U.S. patent application number 10/831467 was filed with the patent office on 2004-10-28 for monitoring system for reciprocating pumps.
Invention is credited to Kight, Russell D., Matzner, Mark D..
Application Number | 20040213677 10/831467 |
Document ID | / |
Family ID | 33303199 |
Filed Date | 2004-10-28 |
United States Patent
Application |
20040213677 |
Kind Code |
A1 |
Matzner, Mark D. ; et
al. |
October 28, 2004 |
Monitoring system for reciprocating pumps
Abstract
A reciprocating pump assembly includes a pump housing that
houses a crankshaft. Pistons are mechanically connected to the
crankshaft for pumping fluid through cylinders. Each cylinder has a
fluid inlet and a fluid outlet. The pump also has a monitoring
housing connected to the reciprocating pump. Within the monitoring
housing is a computer with memory. Pressure sensor assemblies sense
a pressure value of a fluid within the pump, and are in electrical
communication with the memory. An accelerometer positioned on the
pump measures vibrations of the pump and is also in electrical
communication with the memory for storage of sensed vibrations or
displacements during operations. A proximity sensor in electrical
communication with the memory is located within the pump housing to
determine the rotational velocity of the crankshaft.
Inventors: |
Matzner, Mark D.; (Burleson,
TX) ; Kight, Russell D.; (Weatherford, TX) |
Correspondence
Address: |
Attention: James E. Bradley
BRACEWELL & PATTERSON, L.L.P.
P.O. Box 61389
Houston
TX
77208-1389
US
|
Family ID: |
33303199 |
Appl. No.: |
10/831467 |
Filed: |
April 23, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60465043 |
Apr 24, 2003 |
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Current U.S.
Class: |
417/63 |
Current CPC
Class: |
F01B 25/00 20130101;
F04B 51/00 20130101; F04B 2201/0804 20130101; F04B 2205/05
20130101; F04B 2203/0206 20130101; F01B 25/04 20130101 |
Class at
Publication: |
417/063 |
International
Class: |
F04B 049/00 |
Claims
That claimed is:
1. In a reciprocating pump assembly having a pump housing that
houses a crankshaft, a plurality of pistons mechanically connected
to the crankshaft for pumping a fluid through a plurality of
cylinders, each of the cylinders having a fluid inlet and a fluid
outlet, the reciprocating pump, comprises: a monitoring housing
mounted to the reciprocating pump assembly; a computer located
within the monitoring housing, the computer having a memory; and a
plurality of pressure sensor assemblies mounted to the pump and in
electrical communication with the memory to sense a pressure value
of a fluid within the pump.
2. The pump assembly according to claim 1, further comprising a
proximity sensor assembly in electrical communication with the
memory and positioned adjacent the crankshaft to calculate a
rotational velocity of the crankshaft.
3. The pump assembly according to claim 2, wherein the crankshaft
is mechanically connected to a gear assembly having a plurality of
teeth, and the proximity sensor counts teeth on gear assembly to
calculate the rotational velocity of the crankshaft.
4. The pump assembly according to claim 1, further comprising an
accelerometer in electrical communication with the memory and
positioned on the pump housing to sense vibrations of the pump.
5. The pump assembly according to claim 1, further comprising a
port extending through a sidewall of the reciprocating pump;
wherein each pressure sensor assembly further comprises a plug
member having an aperture that registers with the port; and a seal
member positioned between the sidewall of the reciprocating pump
and the plug member.
6. The pump assembly according to claim 5, wherein the seal member
further comprises a passageway extending longitudinally
therethrough, so that the aperture registers with the port.
7. The pump assembly according to claim 1, wherein at least one of
said plurality of sensor assemblies is positioned adjacent the
fluid outlet of each of the cylinders to sense the fluid pressure
of the fluid exiting the pump.
8. The pump assembly according to claim 7, wherein the fluid outlet
further comprises a discharge flange for receiving fluid from one
of the plurality of cylinders, with at least one of said plurality
of sensor assemblies being positioned on the discharge flange.
