Condition Based Maintenance: A New Early Leak Detection System for Mud Pumps

Kyllingstad, Åge; Nessjøen, Pal Jacob

doi:10.2118/139888-ms

Cited by 6 publications

(1 citation statement)

References 1 publication

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“…The magnitude of the pressure fluctuations are comparable with the values reported in Fig. 2 of the paper by Kyllingstad et al [5].…”

Section: Resultssupporting

confidence: 90%

Hexagonal reciprocating pump: advantages and weaknesses

Stanko¹,

Golan²

2013

International Journal of Fluid Machinery and Systems

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This paper reports the 1-D fluid transient simulation results of the discharge flow conditions in a 6-cylinder reciprocating slurry pump. Two discharge manifold configurations are studied comparatively; a case with a hexagon shaped discharge manifold where each cylinder discharges at a single vertex, and a case where all the cylinders discharges are lumped together into a tank shaped manifold. In addition, the study examines the effect of two pulsation mitigation measures in the case of hexagonal manifold; a single inline orifice in one of the hexagon sides and a volumetric dampener at the manifold outlet. The study establishes the pressure and flow fluctuation characteristics of each configuration and decouples the pulsation characteristics of the pump and the discharge manifold.Keywords: Hexagonal piston pump, pressure pulsation, reciprocating piston pump. SummaryReciprocating pumps produce flow variations in their discharge end that may excite severe pressure pulsation in their discharge manifolds and piping systems. Therefore, developing of new designs of such pumps or introduction of novel configurations of discharge manifold warn an investigation of their flow dynamic characteristics and their susceptibility to acoustic and mechanical resonance. Numerical transient flow simulation is an effective front-end engineering measure to assess the susceptibility to detrimental pulsation flow acoustic performance. This paper reports the simulation results of the discharge flow conditions in a 6-cylinder hexagon shaped reciprocating slurry pump (Hexagonal pump). Two discharge manifold configurations of the same pump are studied comparatively; a case with a hexagon shaped discharge manifold where each cylinder discharges at a single vertex, and a case where all the cylinders discharges are lumped together into a tank shaped manifold. The study establishes the discharge pressure fluctuation characteristics of each configuration, quantifies the flow and pressure pulsation, and decouples the pulsation characteristics of the pump and the discharge manifold.In addition, the study examines the effect of two pulsation mitigation measures in the case of hexagonal pump with hexagonal manifold; a single inline orifice in one of the hexagon sides and a volumetric dampener at the manifold outlet. Finally, it compares the discharge pulsation characteristics of a reciprocating hexagonal pump with those of similar capacity triplex pumps conventionally used in oil wells drilling and in the mining industry.A one-dimensional transient flow simulator is used to investigate the pumping hydrodynamic of a slightly-compressible homogeneous slurry flow. The Hexagonal pump analyzed is based on an emerging industrial product design where the vertical reciprocating motion of the pistons is driven by a rotating cam, and where the kinematic of the piston motion is carefully configured, by the cam profile, to smooth the compound pump discharge flow/pressure.The simulation results of the common discharge tank case show that, under realisti...

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“…The magnitude of the pressure fluctuations are comparable with the values reported in Fig. 2 of the paper by Kyllingstad et al [5].…”

Section: Resultssupporting

confidence: 90%

Hexagonal reciprocating pump: advantages and weaknesses

Stanko¹,

Golan²

2013

International Journal of Fluid Machinery and Systems

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Self-Learning Probabilistic Detection and Alerting of Drillstring Washout and Pump Failure Incidents During Drilling Operations

