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  • By IRE & PPC

    Charge Up Your Mud Pump Performance: A Pulsation Dampener Challenge

  • • Stocking Distributor

    • OEM Service Provider

    • Focused on Innovative Products and Services

    • Specialised in Value-Added/Cost Saving Solutions

    IRE – International Rig Equipment

  • • 22 year old private company

    • Manufacturer of pulsation dampeners and related technologies

    • Holder of several established industry patents

    • Community Focused

    PPC – Performance Pulsation Control

  • Enhancing Mud Pump Performance =

    Why We Are Here

    1. Prevent Downtime

    2. Reduce Costs

    3. Improve reliability

  • • HIGH MAINTENANCE

    • HIGH SPARES COST

    • FREQUENT DOWNTIME

    • UNPREDICTABLE

    • UNSAFE

    What problems do we face with mud pumps?

    • INTERFERENCE WITH MWD SIGNAL

    • EXCESSIVE VIBRAITON

    • EXCESSIVE WEAR FOR HIGHER PRESSURES/PERFORMANCE

  • LOCAL CONTRACTOR, 16 RIGS OVER 2 YEARS

    - 620 hours NPT billed - 258 failures leading to NPT - 63% failures due to wear and tear of parts

    COMMON DATA ON NPT AND FAILURES

  • DAMPENER EXPLOSIONS

  • Better Performance  Faster Wells  Less Maintenance Cost  Less Expense – More Profit  Less Hazards  Less Vibration in your fluid path Better MWD signal = HAPPY

    CLIENT!!!

    The Benefits of Good Pump Performance

  • • Improve type of fluid

    • Improve design of pump • Better quality spares • Less heat • Less pressure • Pulsation Control…

    REDUCE PULSATION – IMPROVE PUMP PERFORMANCE

    How do we get better pump performance?

  • Fluid end damage from Pulsation – How Does it Happen?

    Pulsation – Discharge • Huge spike in flow/pressure into manifold upon valve opening

    • High fluid velocity/pressure from high acceleration at valve opening wears the valve seats

    • Spike levels reduced by having dampener in proximity

    • Dampener introduces capacitance to the discharge line.

    • Capacitance gained by through adding gas or fluid mass in the system

    Fluid Dynamics

  • Fluid end damage from Pulsation – How Does it Happen?

    Suction – Stabilizing – most discharge concerns start on the suction side

    • Drawing in fluid to fill cylinders could lead to cavitation • Some pressure destabilization due to higher piston stroke velocity. • Higher stroke velocity requires more/faster fluid intake which

    increases risk of cavitation. • Vapor bubbles can form which affects cylinder fill volume creating

    variable fluid delivery on discharge (turbulence) • Variable fluid delivery places greater demand on pulsation control to

    limit the pressure spike variation.

    Fluid Dynamics

  • Fluid Dynamics

  • Case Study: 6.5” plungers before and after discharge dampener @5000psi operating pressure:

    The Dampener Effect

    Without Dampener With Dampener

    1350 psi Pressure Variation

    Potentially violent and unsafe piping system vibration

    175 psi Pressure Variation

    Prolong Pump Life and Maximize Pumping System Efficiency

    72% improvement

  • Pulsation Dampening Options in Today’s Market

  • Gas-charged bladder pushes back against pressure variation to absorb spikes

    1. Gas Charged – How it works?

    High Pump Pressure Mid-Pressure/Transition Low Pump Pressure

  • 1. Gas Charged

    PROS

    • Inexpensive

    • Readily available

    • Easy to install

    • Small and convenient to install

    CONS

    • Frequent bladder failures

    • Unsafe with potential for oxygen

    • Not effective at high pressure

    • Reliant on correct pre-charge setting

  • Pumped media reacts with system/fluid mass for pulsation reduction –

    Liquid Only – No Moving Parts

    Sized to Application

    2. Maintenance Free (Reactive) – how it works

  • 2. Maintenance Free (Reactive) - Benefits

    Improved Safety

    Gas-Charging Eliminated • No Bladders • No Valves/Gauges

    Simple, Safe, Service • No Cover Removal Required • Minimal Annual Inspection • Simple Components • Easy Refurbishment