9. The pump assembly according to claim 1, wherein at least one of
said plurality of sensor assemblies is positioned adjacent the
fluid inlet of the cylinder to sense the fluid pressure of the
fluid entering the pump.
10. The pump assembly according to claim 1, further comprising a
cover plate connected to each of the cylinders on a side of each
cylinder opposite from the crankshaft; and wherein one of said
sensor assemblies is mounted to each of the cover plates to sense a
discharge fluid pressure within each of the cylinders.
11. A reciprocating pump assembly, comprising: a pump housing that
houses a crankshaft for the reciprocating pump; a plurality of
piston rods extending from the pump housing, each being
mechanically connected to and driven by the crankshaft, each of the
piston rods having a piston portion on the end extending away from
the crankshaft; a plurality of piston chambers in fluid
communication with the piston portion of each of the piston rods,
each of the piston chambers receiving fluid to be pumped by the
piston portion of each of the piston rods, each of the piston
chambers having a fluid inlet and a fluid outlet; a plurality of
ports extending through a selected plurality of sidewalls of the
reciprocating pump, each of the ports having a threaded
counter-bore, defining an outward facing shoulder; a monitoring
housing mounted to the reciprocating pump; a computer located
within the monitoring housing, the computer having a memory; and a
plurality of pressure sensor assemblies in electrical communication
with the memory to sense a pressure value of a fluid within the
pump, each pressure sensor assembly comprising: a threaded plug
member that secures to one of the ports, the plug member having an
aperture therethrough that registers with the port; a metal annular
seal member compressed between an inward facing end of the plug
member and the outward facing shoulder; and a transducer mounted to
the plug and in fluid communication with the aperture.
12. The pump assembly according to claim 11, wherein the transducer
is mounted on an outer end of the plug member.
13. The pump assembly according to claim 11, further comprising an
accelerometer in electrical communication with the memory and
positioned on the pump housing to sense vibrations of the pump.
14. The pump assembly according to claim 11, further comprising a
proximity sensor assembly in electrical communication with the
memory and positioned adjacent the crankshaft to calculate a
rotational velocity of the crankshaft.
15. The pump assembly according to claim 11, wherein the seal
member has a pair frusto-conical surfaces on opposite ends of the
seal member and through which a passageway extends and wherein the
pump assembly further comprises: a first conical counter-bore
formed in the plug member adjacent an inner end of the aperture,
the first conical counter-bore engaging one of the frusto-conical
surfaces of the seal member; and a second conical counter-bore
formed in the outward facing shoulder, the second conical
counter-bore engaging the other of the frusto-conical surfaces of
the seal member.
16. The monitoring assembly according to claim 11, wherein at least
one of said pressure sensor assemblies is positioned adjacent a
fluid outlet of the piston chambers to sense an overall fluid
pressure of the fluid exiting the pump.
17. The monitoring assembly according to claim 11, wherein at least
one of said pressure sensor assemblies is positioned adjacent a
fluid inlet of the piston chambers to sense an overall fluid
pressure of the fluid entering the pump.
18. The monitoring assembly according to claim 11, further
comprising a cover plate enclosing a side of each of the piston
chambers opposite from the crankshaft; and wherein at least one of
said sensor assemblies is mounted to each of the cover plates to
sense an individual fluid pressure of the fluid within each of the
piston chambers.
19. The monitoring assembly according to claim 11, further
comprising a memory housing, and wherein the memory is a portable
module that adapted to be removed to have information retrieved
from the memory at another location and replaced with another
portable module to receive data from the sensors.
20. A method of monitoring the operating conditions of a
reciprocating pump assembly having a pump housing that houses a
crankshaft, a plurality of pistons mechanically connected to the
crankshaft for pumping a fluid through a plurality of cylinders,
each of the cylinders having a fluid inlet and a fluid outlet, the
method comprising: providing a computer with a memory, mounting the
computer in a monitoring housing, and mounting the monitoring
housing to the reciprocating pump; positioning a plurality of
pressure sensor assemblies in fluid communication with ports formed
in a selected location and electrically connecting the sensor
assemblies to the computer of the reciprocating pump, operating the
pump, sensing fluid pressure with the sensor assemblies; and
communicating pressure values from each of the sensor assemblies to
the memory.
