Presented By: Dipak Sarmah Rajkamal Arya Deerandra Singh Yadav Raghunandan Chakka Sunil Kakran Deepak Kumar

CONTENTS
Introduction
Triplex & Duplex Pump Characteristics Suction System Design & Performance Suction Charge Pump Air Intrusion Prevention Valve Behavior Pulsation Dampener Piston Motion Effects

INTRODUCTION
WORKING PRINCIPLE
The chain driven sprocket from the power source is

attached to the pinion shaft and causes it to turn a smaller gear. The pinion drives a larger gear i.e. bull gear. The bull gear is attached to the crankshaft; the crankshaft turns to give a back-and-forth motion to the connecting rods. The connecting rods are linked to the crossheads. The crossheads are connected to the piston rods and impart back-and-forth, or reciprocating, motion to the rods.

Cross Section of Typical Mud Pump

Fluid End

Power End

Rotation of Crankshaft: Clockwise viewed from Right. View from Power end towards Fluid End.

Specifications of PT Series Pumps

Sr. Descriptio A600PT No. n Relevant Rigs 01 02 Rated in HP Pump size
(piston dia x stroke) IR 750 600HP

A850PT
E-760 IR900 850HP at 175RPM

A-1100 PT
E1400 1100HP at 160RPM

A-1400PT
E-2000 1400HP at 150RPM

A-1700 PT
E-3000 1700HP at 150RPM

7 x 8

71/2 x 9 71/2 x 10

71/2 x 10

71/2 x 12

03 04 05

piston size Gear Ratio Max Pressure (delivery)

4, - 7

5, - 71/2 5, - 71/2 4.48:1 4.48:1 5000 psi

5, - 71/2

5, - 71/2

6000

5000 psi

5000

5000

06

Rated Max 275 Pressure (Suction)

250 psi

250 psi

250

250

COMPONENTS
POWER FRAME: Power is made up of fabricated

steel, reinforced to assure maximum strength and rigidity. It housessupport for main bearings. PINION SHAFT: It is integral with pinion , is heat treated and ground. It extends on both sides of pump. It rotates on double row taper roller bearing. CRANK SHAFT: It is high quality rib reinforced casting with integral flange for mounting on gears. BEARINGS: Main bearings double row tapered roller. Eccentric straight roller.

Pinion shaft double row tapered roller/spherical bearing. cross head pins double row needle roller bearings. CONNECTING RODS: These are T sections with solid ends made of ductile iron castings. CROSS HEADS: Nodular cross heads has bronze shoes. FLUID CHAMBER: It is made of forged steel, fully and individually interchangable. Solid type cylinder heads used, and also threaded valve covers. Fluid liners have uniform lining of corrosion and abrasion resisting metal which increases liner and piston life.

 METAL TO METAL LINER RETENTION: This method

holds liner in place when operating in high pressures. FLUID PISTON RODS: Rods are induction hardened high strength alloy steel. Pistons are heavy duty slurry type. VALVES: Valves and seats are made up of heat treated forged alloy steel. Valves have replaceable polyurethane valve inserts. LUBRICATION: The oil pump which is externally mounted supplies oil through filter to all bearings and cross head guides. Other oil pump for piston rod flushing system. Pump base is made up of heavy structural steel, supports all elements.

DUPLEX VS TRIPLEX PUMP

Duplex & Triplex Pump

Double Acting Duplex Pump

Single Acting Triplex Pump

Rate of Flow
Rate of Flow = (Total volume per Stroke ) X RPM
Total volume per stroke for
DADP = [4(Piston Area) 2(Rod area)] X Stroke length TRI = 3(Piston Area) X Stroke length

Stroke Length
Usually triplex pump stroke length is shorter as compared to the duplex pump.
Speed Comparison for same flow rate
Duplex Stroke length Piston Diameter Speed (for Same flow) 16 6 Triplex 12 6.5

