maintenance of mud pump pricelist

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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.

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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.

Since horizontal directional drilling (HDD) work tends to be slower in the winter months, particularly when the ground is frozen, winter is a prime time to inspect the power end of the pump and prevent downtime on the job later.

If one waits until an audible problem can be detected, it is often very expensive to repair. All smaller HDD pumps – 100 hp and smaller — tend to use the same type of internal components regardless of the manufacturer.

The power end should last for years if it is given proper maintenance. Clean lubricant is essential for longevity along with wiper box seals that are in good condition. External influences such as allowing the pistons to leak profusely and or cavitation tend to shorten the life span of the power end components quickly. It is easy to visually inspect the power end components for wear and detect a problem before it becomes very expensive to repair.

The largest load bearing area of the pump is the crosshead pin and bushing area. Wear can be detected by locking the intermittent or piston rod with a pipe wrench and rotating the crank shaft slightly. If one can feel any slack it can only be coming from the pin and bushing or the connecting rod bearing. It then becomes necessary to remove the connecting rod assembly consisting of the connecting rod and cross head. If slack is determined in the pin bushing, it will be necessary to press out the pin and inspect the bushing and the crosshead pin in the eye of the connecting rod. Some manufacturers ship bushings that are designed to fit. Others ship them and they have to be reamed to fit the pin after the bushing is installed. The installation instructions and dimensional fits are provided by the manufacturer in the pump manual.

The next area of concern is the connecting rod bearings themselves. If visual wear can be seen, use a micrometer and measure the crankshaft journals to make sure they are not out of round. If the journals check out, then all is needed is new connecting rod bearings. Some manufactures utilize shims to get the correct fit to the journal. Others provide automotive style bearings that only require correct torque to the rod cap for correct installation. There are pros and cons concerning automotive style vs shim bearings. Shim type bearings does allow for oversized connecting rod bearing should the journals be worn. This allows for turning down the crank journals a few thousands and utilizing a larger connecting rod bearing. If a pump uses automotive style precision bearings and the journals are out of round, it is necessary to replace the crankshaft.

The tapered roller bearing should last for years. If the rollers and races are not pitted, utilizing the same set of roller bearings is allowable. Checking the end play on the crankshaft is a simple task. With the use of a dial indicator, check for the lateral movement of the shaft. It if falls within the manufacturer’s tolerances, nothing needs to be done, If not, then it will be necessary to add or remove shims. Shims packs are provided by the manufacturer so one can get the proper end play on the crankshaft. The shims themselves come in different thickness allowing one to add or remove to get the correct end play.

Wiper box packing keeps the oil within the power frame and external contamination from entering the power end. The packing is easy to inspect and essential for longevity of the power end. The wiper box packing must remain in excellent condition at all times. Allowing the pump to set for extended periods of time or letting external contamination build on the packing shortens the lifespan.

If one waits until an audible problem can be detected, it is often very expensive to repair. All smaller HDD pumps – 100 hp and smaller — tend to use the same type of internal components regardless of the manufacturer.

Inspection of the power end allows the owner to dictate when repairs are necessary rather than allowing the pump to dictate during the middle of a job when repair is required. If problems are detected early, repair is relatively inexpensive. If a problem is not detected early, that problem often leads to more unnecessary wear and affects other components of the pump. An early fix to any problem is relatively inexpensive. Allowing the problem to continue can often cost several thousands of dollars and downtime on a job.

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.

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.

abstractNote = {Based on extensive research, development, and field testing of mud pumps and accessory equipment, this book offers cost-saving methods in operation and maintenance of triplex and duplex pumps. It covers practical engineering concerns such as pressure losses from friction in the piping and inertia in the drilling mud; suction dampeners in pump operation; charging the suction pipe for greater efficiency and smoother operation; hydraulic and mechanical knocking; hydraulic pressure losses; discharge lines.},

Prior check to the start of a mud pump for clear water inlet and outlet pipes, buttered front and rear bearings and a filled packing. The China mud pump should be equipped with a high-pressure water pump, which pumps water to the sealing fill with a pressure greater than that of the mud pump. As a protection to the fill, never turn off the water pump while the mud pump is in its working state. Otherwise, the sealing part is of immediate wear.

