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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
+971 50 559 6934
JON SEGELHOST BDM– PPC
+1 972-896-4383
