how does a mud pump pulsation dampener work in stock

For more information about pulsation dampeners, we sat down with Brandon Dalrymple and Nathan Ackeret fromBlacoh Fluid Control(manufacturer of pulsation dampeners, surge suppressors, and inlet stabilizers), and asked them to answer a few of our customers’ most common questions about pulsation dampeners.

Pulsation dampeners absorb the energy from the pulse wave created by a positive displacement pump, much like a shock absorber on a vehicle. Absorbing those pulse waves protects pipe welds and supports, and system components from damage due to pressure or excess movement.

A pulsation dampener creates an area of low pressure in the system with enough volume to absorb the pulsation. The pulsation dampener has a membrane with a "cushion" of compressible gas/air behind it that flexes to absorb the pulse, allowing a laminar flow downstream of the dampener.

Pulsation dampeners are commonly used wherever a positive displacement pump discharges flow in an unsteady manner, and where the pulse is not desired for the piping system. Air operated double diaphragm, metering and hose/peristaltic pumps typically benefit from a pulsation dampener.

The type of pulsation dampener used is typically defined by where they are placed in the system, and what they need to do. For example, "pulsation dampeners" are on the downstream side of the pump, "inlet stabilizers" are on the inlet side of the pump, and an accumulator or "surge suppressor" is used next to a valve or other device that restricts the flow in a system.

This video shows where you would place an inlet stabilizer, and how it is used to reduce the pulsation with an air operated diaphragm pump in suction lift conditions.

If you"re experiencing problems with rattling pipes, intermittent flow, water hammer, or pulsations in your system, don"t ignore it. Take the steps necessary to control these symptoms to prevent system deterioration down the road.

Need help with pulsations or water hammer problems? Ask us about it! We gladly provide technical assistance to businesses in Wisconsin and Upper Michigan.

All pulsation dampeners utilize one of two methods for mitigating energy produced by reciprocating pumps; compression or exchange. The traditional gas-charged dampeners use a compressible gas cushion, either by a gas over liquid or gas-filled diaphragms, bladders, or cartridge. As the reciprocating pump produces pressure spikes, the gas compresses, thus absorbing the pressure difference and smoothing the pumped media flow. For maintenance free pulsation dampeners, rely on energy exchange. There is a common misconception regarding maintenance free pulsation control devices that the pumped media is compressible enough to absorb the reciprocating pumps’ pressure spikes. This is not true. However, the maintenance free pulsation dampeners work by utilizing the kinetic energy exchange. This kinetic energy exchange can only happen if the pulsation dampener’s volume is large enough to dissipate enough energy to reduce the adverse effects caused by the reciprocating pump. This is why maintenance free pulsation devices require massive volumes to be effective. Sigma Drilling Technologies has developed a pulsation dampening system that utilizes both methods for reducing the harmful effects of positive displacement pumps, both compression and exchange.

A properly serviced pulsation dampener is critical for your mud pumps’ efficiency, safety, and performance. Unfortunately, there aren’t many resources available to educate personnel on executing safe and effective servicing procedures. Please review the following steps with your personnel for safe pulsation dampener maintenance.

Should you or your personnel have any questions regarding pulsation dampener maintenance, please don’t hesitate to ask. Sigma is more than happy to help you to ensure safe and proper care is being completed on your pulsation dampening equipment.

Mud Pump Pulsation Dampener is usually installed on the discharge line to reduce the fluctuation of pressure and displacement of the drilling mud pump.

Mud Pump Pulsation Dampener is a pneumatic device built into the outflow line of each UUD pump to dampen the pressure fluctuations resulting from the action of the pump. Although presented as a surge tank, this device is really a device that can be tuned to greatly diminish the output pulsations transmitted downstream from the mud pump. Unfortunately, the effectiveness of the pulsation dampener is a function of both output pump pressure and frequency of the pump pulsations.

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.

Positive displacement pumps effectively pump fluid at a constant average flow rate. However, because the individual pumping elements of these pumps discharge discrete quantities of fluid, the instantaneous flow rate varies in a cyclic fashion.

Pulsations are observed in the system as pressure spikes. In the positive displacement pump family, single-shoe peristaltic pumps generally create the largest pulse, followed by two-shoe peristaltic pumps. Triplex and quintuplex pumps have smooth output curves because of piston overlap. Gear pumps can have extremely small pulses, but pulsations still exist. This pulsating flow can cause operational problems and shorten equipment’s service life.

