drilling rig mud pump knocking sound price

Cavitation is an undesirable condition that reduces pump efficiency and leads to excessive wear and damage to pump components. Factors that can contribute to cavitation, such as fluid velocity and pressure, can sometimes be attributed to an inadequate mud system design and/or the diminishing performance of the mud pump’s feed system.

When a mud pump has entered full cavitation, rig crews and field service technicians will see the equipment shaking and hear the pump “knocking,” which typically sounds like marbles and stones being thrown around inside the equipment. However, the process of cavitation starts long before audible signs reveal themselves – hence the name “the silent killer.”

Mild cavitation begins to occur when the mud pump is starved for fluid. While the pump itself may not be making noise, damage is still being done to the internal components of the fluid end. In the early stages, cavitation can damage a pump’s module, piston and valve assembly.

The imperceptible but intense shock waves generated by cavitation travel directly from the fluid end to the pump’s power end, causing premature vibrational damage to the crosshead slides. The vibrations are then passed onto the shaft, bull gear and into the main bearings.

If not corrected, the vibrations caused by cavitation will work their way directly to critical power end components, which will result in the premature failure of the mud pump. A busted mud pump means expensive downtime and repair costs.

Washouts are one of the leading causes of module failure and take place when the high-pressure fluid cuts through the module’s surface and damages a sealing surface. These unexpected failures are expensive and can lead to a minimum of eight hours of rig downtime for module replacement.

To stop cavitation before it starts, install and tune high-speed pressure sensors on the mud suction line set to sound an alarm if the pressure falls below 30 psi.

Although the pump may not be knocking loudly when cavitation first presents, regular inspections by a properly trained field technician may be able to detect moderate vibrations and slight knocking sounds.

Gardner Denver offers Pump University, a mobile classroom that travels to facilities and/or drilling rigs and trains rig crews on best practices for pumping equipment maintenance.

Severe cavitation will drastically decrease module life and will eventually lead to catastrophic pump failure. Along with downtime and repair costs, the failure of the drilling pump can also cause damage to the suction and discharge piping.

When a mud pump has entered full cavitation, rig crews and field service technicians will see the equipment shaking and hear the pump ‘knocking’… However, the process of cavitation starts long before audible signs reveal themselves – hence the name ‘the silent killer.’In 2017, a leading North American drilling contractor was encountering chronic mud system issues on multiple rigs. The contractor engaged in more than 25 premature module washes in one year and suffered a major power-end failure.

Gardner Denver’s engineering team spent time on the contractor’s rigs, observing the pumps during operation and surveying the mud system’s design and configuration.

The engineering team discovered that the suction systems were undersized, feed lines were too small and there was no dampening on the suction side of the pump.

Following the implementation of these recommendations, the contractor saw significant performance improvements from the drilling pumps. Consumables life was extended significantly, and module washes were reduced by nearly 85%.

Although pump age does not affect its susceptibility to cavitation, the age of the rig can. An older rig’s mud systems may not be equipped for the way pumps are run today – at maximum horsepower.

It may be impractical to flush system piping during drilling operations. However, strainer screens should be checked daily to remove any debris or other flow restrictions.

A well-placed suction stabilizer can also prevent pump chatter. Pump chatter occurs when energy is exchanged between the quick opening and closing of the reciprocating pump’s valves and the hammer effect from the centrifugal pump. Pump isolation with suction stabilizers is achieved when the charge pumps are isolated from reciprocating pumps and vice versa. The results are a smooth flow of pumped media devoid of agitating energies present in the pumped fluid.

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.

Bentec completely redeveloped the concept of Mud Pumps. Being equipped with a direct-driven gearbox, an own developed motor, and a state-of-the-art pump housing, there is no need for an internal gear coming with many disadvantages and no more belt tensioning.

Bentec Mud Pumps are light weight and have a small footprint. The AC-powered motor is top or rear mounted – suitable for any drilling rig arrangement. The pump is available with 5 000 or 7 500 psi fluid ends, and all its parts that are subject to wear and tear meet API standards and are available worldwide.

A handling crane makes it easy to handle the fluid end components. Furthermore, Bentec uses a patented liner and valve clamping technology to reduce the maintenance time significantly. A quick-change liner and piston system serves for easy maintenance. A special feature of the Bentec MUD PUMP is the side-mounted gear drive.

