Mechanical Training Program

Mud Pump Mechanical

1
 Course Objectives
Course Objectives

• Identify different kinds of Mud Pumps specifications

• Explain the function and theory of Mud Pump operation
• State power end major components and explain function of each one
• Explain the importance of wiper seal and how to replace it
• Explain function of fluid end components
• Explain function of pulsation dampener and how to inspect and charge it
• Explain function of the safety pressure relief valve and how to inspect it
• Identify the lubrication system and its importance and effect of lubrication failure
• Explain the importance of the cooling system and how to check it
• Identify Mud Pump maintenance intervals
• Demonstrate Mud Pump measurements and how to measure it
• State most of Mud Pump common problems and explain how to fix it

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 Course Contents
Mud Pump Mechanical Course Contents

• Introduction
• Theory of Mud Pump operation
• Power End Major Components
• Fluid End Components
• Pulsation Dampener
• Safety Pressure Relief Valve (Pop off valve)
• Lubrication System
• Cooling and Flushing System
• Mud Pump Maintenance Intervals
• Mud Pump Measurements & Alignment
• Mud Pump Troubleshooting

3
Introduction

4
 Introduction
Function Of Mud Pump
Mud pump is the heart of the circulating system, providing power to move the fluid at the required pressure and volume.
Mud pumps are either duplex (two-cylinder, double acting) or triplex (three-cylinder, single acting). Triplex pumps are by
far the type most commonly used on modern rigs. It is designed to circulate drilling fluid under high pressure (up to 7,500
psi (52,000 KPa) down the drill string and back up the annulus.

•With the positive displacement design, each revolution

of the crankshaft creates a positive flow from the pump.
•The output flow from the pump is in direct relation to
the RPM of the pump.
•The bore of the liners determines the amount of liquid
handled with each stroke and revolution.
•Mud pumps can be driven by DC Motors, AC Motors or
diesel engines.
•They can be direct drive, belt or chain driven.
•The normal mud pump consists of two main sub-
assemblies, the fluid end and the power end
•A drilling rig generally has 2 or 3 mud pumps.
•Thus moving the fluid from the tank, through the drill
stem, to the bit, back up the annulus and back to tank.
5
 Introduction
General Information

• The mud pump mainly consists

of two components, power and
fluid ends.

• The power end includes the

assemblies of frame, pinion shaft,
crankshaft, crossheads etc.

• The fluid end includes the

assemblies of valves, cylinder
liner, piston, suction and
discharge manifolds and so on.

6
 Introduction
Pump Classification

Mud Pumps are positive displacement, reciprocating, triplex pumps.

This classification of mud pump implies the severe damage that could happen to the pump if the pump runs
with delivery valve closed.

Mud Composition
Working fluid of mud pumps, has an impact on pump parts. This impact would affect pump performance, down
time and overall efficiency.

Theoretically, Mud is composed of:

1.Base: Water or oil is used as a base for mud. Each of them could have an impact on pump parts. For
example, oil base is corrosive to rubbers which would affect gaskets, valves and piston heads.

2.Additives: These are chemicals which are added to the base fluid to maintain its functions as drilling fluid.
These chemicals have a negative impact on pump parts. 7
 Introduction
Mud Pumps Make & Model used in Abraj rigs

Power
Make Model SPM Rig No.
HP
National Oil Well 12-P - 160 1600 120 201 & 202

JIENENG - TF1 JF - 1600 1600 120 203 & 204

National Oil Well FD- 1600 1600 120 205 To 210

Hong Hua Petroleum HHF – 1600 1600 120 301 To 306

Hong Hua Petroleum HHF - 1000 1000 100 101&102 &104

Hong Hua Petroleum HHF - 1300 1300 120 103

National Oil Well
10-P - 130 1300 120 105

8
 Introduction

Mud Pumps FD -1600

General Specifications
1-Type 3 - cylinder Single-Action Piston
2-Pressure with 7’’ Liner psi 3,423
3-Pressure with 5 ½’’ Liner, psi 5,000
4-Volume with 7’’ Liner @ 120 SPM, ( gpm 719 ) (Liters/min 2,721)
5-Volume with 5 ½’’ Liner @ 120 SPM, ( gpm 444 ) (Liters/min1,680)
6-Nominal HP rating @ 120 SPM, ( HP 1600 ) (KW-1,193)

7-Type Gear Double Helical

8-Lubrication Pressure and splash to all moving parts

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Theory Of Operation

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 Mud Pump Operation
Theory Of Operation

11
 Introduction
Theory Of Operation

• A prime mover rotates pinion shaft (2) via drive belts.

