500 gpm mud pump free sample

Single Acting Triplex pumps come with three cylinders and are commonly used for various applications requiring low to medium flow rates including mud pumping, cement pumping, salt water disposal, descaling, high pressure pumping, Frac pumping and pipeline systems for the Oil & Gas, Agriculture, Mining, Municipal and Manufacturing sectors. We have new, used and rebuilt API 674 triplex pumps of all leading manufacturers like Union, Gaso, Emsco, Apex and Wheatley.

For drilling companies with the need to pump slurries with bentonite, concrete, and other thick mud, Elepump triplex, high pressure piston mud pumps are the ideal choice for long life and minimal maintenance.

Featuring superior construction and high quality materials, Elepump mud pumps are built to last. They require minimal maintenance, so your costs stay low so and your drilling operations stay profitable.

The KT-45 mud pump is the most compact of the whole range of Elepump pressure pumps. This small capacity pump is still mighty enough to pack a big punch, with enough flow for drilling up to HQ sizes. It is very light and very maneuverable, making it a great choice for geotechnical drilling, fly jobs or heliportable jobs. Elepump mud pumps can be configured for diesel, gas, electric and air power.

The KF-50M is the pump to choose if you want a pump you can count on to keep pumping without missing a beat. This powerful pump is a standard size and can handle all slurries including bentonite, concrete and more. With its stainless steel ball and seat style valves, it is the ideal choice for pumping grit, cement, chunks of rock and other hard material, without the worry of damage to fragile parts. Elepump mud pumps can be configured for diesel, gas, electric and air power.

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.

However, the electrical and motor cooling requirements are certainly different with voltage drop to the motor and various other factors becoming much more important. In Part 2 of this three-part series on the design of a submersible pump we will design our pump end using the hydraulic design data to fit the same sample application we previously used for a vertical turbine pump.

Using our example installation in previous columns of The Water Works, we have successfully designed a sample water pumping installation for a vertical turbine pump with the following conditions:

Now that we have completed the determination of the required pump capacities and operating head, the first step in actually selecting a submersible pump end is to estimate the target horsepower required for the design conditions. From Part 1 (WWJ, January 2017):

From the above brake horsepower (BHP) estimates, it is apparent there will be a wide disparity of required horsepower (almost 30 BHP) between the two operating points. Generally, an application that requires two operating points so far apart requires strong consideration of either using a variable frequency drive (VFD) to use the affinity laws to lower the pump and motor speed for the alternate condition, an inline control valve to regulate outlet pressure and pump discharge, or a pump with an extremely flat head-capacity (H-Q) curve.

In our example, the use of a VFD has previously been determined to be the most cost effective solution, although an inline control valve could also have been used. However, it is highly unlikely the desired horsepower of 14.5 BHP at the alternate COS would have been met as the majority of submersible units have steep operating curves, owing to multiple stages plus the pump speed of 3450 RPM.

The final option, use of a flat curve pump, would also be unlikely as a preferred choice. Again, this is due to the pump’s rotation speed and number of pump stages required, except for the possible use of a 10-inch or 12-inch-diameter pump, which would require fewer stages than a smaller unit.

Although the hydraulic design is primarily vested in the pump’s capacity and head, the bowl diameter is also a critical factor. With a submersible pump, the bowl diameter is generally dictated by two primary conditions: the required pumping rate needed (in gallons per minute) and the limiting diameter of the well casing or wet well the bowl will be placed into (the maximum bowl outer diameter [O.D.]).

The maximum rated capacity for each bowl diameter and speed are based on the typically highest BEP from various manufacturers, while the minimum flow for each bowl diameter and 3600 RPM speed represents an approximate maximum pump and motor speed reduction of 40% from the practical BEP at the lowest rated flow rate for each diameter and speed.

This would approximate correction of the performance of a submersible pump and motor when used on a VFD or when used with a control valve to maintain a minimum motor speed of 36 hertz (~2100 RPM) to maintain proper motor cooling and bearing lubrication, well above the manufacturer’s typical minimum of 30 hertz (~1750 RPM).

Vertical turbine pumps (VTPs) do not generally operate with the same flow range limitations as submersible pumps and motors. Therefore, the range of allowable flow rates with a VTP is often greater than that with a comparable submersible unit. The vast majority of 6-inch and most 8-inch-diameter submersible pump motors below 100 HP operate at a two-pole speed, or 3600 RPM. Therefore, this example pump selection should also be conducted using that same speed.

