how to calculate mud pump efficiency for sale

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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.

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Oil and Gas drilling process - Pupm output for Triplex and Duplex pumpsTriplex Pump Formula 1 PO, bbl/stk = 0.000243 x ( in) E.xample: Determine the pump output, bbl/stk, at 100% efficiency for a 7" by 12". triplex pump: PO @ 100%,= 0.000243 x 7 x12 PO @ 100% = 0.142884bbl/stk Adjust the pump output for 95% efficiency: Decimal equivalent = 95 + 100 = 0.95 PO @ 95% = 0.142884bbl/stk x 0.95 PO @ 95% = 0.13574bbl/stk Formula 2 PO, gpm = [3(D x 0.7854)S]0.00411 x SPM where D = liner diameter, in. S = stroke length, in. SPM = strokes per minute Determine the pump output, gpm, for a 7" by 12". triplex pump at 80 strokes per minute: PO, gpm = [3(7 x 0.7854) 1210.00411 x 80 PO, gpm = 1385.4456 x 0.00411 x 80 PO = 455.5 gpm

Example:Duplex Pump Formula 1 0.000324 x (liner diameter, in) x ( stroke lengh, in) = ________ bbl/stk -0.000162 x (rod diameter, in) x ( stroke lengh, in) = ________ bbl/stk Pump out put @ 100% eff = ________bbl/stk Example: Determine the output, bbl/stk, of a 5 1/2" by 14" duplex pump at 100% efficiency. Rod diameter = 2.0": 0.000324 x 5.5 x 14 = 0.137214bbl/stk -0.000162 x 2.0 x 14 = 0.009072bbl/stk Pump output @ 100% eff. = 0.128142bbl/stk Adjust pump output for 85% efficiency: Decimal equivalent = 85 100 = 0.85 PO@85%)= 0.128142bbl/stk x 0.85 PO@ 85% = 0.10892bbl/stk Formula 2

PO. bbl/stk = 0.000162 x S[2(D) - d] where S = stroke length, in. D = liner diameter, in. d = rod diameter, in. Example: Determine the output, bbl/stk, of a 5 1/2". by 14". duplex pump @ 100% efficiency. Rod diameter = 2.0in.: PO@100%=0.000162 x 14 x [ 2 (5.5) - 2 ] PO @ 100%)= 0.000162 x 14 x 56.5 PO@ 100%)= 0.128142bbl/stk Adjust pump output for 85% efficiency: PO@85%,= 0.128142bb/stkx 0.85 PO@8.5%= 0.10892bbl/stk Metric calculation Pump output, liter/min = pump output. liter/stk x pump speed, spm. S.I. units calculation Pump output, m/min = pump output, liter/stk x pump speed, spm. Mud Pumps Mud pumps drive the mud around the drilling system. Depending on liner size availability they can be set up to provide high pressure and low flow rate, or low pressure and high flow rate. Analysis of the application and running the Drill Bits hydraulics program will indicate which liners to recommend. Finding the specification of the mud pumps allows flow rate to be calculated from pump stroke rate, SPM. Information requiredo Pump manufacturer o Number of pumps o Liner size and gallons per revolution Weight As a drill bit cutting structure wears more weight will be required to achieve the same RoP in a homogenous formation. PDC wear flats, worn inserts and worn milled tooth teeth will make the bit drill less efficiently. Increase weight in increments of 2,000lbs approx. In general, weight should be applied before excessive rotary speed so that the cutting structure maintains a significant depth of cut to stabilise the bit and prevent whirl. If downhole weight measurements are available they can be used in combination with surface measurements to gain a more accurate representation of what is happening in the well bore.

Electronic Pump Stroke Counters are a vital part to any drilling rig operation. When a mud pump is in operation, the driller must know how much mud is flowing down hole in order to keep the operation running at peak efficiency. Pump stroke counters assist the driller by measuring the mud pump’s strokes per minute and total strokes. So, how does a pump stroke counter tally the mud pump’s strokes

Electronic Pump Stroke Counters are a vital part to any drilling rig operation. When a mud pump is in operation, the driller must know how much mud is flowing down hole in order to keep the operation running at peak efficiency. Pump stroke counters assist the driller by measuring the mud pump’s strokes per minute and total strokes. So, how does a pump stroke counter tally the mud pump’s strokes, and why it is important? In order to understand that, you’ll need to know some basic information about mud pumps.