60

81.5

Discharge Comparison

Duplex Pump Discharge

Triplex Pump Discharge

SUCTION SYSTEM DESIGN & PERFORMANCE

Suction Pressure Losses

Velocity Pressure Loss (V2/2g) Frictional pressure Loss (fLV2/2gD)

Vapor Pressure Loss

Inertia Loss

Inertia Loss
Depends upon System Acceleration Piston Acceleration Ap = 0.000457 SN2 ft/sec2 Required head at inlet of the pump H = L Ap/ g

Piston Acceleration

Problems Arising from Insufficient Suction Pressure

Knocking

Collision of mud against the piston because of difference of acceleration due to inertia.
Settling

Settling of solid particle during operation and shut down

Ways to Increase Suction Presure

Raise level of mud in the tank
Cool the pump Reduce the pump speed Reduce suction pipe length Increase suction pipe diameter Add a suction dampener Add a charging pump

SUCTION CHARGE PUMP

SUCTION CHARGE PUMP

Triplex piston pump performance is optimized by adding

centrifugal auxillary charge pump to the suction system of mud pump. The advantages with this suction charge pump are 1.Inherent flexibility 2.Easy operation and installation 3.Low cost

Charger Size
Charger size depends upon
Diameter

Friction
Inertia and Acceleration.

Required Pressure
Total required pressure for triplex suction system with

charger pump consists of the following Inertia head Friction Vapour pressure Velocity head

Charger Pump Capacity

The flow rate of the charger must be equal to the maximum instantaneous flow of the piston pump as follows Q = V*0.01068*S*N*D^2 Q = capacity in gpm V= velocity correction factor S = stroke in inches N = pump speed in RPM D = piston diameter in inches

Charger Location
Inertia calculations determine if charger pump should be located close to the mud tank or at triplex pump.
If inertia requirements are larger than atmosphere pressure, it would be necessary to push on the mud with the charger.

Charger Piping
As charger pump is centrifugal it is required that entrance to pump must be straight for a distance of about eight suction pipe diameters.
The use of very long suction pipes from triplex pump to mud tank is undesirable as it causes friction and inertia heads requiring greater charger pump pressure.

AIR INTRUSION PREVENTION

Air Intrusion

When piston seals are worn and cylinder pressure falls to insufficient levels, air can enter triplex cylinders and lead to partial filling . This in turn results in poor pump performance and increased wear .

Effect Of Air Intrusion On Pump Performance

Improper filling of cylinder Low discharge pressure Fluid slippage takes place Erroneous guage reading Knock and vibration takes place in the discharge line

Remedies For Air Intrusion

Use supercharger to prevent air intrusion

Supercharger increase pressure of fluid and overcome inertia so that complete filling of cylinder takes place and thus stops hydaulic knock and separation
Back flash on: it prevents heating of liner.

VALVES
Optimum pump performance largely depends upon proper selection, installation and operation of suction and discharge valves The effects of excessive lag, sticking, hammer are studied in this chapter.

 A pump valve operates like flowmeter, a device which is

used to measure the flow of fluid.

The valve of pump has usually a tapered seat so seat is short

than that of taper of flowmeter and valve rise is not linearly proportional to flow.
The actual behaviour of the valve depends on the four

operating regimes occur during valve operation. They are 1. Initial opening 2.Medium flow 3.Maximum flow 4.closing response or lag

 INITIAL OPENING

The valve operates like low pressure relief valve, where

weight and spring force resist pressure in cylinder for discharge valve and pressure in suction for suction valve. Top area of valve is large than bottom seat area, so some over pressure is needed to lift valve. The initial pop takes some time and causes piston over travel. This initial pop does not cause and problem when pump runs at low speed, but if pump speed increases such that stoke time equals initial opening then valve lag & wear occurs.

 MEDIUM FLOW

During this peroid valve position depends upon

flow rate of piston. Initial piston acceleration ceases and flow becomes steadier. The lift of valve is directly proportional to instantaneous flow. Vale completely surrounded by pressurzied fluid, fluid pressure does not affect the lift of valve. The lift of suction or discharge valve depends upon the flow rate of fluid .