Given the knowledge of the primary and secondary (alternate) design capacities (500 GPM and 156 GPM) and the well diameter (12 inches) creates a fairly easy determination of the bowl diameter. From Table 1 it is apparent either a 6-, 7-, 8-, 9-, or even a 10-inch-diameter bowl assembly at 3450 RPM will likely work for this application with a 6-inch-diameter bowl at the extreme end of its practical and efficient flow range for 500 GPM.

The minimum recommended flow for a 10-inch-diameter bowl is also above the BEP for the low flow of 156 GPM and will most likely only require two or three stages to produce the needed head, which will result in a flatter total head curve. This is generally not as desirable for use with a VFD and compromises the pump efficiency and optimum clearance inside a 12-inch-diameter well by using a 10-inch-diameter bowl. This tends to limit the best overall selection to a 7-, 8-, or 9-inch-diameter bowl.

Building a unit through an analysis of a per-stage performance of individual stages (Figure 1), as with a VTP, and then dividing the total head required by the head per stage to determine the number of stages and horsepower needed to create an assembled pump.

Evaluating a manufacturer or supplier’s preselected and preassembled units and then selecting a pump that comes closest to the required flow and head (Figure 2).

When using a single-stage performance curve to evaluate a potential submersible pump, always be cognizant multi-stage pumps almost always display a higher efficiency at the same operating point, impeller trim, and capacity than a single-stage unit, so an efficiency correction may be needed.

For example, the single-stage bowl assembly shown in Figure 1 is the same bowl assembly with the same impeller trim (4.875 inches) and nominal speed (3600 RPM) as the 4-stage bowl assembly in Figure 2. However, the efficiency is three points higher (77.9% vs. 74.9%) for the 4-stage bowl. This relationship holds true for both VTPs and submersible pumps.

Usually, if any correction is required for multiple stages, this is generally indicated on the pump curve itself. In many cases this type of unit is further classified by the bowl’s BEP design flow and/or motor horsepower, especially when stainless steel impellers are used. Stainless steel impellers are not as easy to trim. Therefore, knowledge of the well diameter and the approximate required horsepower will often provide a shortcut to a pump selection.

For our example, 43.77 of estimated HP translates to the probable need for a 50 HP motor. This could provide the information required to select a preassembled submersible pump with a rating of 500 GPM and a 50 HP motor. This procedure is often shown on pump selection data sheets or curves with nomenclature to indicate the bowl diameter first, followed by the pump’s rated capacity or relative rating, the number of stages, or the motor horsepower.

For example, a specific manufacturer may use a model number such as 7TLC, 7CHE, 8RJO, or 8M23. The first number (7 or 8) usually signifies the bowl’s outer (nominal) diameter. The second and/or third letter (TL, CH, RJ, or M) may designate the manufacturer’s bowl capacity or head rating, such as L for low, M for medium, or H for high. The final letter or number often describes whether the impeller is an open (using an O) or enclosed (E or C) impeller. The use of a specific number (as in 23 for 230 GPM) may indicate the bowl’s rated capacity at its BEP. In some cases, “S” is inserted into the model number to signify the unit is a submersible pump.

Finally, the number of stages and the horsepower rating is often applied to the end or sometimes as part of the model number. A complete model number for an assembled submersible pump unit, for example, may be an 8SHHE-7-100, to signify an 8-inch nominal bowl diameter submersible pump, with a high capacity and head rated enclosed impeller, equipped with seven stages, and a 100 HP rated horsepower motor. In all cases, you should verify the breakdown of a specific model number with the manufacturer as many pumps do not follow these criteria.

Occasionally, I receive a request from someone to design a submersible pump using a semi-open impeller. Although I have used this type of impeller numerous times on VTPs, I do not routinely use them on subs for several reasons.

First, since they are locked onto the pump shaft and often situated several hundred feet down a well, they cannot be adjusted to regain performance or efficiency without pulling from the well. Secondly, although semi-open impellers are often a few points higher in efficiency, they usually display more axial and radial thrust than enclosed impellers, making them undesirable for use on the lower thrust rated submersible motor.

Finally, designing an application using semi-open impellers is at best an estimation since the pump’s performance and horsepower draw is primarily a factor of the impeller’s proper running clearance from the bowl. Any variation to this clearance from the manufacturer’s published curve data will adversely impact the performance by underperforming, overperforming, over possibly overloading the motor.