Knowing how a mud pump functions is important in understanding the role a pump stroke counter plays in rig operations. Mud pumps act as the heart of the drilling rig, similar to how our heart works. Just as our heart circulates blood throughout our bodies, a mud pump circulates essential drilling mud down the hole and back up to the surface. Mud tanks house drilling mud, and a mud pump draws the fluid from the mud pump. A piston draws mud in on the backstroke through the open intake valve and pushes mud through the discharge valve and sends it towards the rig. By circulating fluid, the mud pump ensures that the drill bit is cool and lubricated and that cuttings are flushed from the hole. The two main kinds of pumps used are duplex and triplex pumps, where the duplex pump has two pistons and the triplex pump has three. Whether the rig is using a duplex or triplex pump, it is important to know how many strokes per second the pistons are moving. The driller monitors strokes per minute to determine how much costly, yet essential, mud is being pumped into the system with the use of a mud pump stroke counter system. Now, that you know about mud pumps, you’ll need to know what’s in a stroke counter system.

Stroke Counter — The stroke counter stainless steel box is mounted on the driller’s console and is either square or rectangular in shape, depending on the number of pumps it is monitoring. Stroke counters will show strokes per minute and total strokes, and when a particular mud pump is operating the strokes/minute and total strokes will be displayed. Power is supplied by a 3.6 volt lithium battery, and the counter contains a crystal-controlled real time clock with 100 parts per million accuracy or better. Each counter is mounted to the console with 1/4” stainless steel hex head bolts, lock washers and nuts.

Micro Limit Switch — The micro switch is connected to a c clamp near the mud pump piston. The micro switch stainless steel rod (sometimes called a whisker) sticks out in the piston housing near the piston. As the piston passes the rod, it moves the rod and the switch sends an electronic signal back to the counter. The counter increases by one each time the piston moves the rod, counting the mud pump’s strokes. The switch’s signal is then transmitted to the stroke counter. These micro switches are built to stand up to demanding outdoor conditions. They can withstand shock, equipment vibration, extreme temperatures, water and dust.

Cable and Junction Box – A cable is connected to the back of the pump stroke counter and then to the junction box. From the junction box, the cables travel to the limit switches.

Pump Stroke Counters are like a blood pressure machine. Each time our heart pumps, a blood pressure machine reads our systolic and diastolic blood pressure by way of our pulse. A mud pump stroke counter functions in much the same way. Just as a blood pressure machine detects our pulse so too does a limit switch rod detect the movement of the piston. When the stainless steel rod is moved, the micro limit switch detects the movement. The signal is sensed as a contact closure, and it is transmitted to the stroke counter where the contact closure is converted to a logic pulse. The pulse feeds two separate circuits. The total strokes circuit reads and displays the closures one at a time, totaling them up to reveal the total strokes in the LED window. The second pulse is sent along a separate circuit which is a rate circuit. This rate circuit will average the closures against the real time clock. The result is displayed as the total strokes per minute.

Pump stroke counters are essential to drilling rig operations because they measure the efficiency of mud pumps. Knowing strokes per minute and total strokes of the pistons helps the driller to determine if the correct amount of mud is going down hole. Having this information aids in running a drilling rig at peak efficiency, assists in extending drill bit life, and avoids costly overuse of drilling rig mud. Unsure which pump stroke counter is right for your application? Give our friendly, knowledgeable staff a call or email. We’ll keep you turning right.

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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 small mud pump 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 small mud pump 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 small mud pump of choice from the collection at Alibaba.com.

Alibaba.com has been an excellent wholesale supplier of small mud pump 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 Small mud pump, you can find the product you want from the vast collection at Alibaba.com.therther it is for refrigeration, air conditioning, transfer, or a simple car wash business, anything you want, Alibaba.com has it.

We, at Waters, provide high-standard, quality built mud pumps and its parts for oil and gas drilling operations on sale! We provide both sparingly used mud pumps and its parts to our customers in Houston and other areas in the United States.