    ASME Div-1 and Div-2 Code Stamped

    Improved Performance

    Better Pulsation Control • Lower DP – 3-5% (8-10+% for Gas) • Consistent Across Full Discharge

    Pressure Range – No High Pressure Degradation

    • -20 to 650F (Temp Range)

    Easy Operation - Long Duty Cycles • Always Ready to Use • No Adjustments Required • Few, Long-Wear Components • Lowest Life Costs

    No MWD Signal Interference

  • Legacy Installations

    • Space and Support is Key

    • Flow-Through In/Out Piping Required

    Historical Retrofit Challenges

    • Appendage-Mounted Gas Units Eliminated

    • Pump Skids/Piping Modified

    • Space Made In Pump Room

    • Expensive

    2. Maintenance Free (Reactive) - Installation

    Maintenance-Free Flow-Through

    Discharge

  • PROS

    • Least vibration

    • Least pulsation/harmonics

    • Maximum Dampening Effect

    • No maintenance

    • 20+ year old proven technology

    2. Maintenance Free (Reactive)

    CONS

    • Large space need to install.

    • Piping modification often required

    • Most expensive solution

  • Gas Charge vs. Maintenance Free: Pressure Fluctuations

  • • Uses compression and kinetic energy exchange

    • Install gas-infused cellular compression blocks or wedges (not rubber or plastic) that compress and react at different pressures

    • Amplify energy exchange and compression through an larger surface area than traditional bladder

    3. Charge Free Dampener (Reactive) – how it works

  • 3. Charge Free Dampener (Reactive)

    PROS

    • Inexpensive, uses existing dampener

    • Easy to install

    • Reactive pulsation control

    • No Gas Charge

    CONS

    • Not Maintenance Free

    • MWD interference still an issue

    • Pre-charged wedge blocks are limited in compression capacity, less effective at higher pressures

    • INEFFECTIVE OVER 500 PSI

  • High peak to peak variation =

    • poor pump operation

    • Possible cavitation

    Tighter control of suction flow =

    • 1. More efficient pump operation

    4. Suction Stabilizers

  • • Sized through design analysis (DA) and located downstream of legacy pump/dampening equipment

    • Bladder removed from gas charged dampener and converted to fluid filled maintenance-free

    • No Piping/Pump Mods

    • Standalone maintenance reactive dampener placed in Discharge Network

    • Retrofit Optimized Through DA/PPC Engineering

    5. System Dampener (Reactive) – How it works?

  • System Dampener (Reactive) - FEA

    Dual 80-gal Single 80-gal Single 100-gal

  • PROS

    • Gas-Charged Vessel Retained – Bladder Removed

    • Cost Effective

    • Eliminates safety issues from gas charging

    • All existing pipework retained, no modification req’d.

    System Dampener (Reactive)

    CONS

    • Require design analysis to be done on piping system

  • If you want to succeed at anything, you have to???

    What next??

    MEASURE IT!

  • COMPLETE MUD PUMP MONITORING SYSTEM

  • MUD PUMP MONITORING SYSTEM – HOW IT WORKS

    Install instrumentation and digital readout device

    Analyse and record data. Provide pump diagnostic reports correlated to drilling conditions

    Set up triggers and alarms to notify driller of unusual activity… PREDICTIVE MAINTENANCE

    Continuously record and analyze data. Constant learning for optimized performance

  • MUD PUMP MONITORING SYSTEM – HOW IT WORKS

    • Data sensors installed at strategic locations around the pump

    • Monitor performance effectively from drillers control room or HQ.

    • The data is processed through automated learning software which learns the data signatures that lead to failure. Then it can learn to predict failures before they happen and initiates a trigger or alarm to notify rig personnel.

    • Can be monitored from field or office.

  • MUD PUMP MONITORING SYSTEM

    Coming soon… 

  • THANK YOU!

    DAN J ASHER MD– IRE

    danjasher@iretrading.com

    +971 50 559 6934

    JON SEGELHOST BDM– PPC

    jsegelhorst@performancepulsation.com

    +1 972-896-4383

    mailto:danjasher@iretrading.com mailto:jsegelhorst@performancepulsation.com

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