21. A method of claim 20, further comprising: mounting an
accelerometer to the pump housing and electrically connecting the
accelerometer to the computer; operating the pump and sensing
vibrations with the accelerometer; and communicating a sensed
vibration value from the accelerometer to the memory.
22. A method of claim 20, further comprising: positioning a
proximity sensor adjacent the crankshaft to calculate a rotational
velocity of the crankshaft; communicating a counted value of sensed
proximity values from the proximity sensor to the memory.
23. A method of claim 20, further comprising downloading the sensed
values from the memory to a remote computer via an access
terminal.
24. A method of claim 20, further comprising removing the memory
after a predetermined length of time through a memory drive located
within the monitoring housing and inserting a replacement memory
for the computer through the memory drive.
Description
RELATED APPLICATIONS
[0001] This nonprovisional patent application claims the benefit of
co-pending, provisional patent application U.S. Serial No.
60/465,043, filed on Apr. 24, 2003, which is hereby incorporated by
reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to reciprocating
pumps, more specifically to an apparatus for monitoring operating
conditions of the reciprocating pump.
[0004] 2. Background of the Invention
[0005] In oil field operations, reciprocating pumps are often used
for various purposes. Some reciprocating pumps, generally known as
"service pumps," are typically used for operations such cementing,
acidizing, or fracing the well. Typically, these service pumps run
for relatively short periods of time but on a frequent basis. Often
they are mounted to a truck or a skid for transport to various well
sites. A pump might operate several times a week. Many times,
several pumps will be connected in parallel to a flow line. The
operator will know the output pressure of the group of pumps due to
a pressure gauge on the flow line, but may not know the individual
pump output pressure. The operator will often not know the intake
pressure, the individual pump speed, or the extent of vibration of
a particular pump. A pump might be performing poorly, yet the
operator not know.
[0006] To periodically monitor the performance of the pump, an
operator typically calls on the services of testing companies that
will set up temporary sensors and monitor the performance of the
pump during a test period. Generally, the testing service connects
pressure gauges to the overall intake and discharge, as well as
each individual pressure chamber. The testing service might also
monitor the rotational speed and vibration. Then the testing
service removes the test equipment and the pump continues
operations without monitoring equipment.
[0007] Continuous monitoring of the pump through testing companies
is not practical. Moreover, during operations, the pressure of the
fluid inside of the pump can become quite high which makes it
difficult to obtain readings of pressures within the pump at
certain locations without leakage. Operators typically will not
often use the testing equipment due to the cost associated with the
testing companies. An operator may not have a pump tested unless
something appears to be wrong with it. Accordingly, operators are
often left in the situation of not knowing what the performance
conditions of a pump for long periods of time.
SUMMARY OF THE INVENTION
[0008] In this invention, a reciprocating pump assembly includes a
pump housing that houses a crankshaft. A plurality of pistons are
mechanically connected to the crankshaft for pumping a fluid
through a plurality of cylinders or piston chambers. Each of the
cylinders has a fluid inlet and a fluid outlet. The pump also has a
monitoring housing connected to the reciprocating pump. Within the
monitoring housing is a computer having a memory. The pump also has
a plurality of pressure sensor assemblies. Each pressure sensor
assembly is in electrical communication with the memory. Each
pressure sensor assembly is used to sense a pressure value of a
fluid within the pump.
[0009] The invention can optionally also include an accelerometer
to measure vibrations by sensing displacement. The accelerometer is
typically positioned adjacent the pump housing. The accelerometer
is also in electrical communication with the memory of the computer
so that the computer can store sensed vibrations or displacements
during operations. The invention can also have a proximity sensor
located within the pump housing to determine the rotational
velocity of the crankshaft. The proximity sensor is in electrical
communication with the memory of the computer so that the computer
can store sensed proximity values during operations.