The seven submersible pump ends in Table 2 represent only a fraction of those available for the primary conditions of service. However, these potential selections nonetheless represent a cross-section of the typical bowl diameters and number of stages to consider for this application.

The final determination of the selected pump must weigh several factors. Some are universal while others may be site or locality specific. And since it is fairly obvious all the selected bowls will fit inside the 12-inch well casing, this initial factor can be ignored.

The next selection criteria I generally examine is the BHP requirement and pump efficiency at the specific operating condition that will be subject to the highest use. In our example, even though the bowl assembly has been designed for a primary design condition of 500 GPM, in actuality the pump will usually operate somewhere between the two design points with the alternate COS (156 GPM) in service much more than the primary COS. The three units with the lowest BHP requirement at the alternate design condition in the table are pumps R-1, F-1, and M-1.

My next criteria, particularly since the efficiency at the primary COS is close for all units, is to evaluate the operating speed at the alternate COS. This is more important to the success of the installation than one might imagine, particularly when a VFD will be used for motor control. Most motor (and some pump) manufacturers dictate the motor speed shall not fall below 50% speed (30 hertz, or ~1750 RPM). This is to provide adequate bearing lubrication in the motor as well as maintain enough velocity past the motor for cooling. As previously stated, when feasible, I prefer to design an installation so the pump and motor will not exhibit a minimum speed below 40% of the motor’s rated speed or about 2050-2100 RPM.

Tempered with this fact, however, is the knowledge the motor must be permitted to operate at a low enough speed to facilitate a reasonable VFD operating range and proper control settings. Experience has taught me this factor works best for a multi-stage submersible unit when using a shutdown speed between 70%-90% of full load (FL) speed—a range of 75%-85% of FL motor shutdown motor speed often works the best. Obviously, all these criteria must be ascertained after a full evaluation of the pump curve (flat vs. steep) and HP at the minimum speed.

From an examination of the pumps in Table 2, it is evident all the sample pumps fulfill these desires, with pumps G-1, R-1, L-1, G-2, and F-1 fitting the best at the reduced flow of 156 GPM along with a reduced speed range between 75%-85% of FL speed.

Finally, when cost is a factor, weighing the individual options for the lowest initial and operating cost is often conducted. For this final evaluation, pumps R-1 and F-1 were both good choices, although my ultimate selection was for pump R-1 as the runout capacity (Q = 575 GPM) was lower than F-1. The BEP for the R-1 pump was also slightly to the left of the primary design point which helps to retain higher operating efficiencies at lower speeds, plus the pump was represented locally and replacement parts were more readily available.

The runout capacity of ~575 GPM is an important selection criteria for this example to avoid excessive well overdraft, especially since flows above 500 GPM will be served from a supplementary source. See Figure 3 and Figure 4 for full speed and variable speed curves for pump R-1, a 7-inch × 3-stage bowl assembly.

Now that the pump end has been selected, we generally examine any special construction or metallurgy required for the pump end. If sand or abrasives were a concern, bowl wear rings might be warranted. If the bowl’s upper stages were exposed to excessive high pressures, O-rings or gaskets may be indicated to prevent inter-stage leakage. Since most 6- and 8-inch bowl assemblies are constructed using threaded construction between stages, this would usually not be a concern unless a 10-inch or larger diameter bowl was selected and only then with pressures in excess of the manufacturer’s pressure rating.

Next, static or dynamic balancing of the impellers should be considered. On one side, this pump uses a stock pump with only three stages and fairly small diameter (4.875 inches) impellers, plus we plan to use a 7-inch-diameter bowl inside a 12-inch well casing, so balancing of the impellers is probably not needed. However, the added cost for balancing just three impellers does not generally represent a huge added cost to the bowl assembly. So if there is any concern regarding the well’s alignment, this may be a desirable option.

Finally, many firms feel all larger capacity units should be factory tested to verify performance. Although I often require factory testing for expensive or large or deep well pumping units, submersible and vertical turbine, I rarely require or recommend factory testing on smaller (<10 inches) wet ends for various reasons.

Besides the added cost (which can actually cost more than the pump itself) and the associated time delay, experience has shown conducting factory testing on smaller diameter, multi-stage pumps does not generally result in any true power savings or added assurance to the owner, especially since the selection curves from the majority of pump manufacturers have repeatedly been shown to be accurate for capacity, head, and horsepower. Also note the majority of submersible pump models between 6 and 12 inches have been tested by their manufacturer during development.

