cost per day to operate a mud pump manufacturer

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The drilling industry has roots dating back to the Han Dynasty in China. Improvements in rig power and equipment design have allowed for many advances in the way crude oil and natural gas are extracted from the ground. Diesel/electric oil drilling rigs can now drill wells more than 4 miles in depth. Drilling fluid, also called drilling mud, is used to help transfer the dirt or drill cuttings from the action of the drilling bit back to the surface for disposal. Drill cuttings can vary in shape and size depending on the formation or design of the drill bit used in the process.

Watch the video below to see how the EDDY Pump outperforms traditional pumps when it comes to high solids and high viscosity materials commonly found on oil rigs.

Solids control equipment including shakers, hydro-cyclones, and centrifuges are utilized to clean the drill cuttings from the drilling fluid, which then allows it to be reused and recirculated. The circuit includes the mixing of the drilling fluid in the rig tanks.

The drilling fluid is prepared to control fluid loss to the formation by the addition of chemicals or mineral agents. Commercial barite or other weighting agents are added to control the hydrostatic pressure exuded on the bottom of the well which controls formation pressures preventing fluid or gas intrusion into the wellbore.

The fluid is charged into high-pressure mud pumps which pump the drilling mud down the drill string and out through the bit nozzles cleaning the hole and lubricating the drill bit so the bit can cut efficiently through the formation. The bit is cooled by the fluid and moves up the space between the pipe and the hole which is called the annulus. The fluid imparts a thin, tough layer on the inside of the hole to protect against fluid loss which can cause differential sticking.

The fluid rises through the blowout preventers and down the flowline to the shale shakers. Shale shakers are equipped with fine screens that separate drill cutting particles as fine as 50-74 microns. Table salt is around 100 microns, so these are fine cuttings that are deposited into the half-round or cuttings catch tank. The drilling fluid is further cleaned with the hydro-cyclones and centrifuges and is pumped back to the mixing area of the mud tanks where the process repeats.

The drill cuttings contain a layer of drilling fluid on the surface of the cuttings. As the size of the drill cuttings gets smaller the surface area expands exponentially which can cause rheological property problems with the fluid. The fluid will dehydrate and may become too thick or viscous to pump so solids control and dilution are important to the entire drilling process.

One of the most expensive and troubling issues with drilling operations is the handling, processing, and circulation of drilling mud along with disposing of the unwanted drill cuttings. The drilling cuttings deposited in the half round tank and are typically removed with an excavator that must move the contents of the waste bin or roll-off box. The excavators are usually rented for this duty and the equipment charges can range from $200-300/day. Add in the cost for the day and night manpower and the real cost for a single excavator can be as much as $1800/day.

Using the excavator method explained above, the unloading of 50 barrels of drill cuttings from the half round can take as long as two hours. This task is mostly performed by the solids control technicians. The prime duty for the solids control technicians is to maintain the solids control equipment in good working order. This involves maintenance for the equipment, screen monitoring and changing, centrifuge adjustments, and retort testing to prepare a daily operational summary of the solids control program.

Operating the excavator takes the technician away from these tasks and can lead to poorly performing equipment. Additionally, the excavator has the potential for abuse as some solids control technicians use the climate-controlled cab as a break area or refuge from the elements. Many times, these guys are found asleep on the job.

One solids control company reported the idle time for the excavator can be more than 8 hours for a 24-hour period with 8 hours of operation and 8 hours of shut down time. Fuel and time lost can cause an economic drag on rig operations. And lastly, there have been several accidents on each rig causing a potential for injury, loss of production, and lost revenue as the excavator must be repaired.

Offshore drilling rigs follow a similar process in which the mud is loaded into empty drums and held on the oil platform. When a certain number of filled drums is met, the drums are then loaded onto barges or vessels which take the drilling mud to the shore to unload and dispose of.

Oil field drilling operations produce a tremendous volume of drill cuttings that need both removal and management. In most cases, the site managers also need to separate the cuttings from the drilling fluids so they can reuse the fluids. Storing the cuttings provides a free source of stable fill material for finished wells, while other companies choose to send them off to specialty landfills. Regardless of the final destination or use for the cuttings, drilling and dredging operations must have the right high solids slurry pumps to move them for transport, storage, or on-site processing. Exploring the differences in the various drilling fluids, cutting complications, and processing options will reveal why the EDDY Pump is the best fit for the job.