[0010] A pressure sensor assembly that can be used in this
invention includes a plug member. The plug member is positioned
adjacent a sidewall of the pump. The sidewall can be selected from
various sidewalls that are in fluid communication with the fluid
pumped within the reciprocating pump. A port is located in the
sidewall of the pump that is in fluid communication with the fluid
within the pump. The plug member has an aperture that registers
with the port when the plug member is positioned adjacent the side
wall. A seal member is positioned between the plug member and the
sidewall. The seal member has a passageway that allows the aperture
to register with the port when the seal member and the plug member
are in place. A transducer is located within the plug member and is
in fluid communication with the aperture. The transducer converts
the pressure into electronic signals that can be communicated to
the computer.
[0011] The computer of the pump assembly can also have a port that
allows an operator to download the stored sensed values in the
memory. This allows an operator to collect the sensed values of the
operating conditions over long periods of operation for analysis
and monitoring purposes. Alternatively, the memory of the computer
can be a replaceable memory device such as a chip or disk. The
computer can include a drive for receiving and ejecting the memory
so that the operator can easily retrieve and replace the memory
after predetermined periods of operations for analysis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic elevational view of a reciprocating
pump assembly constructed in accordance with this invention.
[0013] FIG. 2 is a top plan schematic view of the reciprocating
pump assembly shown in FIG. 1.
[0014] FIG. 3 is a sectional view of a portion of the pump assembly
shown in FIG. 1.
[0015] FIG. 4 is a perspective view of the reciprocating pump
assembly shown in FIG. 1.
[0016] FIG. 5 is an enlarged sectional view of a monitoring sensor
assembly shown in a cover plate of the reciprocating pump assembly
shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Referring to FIGS. 1 and 3, reciprocating pump or pump
assembly 12 includes a monitoring assembly 11 is shown attached to
a reciprocating pump 12. In the preferred embodiment, reciprocating
pump 12 includes a crankshaft housing 13 that comprises a majority
of the outer surface of reciprocating pump 12 shown in FIGS. 1 and
3. A plunger or piston rod housing 15 attaches to a side of
crankshaft housing 13 and extends to a cylinder 17. Each cylinder
17 preferably includes a fluid inlet 19 and a fluid outlet 21 (FIG.
2). As best shown in FIG. 3, a cover plate 22 connects to an end of
each cylinder 17 opposite from the piston rod housing 15. While
pump 12 is shown in FIG. 4 as free-standing on the ground, pump 12
can easily be mounted to a trailer that can be towed between
operational sites, or to a skid such as for offshore operations.
Accordingly a pump assembly is defined as including either a pump
12 mounted directly to the ground or support structure, a skid, or
a trailer.
[0018] Referring to FIG. 2, piston rod housing 15 is segmented into
three portions, each portion comprising a plunger or piston throw
23. Reciprocating pump 12 as shown in FIG. 2 has three piston
throws 23, which is commonly know as a triplex, but could also be
segmented for five piston throws 23, which is commonly known as a
quintuplex pump. The description focuses on a triplex pump, but as
will be readily apparent to those skilled in the art, the features
and aspects described are easily applicable for a quintuplex or
other type of pump. Each piston throw 23 houses a piston rod 33
(FIG. 3) extending to cylinder 17. As shown in FIG. 2, each piston
throw 23 extends in the same longitudinal direction from crankshaft
housing 13.
[0019] Referring to FIG. 3, a portion of reciprocating pump 12
housed within crankshaft housing 13 is shown. Crankshaft housing 13
houses a crankshaft 25, which is typically mechanically connected
to a motor (not shown). The motor (not shown) rotates crankshaft 25
in order to drive reciprocating pump 12. In the preferred
embodiment, crankshaft 25 is cammed so that fluid is pumped from
each piston throw 23 at alternating times. As is readily
appreciable by those skilled in the art, alternating the cycles of
pumping fluid from each of cylinders 17 helps minimize the primary,
secondary, and tertiary (et al.) forces associated with
reciprocating pump 12.