• Power is transmitted from pinion shaft to crankshaft (1) by meshing of pinion with main gear
on crankshaft.
• The rotation of crankshaft causes angular movement of the three connecting rods (3). Each
of the three connecting rods is pinned to a crosshead (4) which moves between top and
bottom guides.
• As the crankshaft continues running, a reciprocating linear movement is achieved for
crossheads.
• Intermediate rods (5) connected to the crossheads transmit power to the piston assembly (6)
that runs inside the cylinder liner.
• The reciprocating linear movement of pistons inside liners causes pumping of fluid filling
liners.

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 Introduction
Theory Of Operation
• A charging pump is installed to feed suction manifold. Drilling fluid then flows through the
three suction modules. The flow of fluid to the liners is controlled by three suction
• Valve mechanisms, where suction valves move up against spring to permit drilling fluid to fill
up the cylinder liners to be pumped by the forward movement of pistons. When piston
pushes fluid in liners it closes suction valve, then it starts flowing into discharge module
building up pressure. When pressure in discharge module becomes higher than the
pressure in discharge manifold, discharge valves open and drilling fluid is pumped in
discharge manifold and then to delivery lines.

• When crankshaft turns one complete revolution, uniformly one pumping stroke occurs in
each cylinder, i.e. a pumping stroke every 120° of crank revolution.
• This will cause pressure fluctuations in delivery lines. In order to minimize these fluctuations
and the consequent vibrations in standpipe and mud hoses, a pulsation Nitrogen charged
dampener is used.

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Power End Major
Components

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 Major Components

Power End Major Components

• Prime Mover
• Drive
• Frame
• Pinion Shaft
• Crankshaft
• Connecting Rods
• Crossheads
• Intermediate Rods
• Lubrication System
• Wiper Seals

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 Major Components

Fluid End Major Components

• Suction Manifold

• Suction And Discharge Modules

• Suction And Discharge Valves

• Piston And Liners

• Pulsation Dampener

• Cooling And Flushing System Safety

Relief Valve

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 Power End
Power End Definition
It is the compartment of mud pump concerned with mechanical power transmission. Power end components
are responsible to transform rotation movement of prime mover into linear movement for intermediate rod.

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 Power End
Prime Mover
• Is the initial source of power that is transformed into hydraulic power in drilling fluid due to pump
operation

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 Power End
Drive
It transmits power from prime mover to the pinion shaft. It is either V-belts or chain belt.

Chain belt has higher efficiency in power transmission. However, V-belts are preferred due to
the following:
 Less noise

 Easier in maintenance and replacement

 Do not require extra lubrication system

 V-belts often show signs of damage before they fail. While chain belts might fail suddenly

Chain Drive Belt Drive 19

 Power End

Frame

• The frame is made of welded

steel plate and by stress relief
treatment to obtain good rigidity
and high strength.
• Ribbed plates are used to
strengthen the place where the
crankshaft bearing is fitted.
• The frame is furnished with the
necessary oil basin and oil way
system for cooling and lubricating
purposes.

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 Power End
Pinion Shaft
It transmits power from belt drive to crankshaft by meshing of integrated pinion with main gear on
crankshaft.
The pinion shaft is extended on both sides of the power frame to permit driving forces to be applied
to either the right hand side, left hand side or both sides.
It is mounted on two roller bearings whose type is different from a manufacturer to another.

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 Power End
Pinion Shaft Assembly

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 Power End
Crankshaft
• When it is turned by main
gear, it transmits power from
pinion shaft to connecting
rods.
• Crankshaft is mounted to the
power main frame on main
bearings whose type is
different from a manufacturer
to another.
• It is responsible to convert
rotation motion to angular
motion in the connecting
rods.