Liner cooling and gear oiler systems are included; a supercharge pump and a noise reduction package can be installed upon request. The Bentec MUD PUMP is the right choice especially when it comes to noise-sensitive environments such offshore or densely populated environments.

Beyond the supply of Mud Pumps, Bentec acts as system supplier. The pumps can be delivered together with a Bentec Power Control System and a Bentec Soft Pump System.

When choosing a size and type of mud pump for your drilling project, there are several factors to consider. These would include not only cost and size of pump that best fits your drilling rig, but also the diameter, depth and hole conditions you are drilling through. I know that this sounds like a lot to consider, but if you are set up the right way before the job starts, you will thank me later.

Recommended practice is to maintain a minimum of 100 to 150 feet per minute of uphole velocity for drill cuttings. Larger diameter wells for irrigation, agriculture or municipalities may violate this rule, because it may not be economically feasible to pump this much mud for the job. Uphole velocity is determined by the flow rate of the mud system, diameter of the borehole and the diameter of the drill pipe. There are many tools, including handbooks, rule of thumb, slide rule calculators and now apps on your handheld device, to calculate velocity. It is always good to remember the time it takes to get the cuttings off the bottom of the well. If you are drilling at 200 feet, then a 100-foot-per-minute velocity means that it would take two minutes to get the cuttings out of the hole. This is always a good reminder of what you are drilling through and how long ago it was that you drilled it. Ground conditions and rock formations are ever changing as you go deeper. Wouldn’t it be nice if they all remained the same?

Centrifugal-style mud pumps are very popular in our industry due to their size and weight, as well as flow rate capacity for an affordable price. There are many models and brands out there, and most of them are very good value. How does a centrifugal mud pump work? The rotation of the impeller accelerates the fluid into the volute or diffuser chamber. The added energy from the acceleration increases the velocity and pressure of the fluid. These pumps are known to be very inefficient. This means that it takes more energy to increase the flow and pressure of the fluid when compared to a piston-style pump. However, you have a significant advantage in flow rates from a centrifugal pump versus a piston pump. If you are drilling deeper wells with heavier cuttings, you will be forced at some point to use a piston-style mud pump. They have much higher efficiencies in transferring the input energy into flow and pressure, therefore resulting in much higher pressure capabilities.

Piston-style mud pumps utilize a piston or plunger that travels back and forth in a chamber known as a cylinder. These pumps are also called “positive displacement” pumps because they literally push the fluid forward. This fluid builds up pressure and forces a spring-loaded valve to open and allow the fluid to escape into the discharge piping of the pump and then down the borehole. Since the expansion process is much smaller (almost insignificant) compared to a centrifugal pump, there is much lower energy loss. Plunger-style pumps can develop upwards of 15,000 psi for well treatments and hydraulic fracturing. Centrifugal pumps, in comparison, usually operate below 300 psi. If you are comparing most drilling pumps, centrifugal pumps operate from 60 to 125 psi and piston pumps operate around 150 to 300 psi. There are many exceptions and special applications for drilling, but these numbers should cover 80 percent of all equipment operating out there.

The restriction of putting a piston-style mud pump onto drilling rigs has always been the physical size and weight to provide adequate flow and pressure to your drilling fluid. Because of this, the industry needed a new solution to this age-old issue.

As the senior design engineer for Ingersoll-Rand’s Deephole Drilling Business Unit, I had the distinct pleasure of working with him and incorporating his Centerline Mud Pump into our drilling rig platforms.

In the late ’90s — and perhaps even earlier —  Ingersoll-Rand had tried several times to develop a hydraulic-driven mud pump that would last an acceptable life- and duty-cycle for a well drilling contractor. With all of our resources and design wisdom, we were unable to solve this problem. Not only did Miller provide a solution, thus saving the size and weight of a typical gear-driven mud pump, he also provided a new offering — a mono-cylinder mud pump. This double-acting piston pump provided as much mud flow and pressure as a standard 5 X 6 duplex pump with incredible size and weight savings.

The true innovation was providing the well driller a solution for their mud pump requirements that was the right size and weight to integrate into both existing and new drilling rigs. Regardless of drill rig manufacturer and hydraulic system design, Centerline has provided a mud pump integration on hundreds of customer’s drilling rigs. Both mono-cylinder and duplex-cylinder pumps can fit nicely on the deck, across the frame or even be configured for under-deck mounting. This would not be possible with conventional mud pump designs.