In a tight market, leasing or renting rig equipment is the smart move. Waters International offers its customers a wide range of leasing and rental programs that can significantly reduce capital costs and accelerate ROI

The drop-down menu at the top lists the items we usually have in-stock. All of them are also normally available for sale or for rent. Rental products also include additional systems such as Triplex Mud Pumps (Diesel or Electric), Mud Tanks and Solids Control Equipment. For fast and easy equipment request, we have provided online forms customized to each specific area of interest. The photos below illustrate just a few of the items available in our inventory.

The mud pump is an integral part of drilling operations. Also called mud drilling pump, it is a kind of plunger pump or a reciprocating piston, which circulates the drilling fluid through the drill string and back up the annulus. The operation takes place under very high pressure of about 7,500 psi or 52,000 kPa.

Waters provide mud pumps of varying configurations and sizes according to our customer’s requirements. Every oil rig requires a different kind of mud pumps and parts. That is why, at Waters, we offer customized mud pumps according to your requirements. Be it the triplex or three-piston pump for the petroleum rig or the duplex mud pumps, we have with us a wide range of products to satisfy your oil rig specifications.

A mud pump is pivotal to rig drilling operations and at Watersintl, we attach great importance to the quality, make and build of every drilling rig mud pump that we offer for rental. With competition causing margins to shrink, the way to financial and operational success is mud pump rental.Operational efficiency is the key to success and a mud pump can actually be the single biggest contributor to drilling operations. With a lot riding on the capacity and rugged build of a mud pump, a rental is definitely a better choice.

We, at Waters, believe in quality over quantity. For the past five decades, we have gathered enough inputs and experiences to ensure our clients go satisfied after the purchase of our mud pumps and parts.

We, therefore, offer a comprehensive price range on our mud pumps for drilling in Houston. We have both sparingly used and new mud pumps to suit our customers’ requirements. Whatever your budget is, we will provide you the best choice in mud pumps and promise to deliver quality products at an affordable price range.

We know how difficult it is to find that one perfect part or the whole mud pump to fit in your drilling operations. That is why; we keep minimum delivery time to ensure our customers do not suffer downtime.

If you are looking for a mud pump, we would be happy to help! Just call us with your requirements or talk to our experts to know more about our mud pumps and other products!

At Watersintl, our specialization in equipment for drilling, lends us with greater exposure on the all- important mud pump, permitting us to offer the best models. Choose from a wide range of models that feature on our list of equipment available for rental. Benefit from our technical expertise that improves the operational efficiency and reliability of every single mud pump we offer on rent. The inspection routines and servicing that we follow transforms every mud pump into a rugged workhorse that will help you improve operational ability. Browse through our extensive list of drilling equipment and benefit from qualitative superiority and our reputation as one of the very best in the industry.

NEW YORK CITY, UNITED STATES, UNITED STATES, June 23, 2022 /EINPresswire.com/ -- Mud pumps or Drilling mud pumps are a reciprocating piston or plunger pump used in onshore and offshore oil field drilling rigs. Mud pumps are used to circulate the drilling fluid at high pressure (about 7,500 psi) in the down string and carry back the sand and rock produced by drilling bits in the process of crushing. Mud Pumps ensure that the drilling fluid is circulated to the bottom of the well at constant high pressure to clear out the drilling debris. Mud pumps are also referred to as the Heart of a Drilling Rig. Mud pumps are an essential equipment used during drilling and thus, the global market for mud pumps is expected to witness significant growth during the forecast period of 2018-2026 and will reach a market value of US$ 1.08 Bn by 2026.

Based on product type, the mud pumps can be classified into duplex, triplex and quintuplex. Duplex mud pumps are generally double acting pumps and use two pistons to circulate the drilling fluid. Duplex mud pumps are not common nowadays because of the better alternatives available in the market. Triplex mud pumps are the most commonly used option in drilling rigs. In triplex mud pumps, three pistons are used to circulate the drilling fluid. The triplex mud pumps segment will continue to dominate the Mud Pumps market in terms of global market share and is expected to account for more than 74% share of the total absolute dollar opportunity in the mud pumps market by the end of 2026.

In the Oil & Gas Industry, Mud Pumps find applications: Onshore Drilling Rigs and Offshore Drilling Rigs. The onshore segment will lead the global mud pumps market and is expected to account for absolute dollar opportunity of US$ 282 Mn by the end of the forecast period.