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 Power End
Crankshaft

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 Power End
Crankshaft Main Bearing Assembly

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 Power End
Connecting Rods
They transmit power from crankshaft to crossheads.
There are three connecting rods, one for each cylinder. Connecting rods are mounted to crank
shaft by connecting rod bearings, also known as eccentric bearings. Connecting rod
bearings are of straight (cylindrical) roller type.
Connecting rods move in an angular movement as a transition phase between rotation
movement and linear movement

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 Power End

Crankshaft And Connecting Rod

• The crankshaft is made of cast alloy steel

and is fitted with a gear ring, connecting
rods and bearings. The tooth form of the
gear ring is herringbone

• The big end of the connecting rods are mounted

on three eccentric straps of the crankshaft
through single row long cylindrical roller
bearings
• The small end of the connecting rods are
connected with the crosshead pin through double
row long cylindrical (Needle) roller bearing.
Connecting Rod
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 Power End
Crossheads
• The crossheads are heavily constructed,
accurately machined and fitted into
replaceable upper and lower crosshead
guides.
• Shim adjustment of the guides will permit
the maintenance of proper running
clearance and compensate for wear.
• Correct crankshaft rotation is important to
the service life of the crosshead assembly.
• The force transferred from the crankshaft
to the crosshead should be above the
horizontal center line of the crosshead
which allows the crosshead to rest in the
lower guide, and it is not being lifted to the
upper guide during pumping,

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 Power End

Crosshead Crosshead Guide

Crosshead Pin Crosshead Pin Bearing 29

 Power End
Crossheads
Crossheads movement is guided between upper and lower guides converting angular movement
of connecting rods into linear reciprocating movement.

Alignment is critical to
the proper function of
the diaphragm, true
axial movement of the
piston, and
concentricity of the
piston in the liner.

Crossheads are pinned to the connecting rods. Upon movement transmission from
connecting rod to crosshead, there is a limited angular movement in the cross head pin.
Thus, a needle type crosshead pin bearing is used. 30
 Power End
Intermediate Rod (Pony Rod)
An intermediate rod (pony rod) is connected to each crosshead. Power is transmitted from
crossheads to intermediate rods to move them in a linear reciprocating movement.
Proper installation for intermediate rods is essential for the alignment of crossheads all the way
to the piston head.

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 Power End
Wiper Seals
• They wipe intermediate rods during their
reciprocating linear movement. They protect
power end by preventing lubricating oil
from getting out and flushing water from
getting in.
• There are two groups of lip seals. One group is
to wipe lubricating oil off intermediate rods. The
other group is installed so that the lip wipes
flushing water.
• There is a drain hole in the assembly that
should be positioned in the bottom during
installation.
• Should leakage occur, replace the wiper rings
immediately and if necessary, replace the
intermediate rod.

In order to keep them in good condition, wiper seals have to be greased on daily basis. (If
available grease fitting)
Note: Over-greasing could damage the seals. 32
 Power End
Roller Bearings
Although the basic construction of the various sizes of slush pumps varies somewhat, they all have one very
important detail in common-- roller bearings. A roller bearing is a precisely built machine within itself; therefore,
careful handling is required in order to obtain the long service life and high load carrying characteristics
associated with anti- friction bearings

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 Power End
Bearings Types

Ball Bearing Roller Bearing

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 Power End
Roller Bearings

Tapered double row Spherical double row self alignment

Straight roller (Cylindrical) Needle double row

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 Power End
Roller Bearings
• None of the bearings require special adjustments. All inner and outer races are assembled by means of
very accurate fits. This accuracy is necessary; therefore, if the bearings are to be used again, the inner
and outer races and the roller assemblies of each bearing must be kept together, and re-installed
exactly as they came off.

• It is always necessary to completely replace any roller bearing that fails even though only one part of the
bearings shows damage. Since the running clearances of these bearings are extremely small,
excessive clearances, worn or grooved raceways, and any pitting or flaking of the parts is indicative of
failure and the entire bearing should be changed as soon as possible.

• All roller bearings are assembled to their shafts by means of shrink fits. For removing bearings it can be
cut off the shaft with a burning torch, but care must be taken not to damage the shaft.

• Bearings can be heated by induction heater or by oil bath, the temperature should not exceed 300°F
(148°C). Be certain that both the oil and the container are very clean. Do not leave the bearings in the
oil bath longer than three minutes.

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 Power End
Roller Bearings
• Do not heat the bearings with a torch unless it is the only possible means available. When it is necessary to
use a torch, it should be used only by an experienced welder. Hold the torch at least 6 inches away from the
bearing and keep the torch moving at all times. DO NOT OVERHEAT THEBEARING.

• Once the heated bearing is in place on the shaft, hold it in place until it cools. NEVER USE WATER OR ANY
OTHER LIQUID TO COOL A HOT BEARING. Rapid cooling will cause the surfaces of the races and rollers
to crack and the bearing will fail immediately. Never strike a roller bearing with a steel hammer. If the bearing
must be driven into position, use wood or a soft hammer and strike lightly.