Centerline stuck with their original design through all of the typical trials and tribulations that come with a new product integration. Over the course of the first several years, Miller found out that even the best of the highest quality hydraulic cylinders, valves and seals were not truly what they were represented to be. He then set off on an endeavor to bring everything in-house and began manufacturing all of his own components, including hydraulic valves. This gave him complete control over the quality of components that go into the finished product.

The second generation design for the Centerline Mud Pump is expected later this year, and I believe it will be a true game changer for this industry. It also will open up the application to many other industries that require a heavier-duty cycle for a piston pump application.

American Augers mud pumps are standardstand-alone, self-powered machines thatare the perfect accessories to use with mudmotors, large reamers or whenever moremud volume is needed down hole.* Optional Quiet Pak for optimum noise reduction controlP-600 and P-750 Mud Pumps• allow the operator to get enoughflow to keep the bore flushed cleanof cuttings• are designed with a compact skidmounting and provide a smallfootprint that are ideal for mostdrilling environments.• are compatible with any drill brandmaking them suitable for contractorsoperating a variety of sizes, makesand models of drilling equipment.www.AmericanAugers.com

P-600Mud PumpTypical Flow Rates for Popular Size Mud MotorsBe sure to allow enough extra mud flow to flood the boreMUD MOTOR SIZEFLOW RATE/MINUTEInches Millimeters U.S. Gallons Liters3 3/8 85.72 30 - 120 113.6 - 454.23 1/2 88.9 75 - 160 283.9 - 605.74 3/4 120.6 100 - 250 378.5 - 946.46 3/4 171.4 300 - 600 1,136 - 2,271

What Type of Contractor Should Use aMud Pump?• Users of drilling equipment withpumping capacities of 25 U.S.Gallons (95 L)/minute or largerregardless of soil type or conditions.• Drillers typically making bores thatare greater than 6 1/2 in. (165 mm)diameter and more than 200 ft.(61 m) long.• Owners of mud motors for rockdrilling applications.• Operators in areas where muddisposal is expensive or restricted.Both the P-600 and the P-750should be considered when workingin rock formations where the operatingdrill"s on-board mud pump has fluidlimitedcapacities and cannot produceenough pressure to drive the mud motor.www.AmericanAugers.com

MUD MOTOR SIZEP-750Mud PumpTypical Flow Rates for Popular Size Mud MotorsBe sure to allow enough extra mud flow to flood the boreFLOW RATE/MINUTEInches Millimeters U.S. Gallons Liters3 3/8 85.72 30 - 120 113.6 - 454.23 1/2 88.9 75 - 160 283.9 - 605.74 3/4 120.6 100 - 250 378.5 - 946.46 3/4 171.4 300 - 600 1,136 - 2,2718 203.2 400 - 900 1,514 - 3,407

P-600PERFORMANCE SPECIFICATIONSPower TrainEngine:Caterpillar ® C-15 Tier III Diesel* Tier III or Tier 4i determined by country of purchaseFuel Capacity: 300 U.S. Gallons (1,136 L)Rating:475 HP (354 kW)Transmission: Eaton-FRO-16210B, 10 speedMaximum Speed: 2100 RPMClutch:15 1 /2 in. (394 mm) twin diskNoise Rating: 1 meter distance 104 dB(A)3 meter distance 95 dB(A)Battery:(2) Deka 908DMF 12V, 1450 CCAPumpPump Design:Maximum Pressure:Rated Capacity:Bore x Stroke:Tri-Plex 600GPM1,505 psi (104 bar)600 U.S. Gallons* (2,067 L)/minute6 x 6 in. (152.4 x 152.4 mm)* Note: Pump capacity will vary depending on the overall mud weight,drilling fluid mixture/content and working elevationControlsRemote Controls:Instruments:Mud pump throttle, Mud pump start/stop,clutch actuator, horn remoteDigital mud flow meter (gallons/liters per minute)DimensionsLength: 20 ft. (6.096 m)Height: 9 ft. (2.7 m)Width: 8 ft. (2.49 m)WeightTotal Weight:29,800 lbs. (13,520 kg) estimated39,600 lbs. (17,962 kg) with sound enclosureAccessoriesPulsation dampener on inlet and discharge(2) 25 ft. (7.6 m) suction hoses with 6 in. (152.4 mm)kamlock fittings(2) 25 ft. (7.6 m) discharge hoses with 3 in. (76.2 mm)NPT hammer unionsLiner wash system with supply tank(2) 24 volt work lights* Note: All product performance specifications,components, weights, dimensions and otherrelated information is subject to change withoutnotice from the manufacturer.