[0020] In the preferred embodiment, a gear 24 is mechanically
connected to crankshaft 25. Gear 24 can be for mechanically
connecting crankshaft 25 to the motor (not shown), or for conveying
rotational energy to another gear for driving another assembly,
such as a lubrication pump for lubricating. Gear 24 typically has
teeth 26 spaced around the circumference of gear 24. In the
preferred embodiment, a proximity sensor 28 is positioned adjacent
crankshaft 25 for calculating the rotational velocity of crankshaft
25. One manner proximity sensor 28 can help calculate rotational
velocity is by counting teeth 26 as gear 24 rotates. For example,
one type of proximity sensor creates a magnetic field within its
close proximity. As the each tooth 26 rotates past the proximity
sensor 28, there is a disruption in the magnetic field. These
disruptions can be counted and compared to time to help calculate a
rotational speed of the gear 24, which in turn can be used to
calculate the rotational speed of crankshaft 25.
[0021] In the preferred embodiment, a connector rod 27 includes an
end that connects to crankshaft 25 and another end that engages a
crosshead 29. Connector rod 27 connects to crosshead 29 through a
crosshead pin 31, which holds connector rod 27 longitudinally
relative to crosshead 29. Connector rod 27 pivots about crosshead
pin 31 as crankshaft 25 rotates with the other end of connector rod
27. A piston rod 33 extends from crosshead 29 in a longitudinally
opposite direction from crankshaft 25. Connector rod 27 and
crosshead 29 convert rotational movement of crankshaft 25 into
longitudinal movement of piston rod 33.
[0022] A piston 35 connects to piston rod 33 for pumping the fluid
passing through reciprocating pump 12. Cylinder 17 connects to the
end of piston rod housing 15 extending away from crankshaft housing
13 (FIG. 1). Cylinder 17 typically includes a cylinder chamber 39,
which is where the fluid being pumped by reciprocating pump 12 is
compressed by piston 35. Cylinder 17 preferably includes an inlet
valve 41 and an outlet valve 43. Valves 41 and 43 are preferably
spring-loaded valves, which are actuated by a predetermined
differential pressure. Inlet valve 41 actuates to control fluid
flow through fluid inlet 19 into cylinder chamber 39, and outlet
valve 43 actuates to control fluid flow through fluid outlet 21
from cylinder chamber 39. Piston 35 reciprocates, or moves
longitudinally toward and away from cylinder 17, as crankshaft 25
rotates. As piston 35 moves longitudinally away from cylinder
chamber 39, the pressure of the fluid inside chamber 39 decreases
creating a differential pressure across inlet valve 41, which
actuates valve 41 and allows the fluid to enter cylinder chamber 39
from fluid inlet 19. The fluid being pumped enters cylinder chamber
39 as piston 35 continues to move longitudinally away from cylinder
17 until the pressure difference between the fluid inside chamber
39 and the fluid in fluid inlet 19 is small enough for inlet valve
41 to actuate to its closed position. As piston 35 begins to move
longitudinally towards cylinder 17, the pressure on the fluid
inside of cylinder chamber 39 begins to increase. Fluid pressure
inside cylinder chamber 39 continues to increase as piston 35
approaches cylinder 17 until the differential pressure across
outlet valve 43 is large enough to actuate valve 43 and allow the
fluid to exit cylinder 17 through fluid outlet 21. In the preferred
embodiment, fluid is only pumped across one side of piston 35,
therefore reciprocating pump 12 is a single-acting reciprocating
pump. If fluid were also being pumped on the side of piston 35 that
connects to piston rod 33, this would be a double acting pump.
