occurs enabling easier troubleshooting.

indicates which areas should be checked, but note that a units maintenance routine is dependent on several factors such as hours of operation, duty, aggressiveness of pump medium, rpm of motor, temperature, inlet conditions and location of equipment.

Whether onshore or offshore, well drilling sites rely on a multitude of systems to successfully perform the drilling operation. The mud pump is a key component tasked with circulating drilling fluid under high pressure downhole. The mud pump can be divided into two key sections: the power end or crosshead and the fluid end. Proper alignment of the pump’s crosshead to the fluid end liner is necessary to maximizing piston and liner life. Misalignment contributes to

accelerated wear on both the piston and the liner, and replacing these components requires downtime of the pump. Traditional methods of inspecting alignment range from using uncalibrated wooden rods, Faro Arms and micrometers to check the vertical and horizontal alignment of the piston rod OD to the piston liner ID. These are time consuming and cumbersome techniques that are ultimately not well suited to troubleshoot and solve alignment issues.

A “Mud Pump Laser Alignment Kit” enables you to measure where the piston will run through the liner at various positions along the pump’s stroke. It will also project a laser centerline from the fluid end back towards the rear power end of the pump that can be used to determine how much shimming is required to correct any alignment issues. The kit can include either a 2-Axis receiver or a 4-Axis which accepts the laser beam and documents where it falls on the active surface of the receiver. The 4-Axis receiver can decrease alignment time by as much as 50% as it will measure angularity as well as X and Y while the 2-Axis does not and will need multiple measurement locations to get the same information. In addition, the alignment system is a non-intrusive service requiring the removal of only the piston rod which allows for much quicker service and less down time on the pump. As the mud pumps in question are located globally both on and offshore, having a small, portable system is another great advantage. Our recommendation would be Pinpoint laser System’s “Mud Pump Alignment Kit”. They are being used by many of the leading repair service companies and have been their main alignment tool for over 15 years. Manufacturers are also utilizing these for new pump set-up.

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Our Premium Series liners feature bi-metallic construction utilizing a steel outer shell with an industrial chrome insert. Along with proper maintenance, can provide up to 800+ hours of service.

Manufacturer of a wide range of products which include sewage & mud pump repairing service, mud pumps services center, rental pump services sewage dewatering pumps and mud pump repairing services.

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Service TypeRepair ServiceWe are ranked amongst the renowned organizations that are engaged to render the best quality Pump Repairing Service. The repairing work of pumps is executed by our highly qualified professionals using premium grade tools and the lates

BrandJay Bajarangur company is one of the most preferred service provider of the most qualitative and reliable services for Vicker Hydraulic Pump Repairing, which is rendered by technical professionals and mechanical engineers who are not only well qualified but who also have a very rich experience in the domain of Pump Repairing. Moreover, we also conduct these Repair

If you are supplying pump supplies, you can find the most favorable prices at Alibaba.com. Whether you will be working with piston type or diaphragm type systems, reciprocating or centrifugal, Alibaba.com has everything you need. You can also shop for different sizes drilling mud pump price wholesale for your metering applications. If you operate a construction site, then you could need to find some concrete pump solutions that you can find at affordable rates at Alibaba.com. Visit the platform and browse through the collection of submersible and inline pump system, among other replaceable models.

A drilling mud pump price comes in different makes and sizes, and you buy the tool depending on the application. The pump used by a filling station is not the one you use to fill up your tanks. There are high flow rate low pressure systems used to transfer fluids axially. On the other hand, you can go with radial ones dealing with a low flow rate and high-pressure fluid. The mixed flow pump variety combines radial and axial transfer mechanisms and works with medium flow and pressure fluids. Depending on what it will be pumping, you can then choose the drilling mud pump price of choice from the collection at Alibaba.com.

Alibaba.com has been an excellent wholesale supplier of drilling mud pump price for years. The supply consists of a vast number of brands to choose from, comes in different sizes, operations, and power sources. You can get a pump for residential and large commercial applications from the collection. Whether you want a water pump for your home, or run a repair and maintenance business, and need a supply of dr drill mud pump prices, you can find the product you want from the vast collection at Alibaba.com.ther it is for refrigeration, air conditioning, transfer, or a simple car wash business, anything you want, Alibaba.com has it.

A Mud pump features robust reciprocating pumping technology for mud circulation on the drilling array. Reciprocating pumps follow the conventional mechanism of the auto engine.

Having a crosshead crankshaft gear makes the mud pump mechanism more effective. And the specific placement of the connecting rod helps the piston to play its role.

The fixed part of the piston rod, along with a sleeve, ensures compelling performances. In this position, it can work without any force on pistons from sideways.

