![]() ![]() Washouts are one of the leading causes of module failure and take place when the high-pressure fluid cuts through the module’s surface and damages a sealing surface. Typically, cavitation pits create a stress concentration, which can reduce the module’s fatigue life. A busted mud pump means expensive downtime and repair costs.Īs illustrated in Figures 1 and 2, cavitation causes numerous pits to form on the module’s internal surface. If not corrected, the vibrations caused by cavitation will work their way directly to critical power end components, which will result in the premature failure of the mud pump. The vibrations are then passed onto the shaft, bull gear and into the main bearings. The imperceptible but intense shock waves generated by cavitation travel directly from the fluid end to the pump’s power end, causing premature vibrational damage to the crosshead slides. In the early stages, cavitation can damage a pump’s module, piston and valve assembly. While the pump itself may not be making noise, damage is still being done to the internal components of the fluid end. Mild cavitation begins to occur when the mud pump is starved for fluid. However, the process of cavitation starts long before audible signs reveal themselves – hence the name “the silent killer.” When a mud pump has entered full cavitation, rig crews and field service technicians will see the equipment shaking and hear the pump “knocking,” which typically sounds like marbles and stones being thrown around inside the equipment. Over time, cavitation can lead to expensive maintenance issues and a potentially catastrophic failure. Mild vs severe cavitation Figures 1 (left) and 2: Long-term, severe cavitation can cause surface pitting on a module crossbore and reduce the module’s fatigue life. Over time, cavitation can also lead to expensive maintenance issues and a potentially catastrophic failure. Lack of or inadequate suction and discharge dampening.Īlthough cavitation is avoidable, without proper inspection of the feed system, it can accelerate the wear of fluid end parts.Elevation changes and excessive elbows in plumbing from mud tank to mud pump and.Improper size of plumbing from charge pump to mud pump.Dirty or clogged charge pump feed and discharge lines.Improper maintenance of charge pump impellers – worn impellers cause a reduction of fluid pressure.Other factors that contribute to cavitation include: Factors that can contribute to cavitation, such as fluid velocity and pressure, can sometimes be attributed to an inadequate mud system design and/or the diminishing performance of the mud pump’s feed system. With pumps being run at max horsepower at today’s well sites, best practices can help contractors to avoid premature damage, extend consumables lifeĬavitation is an undesirable condition that reduces pump efficiency and leads to excessive wear and damage to pump components. ![]()
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