[0023] In the preferred embodiment, a pressure sensor assembly
monitors the pressure of fluid being pumped by reciprocating pump
12. Preferably there are a plurality of pressure sensor assemblies
advantageously positioned adjacent various sidewalls of pump 12 to
sense fluid pressure values at various locations throughout pump
12. For example, as best shown in FIG. 4, there is a pressure
sensor assembly 45 mounted to each cover plate 22, which allows for
sensing the output fluid pressure individually within each cylinder
17. In the embodiment shown in FIG. 4, there is also preferably a
pressure sensor assembly 46 mounted to fluid inlet 19, which feeds
into each of cylinders 17, to sense the overall suction fluid
pressure of the fluid entering pump 12. Additionally, there is also
preferably a pressure sensor assembly 47 mounted to each discharge
flange or well fluid outlet 21 to sense the individual fluid
pressure of the fluid exiting each cylinder 17. In the preferred
embodiment, wires 49 are in electrical communication with pressure
sensors 45, 46, and 47. In the preferred embodiment, each pressure
sensor assembly 45 includes a plurality of wires 49 extending
therefrom. A preferred structure of each pressure sensor assembly
is provided in more detail below.
[0024] As best illustrated in FIGS. 2-4, wires 49 extending from
each pressure sensor assembly 45 combine to form a single bundle or
wire harness 51. Wire harness 51 preferably extends below cylinders
17 toward crankshaft housing 13. Referring back to FIG. 2, the end
of wire harness 51 extending toward crankshaft housing 13 connects
to a wire harness disconnect 53 located on crankshaft housing 13.
Wire harness disconnect 53 preferably allows an operator to
selectively disengage wire harness 51 while replacing or repairing
cylinders 17. A second bundle or wire harness 55 extends from wire
harness disconnect 53 toward an upper portion of crankshaft housing
13.
[0025] In the preferred embodiment, a monitoring housing or data
collector 57 is located on an upper portion of crankshaft housing
13. Data collector 57 preferably comprises a computer 58 (FIG. 1)
that receives and stores data about the operating conditions of
pump 12. In a manner known in the art, computer 58 includes memory.
As shown in FIG. 4, computer 58 can include a port 60 for
downloading data from the memory to another computer. Additionally,
computer 58 can optionally include portable memory that is
removable and insertable through a drive 62. Such replaceable
memory allows an operator to store operating conditions on the
memory of computer 58 for a predetermined length of time, and then
retrieve the memory with the stored data for analysis and replace
the previous memory with a replacement memory for storing data for
another predetermined length of time.
[0026] The end of wire harness 55 extending from wire harness
disconnect 53 connects to data collector 57. Data collector 57
receives and records the inlet and outlet pressures for each of
cylinders 17 associated with reciprocating pump 12 as pistons 35
stroke. As will be appreciated by those skilled in the art, the
inlet and outlet pressures from each cylinder 17 can then be
transmitted from data collector 57 to a centrally located facility
or the measurements can be digitally stored until retrieved by an
operator. Additionally, proximity sensor 28 (FIG. 3) is also
preferably in electrical communication with the memory of computer
58 so that proximity sensor can transmit the sensed proximities of
teeth 26 for storage in the memory of computer 58. Computer 58
computes speed of rotation based on the rate that proximity sensor
28 senses teeth 26. In the preferred embodiment, data collector 57
includes memory that receives and stores the information.
Monitoring inlet and outlet pressures within cylinder chambers 39
allows operators to monitor the efficiency of reciprocating pump 12
as well as the differential pressures associated with inlet and
outlet valves 41, 43. By monitoring inlet and outlet pressures
within cylinder chamber 39, operators can more effectively
determine the appropriate time for replacing inlet and outlet
valves 41, 43.
[0027] Accelerometer 59 is supported on pump housing 13 and
monitors the vibrations of reciprocating pump 12 as crankshaft 25
drives each piston 35 with piston rods 33. Typically, accelerometer
59 transmits various voltages responsive to vibrations to data
collector 57 for computer 58 to calculate vibrations. Monitoring
vibrations associated with reciprocating pump 12 allows operators
to detect any abnormal operating conditions of reciprocating pump
12. In the preferred embodiment, the chip (not shown) in data
collector 57 also receives and stores the information from
accelerometer 59. In the preferred embodiment, monitoring assembly
11 includes the combined assembly of data collector 57,
accelerometer 59, proximity sensor 28, wires and wire harnesses 49,
51, 55, wire harness disconnect 53, and pressure sensor assemblies
45, 46 and 47.
