Drilling Mud Pump Selection Tips, and a Notable Innovation

When choosing the size and type of mud pump for your drilling project, several factors must be considered. These factors include not only the cost and size of the pump that best fits your drilling rig but also the diameter, depth, and conditions of the hole you are drilling through. While this may seem overwhelming, setting things up correctly before the job begins will prove beneficial in the long run.

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It is advisable to maintain a minimum upward velocity of 100 to 150 feet per minute for drill cuttings. Larger diameter wells, used for irrigation, agriculture, or municipal purposes, may not always adhere to this guideline, as it may not be economically viable to pump that much mud for the job. The upward velocity is determined by the mud system's flow rate, the borehole diameter, and the drill pipe diameter. Various tools, including handbooks and apps on your mobile device, can help calculate velocity. Remember that the time taken to remove cuttings from the bottom of the well is crucial. For example, if you are drilling at 200 feet, a velocity of 100 feet per minute means it would take two minutes to clear the cuttings. This reminder helps you stay aware of your drilling progress and the changing ground conditions and rock formations as you delve deeper. Wouldn't it be ideal if these conditions remained constant?

Centrifugal-style mud pumps are prevalent in the industry due to their size, weight, and flow rate capacity at an affordable price. Numerous models and brands are available, many of which offer excellent value. How does a centrifugal mud pump function? The impeller's rotation accelerates the fluid into the volute or diffuser chamber, increasing the fluid's velocity and pressure. However, these pumps tend to be inefficient, requiring more energy to enhance fluid flow and pressure compared to piston-style pumps. On the positive side, centrifugal pumps can yield higher flow rates than piston pumps. When drilling deeper wells with heavier cuttings, you will eventually need to utilize a piston-style mud pump, as they are significantly more efficient in converting input energy into flow and pressure, leading to much higher pressure capabilities.

Piston-style mud pumps operate by a piston or plunger moving back and forth in a cylinder. They are classified as 'positive displacement' pumps because they literally push the fluid forward. This fluid builds pressure, forcing a spring-loaded valve to open and allow the fluid to escape into the pump's discharge piping and down the borehole. The expansion process in these pumps is much smaller compared to centrifugal pumps, resulting in significantly lower energy loss. Piston pumps can generate pressures exceeding 15,000 psi for well treatments and hydraulic fracturing, while centrifugal pumps typically operate below 300 psi. Most drilling pumps operate between 60 and 125 psi for centrifugal pumps and around 150 to 300 psi for piston pumps, with certain exceptions and specific applications accounting for approximately 80% of the equipment in use.

The traditional limitations of using piston-style mud pumps on drilling rigs have been their physical size and weight, which hinder sufficient flow and pressure for drilling fluids. Consequently, the industry sought a new solution to this enduring issue.

A Tribute to Innovations

Enter Cory Miller of Centerline Manufacturing, who I recently proposed for recognition by the National Ground Water Association (NGWA) for his significant contributions to the industry.

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As the senior design engineer for Ingersoll-Rand's Deephole Drilling Business Unit, I had the pleasure of collaborating with him and incorporating the Centerline Mud Pump into our drilling rig platforms.

In the late '90s and possibly earlier, Ingersoll-Rand attempted several times to develop a hydraulic-driven mud pump that would possess an acceptable lifecycle and duty cycle for well drilling contractors. Despite all our resources and design expertise, we could not resolve this issue. Miller not only provided a solution, effectively minimizing the size and weight of a typical gear-driven mud pump, but he also introduced a new mono-cylinder mud pump. This double-acting piston pump achieved flow and pressure levels comparable to a standard 5 x 6 duplex pump while offering remarkable size and weight benefits.

The real innovation was offering well drillers a solution for their mud pump requirements that fit seamlessly into both existing and new drilling rigs. Regardless of drill rig manufacturer and hydraulic system design, Centerline has integrated mud pumps into hundreds of customers' drilling rigs. Both mono-cylinder and duplex-cylinder pumps can be efficiently mounted on the deck, across the frame, or even configured for under-deck mounting—something traditional mud pump designs cannot accommodate.

Centerline persevered with its original design through the usual challenges associated with new product integration. Over the first several years, Miller discovered that even the highest quality hydraulic cylinders, valves, and seals were not as dependable as they claimed. Consequently, he embarked on a mission to manufacture all of his components in-house, including hydraulic valves, which offered him complete control over the quality of the finished product.

The second generation of the Centerline Mud Pump is anticipated later this year, and I believe it will revolutionize the industry. It will also expand applications across various sectors requiring robust cycle capabilities for piston pump applications.