To alleviate the problem, pulsation dampeners can be added to the pumping system to absorb pressure spikes and smooth fluid flow. Figure 1 shows the undampened pressure spikes from a triplex pump in green. The dampened pressure curve from the same pump with the same system settings are indicated in blue. Six pulses per revolution occur instead of the expected three. This is a result of piston overlap.

The most common type of pulsation dampener is a hydro-pneumatic pressure vessel containing compressed air or nitrogen and a bladder—or bellows—that separate the process fluid from the gas charge. To maximize the dampening effect, pulsation dampeners should be installed as close as possible to the pump discharge with a gas charge that is slightly below the normal system pressure. More important, pulsation dampeners must be properly sized for the system.

A dampener that is undersized cannot adequately compensate for pressure and flow fluctuations. An oversized dampener will act as an accumulator, storing too much fluid. This will cause slow stabilization and a delayed response to system changes. The first step in sizing a dampener is to quantitatively define the acceptable performance.

The specific requirements of the application and the components that make up the system are all factors that need to be considered. Once an acceptable pressure variation is defined, the unit size required for the desired performance should be determined. Engineers and designers are interested in making accurate predictions. Avoiding a problem is better than finding a way to fix it.

Sizing pulsation dampeners is straightforward. However, calculating the system pressure fluctuations is more complex. Fluid discharge rates from pumps are difficult to mathematically model. For example, in Figure 1, the spikes are not even. Theoretically, they should be equal. Mathematical models must be physically tested to verify their accuracy.

Pumps with multiple heads and higher pulse frequencies can make the calculations more difficult. The distance from one output port to the next is generally not constant. This creates a shift in the piston overlap with intermittent larger and smaller pulses. Calculating the magnitude or frequency of noise pulses that can develop or resonate in a system is difficult.

Piping arrangement—such as bends, reducers and valves—combined with the opening and closing of pump discharge check valves can create noise in the fluid called pressure pulses. Because many variables must be considered, each pump type should be tested with and without a dampener. The pressure curve data can be recorded and used to find the pump’s formula constant. This constant can be used in future calculations. As long as other pump models are similar to the test unit, accurately predicting the magnitude of line pressure variation with a given size dampener is possible.

The pressure in a piping system will rise sharply when a volume of fluid is added to the line. It accelerates the mass of the fluid in the piping system. This is acceleration head, and it needs to be minimized with a dampener. The effect and its impact must be considered on both the inlets and outlets of positive displacement pumps. On the inlet side, cavitation and partial filling of pump cavities can damage pump components and make the pump much louder than normal.

A non-snubbed pressure transducer can accurately measure the system’s pressure spikes. A pressure transducer can react much faster than a bourdon tube gauge, and it can measure noise if the sample rate is high enough.

Bourdon tube gauges require time to equalize and can undershoot and overshoot the actual pressure depending on the magnitude and frequency of the pressure pulse. Even if the gauge could read accurately, reading a quickly moving dial is difficult. Electronically measured and recorded data can determine how the system is operating.

System noise must be considered when taking measurements because it can give higher-than-expected results. Noise in the pumping liquid can generally be ignored, but in some situations, system noise needs to be controlled. Noise can cause pressure relief valves to leak, damage sensitive components and create occupational safety hazards. Dampeners typically reduce noise, and some are specifically designed for this purpose.

Several different styles of dampeners are available, and each has advantages and disadvantages. This article focuses on reducing the pressure pulses caused by pulsing flow. The principles and the method for calculating the appropriate size dampener for this application are the same for most dampeners.

A dampener absorbs a fluid pulse and then allows the fluid to flow back into the system between pulses. Most dampeners use a gas charge that is set slightly below the normal system pressure and is compressed by the pulse of fluid. The gas then expands when fluid is released.

In this formula, n is a constant that is specific to the gas being used. For example, for air at room temperature, 
n ≅ 1.4, and for nitrogen, n ≅ 1.399.

Some heat transfer almost always occurs. The process is rarely slow enough for the gas temperature to equalize, so the actual answer will be between these two calculations. In most cases, the fluctuations are fast enough that the actual value is significantly closer to the isentropic formula. The isentropic formula gives the most conservative result. Therefore, it is the more accurate formula in most cases.

In actual practice, either formula would probably work if the pressure fluctuations are small relative to the system pressure. The pump constant that is developed would cover the inaccuracies in the formula as long as the pressure variations are similar. In this article, the isentropic formula is used.