The service life of the mud pump depends on the clearance between the impeller and the guard plate. An unreasonable clearance is responsible for the vibration and the noise of the pump and the damage of overflowing parts. Therefore, when it comes to the impeller replacement, the clearance shall meet the requirements of the design drawing by adjusting screws on the rear bearing. Take the suction capacity of mud into account for the allowable suction range of the mud pump is determined by water transported.

The Construction Department shall have some professional person responsible for the maintenance and repair of the construction machinery. Regular check and maintenance of the mud pump and other machinery, such as the drilling mud pump parts, are useful for the early detection and a prompt solution.

Pay attention to the size of sediment particles, among which the large ones are prone to wear the vulnerable parts of the China mud pumpsuch as pump shells, bearings, impellers, and so on. Timely maintain the use and replace the damaged. Take advanced anti-wear measures to lengthen the service life of vulnerable parts, which can downturn the cost and up forward the efficiency. Meanwhile, keep backup vulnerable parts in stock in case of unexpected replacement needs.

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.

Mud systems have a lot of moving parts that must be kept in order to keep them in premium working order. If you do not grease and adjust centrifugal packing on a regular basis, it will leak causing not only a mess but also hazardous work environment. Bearings require lubrication for long life. Cones can get plug with debris making them inactive thus reducing your cleaning capacity. Screens get torn allowing trash to go into the system causing plugging problems.

Routine maintenance can extend the life of not only the complete mud system but also individual components and prevent premature failure of the unit. This is also a great time to inspect the unit for stressed or damaged components.

When the mud system is operating properly it is easy to forget to check and grease components as a preventative measure. The focus on a jobsite is to increase production while decreasing operating cost. While this makes for a better bottom line (on the books), it does not always allow for the time or personnel to maintain and repair the equipment. For this reason as they say “the squeaky wheel get the oil” and if it is running we have a tendency to focus on the larger problems of keeping the drill bit turning.

This is a hard question to respond to due to variables such as the location of service (ex: heavy sand areas verse slow hard rock drilling or shale). The amount of time per day the unit is used: 12 hours vs. 24 hour per day jobs. Number of days per week and number of weeks per year for the unit is utilized.

Always check the oil and water from the power unit at least once a day. Change the oil and filters as recommended, more often in dirty conditions. Ensure that there is adequate pressure on the cones while drilling to ensure optimum cleaning and always make sure the screens are sized correctly and in good condition.

General maintenance on a recycler is fairly straightforward and I believe most contractors want their systems to last a full lifetime. One area I have seen that could be improved is overall clean up after the job is completed. Wash the machine to eliminate all mud and debris. Flush clean water thru the system to clear out all the suction and discharge lines. This prevents drilling mud from drying in the suction line, cones, hopper, etc.

Aipu Solids Control, Inc. Is dedicated to producing the highest level of quality and durability in all of the systems we manufacture. Our engineering staff can design or modify any of our machines to meet our customer’s particular need. In as much, it is our goal to provide our customers with the ultimate in customer service. If we can help minimize or eliminate downtime, then that will allow our clients to operate at maximum efficiency which translates into big savings for them.

We manufacture a complete line of shale shakers; desilters, desanders and mud pump packages, thus allowing us the ability to keep a higher standard of excellence. Our tank and mixing systems are designed for maximum flexibility and we carry parts for all major brands of equipment.

The dirty fluid flowing thru the mud system is effectively sand blasting away the interior of the pipes, steel, etc. Wear items such as the hydrocyclones, centrifugal impellers, wear plates and volutes are designed to process the undesirable fluid and will over time have to be replaced. As these items were the efficiency of the unit will diminish. This means the maximum cleaning capacity will diminish.