The Eddy Pump is designed to move slurry with solid content as high as 70-80 % depending on the material. This is an ideal application for pumping drill cuttings. Drill cuttings from the primary shakers are typically 50% solids and 50% liquids. The Eddy Pump moves these fluids efficiently and because of the large volute chamber and the design of the geometric rotor, there is very little wear on the pump, ensuring long life and greatly reduced maintenance cost for the lifetime of the pump.

plumbed to sweep the bottom of the collection tank and the pump is recessed into a sump allowing for a relatively clean tank when the solids are removed. The Eddy Pump is sized to load a roll-off box in 10-12 minutes. The benefit is cuttings handling is quicker, easier, safer, and allows for pre-planning loading where the labor of the solids control technician is not monopolized by loading cuttings. Here, in the below image, we’re loading 4 waste roll-off bins which will allow the safe removal of cuttings without fear of the half-round catch tank running over.

Mud cleaning systems such as mud shaker pumps and bentonite slurry pumps move the material over screens and through dryers and centrifuges to retrieve even the finest bits of stone and silt. However, the pump operators must still get the raw slurry to the drill cuttings treatment area with a power main pump. Slurry pumps designed around the power of an Eddy current offer the best performance for transferring cuttings throughout a treatment system.

Options vary depending on whether the company plans to handle drill cuttings treatment on-site or transport the materials to a remote landfill or processing facility. If the plan is to deposit the cuttings in a landfill or a long-term storage container, it’s best to invest in a pump capable of depositing the material directly into transport vehicles. Most dredging operations rely on multiple expensive vacuum trucks, secondary pumps, and extra pieces of equipment.

Using an EDDY Pump will allow a project to eliminate the need for excavators/operators to load drill cuttings, substantially lowering both labor and heavy equipment costs. The EDDY Pump also allows a company to eliminate vacuum trucks once used for cleaning the mud system for displacing fluids. Since the pump transfers muds of all types at constant pressure and velocity throughout a system of practically any size, there’s little need for extra equipment for manual transfer or clean up on the dredge site.

The EDDY Pump can fill up a truck in only 10 minutes (compared to an hour) by using a mechanical means such as an excavator. For this reason, most companies can afford one piece of equipment that can replace half a dozen other units.

This application for the Eddy Pump has the potential to revolutionize the drilling industry. Moving the excavator out of the “back yard” (the area behind the rig from the living quarters) will make cuttings handling a breeze. Trucking can be easier scheduled during daylight hours saving on overtime and incidences of fatigued driving. Rig-site forklifts can move the roll-off boxes out of the staging area and into the pump loading area. The operator can save money on excavators rental, damages, and keep the technician operating the solids control equipment.

The EDDY Pump is ideal for drilling mud pump applications and can be connected directly onto the drilling rigs to pump the drilling mud at distances over a mile for disposal. This eliminates the need for costly vacuum trucks and also the manpower needed to mechanically move the drilling mud. The reasons why the EDDY Pump is capable of moving the drilling mud is due to the hydrodynamic principle that the pump creates, which is similar to the EDDY current of a tornado. This tornado motion allows for the higher viscosity and specific gravity pumping ability. This along with the large tolerance between the volute and the rotor allows for large objects like rock cuttings to pass through the pump without obstruction. The large tolerance of the EDDY Pump also enables the pump to last many times longer than centrifugal pumps without the need for extended downtime or replacement parts. The EDDY Pump is the lowest total life cycle pump on the market.

The HMI HM-1 hydraulic mudjacking pump was the first concrete raising product engineered and manufactured by HMI, just over 40 years ago. It’s reliability and superior engineering maintains its place in the market, but has also acted as the springboard for other, more advanced models / options which offer various options of engine horsepower, hopper size, pumping pressure, and so much more.

Our largest, self-propelled, multi-functional pump. This rugged and durable pump is the top-of-the-line mudjacking unit. With the highest available pumping pressure, largest material hopper, most horsepower and versatility.

Our most popular model, the self-propelled, hydraulic mudjacking pump drives circles around the competition. Affordable and durable, the Power Pump is a great way to start-up or add to a concrete raising business.

Maintaining /monitoring the mud pumps and mud pits during operations. Notifying the Driller immediately of any unexplained pit level increases/decreases Verify and record drilling fluid properties at ...