To determine the pump constant, the volume from a single pulse of the pump must first be determined. Then an initial estimate of dampener size is made, and the corresponding value of dampener volume is applied. The amount of gas in the dampener will be less than the total dampener volume, which needs to be factored into the calculation. A typical range of 80 to 90 percent of the dampener volume should be gas if the dampener is properly charged. These give an initial gas volume:

The constant reduces the pulse volume to account for flow leaving the dampener while the pulse is entering. It also accounts for piston overlap, which changes the effective size of the pulse. Adding the factor to the isentropic formula and solving for the pump factor gives us the following equation:

For example, the pressure curve from an undampened, two-shoe, 2.5-inch peristaltic hose pump shows a sharp increase in flow, followed by a “no-flow” or negative flow zone. In this instance, the line has a ball valve that is creating the flow restriction for back pressure. The blue line shows the undampened pressure spikes (see Figure 2). The red line shows the pressure changes of the same pump with the same back pressure valve setting but now using a dampener. This sample dampener has an actual gas volume of 415 cubic inches, and the dampener is 90-percent gas filled. The base pressure is 14.15 psig, and the pulse is 76.9 cubic inches. If the pressure fluctuation is calculated using the isentropic pressure formula, the result is:

It is important to remember to add 14.7 psi to convert from gauge to absolute pressure, then subtract 14.7 psi again to get the final result in gauge pressure. This pump setup was tested, and the actual pressure variation was determined to be 7.38 psi. Therefore, the result is:

If the example above is used and it is decided that a pressure fluctuation of 15 psi would be acceptable, the formula with the previously calculated pump factor can be used to determine what size of dampener is needed.

Table 1 lists some approximate pump constant factors that can be used when sizing dampeners for different pump types. These factors are approximate, and the results may vary significantly with the many variables involved.

A triplex plunger pump doses methanol, which is metered on the discharge side. Without a dampener to control pulsations and smooth out the flow, the installed flow meters were giving inaccurate readings.

When using a triplex pump, all three chambers of the pump must stay full of fluid with no voids. Any voids or pockets can cause seal leakage, pump vibration and excess pump noise.

The solution was to install a pulsation dampener at the pump discharge to smooth the flow and remove pressure pulsations. This allowed the dosing to be more accurate. An inlet stabilizer (suction dampener) was also installed on the inlet side of the pump to act as an accumulator to keep the pump chambers filled. The inlet stabilizer also removed pulsations created by the pump on its inlet stroke. Both devices were sized based on the pump type, flow rate and operating pressure.

During the filling of a drum with a flexible hose, an automatic valve would close and cause a water hammer effect. All the pipes leading into the system would shake until they broke loose from their supports. The solution was to install a pulsation dampener at the beginning of the flexible hose connection.

The pulsation dampener was sized based on the flow parameters and installed at the beginning of the flexible hose. When the automatic valve closed, the hose and pulsation dampener effectively absorbed a portion of the water hammer, eliminating pipe shake and improving operational safety.

The sizing of a pulsation dampener is critical to achieving the desired result. Finding and using the correct constant pump factor in dampener sizing is a key part of the solution. As long as the pulsation dampener is properly sized, positioned and charged, it will effectively dampen pulsations to protect equipment and keep the pressure pulses within design parameters.

From the law of inertia, an object in motion will stay in motion unless acted upon by an outside force. Sometimes these forces are hard, such as an egg hitting the pavement, and sometimes they are soft, like jumping onto your bed. When the force is hard or sudden, damage is more likely to take place. Fluids have the same properties. When they are in motion, they have inertia. It takes an outside force to change the direction of the fluid.

Imagine a stretch of pipe with a liquid flowing through it. On one end, a valve is suddenly closed. When the valve closes, the moving liquid suddenly needs to come to a complete stop. Since most liquids can be considered incompressible, the force against the valve is a harsh impact. Similar to an egg hitting the pavement. This sudden change in momentum applies a force against the valve. Since there is nowhere for the liquid to flow, it creates a pressure spike.

A discharge dampener is designed and installed in the pipe to help absorb this pressure spike. The dampener consists of a vessel filled with gas or compressible material. When there are sudden changes in flow, the compressible material is able to compress and expand, similar to jumping onto your bed. The video below demonstrates the effects with and without a dampener.

