3000 hp mud pump manufacturers free sample

The GD 3000 is a heavy duty frac pump designed to operate at higher pressures for longer periods of time. Its compact design and 11” stroke results in less fatigue cycles and extended consumable life. With a legacy of 40+ years, this high-performance pump is durable, strong, and time proven.

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.

Black gold is truly the best description to sum up the value of oil. One of the most important contributors to change and industrialization, it drives the wheels of progress. ShalePumps is headquartered in Houston, the global oil capital. Headed by experts, it has a vision to support the industry with superior completion equipment. Frac operators, drilling contractors and well service companies source rely on ShalePumps for superior quality.

The key personnel of ShalePumps have a combined experience of more than a hundred years. This experience is reflected in the quality of our equipment. The fracking pumps, components and all services are much sought after for reliability and long life. This is because of the processes we follow. The design, materials, precision engineering and expertise contribute to an advanced assembly line.

After many years of thought and conscientious engineering, the team at ShalePumps is proud to add the Q5K™ 5000 HP Frac Pump to their list of many product offerings. Perfectly capable and suited for the next generation of hydraulic fracking market demands and technology. The Q5K is the only frac pump that has been designed and developed from the ground up to be capable of accepting true 5000 HP in a continuous duty frac application.

ShalePumps has consistently delivered high quality completion equipment to all stakeholders. The mission is to develop faster, rugged and efficient equipment to help the Oil and Exploration Industry. The vision is to continue leading the race with the best quality in completion equipment.

The mud pumps market size is expected to grow at a significant rate during the forecast period. A mud pump is a large, high-pressure (up to 7500 psi), single-acting triplex reciprocating pump used to circulate mud in a well at a specific flow rate (between 100 and 1300 gallons per minute). Instead of a triplex reciprocating pump, a double-acting two-cylinder reciprocating pump is occasionally utilized as a mud pump. Typically, a rig operator keeps two or three mud pumps on hand, one of which is active and the others on standby in case of an emergency. Mud is gathered up with the use of mud pumps, which use suction to circulate the mud from the wellbore to the surface during the drilling process.

Increased demand for directional and horizontal drilling, higher pressure handling capabilities, and some new oil discoveries are the main drivers of this market"s growth. Mud pumps are specialized pumps that are used to transport and circulate drilling fluids and other related fluids in a variety of industries, including mining and onshore and offshore oil and gas. The global energy demand is boosting the market for mud pumps. However, high drilling costs, environmental concerns, and shifting government energy and power laws may stymie industry growth.

Innovation in technology is the key for further growth for example, MTeq uses Energy Recovery’s Pressure exchanger technology in the drilling industry, as the ultimate engineered solution to increase productivity and reduce operating costs in pumping process by rerouting rough fluids away from high-pressure pumps, which helps reduce the cost of maintenance for operators.

The major key player in global mud pumps market are Flowserve (U.S.), Grundfos (Denmark), Halliburton (U.S.), Sulzer (Switzerland), KSB Group (Germany), Ebara Corporation (Japan), Weir Group (U.K), and SRS Crisafulli, Inc (U.S.). Tsurumi Pump (Japan), Shijiazhuang Industrial Pump Factory Co. Ltd (China), Excellence Pump Industry Co.Ltd (China), Kirloskar Ebara Pumps Limited (India), Xylem Inc (U.S.), and Goulds Pumps (U.S.) are among others.

In the drilling business, MTeq uses Energy Recovery"s Pressure exchanger technology as the ultimate engineering solution to boost productivity and lower operating costs in the pumping process by rerouting abrasive fluids away from high-pressure pumps, which helps operators save money on maintenance. The latest trend reveals that regulatory agencies are persuading manufacturers and consumers to choose electric mud pumps over fuel engine mud pumps to reduce the environmental impact of fuel engine mud pumps.

The global mud pumps market is segmented on the basis of type (duplex pump, triplex pump, and others), component (fluid end and power end), application (oil & gas industry and building industry), and Region (North America, Europe, Asia Pacific, and Rest of the World).

Based on type, mud pumps can be segmented as duplex and triplex pumps. Triplex pumps are expected to progress because of the ~30.0% lesser weight than duplex pumps offering similar efficiency. The pump transfers the fluids with the help of mechanical movements.

Based on application, mud pumps market can be segmented as oil & gas industry and building industry. As oil and gas fields going mature, operators must drill wells with large offset, high laterals, widening their applicability by using mud motors, and high-pressure pumps. To fulfill the demand drilling companies increase their mud pumping installation capacity, with higher flexibility. For instance, LEWCO has developed W-3000 mud pump model for oil drilling, which can handle power up to 3000 HP.

