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Most mud pumps used in directional drilling rigs use either piston and liner technology or plunger and sealing technology.
Mud pump manufacturers often provide two types of mud pumps. In fact, the power end and the hydraulic end of the pump are the same. The difference lies in the way the pump discharges the mud.
In the early 1990s, it was generally recognized that medium and small drilling rigs used text boxes:, high pressure (1800-2200ps i, ie 124-152bar) and low flow (5-25gpm, ie 19-95Lpm) pumps to send flushing fluid In the hole.
With the maturity of the drilling industry and the rich experience of operators, it has been found that higher mud flow and lower mud pressure are an excellent method for drilling. In some formations, high pressure and low flow are still the first choices, and have achieved the greatest success. However, in most areas, a higher flow rate can best ensure the cleanliness of the hole (removal of cuttings) and provide sufficient bentonite for formation plugging and lubrication.
1. Plunger and seal
When high pressure (800-1000psi, 55-69bar, and higher) and lower flow are required, plunger and sealing technology are used. The fluid pressure pushes the front part of the seal, pressing the seal around the smooth surface of the reciprocating plunger, preventing leakage. When the pressure is lower than 800-1000 psi (55-69 bar), the liquid flow pressure is not enough to promote this isolation, and the seal leaks. The leaked liquid carries sand and other abrasive solid particles into the well and collects between the seal ring and the plunger, causing rapid wear of the plunger surface and/or seal, and failure of good packing.
One advantage of the plunger and sealing technology is that the operator can adjust the leakage of the seal to a minimum until the pump can be used effectively and the borehole is completed.
2. Pistons and cylinder liners
Pumps with piston and liner technology work in the opposite way. In the case of low hydraulic pressure (less than 1200psi, that is, 83bar), the piston prevents leakage well. The diameter of the piston is usually larger than that of the plunger. It is an advantage to allow the pump to run slower when discharging the same flow rate.
The piston has two disadvantages. First, when the piston is damaged or starts to leak, the operator cannot maintain the status quo until repairs. Therefore, after an obvious leak, it usually must be repaired immediately. Second, the piston is suitable to run under cooling and lubrication. Therefore, a cooling and lubrication system must be used to increase the durability of the piston.
The cooling and lubrication system includes small centrifugal pumps, nozzles, pipes and collecting tanks. The system sprays a mixture of water and lubricant (non-foaming soap or liquid polymer) onto the back of the piston.
Many drilling rigs are equipped with plunger pumps. Plunger pumps are often used in applications where piston pumps should be used (mainly low pressure and high flow), and often have leakage problems. In order to help operators eliminate the leakage of these pumps, some pump manufacturers are developing conversion components that can change the pump from a plunger type to a piston type. Ask the manufacturer of your drilling rig or pump if it is available from stock.
From an economic point of view, when the plunger is no longer applicable and must be replaced, you should consider changing the pump from the plunger type to the piston type. The conversion component can be installed on site, and it is very easy to operate.
If your mud pump has a leakage problem, you should think about whether your pump is working under conditions or uses that do not meet the original design.
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