Perform daily inspections and maintenance on electrical equipment. Comply with the permit to work and isolation systems. Carry out periodic maintenance according to the guidelines Maintain, troubleshoot ...

and decisivemanner Otherduties as required by the Rig Manager Minimum Qualifications: Ability to perform essential functions of this position with or without reasonable accommodations. Previous ...

and decisivemanner Otherduties as required by the Rig Manager Minimum Qualifications: Ability to perform essential functions of this position with or without reasonable accommodations. Previous ...

and decisivemanner Otherduties as required by the Rig Manager Minimum Qualifications: Ability to perform essential functions of this position with or without reasonable accommodations. Previous ...

Field Specialist - Directional Driller (DD)Have excellent Directional Driller experience?Do you enjoy working with cutting-edge energy equipment?Join our innovating Drilling Services Team!Our Drilling ...

Assist internal and external customers with troubleshooting of Rig Equipment (Top Drive, Catwalk, Wrench, Drawworks, VFDs, Generators, Mud Pumps, BOP) Expeditiously work to troubleshoot and resolve downtime ...

include but are not limited to safely and efficiently performing all tasks within the Rig Operations Areas of the Platform at the direction and under the supervision of the Crane Operator. Tasks may include ...

Our Technical Sales Representative (TSR) is responsible for building on a very high level of product line & operational knowledge and experience to proactively and strategically sell specific tools, technologies ...

Field Specialist - Directional Driller (DD)Have excellent Directional Driller experience?Do you enjoy working with cutting-edge energy equipment?Join our innovating Drilling Services Team!Our Drilling ...

include but are not limited to: Safely and efficiently performing all tasks on the rig floor and B.O.P. area under the direction and supervision of the Driller. Operating the tongs, slips, and spinners ...

Assist higher level technicians, as well as work independently with minimal supervision. Promote a safe and quality environment in which to work Perform preventative maintenance requirements and maintain ...

Please note that we are planning to come to the following countries for Recruitment Campaign in the month of May 2023 - Romania - Azerbaijan - Croatia Minimum requirement/ Basic Function Carries out the ...

as required by the Driller, Derrickhand or Rig Manager Minimum Qualifications: Ability to perform essential functions of this position with or without reasonable accommodations Ability to ...

Assists the Driller, Derrickman and/or Motorman in carrying out all routine, non-routine and emergency operational activities around the rig floor areas or any other area of the rig location as designated ...

as required by the Driller, Derrickhand or Rig Manager Minimum Qualifications: Ability to perform essential functions of this position with or without reasonable accommodations Ability to ...

Assists the Crew Pusher and/or TRS Lead in carrying out all routine, non-routine and emergency operational activities around the rig floor areas or any other area of the rig location as designated by ...

are prominent in every aspect of drilling the well, manual handling of tubular and tools, making up or breaking out during making connections or tripping pipe. The position is responsible for the processes ...

are prominent in every aspect of drilling the well, manual handling of tubular and tools, making up or breaking out during making connections or tripping pipe. The position is responsible for the processes ...

Regular inspection of machinery, as well as the bilge, pump rooms, and tanks. Ensure the engine room is neatly kept and all equipment is properly stowed. Examination of equipment such as turbines, condensers, ...

The PD 3 diaphragm / mud pumps can move almost anything that flows. A 3-inch pump that can handle solids up to 1.625 inches (41 mm) and up to 88 gpm (333 l/min), these pumps are ideal for moving water with mud, slurries and in seepage areas. Built with high quality component, you will be assured of many years of top performance and durability. Large solid rubber tires provide excellent traction and smooth rolling over rough terrain.

Oil bath lubricated transmission ensures continuous lubrication to all parts of the gear transmission system, reducing both maintenance costs and lost production time.

Ductile iron crankcase provides maximum durability. Hardened forged gears extend pump life and provide efficient power transmission from the engine to the pump.

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Recycling and reusing drilling fluids is becoming increasingly common on jobs with mid-size horizontal directional drill (HDD) projects where previously that practice was uncommon.

Recycling isn’t for every job – it would not be practical on jobs with small machines making short bores – but contractors who are recycling on larger projects with 30,000 to 60,000 pound pullback equipment are reporting surprising cost savings resulting in overall lower project costs.

Savings come from using less water and drilling additives, less time in mixing fluids, reduced clean-up requirements and significant reduction in costs of hauling water to make the fluid and dispose of it after a job is complete.

