U.S. patent application number 14/600230 was filed with the patent office on 2015-05-14 for reinforced smart mud pump.
The applicant listed for this patent is Gerard S. Lazzara. Invention is credited to Gerard S. Lazzara.
Application Number | 20150132152 14/600230 |
Document ID | / |
Family ID | 41133448 |
Filed Date | 2015-05-14 |
United States Patent
Application |
20150132152 |
Kind Code |
A1 |
Lazzara; Gerard S. |
May 14, 2015 |
Reinforced Smart Mud Pump
Abstract
A pump system for movement of fluids having a reciprocating
piston power pump having at least three reciprocating pistons
operable to displace fluid from a housing having a pumping chamber,
an integrally forged crankshaft operably connected to the pistons,
at least one sensor operable to sense ambient conditions on the
pump, and a computer control for processing data from the sensor to
regulate the operation of the pump in response to the data. The
system also utilizes protective infused treatments for lubricity
and enhanced lubrication sprayers and a reset relief valve and
pressure sensors operably connected to the computer system for
control and monitoring of the pump.
Inventors: |
Lazzara; Gerard S.;
(Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lazzara; Gerard S. |
Houston |
TX |
US |
|
|
Family ID: |
41133448 |
Appl. No.: |
14/600230 |
Filed: |
January 20, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12220876 |
Jul 29, 2008 |
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14600230 |
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60962637 |
Jul 30, 2007 |
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Current U.S.
Class: |
417/213 ;
417/271 |
Current CPC
Class: |
F04B 15/023 20130101;
F04B 49/065 20130101; F04B 15/02 20130101; F04B 49/22 20130101;
F05C 2225/04 20130101; F04B 49/10 20130101 |
Class at
Publication: |
417/213 ;
417/271 |
International
Class: |
F04B 49/06 20060101
F04B049/06; F04B 49/10 20060101 F04B049/10; F04B 49/22 20060101
F04B049/22; F04B 15/02 20060101 F04B015/02 |
Claims
1-15. (canceled)
16. A mud pump system for movement of fluids comprising: a
reciprocating piston power pump having at least three reciprocating
pistons operable to displace fluid from a housing having a pumping
chamber; a crankshaft and integrally extended cams forged from a
single ingot by repetitive open hammer forging generating a tensile
strength of approximately 200,000 p.s.i; at least one sensor
operable to sense pressure spikes on said pump; and a computer
control for processing data from said sensor to modulate the pump
and activate a relief valve in response to said pressure
spikes.
17. The pump system as claimed in claim 16 further comprising a
reset relief valve operably connected to said pump and actuatable
in response to a predetermined pressure.
18. The pump system as claimed in claim 16 further comprising a
reset relief valve operably connected to said pump actuatable in
response to a sensor in communication with said control.
19. The pump system as claimed in claim 16 further comprising data
logging of historical pump activity through said control.
20. The pump system as claimed in claim 16 wherein said pump speed
may be operably controlled in response to said data.
21. The pump system as claimed in claim 16 wherein said put p speed
may be operably controlled in response to said tranducer.
22. The pump system as claimed in claim 16 further comprising a
vessel for collecting pumped fluid before porting to a downstream
pipe.
23. The pump system as claimed in claim 16 further comprising an
alarm.
24. A pump system for movement of fluids comprising: a
reciprocating piston power pump having at least three reciprocating
pistons operable to displace fluid from a housing having a pumping
chamber; an integrally forged crankshaft operably connected to said
pistons; crossheads made of ductile iron having a center line
alignment monitored by a laser; polyflorocarbon infused treatment
applied to at least one crosshead slide in said system; and at
least one sensor operable to sense ambient conditions on said
pump.
25. The pump system as claimed in claim 24 further comprising an
air pressure seal about a portion of a rod connected to at least
one of said pistons.
26. The pump system as claimed in claim 24 further comprising an
oil lubrication shower about said crankshaft.
27. The pump system as claimed in claim 24 further comprising a
vibration sensor.
28. The pump system as claimed in claim 26 wherein said air
pressure seal circumferentially applies pressurized air about said
rod.
29. The pump system as claimed in claim 24 further comprising three
pumping chambers each exposed to their respective plungers and
pistons.