Based on Drive Type, mud pumps are categorized into Electric or Fuel Engine Driven mud pumps. Fuel Engine driven mud pumps are more commonly used due to their better suitability for remote locations. The fuel engine segment in the mud pumps market is estimated to witness significant growth rate over the forecast period. The electric segment of mud pumps is estimated to witness decent growth due to various technological advantages, such as reduced mechanical vibrations, increased reliability and increased efficiency.

In 2018, North America is estimated to be the most lucrative region in the global Mud Pumps market and is likely to account for more than 54% share in the global absolute $ opportunity in the Mud Pumps market share. Furthermore, growing drilling activities for increasing production of oil & gas in China will create new opportunities in the Mud Pumps market. Europe continues to be a strong market for Mud Pumps and moderate growth is being witnessed in the South East Asia Pacific region. In Middle East & Africa region, oilfield drilling activities will increase due to increasing demand for oil & gas.

Moving forward, mud pumps are available in different configurations based on the requirement and rating of drilling rigs. Mud Pumps are equipment made only on demand and as per the requirements of companies. National Oilwell Varco, Gardner Denver, Schlumberger Limited (Cameron International), WeatherFord International plc, Flowserve Corporation, CNPC Baoji Oilfield Machinery Co., Ltd., Honghua Group Ltd., MHWirthTrevi Group (Drillmec), Bentec GmbH Drilling & Oilfield Systems are some of the key players in the global Mud Pumps market.

In terms of market value, the global Mud Pumps market is expected to create absolute $ opportunity worth US$ 316 Mn during the forecast period. North America is likely to witness fastest growing installation of Mud Pumps. The region will grow at a CAGR of 4.9% over the forecast period.

Mechanical Diaphragm Pumps Market-PMR’s study on the mechanical diaphragm pumps market is divided into five significant segments - type, diaphragm material, flow rate, end-users & regional outlook.

Thailand Water Pump Market-According to the study of Persistence Market Research, the Thailand water pump market is projected to grow at ~6% CAGR in the forecast period.

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As a user, if you see something we have missed, please do bring it to our attention. Your help is welcome. EIN Presswire, Everyone"s Internet News Presswire™,

Pivotal to drilling and production, multiplex drilling pumps for sale have increased operational efficiency through the ability to ferry large volumes of fluid. At the heart of the quintuplex drilling pump developed by ShalePumps, lies a design that exploits the output of additional cylinders to curb pulsation variance.

Packed into physically smaller dimensions, the power packed quintuplex drilling pump assures a steady flow at the surface. With proven reliability, the quintuplex pump keeps the fluid in circulation, maintaining optimal pressure and volume, fetching debris effortlessly from the wellbore.

The featured quintuplex drilling pump combines structural superiority and engineering knowhow for enhanced life expectancy in continuous operations. Additionally, Measurement While Drilling (MWD) and Logging While Drilling (LWD) operations are substantially improved by the increased data transfer rate bandwidth.

The design accomplishes the added objective of extending life of downhole tools through operational precision of the quintuplex drilling pump. Improved rate of flow helps in cutting overall costs, dispensing with the need for many pumps. ShalePumps, possessing the technical expertise with an extensive range of proven solutions, takes great care to incorporate high quality components in every quintuplex drilling pump. The crankshafts, piston rods, liners, connecting rods, bearings etc are all of the highest quality. Each quintuplex drilling pump, despite the composition of high wear components, is guaranteed to offer longer continuous life.

ShalePumps is proud to bring the quintuplex design to a new level. Built to be smaller, lighter and smoother than any conventional triplex design. The addition of a fourth and fifth cylinder decreases pulsation variance to a minimal level. This increases accuracy and precision during LWD and MWD applications and increases the life expectancy of down-hole tools.

Both the EMP40™ and PITPUMP™ feature advanced telematics for active health monitoring in support of proactive preventative maintenance programs. The variable pump speed of PITPUMP™ allows it to work seamlessly with the smart generator architecture of the EMPOWER™ line. Current job site use has resulted in decreased fuel consumption of over 40% when the EMP40™ is used in tandem with PITPUMP™ across both entry- and exit-side operations.