 MAXIMUM FLOW

During this flow period valve lift is maximum, this

occurs at mid stroke of piston. At mid stroke the piston acceleration is zero. The valve lift can be made limited by means of valve stop. Here the valve stop should be far enough above the valve seat for sufficient lift. So that maximum flow through valve occurs. If the lift of valve is too limited - less opening for the fluid to flow through the valve and it results in abrasive wear and pressure loss.

 CLOSURE

As piston slows down at the end of stroke flow valve drops as flow decreases. Valve responsive valve close in proportion to decline flow However some lag normally occurs. Closure force is the difference between

valve weight + spring weight to hydraulic force from flow.

VALVE LAG

Valve lag means inability of valve to close in time. Valve lag is due to valve without spring.the valve must close due to its own weight so lag can be high in this case.

Valve lag causes reverse flow.

Reverse flow causes a decrease in pumped fluid and it increases the valve speed towards the seat.

Valve hits harder resulting in damage to valve seat and to valve.

Valve lag may in inches.

 Adequate Spring used with valve will nearly eliminate the lag.
Lag can be few thousandths of an inch. Spring should have correct ratio of spring force to valve weight. Spring make the reduction in valve speed so that it may hit valve seat gently.

 VOLUMETRIC EFFICIENCY
Due to valve lag valve being open when piston reaches

180deg. Late closure of suction valve - piston starting discharge stroke and pumping fluid back to suction pipe. Late closure of discharge valve - piston starting the suction stroke even the discharge valve not closed withdrawing fluid from discharge. Due to these effects volumetric efficiency gets reduced. Adequate spring used can reduce spring lag causing no loss in volumetric efficiency

 Valve spring requirements

Spring used in valve is very important because problems concerning the valve are reduced.
Heavy valve avoid structural bending under

pressure. Stronger valve spring is used. Spring breaks or is left out results in valve lag or late closure of valve. springs must be installed carefully. If springs reused it must be checked for strength, resilence,fatigue or corrosion.

 PRESSURE DROP Pressure drops occurs between the faces of the valve

but recovers after valve. Pressure drop across valve chamber is more useful. pressure drop estimates the pressure remaining in the fluid to prevent flashing or air intrusion.

 STICKING VALVES Valve may be stick. Valve sticking resists forces of

weight and spring force for valve closing. Sticking occurs mainly due to friction. All pistons in pump mounted vertically to reduce friction.

 HUNG VALVES

Valves hung due to progressive bad sticking, jamming

by foreign material. The weight of valve and spring force not sufficient for valve to come back to seat. Spring is vital for smooth and long operation of the valve

 VALVE HAMMER It is impact of the valve on the seat with much higher

velocity. Due to lag, sticking or freeing of hung valve. Due to above reasons response time increases causing long delay so that valve hammer occurs. If valve hammer occurs it results in valve peening or wear to valve seat.

PULSATION DAMPENER

Pulsation Dampener
Triplex pump flow naturally fluctuates due to the cyclic nature of the pump and other factors inherent in the system. Flow deficiency at the suction can lead to fluid separation and knock, and at both the suction and discharge , un steady flow ca lead to vibration and increased wear. Dampeners can steady these input and output fluctuation in flow and pressure to acceptable limit.

Contd
Sized , operated and maintained correctly, a dampener can improve pump performance and increased part life by reducing pulsations and vibration in the system.

Dampener
A dampener is a pressure vessel in communication with the mud line. These devices store excess fluid when too much is pumped and supply needed fluid to the line when too little is available. They accomplish this service with a flexible bladder separating two chambers inside the vessel. One of the chambers is charged with gas and sealed off from the other chamber, which is in direct communication with the mud line when the dampener is in operation.

Contd
As the mud line enters the dampener, the bladder retreats, expanding the fluid chamber and compressing the gas to reduce the volume of the gas chamber. When this fluid is needed back in the mud line, the compressed gas exerts pressure on the bladder and pushes fluid from the chamber.