[0028] FIG. 5 shows an example of the preferred embodiment of the
pressure sensor assembly 45. In the example shown in FIG. 5,
pressure sensor assembly 45 is connected to one of cover plates 22
to sense discharge pressure. As will be readily appreciated by
those skilled in the art, this arrangement is easily suitable for
the positioning of pressure sensor assemblies 45, 46, 47 on the
other various selected sidewalls of pump 12, like at pump inlet and
outlets 19, 21.
[0029] Pressure sensor assembly 45 is positioned on the outer
surface of cover plate 22. A port 71 extends from an interior
surface of cover plate 22 toward the outer surface of cover plate
22. Port 71 is in fluid communication with the fluid pumped by one
of the pistons 35. A plug member 73 preferably extends into a
portion of cover plate 22. An aperture 75 extending through a
portion of plug member 73 registers with port 71. In the preferred
embodiment, a thread 77 formed on a portion of the outer
circumference of plug member 73 that engages a counter-bored thread
79 formed in cover plate 22 for securing plug member 73 to cover
plate 22. The counter-bore portion of port 71 defines an outward
facing shoulder 80.
[0030] A metal seal member 81 is sealingly positioned and
compressed between an end of plug member 73 and shoulder 80. A
passageway 83 extends longitudinally through seal member 81 so that
aperture 75 can register with port 71. In the preferred embodiment,
seal member 81 has a pair of frusto-conical surfaces 85 formed at
each longitudinal end for engaging plug member 73 and shoulder 80.
The pair of frusto-conical ends 85 form a metal to metal seal with
seal member 81 between plug member 73 and shoulder 80 when plug
member is installed. A transducer 87 is located within plug member
in fluid communication with aperture 75. A set of electrical prongs
89 extend from transducer 87 for connection to a plug on each wire
49. Wires 49 (FIGS. 1-4) communicate sensed pressure values
electronically to the memory of computer 58.
[0031] In operation, pressure assemblies 45, 46, 47 are fixedly
positioned adjacent various selected sidewalls of pump 12. Seal
member 81 of each pressure sensor assembly 45 provides a seal
against leakage of the fluid pumped by pump 12 from exiting through
pressure sensor assemblies 45. Wires 49 are connected to pressure
sensor assemblies 45 so that wires 49 are in electrical
communication with prongs 89 extending from each transducer 87.
During operation of pump 12, the fluid communicates with transducer
87 through port 71, passageway 83, and aperture 75. Transducer
converts the sensed pressure to an electrical signal and
communicates the signal to the memory in computer 58 via wires 49.
In the preferred embodiment, accelerometer 59 and proximity sensor
28 are also communicating their sensed displacement and proximity
readings to the memory in computer 58.
[0032] Computer 58 stores the sensed values from pressure sensor
assemblies 45, 46, 47, accelerometer 59, and proximity sensor 28 in
the computer memory. The operator can download the sensed values
from the memory via a port 60. In the preferred embodiment, the
operator can alternatively remove the memory with the stored values
from computer 58 via drive 62, and insert a replacement memory for
receiving and storing continued sensed operating conditions. This
allows continuous monitoring of sensed pressure values of fluid at
various positions, and at high pressures within reciprocating pump
12 during long periods of operation rather than only during short
test runs.
[0033] While the invention has been shown in only some of its
forms, it should be apparent to those skilled in the art that it is
not so limited, but is susceptible to various changes without
departing from the scope of the invention. For example, wires 49
can extend through various sides or ends of cylinders 17 to connect
with pressure transducers 45, 46, 47. Furthermore, in situations
where the pump assembly is mounted to a skid or a trailer, it will
be readily appreciated by those skilled in the art that equipment
that is mounted to a pump or crankshaft housing (e.g. data
collector 57) can easily be mounted to the skid or trailer instead
of the crankshaft housing with a minimal changes and a little extra
length of wiring. As a further example, while all the figures
illustrate service pumps that are typically used for cementing,
acidizing, or fracing, the monitoring assembly 11 could also easily
be used on mud pumps for drilling operations.
* * * * *