P-750PERFORMANCE SPECIFICATIONSPower TrainEngine:Caterpillar ® C-18 Tier III Diesel* Tier III or Tier 4i determined by country of purchaseFuel Capacity: 300 U.S. Gallons (1,136 L)Rating:600 HP (447 kW)Transmission: Eaton-RTLO-22918B, 10 speedMaximum Speed: 2100 RPMClutch:15 1 /2 in. (394 mm) twin diskNoise Rating: 1 meter distance 104 dB(A)3 meter distance 95 dB(A)Battery:(2) Deka 908DMF 12V, 1450 CCAPumpPump Design:Maximum Pressure:Rated Capacity:Bore x Stroke:Quintiplex, piston and liner1,500 psi (103 bar)750 U.S. Gallons* (2,839 L)/minute5 1 /2 x 7 7 /8 in. (139.7 x 200 mm)* Note: Pump capacity will vary depending on the overall mud weight,drilling fluid mixture/content and working elevationControlsRemote Controls:Instruments:Mud pump throttle, Mud pump start/stop,clutch actuator, horn remoteDigital mud flow meter (gallons/liters per minute)DimensionsLength: 25 ft. 6 in. (7.8 m)Height: 10 ft. 3 in. (3.12 m)Width: 8 ft. (2.49 m)WeightTotal Weight:47,800 lbs. (21,680 kg)AccessoriesPulsation dampener on inlet and discharge(2) 25 ft. (7.6 m) suction hoses with 6 in. (152.4 mm)kamlock fittings4 in. (102 mm) NPT hammer union discharge connectionLiner wash system with supply tank(2) 24 volt work lights* Note: All product performance specifications,components, weights, dimensions and otherrelated information is subject to change withoutnotice from the manufacturer.

AMERICAN AUGERSThe American Augers line of underground construction equipment is second-to-none.• Auger Boring Machines• Maxi-Rig & Mid-Size Directional Drills• Oil & Gas Drilling Rigs• Mud Pump & Cleaning Systems• Product Tooling & AccessoriesAmerican Augers products are manufactured at the company’s 241,000 square-foot facility in West Salem, Ohio,in the heart of Amish country between Columbus and Cleveland.Since the founding of American Augers in 1970, there has never been a change in the company’s core value:having products developed by a can-do work force that focuses on mechanical, technological and customer-baseddesign improvements. Our goal is to always exceed customer expectations by providing products that are not acost of doing business, but an Investment in Success.Did You Know? American Augers was the first HDD manufacturer to eliminate chain and utilize a rack andpinion carriage design which is now the industry standard. Our rack and pinion drive provides smoother carriagemovement, more precise operating control, long system life and no complicated parts.American Augers machines are supported through a dedicated parts and technical service department. We are hereto help whenever you need us 24 hours a day, 7 days a week, emergency or not.www.AmericanAugers.comEnvironmental CommitmentAmerican Augers is committed to manufacturing equipment that helps to preserve the sanctity of the globalenvironment, and has done so by reducing noise and/or emissions outputs, and emphasizing the fact that ourtrenchless technology equipment requires little or no open cutting, which has very minimal impacts on naturalsurfaces, features, or habitats.1212

A quintuplex pump has a crankshaft supported in the pump by external main bearings. The crankshaft has five eccentric sheaves, two internal main bearing sheaves, and two bull gears.

A quintuplex pump is central to oil drilling and exploration due to the nature of operations. This pump circulates the mud to and from the surface, supporting the process for oil well operations.

The quintuplex pump is designed to circulate mud or drilling fluid under great pressure down the drill hole and back up. The pump is a reciprocating model that features five pistons, hence the name quintuplex mud pump. The right degree of pressure and precision is crucial for efficient well operations.