Mud Pumps - Mud Pump Parts & Complete Units: Liners, Pistons, Rubbers, Rods, Valves, Seats, Springs, Inserts (Bean, BJ, CAT, EMSCO, Ellis Williams, FMC, Failing, GASO, Gardner Denver... More Info

Mud Pumps - Mud Pump Parts & Complete Units: Liners, Pistons, Rubbers, Rods, Valves, Seats, Springs, Inserts (Bean, BJ, CAT, EMSCO, Ellis Williams, FMC, Failing, GASO, Gardner Denver... More Info

Mud Pumps - Mud Pump Parts & Complete Units: Liners, Pistons, Rubbers, Rods, Valves, Seats, Springs, Inserts (Bean, BJ, CAT, EMSCO, Ellis Williams, FMC, Failing, GASO, Gardner Denver... More Info

Mud Pumps - Mud Pump Parts & Complete Units: Liners, Pistons, Rubbers, Rods, Valves, Seats, Springs, Inserts (Bean, BJ, CAT, EMSCO, Ellis Williams, FMC, Failing, GASO, Gardner Denver... More Info

Mud Pumps - Mud Pump Parts & Complete Units: Liners, Pistons, Rubbers, Rods, Valves, Seats, Springs, Inserts (Bean, BJ, CAT, EMSCO, Ellis Williams, FMC, Failing, GASO, Gardner Denver... More Info

Mud Pumps - Mud Pump Parts & Complete Units: Liners, Pistons, Rubbers, Rods, Valves, Seats, Springs, Inserts (Bean, BJ, CAT, EMSCO, Ellis Williams, FMC, Failing, GASO, Gardner Denver... More Info

Mud Pumps - Mud Pump Parts & Complete Units: Liners, Pistons, Rubbers, Rods, Valves, Seats, Springs, Inserts (Bean, BJ, CAT, EMSCO, Ellis Williams, FMC, Failing, GASO, Gardner Denver... More Info

Mud Pumps - Mud Pump Parts & Complete Units: Liners, Pistons, Rubbers, Rods, Valves, Seats, Springs, Inserts (Bean, BJ, CAT, EMSCO, Ellis Williams, FMC, Failing, GASO, Gardner Denver... More Info

Mud Pumps - Mud Pump Parts & Complete Units: Liners, Pistons, Rubbers, Rods, Valves, Seats, Springs, Inserts (Bean, BJ, CAT, EMSCO, Ellis Williams, FMC, Failing, GASO, Gardner Denver... More Info

Within the petroleum industry centrifugal pumps are necessary in order to process fluids especially hydrocarbons. Another important application within the petroleum industry is in the mud circuit on a drilling rig. On drilling rigs, mud which consists mainly of water and bentonite as well as of several different additives depending on many different factors is used. The heart of the mud circuit is the mud pump which is in general a high pressure piston pump. It provides the major part of head to overcome the system’s resistance. The mud is pumped through a piping system to the derrick and through the standpipe to a definite high. Now through the kelly hose via the gooseneck into the upper kelly cock. It flows through the Kelly and the lower kelly cock into the drill string down the borehole. At its end, the mud leaves the drilling collars through the drilling bit.

1. Select a pump to handle the highest anticipated flow. Select an impellersize to provide sufficient discharge head to overcome friction in the lines,lift the fluid as required, and have sufficient head remaining to operatethe equipment being fed.

Initially this guideline suggested that the pump flange size be selected to provide the highest anticipated flow, even though the flange size has nothing to do with the flow rate. Most pump curves are listed in terms of the flange sizes. The size of the pump impeller housing increases as the flange size increases. An impeller rotating at constant speed will create a constant head independent of the size of the housing or the flanges. An impeller that fits inside a 2×3, 3×4, 4×5, or 5×6 pump will produce the same head in each pump if it is rotated at the same speed. Because the housing of a pump with a 2-inch and 3-inch flange is smaller, the internal friction at a high flow rate will be greater than a 56 pump. This means that the capacity of the various pump sizes will be indicated by their flange sizes. The committee decided to only indicate that the pump should be selected to handle the highest anticipated flow rate, instead of indicating that the flange size is commonly used to specify pump size.

2.Install the centrifugal pump with a flooded suction that is sumped so thatsufficient submergence is available to prevent vortexing or air-locking.Foot valves are not needed or recommended with flooded suctions.

A small influx of air into the suction of a centrifugal pump can create cavitation problems and diminished flow. As the air enters the chamber with the impeller, it tends to concentrate in the center of the impeller because of the centripetal acceleration of the drilling fluid.