Mud recycling is standard procedure on HDD projects with big drill rigs – to not recycle fluids on a long, deep bore with a big machine using a mud motor would make the logistics of handling fluids unmanageable and cost prohibitive, and the physical size of recyclers used on these projects would not permit their use on work sites of the mid-size drill rigs that do utility work.

American Augers, Richard Levings, director of product management:Yes, the cost of disposing drilling fluid has become too expensive and often is very difficult to access an approved disposal location. Higher levels of cleaning equipment and new technology will be employed to decrease disposal costs and reduce fluid system wear. Just having a fluid cleaning system is not enough, making it a priority and a focus is necessary to be successful.

Ditch Witch, Seth Matthesen, senior HDD product manager: Yes, in certain areas and certain types of jobs. HDD projects in adverse, rocky soil conditions use much more mud per foot, making it necessary for operators to either spend more time disposing of drill fluid or obtain fluid recyclers that can handle drills with more pullback range. This trend is more likely in urban areas where operators must drive much further to a dump site. Some cities are also implementing tighter restrictions for dumping liquids, making disposal even more costly.

Elgin Separation Solutions, Raymond Pietramale, marketing manager: Packaged mud recycling systems feature an all-in-one unit design, and the use of mud recycling has proven beneficial when used with mid to large size directional drilling rigs. The ability to continuously recycle drilling fluid and decrease the solids slurry waste saves costs associated with new fluid use and less waste for contractors to pay to haul off. The cost savings and environmental friendly impact is a significant trend being seen across the industry.

Mud Technology International (MTI), John Miller, chief executive officer:In this age of environmental consciousness for global sustainability, it is imperative that we look at every HDD job to determine how we can minimize the impact of our operations. Recycling, even with the smaller rigs, reduces the amount of water used, Bentonite needed and fluid haul off; saving time, money and making a contribution to the protection of our planet.

manager:Due to the difficulty and cost of disposing of drilling fluids in many locations across North America and Europe, we expect to see more contractors using reclaimers with smaller horizontal directional drills. The decision really depends on overall job-site mud volume, soil type and the kind of mud mixture. For recycling with smaller rigs, the decision whether to use a reclaimer will be driven by return on investment. It could be more cost-effective to just vacuum excavate the returns and pay disposal fees than purchasing a reclaimer and hauling it to job sites.

American Augers: Depending on the fluid system, a bore can be started with a given amount of fluid, and run the entire bore with that volume of fluid. The soil will consume some fluid so fresh water must be added as needed, but it will not be necessary to continuously run vacuum units to clean up and haul away fluid to be disposed.

Ditch Witch:Recycling fluid reduces water volume and removes the need for multiple trucks to haul and process water for the job site providing significant fuel cost savings. In addition to cost savings, HDD operators also see improvements in rig uptime by removing the need to mix drilling mud during the time the rig remains inactive.

Drilling-fluid recyclers also benefit the environment. With less fluid to clean up, transportation of fluid is reduced lessoning the carbon footprint by decreasing the overall emissions.

Elgin: Decreased costs on drilling fluid use; decreased costs on waste disposal; environmentally friendly; and increased profits for drilling contractors.

Thunder Products:Cost savings.A drill stays productive instead of having down time waiting on a vac.Far less drilling fluid is used.It is the most effective way to increase margins.

Vermeer:The main factor is reduced mud costs – not only water and additives but travel time to dispose of the used drilling mud, travel time to get additional water, the labor that goes into mixing mud and reducing idle time of the drill. If a reclaimer is used, it helps maintain the operation and allows contractors to use mud volumes needed for the job. There are many other factors playing into the decision to use a reclaimer,including the type and size of a project.

American Augers:Savings are very project and location dependent. The variable costs range from state to state and often from city to city. Disposal costs alone can vary immensely. An estimate would be on average of 50 percent or more savings when you consider disposal cost, equipment cost, consumables cost, labor, wear on equipment, mileage and work stoppage due to traffic delays.

Ditch Witch:An HDD rig with 30,000 pounds of pullback can pump approximately 20,000 gallons of fluid during the course of a project (this can vary depending on job-site conditions). Using the Ditch Witch MR90 specifically, the same volume could be pumped using only 1,500 gallons of drilling mud, saving 18,500 gal of water and as much as $1,500 spent for additives.

Elgin:Our experience is that when faced with the combined cost of disposal and new raw material costs, the installation of a recycling system can reduce total expenses by as much as 50 percent, depending on the sophistication of the recycling system deployed and the level of fluid reuse deployed.With that said, median savings will range from 15 to 30 percent. Drillers that manage a minimum of six jobs with a 40,000-pound rig will experience a tangible return on investment.