Based on region, North America is predominant because of tight oil and shale gas sources, followed by Asia-Pacific due to the increased number of wells in the regions, especially in countries such as China and India due to the rapid urbanization and industrialization. Authorities in countries such as India, China are working on enhancing their production capacities for reducing the import bills, which ultimately help in the growth of mud pumps market.

This market is broadly driven by oil and gas industry as mud pumps are used to move massive amount of sludge and mud at the time of drilling. Countries such as China, Russia, Saudi Arabia, and the U.S. have the largest number of oil wells. The demand for mud pumps will increase with the number of oil wells, across the globe.

Drilling of deep HPHT wells in Kuwait requires both local and international drilling contractors to adhere strictly to overall required capacities of equipment for safely and efficiently drilling Jurassic and deeper exploratory prospects from depths of 15,000 ft to more than 22,000 ft TVD. This requires use of 3,000-hp rigs due to heavy casing hookloads for the 24-in. and 18 5/8-in. casings, high mud weights at relatively deep depths in 16-in. and 12 ¼-in. hole sections, and fairly high torques throughout the well. Likewise, mud volumes in these wells require adequate capacities and processing capabilities for the larger hole sections, especially when dealing with 19.5-ppg mud systems with a solids content of around 45% in the 12 ¼-in. hole section at 14,000 ft.

Typical casing loads of 1.3 MM lbs occur during lowering of the 18 5/8-in. intermediate casing, maximum flow rates of 1,200 to 900 gpm (depending on mud weight) with surface pumping pressures greater than 4,500 psi are seen in the drilling of the 16-in. hole section utilizing PDC bits in conjunction with performance type mud motors, and on bottom drilling torques of over 20,000 ft-lbs occur in the drilling of the 28-in. hole section for these wells.

In addition to the basic load requirements in the present Jurassic and Khuff well designs, possible future well design for exploratory HPHT gas wells over 25,000 ft deep dictates that use of even more pumping horsepower as well as semi-automated control system to allow the smoothest transfer of surface parameters to the bit is recommended. Offset data from the Khuff well tended to justify the requirement for more power and capacity if the target depth of 25,000 ft is to be met, and this was a key driver for designing a state-of-the-art rig.

Even more importantly, upgrading or building new 3,000-hp rigs to reduce overall nonproductive time (NPT) and related unscheduled events was an achievable goal that KOC began pursuing in 2001. A prime example of NPT operations improvement can be seen in the reduced instances of stuck pipe by utilization of the top drive to reduce the critical time delay from when the pipe initially sticks to when torque can be applied to free it. Another example is picking up drill pipe offline, using either the iron roughneck or rotating mouse hole, as well as the decreased connection time overall while drilling with stands instead of single joints of drill pipe.

Above all, safety was given the utmost consideration when looking at an upgrade or building of these 3,000-hp rigs. An example of equipment used to reduce risk of repetitive motion injuries can be seen in the iron roughneck and automatic slips used in tripping operations. Use of these devices, from a safety perspective, to reduce the risk of predominant repetitive motion type injuries to the lower back and fingers has been taken into account as a safe working rig environment and has proven to be a more productive rig environment.

Partly as a result of the successes from the earlier rig upgrades, KOC began pursuing a newbuild 3,000-hp rig in mid-2002. Kuwait Drilling Company was awarded the contract, and newbuild KDC Rig 15 was built during 2003 and commissioned in April 2004 as the first Kuwait contractor-owned advanced 3,000-hp drilling rig. This rig has proven to be an asset to deep-drilling strategy and continues to deliver ongoing improvements in performance.

With the anticipation of even deeper exploratory prospects to 25,000 ft in the not-too-distant KOC future, and with the successes of rigs KDC-15 and KSF 24, a deep-drilling contract strategy was developed and presented to management in 2003 to build an even more sophisticated semi-automated 3,000-hp drilling rig for Kuwait.

Item 4 was viewed as key to Kuwait’s future success in building and maintaining a localized 3,000-hp deep-drilling fleet capable of competing in any world market, and this idea was combined with Item 3 to help secure approvals to pursue a single-source local contract for a newbuild state-of-the-art 3,000-hp rig, which offered the following technical advances:

Contracting strategy also involved a detailed justification for the increased dayrate that a proposed rig of this nature would require to be commercially acceptable to both KOC and the contractor, Hamad Al Hamad and Partners (HAH). Therefore, each upgraded component would have to be shown to have a value added benefit over its respective cost increase to the dayrate. This cost comparison was performed using the presently contracted 3,000-hp rig KSF 24 as the reference base rig for dayrate.