The liquid continues to move through the pump. The air does not always continue to the impeller tip, but tends to remain in the center of the impeller. This bubble of air forms a barrier for the incoming fluid, which diminishes the flow rate into the pump. The air also experiences a significant decrease in pressure—possibly even below atmospheric pressure. This causes implosions of vapor bubbles that can remove metal from the impeller. The pump will sound as if it is pumping gravel. If it continues in this mode for a long period of time, the impeller will be severely damaged.

Flooded suctions tend to eliminate most of the air influx problems but sometimes a small vortex will form in the mud tank. These small vortexes can entrain a significant amount of area. Increasing agitation in the tanks may prevent a coherent cylinder of air from reaching the suction line. Alternatively, a plate can be installed in the tank to interrupt the formation of a vortex.

In some cases, a centrifugal pump is placed on the ground above a pond or buried tank. Foot valves are needed if the centrifugal pump is operated above the liquid level of the suction tank. Foot valves are check valves that prevent the suction line from draining when the pump is turned off. Care must be taken to eliminate tiny air leaks in the suction line because the absolute pressure will be below atmospheric pressure. The pump and suction line should be filled with fluid before the pump motor is started. Centrifugal pumps do not move air very well.

A centrifugal pump suction can only lift fluid a certain height above a liquid level. These heights are determined by observing the NPSH (negative pressure suction head) values listed on the centrifugal pump curves. If the NPSH is exceeded, cavitation can destroy the impeller.

3. Install a removable screen over the suction to keep out large solids andtrash. It can be made out of half-inch expanded metal and should have atotal screen area at least five times the cross-sectional area of thesuction line so it will not restrict flow. An extended handle arrangementreaching to the tank surface is desirable to allow the screen to be pulledduring service and cleaned.

An expanded metal screen prevents objects (such as gloves, buckets, pieces of clothing, chunks of rubber, etc.) from plugging the suction line or fouling the impeller. A bucket, turned so that the bottom fits into the suction line, can be difficult to diagnose and locate. A box made from expanded metal that covers the suction can prevent these disasters. If two alignment yokes are welded to the tank walls to hold a 1-inch pipe handle, the screen can be removed, cleaned, and easily returned to the suction opening. Without these alignment yokes, reseating the expanded metal box is difficult.

4. Suction and discharge lines should be properly sized and as short aspractical. Flow velocities should be in the range of 5 to 10 ft/sec. Lessthan 5 ft/sec causes solids to form a tight layer obstructing the bottomof horizontal lines. At velocities at or exceeding 10 ft/sec, pipe-turnstend to erode, headers do not distribute properly, and usually there willbe cavitation in the suction lines. To calculate the velocity inside thepipe, use the following equation:

Horizontal pipes will fill with solids until the flow rate reaches 5 ft/sec. Barite in equalizing lines between mud tanks is normally settled until the velocity between the tanks reaches 5 ft/sec. Increasing the diameter of connection lines only causes more barite to settle. Above 10 ft/sec, pressure losses in the pipe become too great. Elbows and swages tend to cause turbulence in the flow stream, which can lead to cavitation.

5. Eliminate manifolding. One suction and one discharge per pump ismost cost effective over time. Do not manifold two pumps on the samesuction line. Do not pump into the same discharge line with two or morepumps.

Flexibility of piping so fluid can be pumped from any tank through any equipment to any other tank has created more problems over the years than just about any other concept. A properly plumbed system should require only one suction and one discharge for each piece of solids-removal equipment. Ignoring this rule allows rig hands the opportunity to open or close the wrong valves. A leaky or incorrectly opened valve can reduce drilled-solids removal efficiency by up to 50%. This translates to an expensive drilling-fluid system. This problem can be eliminated by storing an extra pump and motor. Arrange the centrifugal pumps and motors so that they may be easily replaced. If a pump or motor fails, simply replace the unit. The damaged unit can be replaced during routine maintenance. Two centrifugal pumps in parallel will not double the head available to equipment because a centrifugal pump is a constant head device. For example, visualize a standpipe that is constantly filled with fluid. If two standpipes of approximately the same height are connected, the flow from both pipes will almost equal the flow from one standpipe. If fluid stands lower in one standpipe than the other. fluid will flow from the highest standpipe to the lowest standpipe. This same flow occurs when two pumps are connected in parallel—fluid will flow backward through one of the pumps.