30. A pump system for movement of fluids comprising: a
reciprocating piston power pump having at least three reciprocating
pistons operable to displace fluid from a housing having a pumping
chamber; an integrally forged crankshaft operably connected to said
pistons; at least one sensor operable to sense pressure spikes on
said pump; a computer control for processing data from said sensor
to regulate the operation of the pump in response to said data; and
pressure sensors for monitoring fluid pressure operably connected
to said computer control.
31. A pump system as claimed in claim 30 further comprising a reset
relief valve.
32. A pump system as claimed in claim 30 further comprising a
vessel for receiving pumped fluid before porting to a pipe.
33. A pump system as claimed in claim 30 further comprising a
pressurized air seal about a portion of a rod connected to at least
one of sand pistons.
34. A pump system as claimed in claim 30 further comprising a
computer display showing discharge piping operating pressure, peak
to peak pressures, fluid flow rate induced peak to peak pressure,
and pump volumetric efficiency.
35. A pump system as claimed in claim 30 further comprising a
sensor for detecting the location of the piston relative to dead
center.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of pending U.S. patent
Ser. No. 12/220,876 entitled "A Reinforced Smart Mud Pump" which
take priority to provisional application for patent filed Jul. 30,
2007 bearing Ser. No. 60/962,637 and is incorporated by reference
herein as if fully set forth.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
DESCRIPTION OF ATTACHED APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] This invention relates generally to the field of mud pumps
and more specifically to a reinforced smart mud pump. Mud pumps
that use piston displacement, produce imposed forces that cause
wear and tear on various pump components, including pump cross head
piping, cylinders, inlet and discharge valves, seal components
including piston or plunger seals, the pump cylinder block or
so-called fluid end, and other components. There has been a need to
provide increased longevity and performance for such pumps and to
determine if deteriorations in pump performance are occurring, to
analyze the source of decreased performance and to further real
time control and data to monitor and in some cases change the
operating characteristics before damage occurs to the pump. The use
of greatly strengthened components in combination with a computer
controlled system integrated with a real time monitored and
controlled reset relief valve may be integrated into an oilfield
application to prevent catastrophic pump failure and extend pump
life.
[0005] Pump operating characteristics often have a deleterious
effect on pump performance. For example, delayed valve closing and
sealing can result in loss of volumetric efficiency. Factors
affecting pump valve performance include fluid properties, valve
spring design and fatigue life, valve design and the design of the
cylinder or fluid end housing. Delayed valve response also causes a
higher pump chamber pressure than normal which in turn may cause
overloads on pump mechanical components, including the pump
crankshaft or eccentric and its bearings, speed reduction gearing,
the pump drive shaft and the pump prime mover. Moreover, increased
fluid acceleration induced pressure "spikes" in the pump suction
and discharge flowstreams can be deleterious. Fluid properties are
also subject to analysis to determine compressibility, the
existence of entrained gases in the pump fluid stream,
susceptibility to cavitation and the affect of pump cylinder or
fluid end design on fluid properties and vice versa.
[0006] Still further, piston or plunger seal or packing leaking can
result in increased delay of pump discharge valve opening with
increased hydraulic flow and acceleration induced hydraulic forces
imposed on the pump and its discharge piping. Moreover, proper
sizing and setup of pulsation control equipment is important to the
efficiency and long life of a pump system. Pulsation control
equipment location and type can also affect pump performance as
well as the piping system connected to the pump
[0007] In prior art, the control of a mud pump has been disclosed
focused on piston position for acquiring information about the pump
and its performance characteristics. For example, U.S. Pat. No.
6,882,960 to Miller, shows a system for monitoring and analyzing
performance parameters of reciprocating piston, or power pumps and
associated piping systems. This patent fails to disclose the
innovative aspects of the present invention.
[0008] Nothing in the prior art shows a computer integrated mud
pump with significant strengthening features that increase the life
cycle of a pump in the manner of the present invention with real
time control of significant operating functions and feedback from
various sensors and reset relief valves.
BRIEF SUMMARY OF THE INVENTION
[0009] The primary advantage of the invention is to provide a mud
pump that is continuously monitored during operation.