The pressure spikes caused by a change in flow rate can be damaging to pipes and equipment within a system. The changes in pressure cause the walls of the pipes and materials to rapidly expand and contract. Over time, these changes can develop cracks in piping and equipment walls. If the pressure spike is large enough, the resulting spike may have enough pressure to cause the pipe to explode.

By installing a pulsation dampener, the intensity of these spikes are reduced to controlled levels.A dampener should be sized and installed in all piping that may experience a harmful level of pressure spikes.

Pulsation dampeners can be purchased in a variety of shapes, sizes, and designs. It is important to size a pulsation dampener for a specific application. Incorrect sizing or incompatible materials may cause a danger to equipment, systems, and personnel.

Membrane Pulsation Dampener: A membrane-type dampener provides a solid separation between the pumping fluid and the compressible gas. The membrane resides within the dampener and allows for the pressure to be transferred to the gas, without any mixing of the gas into the fluid.

Bladder Pulsation Dampener: A bladder type dampener fully encloses the compressible gas within a bladder. This setup ensures there is no leakage of the gas into the pumping fluid. The pressure pulsations are transferred to the gas as the bladder expands and contracts.

Bellows Pulsation Dampener: A bellows-type dampener works the same way as a bladder type dampener. However, by using a bellows-type design, it can be made with other types of materials such as PTFE or Stainless Steel. This type of dampening system is used when pumping corrosive materials that may deteriorate more common materials.

Pressure Vessel Style: A pressure vessel dampener, sometimes referred to as a “zero maintenance” style dampener does not use any moving parts. They are only effective at very high pressures. Fluids, including water, do have some degree of compressibility. Pressure Vessel Style dampeners allow for the pressure of the fluid to be dissipated within the vessel by the small amount of compressibility within the pumping fluid. In very high-pressure applications, a pressure vessel style dampener may be the only type of dampener available. It is important to note that this style of dampener does not operate as effectively as other types of dampeners.

Flexible piping: Although it is not recommended, flexible piping or hose can act as a pulsation dampener in emergency situations. As the fluid flow changes, the flexible piping is able to “move” and allow a dampening effect on the fluid. Flexible piping still requires proper sizing to reduce pressure spikes. Improper usage may result in damage to equipment and endangerment of equipment operators.

Equipment that rapidly changes flow rates is recommended to have a pulsation dampener. Plunger pumps, for example, have a highly variable flow rate. The average flow rate of a plunger pump can be accurately predicted. However, each rotation of the crankshaft produces several changes in flow velocities.

In step 2, the plunger is stopped. It is transitioning from moving backward, to moving forwards. The fluid has stopped moving through the inlet and has come to a complete stop, resulting in a pressure spike beginning at the inlet which then travels through the suction piping. The resulting change in the fluid’s momentum is a change from kinetic energy in the form of linear velocity, to potential energy in the form of pressure.

In step 3, the plunger has begun to move forward. As fluid begins moving through the outlet. The stationary fluid of the outlet is suddenly required to move as well. A pressure spike is created in the discharge, beginning at the outlet, and then carried through the discharge piping.

In step 4, the plunger has again come to a complete stop. Fluid is no longer flowing through either port. As it begins to move back, fluid will suddenly need to begin moving through the inlet.

When a plunger pump is running slowly, these pressure spikes can be ignored. In most cases, they will not produce enough of a spike to create damage. When the pump is running at full speed, this full cycle is taking place many times per second. The pressure spikes caused by these sudden changes will likely need a pulsation dampener.

The image above shows the visible pulsations created by a reciprocating quintuplex pump. Using flexible hoses on the inlet and outlet, the pressure fluctuations through the hose can easily be seen. Since steel piping is more rigid, it may be more difficult to visually see pressure vibrations before damage to piping and the surrounding systems takes place. It is important to correctly determine if a dampener is needed and to correctly install the required size before operating the pump system.

It is important to note that pressure pulsations are not a function of pressure. The operational pressures of a system have very little effect on the resulting pressure pulsations. Both suction and discharge sides of a reciprocating pump are susceptible to pulsations and resulting damage. Both the suction and discharge dampeners operate independently of each other. Proper sizing and installation of both suction and discharge dampeners are required for proper protection of pumping equipment and systems.

A mud pump (sometimes referred to as a mud drilling pump or drilling mud pump), is a reciprocating piston/plunger pump designed to circulate drilling fluid under high pressure (up to 7,500 psi or 52,000 kPa) down the drill string and back up the annulus. A mud pump is an important part of the equipment used for oil well drilling and manufactured according to API specification 7K.