“An ounce of preventative is useful to a pound of cure!” If properly maintained a mud recycling system can remove the undesirable solids from your drilling mud. This will save not only the wear items on the mud system but also increase the life of the drilling rig: swivel, pipe, downhole tools, etc. In addition it will allow you to reuse your drilling mud cutting cost on water, bentonite and labor.

Southwest’s Field Service Team is committed to providing customers with highly-trained personnel who can thoroughly inspect Mud Pumps and troubleshoot equipment issues. Our services are designed to provide customers with valuable information about their mud pump, along with providing cost-effective solutions to keep your equipment running trouble-free.

OEM trained technicians provide installation of fluid end modules ensuring equipment meets OEM standards and is aligned properly to reduce consumption of mud pump wear parts.

Drastically reduce mud pump equipment outages by installing a hydraulic liner retention system. This system decreases liner change-out time from hours to minutes.

Inspections allow you to address problems and issues before a failure occurs. Additional performance enhancements can also be achieved with our laser alignment pump service and customizable preventative maintenance program.

Quick-Change valve covers provide true steel-to-steel tightening of the valve cover assembly. It also reduces the possibility of washouts by converting the original square-seal design to Southwest’s tapered design.

Lapping is an excellent process to enhance the performance of worn fluid ends. This procedure reduces seat deck imperfections which increases metal to metal contact between the seat and seat deck.

As part of Southwest oilfield’s Service and Repair Department, the Zero-N Laser Alignment System is utilized to provide the most accurate fluid-end alignment services available. The Zero-N Laser is accurate to within 0.001” in both X and Y axes with a digital readout for consistent, repeatable measurements.

The system is lightweight and suitcase portable, thus eliminating the cumbersome and difficult-to-transport systems of the past. In addition, the Zero-N Laser Alignment system is a non-intrusive service requiring the removal of only the piston rod which allows for much quicker service and less downtime on the pump. Alignment inspections are performed worldwide by Southwest Oilfield trained service technicians.

With the addition of a fully-tooled heavy-duty service truck, our Southwest service offerings continue to grow! With a 6,000 lb. lift capacity, onboard welding unit, and pneumatic tool system this vehicle is equipped to handle even the most challenging, on-site fluid-end projects.

If the slurry pump is driven by a belt, please check the tension of the rope at least once a quarter. Too tight belts will cause damage to the motor bearing and once the bearing is broken the bearings will start to fail inside the pump. Belt that is operated when it is too loose will cause poor performance and cause slip damage to the belt.

If your dredge pump is using lubricant for cooling, please check it periodically to make sure there is no water or other impurities in the oil. If the pump seal remains stable, changing the oil periodically will increase the life of any pump.

Best performance is achieved by occasionally checking the out-of-wing clearance. Refer to instructions to check gaps appropriately. When checking the clearance, it is also necessary to check the impeller wear and other parts of the dredge pump.

For this problem, the best solution is to install pressure gauges and flowmeters on the discharge lines of the pumps. You can take the display pressure and multiply it by 2.31 to get the relative TDH (total dynamic head). You can then take that TDH along with the measured flow and see if your pump runs near the BEP (best efficiency point) on the pump’s baseline. If not, please contact your provider.

Temperature sensors are provided with our submersible pumps for engine protection. Each guide provided with the pump will outline how to connect and monitor the temperature sensors for the maximum life cycle.

If the engine is overheated, the sensors will automatically shut off and the pump will stop working until the engine cools down. If there is no sensor, or the sensor is not connected to the pump, there is a risk of engine fire.

Horizontal and vertical pump cantilever need to check the temperature of the bearing weekly while the pump is in operation. Use a temperature gun to check the bearing housing temperature closest to the bearing.

While most pump bearings run in the range of 140 to 170 degrees Fahrenheit, it is recommended that users never allow temperatures in excess of 200 degrees Fahrenheit (about 94 degrees Celsius). High bearing temperatures may be a sign of excessive lubrication or a problem with the bearing.

Proper vibration monitoring will provide the operating team with useful information that can increase MTBF (mean time between failures) and improve pump performance. Refer to the Hydraulic Institute’s vibration monitoring guide (American Hydraulic Institute) for vertical, horizontal and submersible pumps for appropriate limits.