[0010] Another advantage of the invention is to provide a mud pump
that utilizes transducers in line with the ambient pressure in
conjunction with a computer controlled pressure relief valve to
record and monitor pump characteristics and control the pump to
prevent catastrophic failure.
[0011] Another advantage of the invention is to provide a mud pump
that transmits data to a computer for later analysis of important
operating characteristics.
[0012] A further advantage of the invention is to provide a mud
pump that can be controlled during its operation to prevent certain
damaging events to the pump or underlying pressurized system.
[0013] Yet another advantage of the invention is to provide a
single piece integrally forged and balanced crank assembly for
greater strength during operation.
[0014] Still yet another advantage of the invention is to provide
increased tensile strength up to 200,000 p.s.i. using advanced
metallurgical engineering.
[0015] In accordance with a preferred embodiment of the invention,
there is shown a pump system for movement of fluids having a
reciprocating piston power pump having at least three reciprocating
pistons operable to displace fluid from a housing having a pumping
chamber, an integrally forged crankshaft operably connected to the
pistons, at least one sensor operable to sense ambient conditions
on the pump, and a computer control for processing data from the
sensor to regulate the operation of the pump in response to the
data.
[0016] In accordance with a preferred embodiment of the invention,
there is shown a pump system for movement of fluids having a
reciprocating piston power pump having at least three reciprocating
pistons operable to displace fluid from a housing having a pumping
chamber, an integrally forged crankshaft operably connected to the
pistons, polyflorocarbon infused treatement applied to at least one
crosshead and one crosshead slide in the system, and at least one
sensor operable to sense ambient conditions on the pump.
[0017] In accordance with a preferred embodiment of the invention,
there is shown a pump system for movement of fluids having a
reciprocating piston power pump having at least three reciprocating
pistons operable to displace fluid from a housing having a pumping
chamber, an integrally forged crankshaft operably connected to the
pistons, at least one sensor operable to sense ambient conditions
on the pump, a computer control for processing data from the sensor
to regulate the operation of the pump in response to the data; and
pressure sensors for monitoring fluid pressure operably connected
to the computer control. In addition, upper and lower limits to
temperature, vibration and pressure can be set. Further, in a
preferred embodiment, all lubrication and water pumps must be on
before the control system will permit unit to be operated.
[0018] Other advantages of the present invention will become
apparent from the following descriptions, taken in connection with
the accompanying drawings, wherein, by way of illustration and
example, an embodiment of the present invention is disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The drawings constitute a part of this specification and
include exemplary embodiments to the invention, which may be
embodied in various forms. It is to be understood that in some
instances various aspects of the invention may be shown exaggerated
or enlarged to facilitate an understanding of the invention.
[0020] FIG. 1 shows a side view of the pump and auxiliary equipment
according to a preferred embodiment of the invention.
[0021] FIG. 2 shows a side view of the pump internal forged crank
and plunger connections according to a preferred embodiment of the
invention.
[0022] FIG. 3 shows a partial cutaway side view of the pump
according to a preferred embodiment of the invention.
[0023] FIG. 3A shows a cross sectional view of the positive air
pressure plunger seal about a synchronized plunger rod according to
a preferred embodiment of the invention.
[0024] FIG. 4 shows a partial cutaway overhead of the pump housing
according to a preferred embodiment of the invention.
[0025] FIG. 4A shows a schematic drawing of a representative
computer controlled monitoring system according to a preferred
embodiment of the invention.
[0026] FIG. 5 shows a perspective view of the pressure relief valve
according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Detailed descriptions of the preferred embodiment are
provided herein. It is to be understood, however, that the present
invention may be embodied in various forms. Therefore, specific
details disclosed herein are not to be interpreted as limiting, but
rather as a basis for the claims and as a representative basis for
teaching one skilled in the art to employ the present invention in
virtually any appropriately detailed system, structure or
manner.
[0028] In a preferred embodiment of the present invention, there is
shown a reciprocating plunger or piston power pump. The pump
includes additional features not found in conventional reciprocal
pumps as heretofore described. The basic operation of the pump is
similar to a triplex plunger pump configured to reciprocate three
spaced apart plungers or pistons, which are connected by suitable
connecting rod and crosshead mechanisms, to a rotatable crankshaft
or eccentric. FIG. 1 shows a side view of the pump and auxiliary
equipment according to a preferred embodiment of the invention.