Position of Dampener
Discharge Dampener Suction Dampener Discharge dampener is usually larger of the two

because it must cope with higher operating pressure, while pressure in the suction line is normally relatively low. Suction perform other function like, they provide added fluid pressure to keep the cylinder full and prevent fluid separation and knock. This in turn allows the pump to run faster . They also steady the flow highly charged suction system to increase the performance.

Four major sources of variation in flow and pressure are

Variations in pumped quantity due to the operating

characteristics of the pump. Delays due to compressibility of the pumped fluid. Flow fluctuation caused by faulty or failing parts in the pump. Reduced fluid delivery caused by air or gas in the cylinder.

Various Fluctuations
Velocity Fluctuation
Pressure Fluctuation Velocity Fluctuation : The combined flow from the three

cylinders of a triplex combine to make six velocity fluctuations per crank revolution, which produces six pressure fluctuations if dampener is not being used. Piston velocities determine flow velocity and thus the amount of pressure surge in the pump. The amount of velocity fluctuation also depends on the connnecting rod/ crank radius ratio. A lower Con rod to crank radius ratio causes greater fluctuations in piston velocity .

Pressure Fluctuations
The actual pressure rise and fall in a triplex system is

dampened so that actual pressures are lower than in a theoretical system. One reason for this that the pump and piping expand under pressure. The piping sees a pressure wave and swells over the distance the wave travels at the speed of sound in the fluid during the time of disturbance. Induced pressure fluctuations: high resistance to flow into the dampener causes additional line pressure fluctuations.

Contd.
Induced pressure fluctuations: high resistance to flow

into the dampener causes additional line pressure fluctuations. The resistance flow into the dampener must be kept to a minimum so the pressure rise is largely due to compression of the gas. There will be inertia head loss much larger than the frictional loss. These induced losses can negate dampener effectiveness if levels are too high.

Selection of Dampener
Care in the selection of of he dampener and in its

installation alongwith attention to its operation will greatly reduces pulses and vibration. This should help us get longer life from the rig compenents.

PISTON MOTION EFFECTS

Piston velocity
Piston movement with respect to crank-

At start of the stroke - 10 degree motion causes the piston movement .86% of the stroke 2. At mid of the stroke 10 degree motion causes the piston movement 8.5% of the stroke
1.

Piston Motion

Contd
If connecting rod is very long same piston movement . Average piston velocity (fpm)=2.spm.stroke length(ft) In real pumps the connecting rod ratio is much less

Peak velocity
When throw is perpendicular to the crank, piston is at maximum velocity Friction decreases with velocity

Least friction occurs at the peak point

Valve effects
Valves are flowmeters
Velocity of the pistons develops the flow which

operates the valves

Lifts is obtained by placing a valve in a flow chamber Lifts can be altered by using different shapes, weights

and springs

Piston friction
Static friction is greater than dynamic friction
At the start and at the end of the stroke friction is

maximum
At the middle of the stroke friction is minimum. Also varies with pressure.

Piston acceleration
Acceleration is the slope of velocity curve At the start and end of the stroke acceleration is

maximum.
At the middle of the stroke acceleration is minimum.

Alternatives
Scotch yoke 1.

Straight sliding bar is used

2. It produces the same piston motion that an infinitely

long connecting rod

 Offset crank1.

The offset crank uses a connecting rod where centre of rotation of the crank is offset from centre line of the cylinder

2. One stroke longer and one stroke shorter

FITS AND CLEARENCES

Connecting rod small end inner diameter and

bearing outer race O.D = 0.03 mm to 0.08mm. Cross head pin O.D. and bearing inner race I.D is 0.055 to 0.075 mm. Connecting rod big end bore and bearing outer race O.D. is -0.094 to -0.15mm. Crank shaft and bearing inner race I.D. is -0.3048 to -0.203mm. Pinion shaft and bearing inner race I.D. is -0.05044 to -0.0804mm.

 Pinion shaft housing and bearing outer race O.D. is

0.0008 to 0.0058mm. Crank shaft and bearing inner race I.D. is -0.0885 to -0.1105mm.

THANK YOU