Currently Thai Khuong Pump is representing the pump brand Schuro Slurry in Vietnam specializes in providing products with large capacity US brand mud pump (you can refer to the productshere).

If you have not yet selected a suitable mud pump product, or have any questions need advice or provide technical information, product prices. Let’s contact right with us.

Titan Oil Tools offers high quality mud pump expendables and mud pump replacement parts for the wide variety of mud pumps, centrifugal pumps found on the world market today. These quality pump parts offer great performance and our pricing will save you money.

We are your oilfield supplier of choice for mud pump spares and mud pump parts: mud pump piston liners and pistons. All mud pump parts can be sourced for fast delivery; Come to us for mud pump liners, pistons, piston rods and parts, pony rods, threaded rings and caps,and more. Try us for duplex and triples pump spares and duplex and triplex mud pump parts, and also valve parts like valve seats. gland nut, and mud pump gaskets.

Mud pump liners may come in chrome, alumina ceramic and zirconia ceramic. Chrome liners and alumina ceramic liners are less costly, their cost of replacement over one year as the chart below shows, is much more than zirconia ceramic liners.

The table below shows a Mud Pump Liner Cost of Ownership which shows a reasonable cost comparison for a rig in continuous service for 36 months. This of course does not include the high cost of maintenance downtime and the cost of labor.

The prices below are based on cost/cylinder. Savings increase when you add up the number of pump cylinders on your rigs and extend the savings to understand the big difference it can make for your budget.

Mud pump is one of the most critical equipment on the rig; therefore personnel on the rig must have good understanding about it. We’ve tried to find the good training about it but it is very difficult to find until we’ve seen this VDO training and it is a fantastic VDO training about the basic of mud pumps used in the oilfield. Total length of this VDO is about thirteen minutes and it is worth to watch it. You will learn about it so quickly. Additionally, we also add the full detailed transcripts which will acceleate the learning curve of learners.

Powerful mud pumps pick up mud from the suction tank and circulate the mud down hole, out the bit and back to the surface. Although rigs usually have two mud pumps and sometimes three or four, normally they use only one at a time. The others are mainly used as backup just in case one fails. Sometimes however the rig crew may compound the pumps, that is, they may use three or four pumps at the same time to move large volumes of mud when required.

Rigs use one of two types of mud pumps, Triplex pumps or Duplex pumps. Triplex pumps have three pistons that move back-and-forth in liners. Duplex pumps have two pistons move back and forth in liners.

Triplex pumps have many advantages they weight 30% less than a duplex of equal horsepower or kilowatts. The lighter weight parts are easier to handle and therefore easier to maintain. The other advantages include;

• One of the more important advantages of triplex over duplex pumps, is that they can move large volumes of mud at the higher pressure is required for modern deep hole drilling.

Triplex pumps are gradually phasing out duplex units. In a triplex pump, the pistons discharge mud only when they move forward in the liner. Then, when they moved back they draw in mud on the same side of the piston. Because of this, they are also called “single acting.” Single acting triplex pumps, pump mud at a relatively high speeds. Input horsepower ranges from 220 to 2200 or 164 to 1641 kW. Large pumps can pump over 1100 gallons per minute, over 4000 L per minute. Some big pumps have a maximum rated pressure of over 7000 psi over 50,000 kPa with 5 inch/127 mm liners.

Here is a schematic of a triplex pump. It has three pistons each moving in its own liner. It also has three intake valves and three discharge valves. It also has a pulsation dampener in the discharge line.

Look at the piston at left, it has just completed pushing mud out of the liner through the open discharge valve. The piston is at its maximum point of forward travel. The other two pistons are at other positions in their travel and are also pumping mud. But for now, concentrate on the left one to understand how the pump works. The left piston has completed its backstroke drawing in mud through the open intake valve. As the piston moved back it instead of the intake valve off its seat and drew mud in. A strong spring holds the discharge above closed. The left piston has moved forward pushing mud through the now open discharge valve. A strong spring holds the intake valve closed. They left piston has completed its forward stroke they form the length of the liner completely discharging the mud from it. All three pistons work together to keep a continuous flow of mud coming into and out of the pump.

