Mud Pump Washouts - Define, Identify, Avoid and Repair
Mud Pump Washouts - Define, Identify, Avoid and Repair
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The positive displacement mud pump is a key component of the drilling process and its lifespan and reliability are critical to a successful operation.
The fluid end is the most easily damaged part of the mud pump. The pumping process occurs within the fluid end with valves, pistons, and liners. Because these components are high-wear items, many pumps are designed to allow quick replacement of these parts.
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Due to the nature of its operation, pistons, liners, and valve assemblies will wear and are considered expendable components. There will be some corrosion and metallurgy imperfections, but the majority of pump failures can be traced back to poor maintenance, errors during the repair process, and pumping drilling fluid with excessive solids content.
What are some of the telltale signs of wear of these parts?
A few signs include cut piston rubber, discoloration, pistons that are hard to remove, scored liners, valve and seat pitting or cracks, valve inserts severely worn, cracked, or completely missing, and even drilling fluids making their way to the power end of the pump.
A washout occurs when fluid and solids enter the area behind or underneath a valve seat and erode the sealing surface.
The fluid end of a positive displacement triplex pump presents many opportunities for issues. The results of these issues in such a high-pressure system can mean expensive downtime on the pump itself and, possibly, the entire rig &#; not to mention the costly repair or replacement of the pump. To reduce severe vibration caused by the pumping process, many pumps incorporate both a suction and discharge pulsation dampener; these are connected to the suction and discharge manifolds of the fluid end. These dampeners reduce the cavitation effect on the entire pump which increases the life of everything within the pump.
RELATED: Mud Pump Maintenance
Poor maintenance &#; such as improper valve and seat installation &#; is another factor. Improper cleaning when replacing a valve seat can leave sand or debris in the valve seat area; preventing the new seat from properly forming a seal with the fluid cylinder, causing a pathway for a washout to occur. It is important to pull up on a seat firmly by hand and make sure it doesn&#;t pop out and is properly seated. The seats must be seated well, before resuming repairs. You should never reuse a valve seat if at all possible.
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The fluid end is the most easily damaged part of the mud pump. The pumping process occurs within the fluid end with valves, pistons, and liners. Because these components are high-wear items, many pumps are designed to allow quick replacement of these parts.
A washout occurs when fluid and solids enter the area behind or underneath a valve seat and erode the sealing surface. Washouts are usually caused by one of three issues: a worn or cracked valve seat, improper cleaning of the valve seat and deck which creates a poor seat seal, and excessive sand content in your drilling fluid. Worn or cracked valve seats can allow fluid to enter the area around the valve seat and seat deck, creating a wash point on the valve seat and causing it to cut into the fluid cylinder and seat deck.
Additionally, the throat (inside diameter) can begin to wash out from extended usage hours or rather quickly when the fluid solids content is excessive. When this happens it can cut all the way through the seat and into the fluid end module/seat deck. This causes excessive expense not only from a parts standpoint but also extended downtime for parts delivery and labor hours to remove and replace the fluid module. With that said, a properly operated and maintained mud recycling system is vital to not only the pump but everything the drilling fluid comes in contact with downstream.
If you spot a washout on any of the fluid end parts, you need to replace the part immediately. A washout can get much worse very quickly, leading to costly repairs.
Terry Flynn is vice president of sales and marketing at Tulsa Rig Iron.
6 Common Faults Of Directional Drilling Mud Pump
During the use of the horizontal directional rotary mud pump, various problems may occur, and these 6 types of failures are the most common.
Fault 1: The pump does not absorb water
Sometimes, during the use of the mud pump, the mud pump does not absorb water due to insufficient filling water and the inability to discharge the air in the pump. In addition, the reason why the mud pump does not absorb water is also caused by the leakage of the suction pipe and the front The gap between the liner and the impeller is too large; when this happens, after finding the cause of the phenomenon, it is necessary to take corresponding measures to solve the problem. The measures include continuing to infuse the water diversion, check the pipeline, and observe Whether there is air leakage, adjust the gap between the impeller and the front liner.
Fault 2: Low water pressure and flow rate
In addition, if the gap between the impeller and the front liner is too large (or the impeller liner is worn), it is also easy to cause the failure of the water pressure and flow rate. This is also one of the common failures of the mud pump. Adjust the gap between them (or replace the impeller and liner). In addition, the reasons for the low water pressure and flow include the air in the pump and the tightness of the clutch. The corresponding solution is to exhaust the air in the pump. Empty, adjust the clearance of the clutch friction plate.
Fault 3: Slow water supply
The slow water supply of the pump is also related to the large gap between the front liner and the impeller. In addition, the failure of the water outlet pipe to seal the air and the full emptying also cause the slow water supply failure of the pump. Therefore, it is necessary to adjust the water outlet pipe. Install the vacuum device.
Fault 4: Water pump vibration
When the pump shaft is not concentric with the diesel engine (motor), it will cause the mud pump to vibrate. Therefore, it is necessary to adjust its concentricity; in addition, the impeller imbalance and bearing damage will also cause the vibration of the water pump. If the impeller is unbalanced, it is necessary to perform a balance test on the impeller. If the bearing is damaged, only the bearing needs to be replaced.
Fault 5: The impeller journal wears quickly
The impeller is one of the most important parts of the pump product. When the high pressure water pump has low lift, misaligned packing, misalignment of the pump shaft and the back cover, etc., the wear of the impeller journal will continue to increase, so it is necessary to adjust the high pressure. The high pressure pump and packing of the mud pump head are replaced. The concentricity of the pump shaft and the back cover can be adjusted appropriately.
Fault 6: Pump wears quickly
When construction is carried out in a place with a poorer construction environment, it will be added to a place with a poorer construction environment, which will increase the wear of the pump. Therefore, it is necessary to maintain a good construction environment to cause this phenomenon The reasons for this also include the long transmission distance and long water inlet pipe, which requires adding an afterburner and shortening the length of the water inlet pipe to reduce cavitation.
There are many common faults of the mud pump, which requires careful inspection of the various parts of the mud pump before construction. Pay more attention to the three processes of startup, operation and shutdown, and operate in accordance with the prescribed procedures to reduce The probability of mud pump failure.
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