In early 2004, meetings were held within the KOC Deep Drilling Team to formulate a strategy to work with the drilling contractor to obtain the best-value equipment for the proposed rig. The criteria included looking at such things as past lessons learned with respect to KDC Rig 15 and KSF Rig 24, adaptability of the equipment with respect to Kuwait’s environment (hot weather and sand), interchangeability of equipment with other 3,000-hp rigs in Kuwait, and detailed technical specifications of the equipment.

Meetings with several rig-building companies were held with both KOC and HAH in attendance to discuss technical details of equipment specifications. Likewise, meetings with mud solids processing companies, BOP companies and drill pipe manufacturers were held to compare specifications. Basically, the tender document from KOC to HAH reflected choices of technically superior equipment similar to a pre-qualification, from which competitive bidding was used to get to the final product.

3,000-hp drawworks – The requirement for enough drawworks to handle the 18 5/8-in. casing loads in a smooth manner led to studying the use of AC versus DC power. Although AC power has become increasingly popular with drawworks and top drive systems, it was ultimately decided in 2003 to continue with DC power in the drawworks, mainly due to familiarity of the same with the present local electricians and mechanics.

Improvements concerning “on-bottom” rate of penetration (ROP) utilizing performance mud motors and PDC bits were also an important item discussed in the meetings. Semi-automated driller (electronic driller) was a feasible way to improve ROP. Use of the pump pressure differential feedback created by on-bottom motor torque as the primary ROP control has been shown to be most effective in both directional and performance type mud motor drilling. This is especially true with slip-stick phenomena where ROP is sacrificed due to manually attempting to control WOB.

The use of a joystick disk brake system to allow proportional control was also agreed upon as the way to better control block speed, especially while running heavy drilling and liner strings with respect to control of surge pressures. As shown in top graph above, mud weights of 19.5 ppg and higher are anticipated in the Gotnia salt section with pore pressure/frac gradient extremely close, and lost-circulation problems, which usually require over a week to cure with associated concerns of well control.

The possibility of drilling a very deep 25,000-ft exploratory gas well in Kuwait required a rig that could deliver more hydraulics in hole sizes even bigger than currently planned. Likewise, future deep directional delineation or development holes targeting intersection of vertical fractures in the Najmah/Sargelu formations required more than 5,000-psi surface pumping pressure to effectively drill with mud motors. For this reason, a comparison was made between 1,700-hp and 2,200-hp mud pumps used in conjunction with drill pipe sizes bigger than 5 in. As the figure to the right indicates, hydraulics availability increased dramatically with the use of 2,200-hp pumps with the added benefits of being able to run the pumps at lower speeds thus reducing wear and tear.

Also, if pump liner change-out was required due to wear and tear in the larger hole sections, the ability to continue drilling at optimum pump rate will be realized with two 2,200-hp pumps. With the 1,700-hp pumps in larger hole sections, the flow rate from two pumps must be restricted while working on the third mud pump.

A KOC Deep Drilling Mud System Workshop was held in early 2004 with an IOC mud consultant to gain insight as to solids control requirements and discuss various solutions for the newbuild rig. The consensus was for high-speed shakers with decanting centrifuges over traditional hydrocyclone equipment.

Discussions with several solids control companies confirmed this consensus. The number of shakers required for the largest hole sections was thoroughly researched, and consensus was to use four high-speed shale shakers for worst-case scenario in 28-in. hole section at 1,500 gpm. This was balanced with the realization of sizing the sand traps to the shakers and downstream plumbing troughs plus feed lines to take into account gas in the mud and other factors. A multi-flow diverter was also proposed to evenly distribute the mud returns from the flowline to each shaker to prevent overloading one or more shakers.

The solids control companies as well as mud companies were invited to visit a deep-drilling rig in Kuwait to gain insight as to what was unique about the fluids systems on these rigs and discuss what could be done to improve the capacity and handling requirements. Reducing the plumbing or dead volume within the pits and optimizing placement of processing equipment within the return flow streams was given top priority.

Reserve mud capacity was also discussed, especially with the requirement to switch from water-based mud to oil-based mud in the 16-in. hole section and problematic mud losses in the 16-in. and 12 ¼-in. hole sections. Agreement was to have at least 3,000 bbls of reserve capacity for the system for worst-case scenario, with a total mud capacity of 4,500 bbls.

Finally, safety on the mud pits and around the solids processing equipment was detailed with such items as double grating (false upper deck) for reduction of trip hazards, mist system for cooling the people working on these pits during the hot Kuwait summers, and roofs over the pits for the same reason, included in the design. These were again balanced with issues such as weight/space limitations on rig moves, access to valves below the upper deck and safety concerns, plus safety glass fogging with the mist system in place.