6. Install a pressure gauge between the pump discharge and the first valve.When the valve is closed briefly, the pressure reading may be used fordiagnostic evaluation of the pump performance.

A centrifugal pump uses the smallest amount of power when no fluid is moving through the pump (that is, when the discharge valve is completely closed). If the valve remains closed for longer than 5 minutes, the fluid within the pump will become hot from the impeller agitation. This hot fluid may damage the seals. Closing the valve for a short time allows a good reading of the no-flow head produced by the pump. This reading should be compared with the pump manufacturer’s charts. The diameter of the impeller can then be determined. (A pump may be stamped 5X6X14. This means that it could house a 14-inch impeller but it does not mean that it has a 14-inch impeller. The impeller size is adjusted so the pump will deliver the proper head.) After the pump has been in service for a period of time, the pressure reading will assess the condition of the impeller. This eliminates the need to dismantle the pump for inspection. If the manifold pressure is incorrect, reading the pump no-flow discharge head will assist in troubleshooting.

7.Keep air out of the pump by degassing the mud, having adequate suctionline submergence, and installing baffles to break mixer vortices. Properly sized, baffled, and agitated compartments will not vortexunless the drilling fluid level becomes extremely low.

Centrifugal pumps cannot pump aerated fluid. The air tends to gravitate toward the center of the impeller while the liquid moves toward the outside. This creates an air bubble at the center of the impeller. When the air bubble becomes as large as the suction line diameter, fluid will no longer enter the pump. This is called airlock. Only a small cylinder of air vortexing into the pump is sufficient to prevent the pump form moving liquid. Since the air accumulates over a period of time, a small vortex the size of a pencil is sufficient to eventually shut down a 6×8 pump. Baffles are inexpensive and easily installed in an empty tank. Any vertical surface that disrupts the swirling motion of the fluid in a compartment is usually sufficient to destroy a vortex. Rig pump efficiency can decrease from 99 to 85% efficiency if the drilling fluid content rises to 6% volume. Air in the drilling fluid may be calculated by measuring the pressurized and unpressurized mud weight.

8. Do not restrict the flow to the suction side of the pump. Starving thepump suction causes cavitation and this will rapidly damage the pump.When a pump begins cavitating, small vacuum bubbles adjacent to the impeller surface start imploding. The pump sounds as if it is pumping gravel. The implosions quickly remove metal from the surface to the impeller blade. In a very short period of time, holes will appear in the metal. Important: Do not close a valve on the suction line while the pump is running!

Starving the suction will decrease the output head. If the head, or pressure produced by the pump, is too high, change to a smaller diameter impeller. On a temporary basis, a discharge valve can be partially closed. On a long-term basis, however, considerable valve erosion will occur so a new, properly sized impeller is necessary. Even a large centrifugal pump is not damaged if only 10 to 20 gpm is discharged from the pump. In fact, the lower flow rates will require less horsepower to the motor than pumping fluid at a much higher flow rate.

Centrifugal pumps will pump fluid even if running in reverse. The head produced by the pump will be lower than it should be. The pressure gauge installed between the pump and the first valve will assist with the diagnosis. Usually, switching two wires in the lead-in panel box will correct the rotation.

10.Startup procedure for an electric motor–driven centrifugal pump with avalve on the discharge side between the pump and the equipment beingoperated is to start the pump with the valve just slightly open. Once thepump is up to speed, open the valves slowly to full open. This approachwill reduce the startup load on the electric motor and will reduce theshock loading on equipment such as pressure gauges and hydrocyclones.

An alternative startup procedure is to completely close thedischarge valve before startup and then open the valve slowly immediatelyafter startup to prevent overheating and possible damage to thepump seals.

An electric motor–driven centrifugal pump will immediately try to produce a constant head when it is turned on. If the pump is pumping into an empty line, the flow rate is enormous. Very high flow rates require very high currents to the electric motor. Circuit breakers can stop the pump and avoid motor burnout. Lower horsepower is required if the pump is started with the discharge valve closed.

Sudenga Industries is a leading manufacturer of durable ag equipment for grain, feed and seed handling applications. Products can be found in farm and commercial agriculture installations as well as industrial material handling applications worldwide. Sudenga was founded in 1888 in the northwest corner of Iowa where it is still located today.