The advantages of the drilling mud pump include the ability to move high-solids-content fluids laden with abrasives, the ability to pump large particles, ease of operation and maintenance, reliability, and the ability to operate over a wide range of pressures and flow rates by changing the diameter of pump liners and pistons.

The fluid end includes cylinders (module), valve assembly, cylinder liners, piston assembly, suction manifold, discharge manifold, piston rod, pulsation dampener assembly, etc.

As an important equipment for oilfield drilling operation, a drilling mud pump delivers circulating high-pressure drilling fluid or drilling mud to the bottom of the oil well, flushes the bottom of the well, breaks the rock, cools, lubricates and clean the drill bit, and carries the cuttings back to the ground.

The drilling mud is also used to suspend and carry out drill cuttings from the drill bits as it is brought in and out of the hole. This ensures that the drill bit does not clog and overheat, and makes the entire drilling operation smooth and safe.

Rotational power is supplied to the mud pump through an external power source like a diesel engine or electric motor. The power end of the mud pump converts the rotational energy through a crankshaft to a reciprocating motion of pistons.

The pistons move back and forth in mud pump liners, exerting a force on the cylinder chamber. During the retraction of the piston, valves open to allow the fluid to be drawn into the cylinder. Once the piston has fully retracted, it is pushed back into the cylinder.

At this time the intake valves are closed and the exhaust valves open, allowing the piston to force the fluid out of the cylinder under pressure. Once the piston reaches its maximum depth into the cylinder, the exhaust valves close and the process repeats.

For Fluid End: piston rod clamp, piston rod, piston assembly, cylinder cover, liner, liner flange, wear plate, cylinder, valve assembly, valve cover, valve guide, flashboard assy., cylinder cover flange, cylinder head, gaskets, studs, nuts, seal rings, pulsation dampener, bladder, discharge manifold, suction manifold, etc.

For more information about pulsation dampeners, we sat down with Brandon Dalrymple and Nathan Ackeret fromBlacoh Fluid Control(manufacturer of pulsation dampeners, surge suppressors, and inlet stabilizers), and asked them to answer a few of our customers’ most common questions about pulsation dampeners.

Pulsation dampeners absorb the energy from the pulse wave created by a positive displacement pump, much like a shock absorber on a vehicle. Absorbing those pulse waves protects pipe welds and supports, and system components from damage due to pressure or excess movement.

A pulsation dampener creates an area of low pressure in the system with enough volume to absorb the pulsation. The pulsation dampener has a membrane with a "cushion" of compressible gas/air behind it that flexes to absorb the pulse, allowing a laminar flow downstream of the dampener.

Pulsation dampeners are commonly used wherever a positive displacement pump discharges flow in an unsteady manner, and where the pulse is not desired for the piping system. Air operated double diaphragm, metering and hose/peristaltic pumps typically benefit from a pulsation dampener.

The type of pulsation dampener used is typically defined by where they are placed in the system, and what they need to do. For example, "pulsation dampeners" are on the downstream side of the pump, "inlet stabilizers" are on the inlet side of the pump, and an accumulator or "surge suppressor" is used next to a valve or other device that restricts the flow in a system.

This video shows where you would place an inlet stabilizer, and how it is used to reduce the pulsation with an air operated diaphragm pump in suction lift conditions.

If you"re experiencing problems with rattling pipes, intermittent flow, water hammer, or pulsations in your system, don"t ignore it. Take the steps necessary to control these symptoms to prevent system deterioration down the road.

Need help with pulsations or water hammer problems? Ask us about it! We gladly provide technical assistance to businesses in Wisconsin and Upper Michigan.

Pulsation Dampener (Surge damper) is installed on the discharge pipeline of the mud pump to balance the peak value of the high-pressure fluid pressure of the mud pump, so as to stabilize the pressure and reduce losses.

The positive displacement mud pump is a key component of the drilling process and its lifespan and reliability are critical to a successful operation.

The fluid end is the most easily damaged part of the mud pump. The pumping process occurs within the fluid end with valves, pistons, and liners. Because these components are high-wear items, many pumps are designed to allow quick replacement of these parts.

Due to the nature of its operation, pistons, liners, and valve assemblies will wear and are considered expendable components. There will be some corrosion and metallurgy imperfections, but the majority of pump failures can be traced back to poor maintenance, errors during the repair process, and pumping drilling fluid with excessive solids content.