Ambrus¹,

Ashok²,

Ramos³

et al. 2018

IADC/SPE Drilling Conference and Exhibition

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The mechanical failure of drilling equipment is an operational risk that can be limited through a robust detection and alerting system, particularly for Drill String Washouts (DSW) and Mud Pump Failures (MPF). The detection of these issues focuses primarily on the time signatures of the real-time and modeled pump pressure in relation to the flow rate trends. Together, these parameters describe the state of the equipment which can be assessed through real-time alerts. A new methodology for real-time detection of washout and pump failure incidents during drilling operations was developed. The methodology behind the detection system uses a Bayesian network that models the drilling hydraulics and their associated failure modes. The network aggregates data from real-time rig floor sensors (standpipe pressure, pump rate, flow out, etc.), contextual information (rig state, mud properties, etc.), and predictions from hydraulic modeling. Cumulatively, they are the determinants of a probabilistic belief system indicative of DSW and MPF. The probabilistic model outputs belief values for DSW and MPF between zero and one. Given past and present trends, the model increases accuracy though self-learning and self-calibration that adjusts for poor sensor data, drilling conditions, and model uncertainty. The Bayesian network was integrated into decision support software with real-time alerting capabilities. The software was then validated by an operator's 100+ onshore wells in North America, some of which contained MPF and DSW incidents with varying degrees of severity. Several case studies drawn from these wells are presented in the paper. Each failure event that exceeded a programmed threshold for a specified period of time generated an alert in the form of a PDF report containing real-time sensor traces and DSW and MPF prediction outputs. The alerts were also displayed on a dashboard on the rig site user interface. Software thresholds were optimized to reduce false alert reports presented to the driller. Through continuous improvement and validation, DSW and MPF detection reached a level of accuracy which, in some cases, detected the warning signs of a failure hours before the problem was noticed at the rig site. Conclusively, the value added by the early detection of mechanical failures is the decreased amount of non-productive time due to pump downtime and maintenance, as well as trips and fishing jobs due to washed out pipe.

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Towards a Practical, Generally-Applicable Condition-Based Maintenance CBM System for Mud Pumps

Yoon

Gul

Ashok

et al. 2022

IADC/SPE International Drilling Conference and Exhibition

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Unexpected failure of mud pumps during drilling operations can result in non-productive time (NPT) and increase well construction cost. Several prior studies and implementations of condition-based maintenance (CBM) systems for mud pumps have failed to provide a generalized solution for the variety of pump types encountered in the field, in particular by failing to detect damage early enough to mitigate NPT. Our research is aimed at improving upon this situation by developing a practical, generally-applicable CBM system for mud pumps. In the study reported here, a laboratory test bed with a triplex mud pump was used to collect data to test a new approach to mud pump CBM. Artificial damage was introduced to the two most frequently replaced parts of the pump, i.e., the valve and piston. An accelerometer and an acoustic emission (AE) sensor were used to collect experimental data. Based on this data, an anomaly detection algorithm was constructed using a one-class support vector machine (OC-SVM) to pin-point the early onset of mud pump failure. The CBM methodology thus developed does not require prior knowledge (data) of the mud pump itself or of the failures of its components. This is key to it being more widely deployable. The trained machine-learning algorithm in the test setup provided an accuracy greater than 90% in detecting the damaged state of the valve and piston. Only the characterization of the normal (i.e., non-damaged) state data was required to train the model. This is a very important result, because it implies that the sensors can be deployed directly onto mud pumps in the field – and additionally, that the first few hours of operation are sufficient to benchmark normal operating conditions. Also, it was observed that a multi-sensor approach improved the accuracy of detection of both the valve and piston damage. The system is able to detect early-stage damage by combining the cumulative sum control chart (CUSUM) with the damage index developed in this project. This work is the first attempt at applying semi-supervised learning for CBM of mud pumps. The approach is applicable for field use with very little or no prior damage data, and in various working conditions. Additionally, the system can be universally deployed on any triplex pump and efficiently uses the data collected in the first few hours of operation as a baseline. Consequently, the practicality and scalability of the system are high. It is expected to enable the timely maintenance of critical rig equipment before catastrophic damage, failure and associated downtime occurs. The system has been deemed promising enough to be field-trialed, and is currently being trialed on rigs in North America.

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Condition Based Maintenance: A New Early Leak Detection System for Mud Pumps

Cited by 6 publications

References 1 publication

Hexagonal reciprocating pump: advantages and weaknesses

Hexagonal reciprocating pump: advantages and weaknesses

Self-Learning Probabilistic Detection and Alerting of Drillstring Washout and Pump Failure Incidents During Drilling Operations

Towards a Practical, Generally-Applicable Condition-Based Maintenance CBM System for Mud Pumps

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