• Always lubricate the shaft or housing before installing the bearing. thinned with light oil, is the best lubricant
for this purpose.

• A good recommendation is to keep records of clearance on a 6 month basis and monitor the changes in
clearances. If there is a large jump in clearances from one inspection to the other, it can indicate that
replacement is needed.

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Fluid End Components

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 Fluid End
Fluid End
It is the component which mud flows from suction manifold to discharge manifold by means of
reciprocating movement of pistons inside cylinder liners.

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 Fluid End
Fluid End
During suction, drilling fluid flows from
precharge pump to suction module (1)
through suction manifold (2). Fluid forces
suction valve (3) to open to fill up piston
liner (4). When piston (5) starts pumping, the
pumped fluid first closes suction valve when
pressure inside modules is higher than the
charging pressure. As the piston continues its
pumping movement, pressure is built up
inside discharge module (6). When pressure
below discharge valve (7) exceeds pressure
above the valve, the valve is forced to open
so that fluid is delivered in discharge
manifold. Then piston starts to move back for
another round, discharge valve closes and the
cycle is repeated

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 Fluid End
Suction Manifold
Triplex slush pumps, equipped with a properly installed Suction Dampener, will operate
satisfactorily with a "natural" suction in many drilling situations. However, there are
circumstances that will require a "charged" suction. The piping design for a "dual" arrangement
permitting both "natural" as well as "charged" suction operation must be such that the suction
dampener remains in the line in either case.

The suction of mud pump must have a positive head (pressure) for satisfactory performance.
The optimum suction manifold pressure is 20-30 psi for maximum volumetric efficiency and
expendable parts life. This head pressure is best supplied by a 5 x 6 centrifugal pump with 40
HP – 1150 rpm electric motor.

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 Fluid End
Suction and Discharge Modules
• The module is the compartment through which
drilling fluid flows from suction to discharge lines
via internal passages within.
• It contains: liners’ wear plates and valves
assembly.

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 Fluid End
Suction and Discharge Valves
• Valves control the flow of drilling
fluid through modules. Suction
valves passes fluid to fill up
cylinders, while discharge valves
passes pumped fluid from liners to
discharge manifold.

• Each valve opens against valve

spring. Opening of the valve is
governed by forces exerted by
fluid on both sides of the valve.

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 Fluid End
Suction and Discharge Valves

• Body
• Insert
• Spring
• Seat
• Guide bushing
• cover

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 Fluid End
Wear Plate

• It is an important plate,
installed inside discharge
module to protect module
body from drilling fluid.

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 Fluid End
Pistons and Liners
• Pumping of drilling fluid occurs due to the
reciprocating movement of the piston
inside the cylinder liner.

• Piston rods are connected to intermediate

rods(Pony rod), so that the linear
movement of intermediate rods is
transmitted to pistons.

• When the piston retreats it permits drilling

fluid to fill the cylinder by means of
charging pump. Piston movement is
reversed in pumping stroke to deliver fluid
to discharge manifold.

• A pumping stroke occurs every 120° of the

crank; i.e. for each complete revolution for
crank there are three pumping strokes.
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 Power & Fluid End
Mud Pump Components

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Pulsation Dampener

48
 Pulsation Dampener
Pulsation Dampener
As for triplex pumps three pumping strokes occur
in every complete revolution of the crankshaft,
there will be fluctuation in pump delivery in the
time period between pumping strokes. This
fluctuation, if not treated, will cause vibration, and
thus, failure in delivery lines.

The pulsation dampener, which is located at the

pump outlet, operates most efficiently when the
nitrogen charge is optimal.

Unless clearly stated by manufacturer, precharge

pressure value must be maintained at 1/3 of
pump working pressure with maximum value of
1000 psi.

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 Pulsation Dampener
Pulsation Dampener
• Dampener’s precharge pressure reading is checked after pump is stopped by 5 minutes
at least so that the reading of dampener’s gauge is correct and settled.

• If the precharge pressure is too low, the dampener will be full of liquid at normal line
pressure.