A few signs include cut piston rubber, discoloration, pistons that are hard to remove, scored liners, valve and seat pitting or cracks, valve inserts severely worn, cracked, or completely missing, and even drilling fluids making their way to the power end of the pump.

The fluid end of a positive displacement triplex pump presents many opportunities for issues. The results of these issues in such a high-pressure system can mean expensive downtime on the pump itself and, possibly, the entire rig — not to mention the costly repair or replacement of the pump. To reduce severe vibration caused by the pumping process, many pumps incorporate both a suction and discharge pulsation dampener; these are connected to the suction and discharge manifolds of the fluid end. These dampeners reduce the cavitation effect on the entire pump which increases the life of everything within the pump.

Poor maintenance — such as improper valve and seat installation — is another factor. Improper cleaning when replacing a valve seat can leave sand or debris in the valve seat area; preventing the new seat from properly forming a seal with the fluid cylinder, causing a pathway for a washout to occur. It is important to pull up on a seat firmly by hand and make sure it doesn’t pop out and is properly seated. The seats must be seated well, before resuming repairs. You should never reuse a valve seat if at all possible.

The fluid end is the most easily damaged part of the mud pump. The pumping process occurs within the fluid end with valves, pistons, and liners. Because these components are high-wear items, many pumps are designed to allow quick replacement of these parts.

A washout occurs when fluid and solids enter the area behind or underneath a valve seat and erode the sealing surface. Washouts are usually caused by one of three issues: a worn or cracked valve seat, improper cleaning of the valve seat and deck which creates a poor seat seal, and excessive sand content in your drilling fluid. Worn or cracked valve seats can allow fluid to enter the area around the valve seat and seat deck, creating a wash point on the valve seat and causing it to cut into the fluid cylinder and seat deck.

Additionally, the throat (inside diameter) can begin to wash out from extended usage hours or rather quickly when the fluid solids content is excessive. When this happens it can cut all the way through the seat and into the fluid end module/seat deck. This causes excessive expense not only from a parts standpoint but also extended downtime for parts delivery and labor hours to remove and replace the fluid module. With that said, a properly operated and maintained mud recycling system is vital to not only the pump but everything the drilling fluid comes in contact with downstream.

If you spot a washout on any of the fluid end parts, you need to replace the part immediately. A washout can get much worse very quickly, leading to costly repairs.

A pulsation damper is an equipment capable of playing a very important role in the use of double diaphragm pumps. As can be seen from the name, this accessory is aimed at reducing pulsations and vibrations during pump operation, thus ensuring a “continuous” and precisely non-pulsed flow rate and a reduction of vibrations on the system pipes.

A pulsation damper works thanks to the same compressed air that feeds the pump. The compressed air introduced into the counter-pressure chamber behind the membrane creates a pneumatic damping cushion that self-adjusts according to the stress exerted by the pressure pulse of the fluid generated by the pump.

EQUAFLUX dampers are used with fluids of high apparent viscosity even in the presence of solid parts in suspension. They automatically adapt to the system conditions, without manual adjustment or calibration. The high ability to minimize pulsations, vibrations and water hammers makes this component a suitable equipment for safeguarding the system, giving regularity to the outgoing flow. The wide choice of construction materials allows you to determine the best chemical compatibility with the fluid and / or the environment without neglecting the correct temperature range. The dampers are also available for use in a potentially explosive environment (ATEX certification).

Inside the hydraulic systems, the pulsations of the fluid can cause phenomena called water hammer consisting of pressure peaks caused by a sudden change in the flow rate inside the pipes or by the sudden closure of a valve. The effects of water hammer vary according to the size of the pipeline and the speed and density of the fluid but can often cause extensive damage to the elements of a system. To preserve the system from water hammer and vibrations, it is possible to use the pulsation dampers of the Equaflux series that can automatically adapt to the operating conditions of the pump.

Equaflux pulsation dampers are normally applied to pneumatic double diaphragm pumps. The latter, during the phases of use, can record pressure peaks which, if not controlled, can damage the elements of a system. The main benefits associated with the use of pulsation dampers can be summarized in the following points.

The application of diaphragm pumps equipped with pulsation dampers refer to the entire process industry: hydraulic systems, use in chemical transformation processes, use within the petrochemical, mining sectors and much more. The EQUAFLUX series is also available with ATEX certification and therefore can be used directly within sectors with the presence of explosive risks.