Crewmembers can change the liners and pistons. Not only can they replace worn out ones, they can also install different sizes. Generally they use large liners and pistons when the pump needs to move large volumes of mud at relatively low pressure. They use a small liners and pistons when the pump needs to move smaller volumes of mud at a relatively high pressure.

In a duplex pump, pistons discharge mud on one side of the piston and at the same time, take in mud on the other side. Notice the top piston and the liner. As the piston moves forward, it discharges mud on one side as it draws in mud on the other then as it moves back, it discharges mud on the other side and draws in mud on the side it at had earlier discharge it. Duplex pumps are therefore double acting.

Double acting pumps move more mud on a single stroke than a triplex. However, because of they are double acting they have a seal around the piston rod. This seal keeps them from moving as fast as a triplex. Input horsepower ranges from 190 to 1790 hp or from 142 to 1335 kW. The largest pumps maximum rated working pressure is about 5000 psi, almost 35,000 kPa with 6 inch/152 mm linings.

A mud pump has a fluid end, our end and intake and the discharge valves. The fluid end of the pump contains the pistons with liners which take in or discharge the fluid or mud. The pump pistons draw in mud through the intake valves and push mud out through the discharge valves.

The power end houses the large crankshaft and gear assembly that moves the piston assemblies on the fluid end. Pumps are powered by a pump motor. Large modern diesel/electric rigs use powerful electric motors to drive the pump. Mechanical rigs use chain drives or power bands (belts) from the rig’s engines and compounds to drive the pump.

A pulsation dampener connected to the pump’s discharge line smooths out surges created by the pistons as they discharge mud. This is a standard bladder type dampener. The bladder and the dampener body, separates pressurized nitrogen gas above from mud below. The bladder is made from synthetic rubber and is flexible. When mud discharge pressure presses against the bottom of the bladder, nitrogen pressure above the bladder resists it. This resistance smoothes out the surges of mud leaving the pump.

Here is the latest type of pulsation dampener, it does not have a bladder. It is a sphere about 4 feet or 1.2 m in diameter. It is built into the mud pump’s discharge line. The large chamber is form of mud. It has no moving parts so it does not need maintenance. The mud in the large volume sphere, absorbs this surges of mud leaving the pump.

A suction dampener smooths out the flow of mud entering into the pump. Crewmembers mount it on the triplex mud pump’s suction line. Inside the steel chamber is a air charged rubber bladder or diaphragm. The crew charges of the bladder about 10 to 15 psi/50 to 100 kPa. The suction dampener absorbs surges in the mud pump’s suction line caused by the fast-moving pump pistons. The pistons, constantly starts and stops the mud’s flow through the pump. At the other end of the charging line a suction pumps sends a smooth flow of mud to the pump’s intake. When the smooth flow meets the surging flow, the impact is absorbed by the dampener.

Workers always install a discharge pressure relief valve. They install it on the pump’s discharge side in or near the discharge line. If for some reason too much pressure builds up in the discharge line, perhaps the drill bit or annulus gets plugged, the relief valve opens. That opened above protects the mud pump and system damage from over pressure.

Some rig owners install a suction line relief valve. They install it on top of the suction line near the suction dampener. They mount it on top so that it won’t clog up with mud when the system is shut down. A suction relief valve protects the charging pump and the suction line dampener. A suction relief valve usually has a 2 inch or 50 mm seat opening. The installer normally adjusts it to 70 psi or 500 kPa relieving pressure. If both the suction and the discharged valves failed on the same side of the pump, high back flow or a pressure surge would occur. The high backflow could damage the charging pump or the suction line dampener. The discharge line is a high-pressure line through which the pump moves mud. From the discharge line, the mud goes through the stand pipe and rotary hose to the drill string equipment.