Pump housing 100 covers the internal pump components and allows for
a variety of conventional means to move the rotatable crankshaft
114 such as an electric motor 102 and belt drive 104. Within pump
housing 100 may be disposed a pressurized lubrication spraying
system that continuously feeds lubricant such as oil around the
crankshaft and associated internal pump components.
[0029] A suction module 104 of conventional design houses each
plunger which operates each section of the triplex plunger pump. A
pressure relief valve mount 110 allows for attachment of a reset
relief valve (show in FIG. 5) to at least one suction module 106 in
a system for pumping drilling mud composed of water, clay and
chemical additives, down through the inside of a drill pipe of an
oil well drilling operation. The drilling mud is pumped at very
high pressure so the mud is forced out through a bit at the lower
end of the drill pipe and returned to the surface, carrying rock
cuttings from the well. In this illustrative example the drilling
mud from the pump system is fed into the attached vessel 112
sometimes known as a dumping ball. In a preferred embodiment all
components are installed on a full unitized skid 120 providing room
for motors, starters, sheaves, belts and any associated test
equipment and a solid platform for installation of bracing 122 for
component parts. Vessel 112 smoothes out the pulsation caused by
the pumping action of the system to deliver pumped fluid out of
port 115 in a more controlled manner.
[0030] With the use of computer modeling, high technology
engineering, metallurgical and mechanical enhancements, the smart
pump is revolutionary in design. The pump is manufactured using
advanced materials and techniques including an integrally forged
and balanced crank. This provides significant strength advantages
and increases the life cycle of the pump. Unlike prior art pump
systems, the crank is not a porous unbalanced crank casting, nor is
it a fabricated with separate plates and bars and later welded
together. As shown in FIG. 2 the crank 200 is fabricated from an
integrally forged single ingot by the open hammer forging process
resulting in a single piece with no welding or pinning of multiple
pieces. A connecting rod 202 for each plunger is attached to the
crank 200 such that the crank freely rotates and creates a
reciprocating action in each connecting rod 202 attached to the
crank 200. A crosshead 204 and crosshead slide 206 attach to each
connector rod to help retain engine oil in the crankcase. A plunger
connection 210 at each connector rod 202 end provides a means of
attachment for a variety of rod and plunger components.
[0031] All of the ground crossheads 204 and honed crosshead slides
206 are treated with a polyflorocarbon coating for more lubricity
and wear performance characteristics resulting in 15% less energy
cost. This process has been used in the racing industry with much
higher performance results. The poly-fluorocarbon coating is
applied to each crosshead and slide and helps retain engine oil on
the component surfaces during intense heat and extreme pressure.
The oil is essentially absorbed into each crosshead 204 and slide
206 in such a way as to increase their lubricity. The crosshead 204
center line alignment is laser monitored for even wear. In a
preferred embodiment of the invention the pump uses suction
modules, discharge modules and discharge manifold and a double
helical gear set. All gear sets are prepared with mesh test
providing contact tapes accompanied by digitals to AGMS 11+
standards. All gear sets are further preferably chemically treated
to 0.4 RMS or better to exponentially increase bearing life.
[0032] In the present invention, the crankshaft is a integrally
forged piece to increase its operating strength significantly, and
is an integral part of the crank 200. The terms crank 200 and
crankshaft are used interchangably although in conventional pumps
and engines the crank 200 and crankshaft may comprise separate
components. Turning again to FIG. 1 we see the crankshaft includes
a rotatable input shaft portion adapted to be operably connected to
a suitable prime mover, such as an internal combustion engine or
electric motor 102, as an exemplary installation. The crankshaft is
mounted in a suitable, so-called power end housing 114 which is
connected to a fluid end structure configured to have a plurality
of pumping chambers, in this example, three separate pumping
chambers exposed to their respective plungers or pistons. Plungers
refer to the rod, rod joints and piston end portions of the plunger
unless otherwise specified.