• The working volume gas

available for the damping effect
will be reduced, thus reducing
the effectiveness of the
dampener itself. Additionally,
excessive flexing of the
diaphragm may cause
premature rubber failure at the
neck or at the equator of the
diaphragm.
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 Pulsation Dampener

Pulsation Dampener

• If the precharge pressure is too

high, the diaphragm insert will
rest on the bottom dampener and
push the liquid out. In this case
there will be no damping effect
until the line pressure exceeds
the charge pressure. Over the
long term, the line pressure will
equalize to the precharge
pressure, reducing the service
life of the diaphragm.

Components of Pulsation Dampener 51

 Pulsation Dampener
Pulsation Dampener Maintenance

It is likely that a leak – which may well be hard to detect – will cause a significant
pressure variation. If the charge pressure drops below the required level, inspect the
points listed below with soapy water before disconnecting the connections.

1.Charge valve and pressure gauge threaded fittings;

2.Remove the charge valve cap and check that the valve is fully closed;

3.Check the tightness of the connection between the cover and the body and around
the stud bolts which mount the cover to the body.

If no leaks are evident at the above points, the diaphragm may be perforated. If the
leak is significant, replace the diaphragm at once. If the leak is negligible, it may be
corrected by adding nitrogen to the charge and checking again after a period of time

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 Pulsation Dampener
Pre-charging the Pulsation Dampener
Follow the following steps in case pressure reading is found less than desired value

Note: USE DRY NITROGEN ONLY

Make sure an outlet valve is opened to make room for diaphragm to expand and the pressure
reading of nitrogen is the actual reading.
1.Install charging kit (1).
2.Open Charging valve (2) to check initial precharge pressure in pressure gauge (3).
3.Gradually open nitrogen source valve (4) until desired pressure is reached in the dampener.
4.Close both valves.
5.Release pressure in charging hose.
6.Open charging valve again to recheck precharge.
7.Close charging valve and release pressure in charging kit.
8.Use some soap to check for leaks from valve or gauge threads.
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 Pulsation Dampener
Pre-charging the Pulsation Dampener

Pre-charging components for Pulsation Dampener

The dampener is charged with a standard piece of

equipment known as “The Charging kit”. This charging
Kit consists of a pressure gauge, charge hose, nitrogen
bottle adaptors and a on / off valve on the charge hose.
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 Pulsation Dampener
Pre-charging the Pulsation Dampener
Pre-charging of pulsation dampener shall be done only with the Nitrogen as it is
inert and non-combustible whereas the oxygen when contacted with combustible
materials such as grease, oil, diesel, oil based mud etc. may cause fire and
explosion as in this instance the oxygen under pressure which during operation of
the mud pump with oil base mud, the diaphragm inside the pulsation dampener may
rupture allowing the oxygen used to pre-charge the diaphragm and get mixed with
the oil base mud and creates a potential fire and explosion

Necessary conditions for a fire

In general for a fire or explosion to occur

three elements are required:

• Combustible material (oil based mud)

• Oxygen
• An ignition source (compression ignition)
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 Pulsation Dampener
PROCEDURE FOR QUALITY TEST
• Check all nitrogen cylinders upon being received at the work site to ensure that cylinders are correctly filled
with nitrogen.
• While using nitrogen gas bottles in pressurized system such as BOP Control Unit, Remote BOP Control
Panels, Pulsation Dampener, Draw-works Brake Hydraulic unit, it is mandatory to check & confirm that
bottles are correctly filled with nitrogen and not oxygen.
• The contents of all other gases shall be zero in the cylinder.
• Nitrogen can be tested by using nitrogen gas detector (single gas detector)
• Open the valve of nitrogen cylinder slightly. Keep the detector in-front of cylinder outlet.
• Detector shall indicate only the presence of nitrogen & zero concentration of other gases.
• Test shall be carried out in open air away from work area or in enclosed space.
• Test shall be carried out in the presence of unit manager by Chief Mechanic who shall be certified as
“Authorizer gas tester”
• After conducting the test reading shall be maintained in nitrogen quality test record - OHS-MS-FM-01-69 and
signed by the authorized gas tester.

WARNINGS:
• Nitrogen charging assembly & nitrogen gas detector shall be under lock in unit manager office.
• At no time should any part of your body be directly above the valve in case of a burst fitting.
• Nitrogen cylinders shall always be stacked in upright position.
• On receipt of Nitrogen Cylinders from Base Store, they should be checked for the correct color code and
store in the area designated for Nitrogen Cylinders.
• Adequate PPE to be used at all times

Pulsation Dampener Accidents Reports 56