And in this position, a cooling spray of water on the pump’s pistons helps it work better. As well as other moving portions like liners also work better with cooling water spray.

The mud pump works as a virtual device featured in the well drilling kit. Unlike a stand-alone device, this kind of pump works as major equipment of robust drilling equipment.

Both output and input fluid flows through the direct pipeline towards the drilling string. The advanced connectivity with structured fixtures of the borehole helps a mud pump to perform the best.

In the case of remote locations, the mechanism of diesel motors suits this kind of pumping unit. On the availability of DC motor kits, a mud pump features electric energy driven AC motors.

The surface of this kind of deep well can be spacious up to 10 miles. So, in these cases, a mud pump must work on the 10 miles below the water surface.

But the type of slurry depends on the well, where the drilling operation is executed. In these operations, the fluids or fluid mixtures also contain synthetic particles.

The types of a mud pump depend on its specific combo of components. According to the requirements of the clients, this pump features the best equipment.

The number of working ends of a pump’s piston defines the pattern of action. Having a single working end of the piston, a Single-acting mud pump can use only one direction.

For a wide range of drilling applications, this kind of pumping unit works the best. In these applications, a pump needs to generate a high amount of pressure.

The Duplex mud pump’s competent mechanism helps to ensure the standard mud circulation as it can reach from the mud picking system to the bottom point of the well.

All these components provide the best performance executing the top-tier mechanism. In case of severe vibration, this pumping unit requires a suction unit.

Maintenance is a vital thing to boost the lifespan of a pump. If you go through the following essential key points, you will learn how to enhance a mud pump’s performance.

Regular servicing is a standard part of maintenance for any mechanical unit. But, most of the maintenance shop complains about the abuse of pumping components without any oil treatment.

Checking and changing the oil daily makes your mud pump more efficient. If you detect any mud or water contamination in existing oil, don’t hesitate to change it.

So, users should take care of the gear end from mud deposits. Otherwise, it will ruin pony rod packing. It’s one kind of mechanical failure, which can shred pistons and liners.

Fluid for Liner wash can contain different fluids. But experts recommend using clean water. In extreme conditions of coldness, using RV antifreeze provides the best result.

This kind of potent system contains a tank along with a spray bar and a small pumping unit. Using the spray bar, the tank moves out the fluid from the tank.

Always remember where a mud pump deals with drilling fluid, it should be free of solids. The drilling fluid can be raw water or other combination of liquid. But it needs to be solids-free.

For the recycling process of your fluid, always prefer a standard mud recycling system. As well as checking the reliable content throughout the day enhance the performance of your system.

A triplex mud pump works with minimal suction pressure. One thing you need to remember is the maintenance of this suction pressure with consistency during application.

Lake Petro provides high quality Mud Pump Parts including Mud Pump Liners, Mud Pump Fluid End Module, piston, Valve and Seat etc. With more than 10 years of experience in the oil and gas industry, we are dedicated to help and support our loyal clients with the most cost-effective and quality Liners and Pistons. We also provide mud pump price and mud pump for sale.

We offer Liners with Ceramic (Zirconia and Aluminium oxide) and Steel (Metal and Bi-metal) materials for all common brands of the mud pump and triplex mud pump.

Bi-metal liners (double metal liners) are made of forged steel shell and wear-resistant sleeve of high chromium iron. In the production process, the size accuracy should be strictly controlled, which can ensure that they can be easily and stably installed. The inner sleeve with high finish and hardness is wear-resistant, corrosion-resistant and has a long service life. The bi-metal liners are suitable for a lot of bad working conditions. Its service life is more than 800 hours.

Ceramic Liners are made of a ceramic inner sleeve and a forged steel outer shell. The service life of ceramic liners is about 4000 to 10000 hours, the minimum time is at least 2000 hours, which is a lot more than bi-metal liners. Because of the phase transformation toughen technology, the ceramic liners have the features of wear-resistance, erosion-resistance, high-pressure-resistance, high hardness and strength. Zirconia type and Alumina type are common type of ceramic sleeve. Compared with Alumina type, Zirconia type liners have better toughness properties and a much longer service life. Piston wear and water consumption for lubrication can be reduced as well.

Seal Rings for Liner packing are also important. Liner Seal Rings is designed and made with hard corner which is an integral part of seal rings and soft nitrile element rubber center. We could provide reliable liner Seal Rings for our customers could order them at the same time.

All Lake Petro liner products are interchangeable with O.E.M. products. Meanwhile, we provide customized Liners according to drawings. Our liners, also with our other mud pump spares, are supplied for use in Honghua, F-Series, Bomco, Emsco and National lines of triplex drilling pumps. Let Lake Petro be your one-stop shop for your whole fleet of pumps. Please refer to “Suitable Pump Models” Lable for more details.