[0033] FIG. 3 shows a partial cutaway side view of the pump
according to a preferred embodiment of the invention. The fluid end
comprises a housing having the series of plural cavities or
chambers for receiving fluid from an inlet manifold by way of
conventional poppet type inlet or suction valves contained each
suction module 300. The piston or plunger 304 projects at one end
into the chamber and is connected to a suitable crosshead mechanism
306, including a crosshead extension. The crosshead extension is
operably connected to the crankshaft using connecting rods 308 as
described above. Each plunger 306 projects through a conventional
packing 310 or plunger 306 seal. Each chamber for each plunger 306
is operably connected to a discharge piping manifold by way of a
suitable discharge valve. Valves may be of a variety of
conventional designs and are typically spring biased to their
closed positions. Valves may also include or are associated with
removable valve seat members. Each valve may also have a seal
member formed thereon engageable with the associated valve seat to
provide fluid sealing when the valves are in their respective
closed and seat engaging positions. A unique feature of a preferred
embodiment of the the smart pump is a positive air pressure plunger
seal 312 to prevent leakage and prevent wear on the plunger. FIG.
3A shows a cross sectional view of the positive air pressure
plunger seal about a synchronized plunger according to a preferred
embodiment of the invention. As the plunger 350 moves reciprocally,
pressurized air is introduced into through seal 352 through a
plurality of pressurized air ports 354 preventing fluid leakage
from the plunger 350 end which engages and moves drilling mud
through the aforementioned valves. The pressurized air flow 356
isolates any material from scoring and etching the plunger 350 and
reduces friction between the seal wall and the plunger 350.
[0034] In a preferred embodiment the pump may be fitted with a
P-QUIP .RTM. fluid end systems including P-QUIP .RTM. kwik clamp
liner retentions system, P-QUIP .RTM. kwik rod system and cover
system. The P-QUIP .RTM. kwik-clamp valve and strainer cover
retention system has a very fast and safe access with much reduced
down time and LTAs (Lost Time Accidents) due to mishaps. Hammers or
cheater bars are not required and the system includes an automatic
clamping means which results in no more under or over
tightening--caps will not loosen off in use. This all results in
easy installation and easy operation with conventional air or hand
operated hydraulic pump. Like the Liner Retention System, the valve
and strainer covers are sealed firmly in the fluid end by means of
a spring mechanism. Similarly, the outer cover is removed when the
clamping force is released by means of the hydraulic pump. This
system heightens safety as it is no longer necessary to tighten OEM
type threaded cap retainers by hammer.
[0035] The P-QUIP .RTM. kwik rod system allows for fast and safe
piston changes and is constructed of 17.4 PH martensitic
high-resistance stainless steel, eliminating corrosion. Three piece
rod system is held together using pins, which eliminates prior
systems and clamp type systems. The P-QUIP .RTM. kwik cover system
allows for fast and save valve access changes with no hammers or
cheater bars. The cover offers a positive retention force against
the plug eliminating the need for retightening. The P-Quip .RTM.
kwik rod pump rod system permits fast and safe piston changes
resulting in reduced down time. There is no need for heavy clamps
or connecting threads and studs. The clamping force is
automatically controlled resulting in no broken rod ends. Due to
its construction, its self alignment facility gives improved piston
and liner life. There are no corrosion problems as all parts are
stainless steel, including hard-surfaced stainless steel power end
rods. It has an integral liner flushing systems.
[0036] On conventional mud-pump rod systems, the rod is held
together by means of taper clamps and screw threads which are slow
and awkward to assemble correctly and readily wear out. Due to
their design, the clamps obscure vision of the rod joints,
preventing a check being made that the rod is correctly aligned.
Uneven loads are imposed on the flanged rod ends, resulting in
premature failure.
[0037] The P-QUIP .RTM. Kwik-Rod system avoids these problems as
the rod components are held together by powerful spring-loaded ends
on a release link in the center of the rod assembly. The ends of
the release link are attached to the pony rod and piston rod by
means of high tensile stainless steel pins held in shear. The shear
force is very quickly and easily released by a few strokes of a
small hydraulic pump.