Another important safety item with respect to the mud pits, especially with the use of flammable oil-based mud systems, was the agreement to install a dedicated foam deluge system on the mud pits to snuff out any fire break-out.

In conjunction with the bigger pump design proposed, larger drill pipe was used to justify the anticipated hydraulics improvement in drilling. Especially for deeper deviated wells, the use of 5 ½-in. and 4-in. drill pipes has been proven to provide better hole cleaning and improved ROP via increased bit hydraulics. The use of premium high torque connections was also seen as critical to reduce NPT due to differential sticking by being able to apply more downhole torque to overcome sticking force. The bigger pipe sizes, although more costly, have proven themselves time and time again with respect to getting the hole drilled through problematic sections.

On the other 3,000-hp deep drilling rigs in Kuwait, two separately sized BOPs are utilized in the drilling of the two different sized higher pressure sections of the well. Below the 18 5/8-in. intermediate casing, a 21 ¼-in. 10M BOP stack is utilized to allow drilling 16-in. or 17-in. hole section and passage of the 13 ½-in. casing string. This has consisted of two each 10M rams with a 5M annular on top. There have been wells drilled in Kuwait that have shown the requirement for a three ram stack, especially with mud losses and kicks in the same 16-in. hole section. This is difficult in the present 3,000-hp rig setup due somewhat to height restrictions as well as winching capacity of the BOP hoists beneath the substructure. The 12 ¼-in. hole section through the Gotnia utilizes a 13 5/8-in. BOP consisting of four sets of rams and an annular.

HAH Rig 124 design discussions also centered on several items based on past experiences within Kuwait Deep Drilling. The substructure was a sling shot type design with a cantilevered type mast, considered the most weight- and cost-effective for the high floor requirements given the BOP stack and HPHT wellhead stack-up. This type design allows for the ability to rig-up and rig-down with lower-capacity requirements and can be split up into easily manageable movable components for the rig move, an important consideration in the desert environment in Kuwait.

One feature on this rig, which is not on the other 3,000-hp rigs, is the addition of a sixth 1,450-hp engine. This provides a total available horsepower of 8,750, which gives increased flexibility of operation.

The doghouse on the rig floor was twice the normal size for 3,000-hp land rigs in Kuwait. This doghouse was air conditioned by large roof units and can comfortably accommodate the entire drilling crew for safety meetings prior to critical jobs where proper noise level is essential to hear the details. The driller’s console was chosen similar to those seen on deepwater drillships, with voice-activated microphone to communicate with the rig floor.

Once the design and tender were finalized, the construction of HAH 124 began in earnest in mid-2004 under the direction of National Oilwell in Edmonton, Alberta, Canada. While the substructure, derrick, power train, SCR, semi-automatic controls and mud system were being built Edmonton, the top drive system was being constructed in Norway, and the 18 ¾-in. 15K BOPs were being built in France.

There were some issues concerning pre-commissioning with such items as full-load testing of the mud pumps within the National facility due to safety regulations, but most of these were discussed and resolved in daily meetings. The rig was impressive in terms of size, power and pumping capacity with the big question the mating and operation of the top drive.

Commissioning of HAH 124 was completed in October 2005, and the first well spudded on 10 October 2005. The initial well was a vertical exploratory Jurassic test with moderate difficulty in the high-pressure sections of the wellbore. The well was successfully drilled to a depth of 14,260 ft in 152 days and made an exploratory discovery in the Marrat formation. The well timing was reasonable compared with the initial well that KDC Rig 15 drilled in 2004, especially considering that it was the first deep HPHT well ever for HAH using a new high-tech rig with new drilling crews.

In all, performance of the rig equipment shows indication of being top-class in the 3,000-hp field once the various issues with electronic connections, software for the automatic drilling function computers, and final sensitivity between the electric system and TDS are fine-tuned.

The mud system is performing as planned, and solids control is not an issue with the high-speed linear shaker system. Some adjustments were made in plumbing to prevent aeration to the drilling mud and cavitation to mud pumps with suction valves too close to discharge in the pits.

8. The 2,200-hp mud pumps have not been put to the full test with 7,500-psi rating but are proving themselves as one liner size is possible for the entire hole (if desirable), and drilling the 28-in. hole has not been adversely affected due to liner change-out since the same gpm can be use with two mud pumps.

This article was adapted from “Kuwait Oil Company’s Latest Semi-Automated Deep Drilling Rig — HAH Rig 124, the Middle East’s Most Modern 3,000-hp Land Rig” (SPE/IADC 103943), presented at the IADC/SPE Asia Pacific Drilling Technology Conference and Exhibition held in Bangkok, Thailand, 13–15 November 2006.