Pulsation dampers are very versatile tools whose use can vary according to the needs of the operating processes and application sectors. For this reason, a sales team is at your disposal to support you in choosing the most suitable configuration for your needs. Contact the Debem team now.

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TSC offers a broad range of drilling and production spherical pulsation dampeners. Volumetric size ranges from 10 gallon to 20 gallon capacities and pressure ranges from 3000 psi to 7500 psi. The body of the TSC spherical pulsation dampeners is manufactured from a one piece steel forging, thereby eliminating the possibility of weld fatigue failure.

If you run a mud rig, you have probably figured out that the mud pump is the heart of the rig. Without it, drilling stops. Keeping your pump in good shape is key to productivity. There are some tricks I have learned over the years to keeping a pump running well.

First, you need a baseline to know how well your pump is doing. When it’s freshly rebuilt, it will be at the top efficiency. An easy way to establish this efficiency is to pump through an orifice at a known rate with a known fluid. When I rig up, I hook my water truck to my pump and pump through my mixing hopper at idle. My hopper has a ½-inch nozzle in it, so at idle I see about 80 psi on the pump when it’s fresh. Since I’m pumping clear water at a known rate, I do this on every job.

As time goes on and I drill more hole, and the pump wears, I start seeing a decrease in my initial pressure — 75, then 70, then 65, etc. This tells me I better order parts. Funny thing is, I don’t usually notice it when drilling. After all, I am running it a lot faster, and it’s hard to tell the difference in a few gallons a minute until it really goes south. This method has saved me quite a bit on parts over the years. When the swabs wear they start to leak. This bypass pushes mud around the swab, against the liners, greatly accelerating wear. By changing the swab at the first sign of bypass, I am able to get at least three sets of swabs before I have to change liners. This saves money.

Before I figured this out, I would sometimes have to run swabs to complete failure. (I was just a hand then, so it wasn’t my rig.) When I tore the pump down to put in swabs, lo-and-behold, the liners were cut so badly that they had to be changed too. That is false economy. Clean mud helps too. A desander will pay for itself in pump parts quicker than you think, and make a better hole to boot. Pump rods and packing last longer if they are washed and lubricated. In the oilfield, we use a petroleum-based lube, but that it not a good idea in the water well business. I generally use water and dish soap. Sometimes it tends to foam too much, so I add a few tablets of an over the counter, anti-gas product, like Di-Gel or Gas-Ex, to cut the foaming.

Maintenance on the gear end of your pump is important, too. Maintenance is WAY cheaper than repair. The first, and most important, thing is clean oil. On a duplex pump, there is a packing gland called an oil-stop on the gear end of the rod. This is often overlooked because the pump pumps just as well with a bad oil-stop. But as soon as the fluid end packing starts leaking, it pumps mud and abrasive sand into the gear end. This is a recipe for disaster. Eventually, all gear ends start knocking. The driller should notice this, and start planning. A lot of times, a driller will change the oil and go to a higher viscosity oil, thinking this will help cushion the knock. Wrong. Most smaller duplex pumps are splash lubricated. Thicker oil does not splash as well, and actually starves the bearings of lubrication and accelerates wear. I use 85W90 in my pumps. A thicker 90W140 weight wears them out a lot quicker. You can improve the “climbing” ability of the oil with an additive, like Lucas, if you want. That seems to help.

Outside the pump, but still an important part of the system, is the pop-off, or pressure relief valve. When you plug the bit, or your brother-in-law closes the discharge valve on a running pump, something has to give. Without a good, tested pop-off, the part that fails will be hard to fix, expensive and probably hurt somebody. Pop-off valve are easily overlooked. If you pump cement through your rig pump, it should be a standard part of the cleanup procedure. Remove the shear pin and wash through the valve. In the old days, these valves were made to use a common nail as the shear pin, but now nails come in so many grades that they are no longer a reliable tool. Rated shear pins are available for this. In no case should you ever run an Allen wrench! They are hardened steel and will hurt somebody or destroy your pump.

One last thing that helps pump maintenance is a good pulsation dampener. It should be close to the pump discharge, properly sized and drained after every job. Bet you never thought of that one. If your pump discharge goes straight to the standpipe, when you finish the job your standpipe is still full of fluid. Eventually the pulsation dampener will water-log and become useless. This is hard on the gear end of the pump. Open a valve that drains it at the end of every job. It’ll make your pump run smoother and longer.