Remember, any of the above concerns will usually result in not only added cost but a delay in constructing and shipping the unit, so consider these carefully. For our example, none of these concerns are present, so the final factor would be the pump setting and drop pipe size.

The riser drop pipe and check valve sizes depend on various factors: the desired minimum and maximum uphole velocities (critical when using a VFD); friction losses; pipe cost; well and drop cable clearance; and adequate space for any additional elements in the well/pipe annulus—sounding tubes, well or water level measurement devices, future chemical treatments. For our example installation, the pump will operate within a range of 156 GPM minimum, up to 500 GPM maximum.

Figure 5b shows flow ranges for various pipe sizes, and indicates a desired flow range of 160-700 GPM for 5-inch drop pipe. These values will maintain a minimum uphole velocity of ~2.5 feet per second (FPS) at 160 GPM to transfer any heavier solids from the well to prevent settlement onto the pump, with a maximum uphole velocity of 10 FPS at 700 GPM as an upper economic sizing. Figure 5b shows friction loss for new 5-inch steel drop pipe at 500 GPM is 4.16 feet per 100 feet of pipe with a velocity of 8.02 FPS.

Figure 6 and Figure 7 are included for those who use either PVC or flexible hose as drop pipe. We will finalize the friction loss calculation upon determining the pump setting.

The desired pump setting is truly a case-by-case determination that must be performed with full knowledge of the well casing diameter and depth, well screen upper termination depth, the reliable pumping water level (PWL), sand or abrasives pumping potential, and a reserve (safety) factor for unusual well drawdown or seasonal drafts.

Typically, I like to plan deep well installations to maintain a minimum of 10 feet of submergence over the top of the pump, not the suction or inlet, at the maximum projected pump capacity. For our example, this translates to a minimum pump setting of 110 feet (~100 feet PWL at 515 GPM + 10 feet of submergence).

In cases such as this example, when more depth is available I prefer to set the pump at least 20 feet deeper in the well to compensate for any future well decline or seasonal shifts. So, I will plan for 150 feet of drop pipe. This results in the use of seven lengths (147 feet at 21 feet per length) plus a 3-foot length for the upper well seal to provide an easy-to-remember figure for future reference.

The total friction loss would therefore be 4.16 feet/c × 1.5 (for 150 feet) = 6.24 feet + 1.60 feet for the riser check valve and miscellaneous loss = 7.84 feet total, well under our original estimate of 10 feet. The riser check valve should be placed between 5 to 20 feet above the pump, with 10 to 11 feet (the first full 21-foot joint above the pump cut and threaded in half), my usual location. This places the check valve at a sufficient distance above the pump to allow for the vertical movement of any entrapped air or vapor from the pump to the check valve and avoid air locking of the pump. It also provides two shorter pipe lengths to enable easy installation of the pump/motor and the well seal.

This concludes Part 2 of the three-part series on sizing of submersible pumps for municipal, industrial, and commercial water supply. In Part 3, we will conclude with a detailed discussion of sizing and installing the submersible motor and drop cable, plus some of the pitfalls and issues associated with using this type of pump and motor.

To help meet your professional needs, this column covers skills and competencies found in DACUM charts for drillers and pump installers. PI refers to the pumps chart. The letter and number immediately following is the skill on the chart covered by the column. This column covers: PIC-5, PIC-6, PIC-10, PID-4, PIE-8, PIE-9, PIE-13, PIE-14 More information on DACUM and the charts are available at www.NGWA.org/Certification and click on “Exam Information.”

(2) Pumps - Triplex W/ Forged Steel Fluid End & Quick Change Caps, 5M Pulsation Dampner, Oteco 3" Shear Relief Valve, Pressure Gauge, Mission 6 X 5 Charge Pump P/B Cat C-18 Diesel Engine, Allison CLT6061 Transmission, Fitted W/ 7" Liners, & Pistons, Master Skidded, (1) Pump No Power or Transmission. Good Condition.

All New Parts In Both Gear & Fluid End, Pump Will Have New Style Gear End, Primered & Painted Buyers Choice, Hyd. Gearbox Available. Rebuilt Condition.

Mud recycling systems were once considered optional equipment. Environmental regulations continue to become more stringent and we must all responsibly make a contribution to protect our fragile ecosystem.