MTI: Using 50 to 70 gallons per minute as a base and a 1,000-gallon mixing system, not recycling requires mixing a new tank of mud every 14 to 20 minutes. Recycling provides the ability to reuse the mud, and only add water and chemicals as needed. This can result in great cost savings.

Thunder:Anywhere from $1,000 to $2,000 per day. There are savings on the dump fees of the vac or several vacs), savings on the driver and fuel hauling the vac, and savings on the amount of drilling fluids used.The productivity of the drill goes up.

Vermeer:Savings vary by job depending on the distance and difficulty of getting water, labor costs to get water to the job site and cost of hauling mud. Other variables are the type of soil, additive costs and whether mud can be processed at required rates. Disposing of high-cost additives instead of reusing fluids is a big factor in the overall cost of a project.

Can you provide brief examples of one or two recent projects with this size equipment that documented the cost savings and other benefits of recycling?

American Augers: On a recent 8-inch pipeline project, the right-of-way was very tight and the number of equipment on site needed to be reduced. The fluid cleaner being compact and productive, allowed the contractor to run continuously without having units in and out hauling fluid away.

Another pipeline project installing 16-inch steel pipe was in an environmentally sensitive area. Both mud motor and reaming passes required approximately 200 gpm flow rates. Once again, it was not feasible to operate any other way than recycling the drilling fluid.

Ditch Witch:Sonoma Underground Services switched to our recycler to reduce its mud-related costs. By recycling drilling fluid, the company reduced the amount of water and mud needed on the job site and eliminated daily vacuuming. On the most water-consuming day, the operators began with 2,000 gallons of mud and ended with 1,750, gaining three hours of drilling time by eliminating disposal runs and saving close to $2,000 for the day.

On another project, MasTec used recycling on a FTTH project. The company saved up to $100,000 per month throughout the length of the project from increased production and savings of drill fluid and disposal.

Elgin: Due to confidentiality we provide our customers, it would not be appropriate to comment on the specific savings achieved.However, Elgin can safely indicate that it has sold more than two dozen mud systems in the last two years to customers that were utilizing 40,000-pound pullback drills. Each of these customers identified a need to reduce operating expenses and lower their disposal costs.

Thunder:In Ohio, a contractor was not using a mud recycler and he was running three vacs to keep his 36,000-pound rig drilling. At some point during the day his rig would be down waiting on water or a vac, and every day his drill crew was idle 30 percent of the time.He introduced our recycler and began saving $2,000 per day. The rig went from 70 percent utilization to 95 percent utilization. Plus, mud pumps last longer.

American Augers:Yes, current margins in the industry will force contractors to employ fluid recycling. Fluid containment and reducing risk of frac outs is paramount. Increasing annular flow to increase velocities to better clean the hole is necessary, and that is made possible by utilizing a fluid cleaning system.

Ditch Witch: Yes. As city restrictions on waste disposal get tighter, contractors will be forced to find other solutions, such as recycling, for HDD job sites.

Elgin: In today’s urban areas, environmental concerns regarding ground contamination of mud pits plays a major factor. Communities and businesses are taking on an increased role in maintaining the environment around them. The use of a mud reclaimer promotes a leave-no-trace ideal when drilling operations are complete.

Thunder: In time it will become the norm. Mud recyclers pay for themselves rather quickly and it goes a long way on increasing margins. In the HDD market now we are seeing it work its way down into the smaller rigs. Five years from now they will become the norm, not just to increase contractor margins but environmental regulations will also drive it.

Vermeer:We expect to see an increased demand for reclaimers. It still is unclear if contractors will use individual reclaimers to support each drill or, if they will purchase a larger reclaimer and position it in a centrally located area to support multiple job sites. We’ve seen a few customers testing this business model.

Ditch Witch:This already is gradually happening. It will be a natural progression for companies to develop a product line to fit all drilling units in the marketplace. The market always is adapting to meet customer demands. We take customer feedback seriously and look for ways to improve their production times, ROI and save costs long term.

Elgin:Over the past several years, there have been new companies enter the reclaimers market. With the projected increase in HDD drilling activities, we expect to see more companies enter the market. In addition, there are companies which manufacture similar equipment for the oil and gas industry entering the HDD arena due to the current drop in that market.