Despite the fact that all mud pumps have pulsation dampeners, noise levels are likely to be high and require modifications to keep noise pollution levels low. This is important, considering the long-running hours of equipment and the need to protect personnel from constant and high noise levels. With a quintuplex mud pump, the pulsation noise and the mud telemetry noise come down by as much as half, making operations less noisy.

Quintuplex pumps can be used in various applications including salt water disposal, descaling, high pressure pumping, Frac pumping, pipeline transfers in the Oil & Gas, Agriculture, Mining, Municipal and Manufacturing sectors.

Mud pumps comes in a variety of sizes and configurations but for the typical petroleum drilling rig, the triplex (three piston/plunger) mud pumps are the pump of choice. Duplex mud pumps (two piston/plungers) have generally been replaced by the triplex pump, but are still common in developing countries. Two later developments are the hex pump with six vertical pistons/plungers, and various quintuplex’s with five horizontal piston/plungers.

Duplex, triplex and quintuplex pumps all have an enviable history of sound engineering, designed to exceed the rigorous requirements of API 674 and customer satisfaction.

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.

Mud pumps can be divided into single-acting pump and double-acting pump according to the completion times of the suction and drainage acting in one cycle of the piston"s reciprocating motion.

Mud pumps come in a variety of sizes and configurations but for the typical petroleum drilling rig, the triplex (three piston/plunger) mud pump is used. Duplex mud pumps (two piston/plungers) have generally been replaced by the triplex pump, but are still common in developing countries. Two later developments are the hex pump with six vertical pistons/plungers, and various quintuplexes with five horizontal piston/plungers. The advantages that these new pumps have over convention triplex pumps is a lower mud noise which assists with better measurement while drilling (MWD) and logging while drilling (LWD) decoding.

The fluid end produces the pumping process with valves, pistons, and liners. Because these components are high-wear items, modern pumps are designed to allow quick replacement of these parts.

To reduce severe vibration caused by the pumping process, these pumps incorporate both a suction and discharge pulsation dampener. These are connected to the inlet and outlet of the fluid end.

Displacement is calculated as discharged liters per minute. It is related to the drilling hole diameter and the return speed of drilling fluid from the bottom of the hole, i.e. the larger the diameter of drilling hole, the larger the desired displacement. The return speed of drilling fluid should wash away the debris and rock powder cut by the drill from the bottom of the hole in a timely manner, and reliably carry them to the earth"s surface. When drilling geological core, the speed is generally in range of 0.4 to 1.0 m^3/min.

The pressure of the pump depends on the depth of the drilling hole, the resistance of flushing fluid (drilling fluid) through the channel, as well as the nature of the conveying drilling fluid. The deeper the drilling hole and the greater the pipeline resistance, the higher the pressure needed.

With the changes of drilling hole diameter and depth, the displacement of the pump can be adjusted accordingly. In the mud pump mechanism, the gearbox or hydraulic motor is equipped to adjust its speed and displacement. In order to accurately measure the changes in pressure and displacement, a flow meter and pressure gauge are installed in the mud pump.

The construction department should have a special maintenance worker that is responsible for the maintenance and repair of the machine. Mud pumps and other mechanical equipment should be inspected and maintained on a scheduled and timely basis to find and address problems ahead of time, in order to avoid unscheduled shutdown. The worker should attend to the size of the sediment particles; if large particles are found, the mud pump parts should be checked frequently for wear, to see if they need to be repaired or replaced. The wearing parts for mud pumps include pump casing, bearings, impeller, piston, liner, etc. Advanced anti-wear measures should be adopted to increase the service life of the wearing parts, which can reduce the investment cost of the project, and improve production efficiency. At the same time, wearing parts and other mud pump parts should be repaired rather than replaced when possible.

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Manufactured to withstand the toughest drilling and environmental conditions, our K-Series triplex mud pumps are ideal for all drilling applications. This legacy product features a balanced forged-steel crankshaft and Southwest Oilfield Products ‘L” Shaped modules which is essential to minimize wear, noise, and operating vibrations. These attributes are essential when drilling deeper high pressure formations, long laterals and when handling corrosive or abrasive fluids and slurries.

Every American Block triplex mud pump is manufactured and fully load tested before leaving our manufacturing campus, and is available in sizes ranging from 800 HP to 2200 HP. The American Block K1600 HP Mud Pump is also available in a 2000 HP up-grade version, when more HP is needed in the same 1600 HP footprint.