Pumping SAND! (or Producing SOLIDS)
Sand-What Doesn't Work and Why
  • (1) Cavins Tool-  This device attempts to spin the fluid in such a way that sand is separated from incoming fluid at the pump intake.  It is very doubtful that frac sand has enough mass to be affected by this.  However, the turbulence incurred on the fluid certainly causes gas to break out and be introduced to the pump intake.
  • (2) Filters-  All EFFECTIVE filters shear fluid and cause gas to break out and enter the pump.  This leads to excessive fluid pound and low pump efficiencies, possibly even gas lock.  This list includes Stren, Johnson, and Stanley (there may be others).  If you open up the filtration ports enough to eliminate the "shear" then the filter is ineffective. RULE : Never restrict your pump intake.
  • (3) Lubri-Plungers The last I heard there were 6 ring types for this plunger.  If any of them worked, why so many?  Most common failure, gas lock, the rings melt from friction.  Although I have pulled some that the metal was so cut by sand as to be junk.
  • (4) Wiper Rings  (Martin, & Sand Shark)  These things are just too fragile. 
  • (5) Large Bore Pumps  The faster you lower the fluid level the faster the sand comes.
  • (6) Martin Ring & Pressure Actuated Plungers-  They work fine if you don't have a frac sand problem.  If you do, expect failures.  The only advantage is that they don't stick solid. 
  • (7) Grooved Plungers  Aww C'mon!  I can sell you anything.  There is no reasonable expectation here.

  • (8) Open Ended Mud Anchors  I covered that somewhere else....

So What Does Work and WHY?
  • (1) 100% Resin Coated FRAC Sand - No Joke!  This is the most effective sand treatment ever.  Some will say it is too expensive, but if you consider the cost of replacing pumps for at least six months and the lost production incurred you will find that this is by far the cheapest way to deal with frac sand.
  • (2) Mother Hubbard Mud Anchors-  Scare you?  It did me at first.  But if you lower the fluid velocity in the mud anchor the chances of sand being pulled into the pump are reduced.  It gives the sand a chance to fall out.
  • (3) HF Purge Valves-  Let the sand in the mother hubbard exit into the rat hole. 
  • (4) Top Hold Down and Ring Valved Top Hold Down Pumps-  If stripping jobs are a problem consider this type pump.  It can usually be extracted without pulling the tubing (reducing pulling costs).  The tight fit of the pull rod may cause it to stick if you have a "flour" sand problem.  Also the cost of conversion may turn you off.
  • (5) Slow the Pumping Unit Down-  Keep things moving, don't give the sand a chance to settle out on top of the plunger.
  • (6) Balance the unit weight heavy- First plunger motion should be downward after the pumping unit stops.  This is the opposite for gas problems where the gas should be held compressed when the unit is down.  Sand settles on top of the plunger.  If the first plunger motion is upwards the sand is wedged between plunger and barrel.
  • (7) Run STROKE-THRU pumps-  Calculate plunger travel when pumped off and then design a pump where less than 1/2 of the plunger comes out into a larger chamber on the upstroke.  This causes turbulence on the upper portion of the plunger and does not allow the sand or solids to build up on the top of the plunger.  By experiment I have determined that it is not necessary that the bottom of the plunger be "wiped".  It is thus      possible to run a "high compression" pump that strokes out the top of the barrel.  This configuration will generally work in frac sand, iron sulfide, "flour" sand, and combinations of sands and iron.  NOTE:  It is NOT necessary to reduce or enlarge standard plunger-barrel clearances to gain this advantage.

  • (8) Try the "Panacea" Gas Tool-  By inserting a barrel extension in the middle of the stroke the plunger is wiped (like the stroke thru) but completely on both the up and downstrokes.
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