Using mud recyclers are a valuable asset to drilling contractors, as well-conditioned drilling fluid can save resources, time and money by reducing the amount of water and chemicals needed by reusing your bentonite and water. This helps maintain borehole stability with consistent mud properties through the entire circulation of the fluid and you haul off mainly the drilled solids, not the entire mud returns, including the liquid.

Drillers considering a mud recycler often ask: “Where do I start?” There are factors to consider before purchasing (or renting) a mud recycler, and, just like sizing the drill rig, sizing the recycler is equally important to your success. The following are some of the questions to ask yourself before making your purchase:

These factors are important to know so that you use a recycler that is sized to clean the mud and protect the components on the rig, pump and cleaner.

As a general rule, size the recycler cleaning capacity to one and a half to two times the pumping volume (max gpm) of the triplex pump. HDD drillers normally run thicker fluids due to the low vertical height and long horizontal lengths of their bores; thicker fluid makes it more difficult for the shakers and cones to process (separate) the solids from the liquids. This is largely due to the natural coating ability of bentonite — It wants to encapsulate the solids and “hold on” to them. By upsizing the recycler, the solid particles have a second or third opportunity to process through the mud recycler for removal before going back to the rig.

Some mud recyclers provide an “onboard” mud pump that was sized specifically to the recycler. This enables the driller to use all available drill rig horsepower toward the rotation and push-pull of the drill pipe, thereby not “robbing” it for an onboard triplex pump.

When choosing a linear shaker for your mud system, look for a long runway (area of length from the front of the shaker to the end where the cuttings dump off). The longer length shaker bed allows extra time for solids to separate from the liquid, and result in drier solids leaving the mud system for disposal. You can also increase the angle of the shaker bed by five degrees to further increase the travel time of the solids.

Proper shaker screen selection enhances the results of the mud recycler, and, combined with the G-Force of the shaker, works in tandem to maximize solids dryness. In the past, shaker screens were sized by mesh size.

Identification of particle sizes from core samples taken on each drilling location provides drillers valuable information and aids in selecting screens. Drilling contractors should carry a couple of testing tools to measure the effectiveness of a of the mud recycler while drilling. These tools are: a Marsh funnel and cup, sand content kit and mud weight scales. Taking mud samples from the return pit or possum belly before the mud is processed, the underflow and overflow of the cones and the clean mud tank help monitor the effectiveness of each component of the recycler, and the driller can make component adjustments to achieve maximum efficiency.

In addition to the shale shakers, another way to size the processing capability of the mud recycler is to look at the hydrocyclone. Depending on the size of the mud recycling system, cone size will be 4, 5, 10 or 12 in. Each size cone has a micron “cut point,” and represents the size of the smallest particle the cone can “pull.” Four- and 5-in. cones have a 20-micron “cut point,” and 10- and 12-in. cones have a 74-micron “cut point.” Smaller mud systems normally have two section tanks, with a ”dirty” tank under the scalping shaker and a “clean” tank under the mud cleaner (shaker with desilting cones), while larger systems can have three section tanks with scalping, desanding and desilting.

One hydrocyclone processes liquid at a rate of 50 gpm/ 4-in. cone, 80 gpm/ 5-in. cone, and 500 gpm/ 10-in. or 12-in. cone. Some manufacturers’ volume amount for their respective cone sizes may differ than those cited herein, but these are the most common within the industry for reference purposes.

Borehole returns require transport into the recycler via a “trash” pump properly sized for the job. Different pumps are available, but the three most common are: 1) submersible, 2) semi-submersible, and 3) aboveground centrifugal with a foot valve. Totally submersible pumps are generally the smallest in size, have a flooded suction to help in priming, and though the most convenient option, are usually the most expensive. Semi-submersible trash pumps still have a flooded suction, but the drive motor is not submerged into the fluid. Semi-submersible pumps work well, but are heavier, and longer than the submersible pumps.  Another option is an above ground centrifugal pump with a foot valve, and once primed, is dependable and normally used on larger recyclers for their increased volume capacities.

If your drilling crew has never operated a mud recycler, be sure that you are provided with training and try renting a unit to make sure it is the right “fit” prior to purchase. Be familiar with the maintenance requirements of your mud system; usually the owner’s manual is sufficient, but inquire if the manufacturer offers training videos, onsite or plant training sessions and — the most important — technical support.

In an age where protection of our planet is a major concern, so should your choice of mud systems. Choose a recycler that is respectful to the environment and leaves your jobsite as clean as possible.  Do your research, talk to other drillers, decide what you need and you will be able to make the best decision for you and your company.