[0038] Dismantling and re-assembly of the complete rod system takes
under one minute. Furthermore, there are no flanged joints on the
rods to chip, wear or break. Hence, rod life is enhanced and,
because rod alignment is readily achieved, significantly improved
swab and liner life is generally obtained. FIG. 4 shows a partial
cutaway overhead of the pump housing according to a preferred
embodiment of the invention. Plunger rods 400 are synchronized
based on the crank speed and can be checked for alignment as
described herein. In a preferred embodiment, a viewing port 402 or
access cover allows access to plunger rods 400 for alignment and
maintenance.
[0039] Further enhancement to the pump is achieved by use of
ductile iron for the crossheads, the crosshead slides and the
connecting rods. The connecting rods are solid ductile iron which
reduces their elongation during setoff to zero. The typical rod
experiences stretching or elongation during set-off when the relief
valve is activated. The benefit of ductile iron in increased
strength and higher tensile strength. All the major components, the
crank, the crossheads, the slides and the rods by use of
mettalurgical engineering are designed to bring the pump tensile
strength up to 200,000 p.s.i.
[0040] The pump is network and web based with a data acquisition
system to monitor pump performance and constantly evaluate pump
valve dynamics. Pressure transducers are located in pump chambers
used to determine valve sealing delays, fluid compression delays,
chamber overshoot pressure, crosshead loading shock forces and
chamber volumetric efficiency. Pressure transducers are also
located in suction piping and manifolds and discharge piping and
manifold. Temperature is similarly monitored for fluid temperature
for mud properties and power end lubrication. Further, there is
real time power input data to calculate system mechanical
efficiency.
[0041] Those skilled in the art will recognize that the present
invention may be utilized with a wide variety of single and
multi-cylinder reciprocating piston power pumps as well as possibly
other types of positive displacement pumps. However, the system and
method of the invention are particularly useful for analysis of
reciprocating piston or plunger type pumps. Moreover, the number of
cylinders of such pumps may vary substantially between a single
cylinder and essentially any number of cylinders or separate
pumping chambers and the illustration of a so called triplex or
three cylinder pump is exemplary.
[0042] The performance analysis system of the invention is
characterized, in part, by a digital signal processor which is
operably connected to a plurality of sensors via suitable conductor
means well known in the art. The processor may be of a type
commercially available as previously described and may wireless
remote and other control options associated therewith. The
processor is operable to receive signals from a power input sensor
which may comprise a torque meter or other type of power input
sensor. Power end crankcase oil temperature may be measured by a
sensor. Crankshaft and piston position may be measured by a
non-intrusive sensor including a beam interrupter mountable on a
pump crosshead extension for interrupting a light beam provided by
a suitable light source or optical switch.
[0043] A vibration sensor may be mounted on the power end or on the
discharge piping or manifold for sensing vibrations generated by
the pump. Suitable pressure sensors are adapted to sense pressures
at numerous locations, including the inlet piping and manifolds.
Other pressure sensors may sense pressures in the pumping chambers
of the respective plungers or pistons. Other pressure sensors sense
pressures upstream and downstream of a discharge pulsation
dampener. Still further, a fluid temperature sensor may be mounted
on discharge manifold or piping to sense the discharge temperature
of the working fluid. Fluid temperature may also be sensed at the
inlet or suction manifold.
[0044] Pump performance analysis using the system may require all
or part of the sensors described above, as those skilled in the art
will understand and appreciate from the description which follows.
The processor may be connected to a terminal or further processor,
including a display unit or monitor mounted in a housing connected
to the pump system and main housing. Still further, the processor
may be connected to a signal transmitting network, such as the
Internet, or a local network.
[0045] FIG. 4A shows a schematic drawing of a representative
computer controlled monitoring system. A computer 450 receives
input from from sensors 452 and modules 454 in the pump system and
uses software algorithyms to analyze pump performance, record and
display operational data on a visual screen display 456. The
computer controlled monitoring system may be adapted to provide a
wide array of graphic displays and data associated with the
performance of a power pump on a real time or replay basis. A
substantial amount of information is available including pump
identification (Pump ID) crankshaft speed, fluid flow rate, time
lapse since the beginning of the display, starting date and
starting time and scan rate. The display 456 displays discharge
piping operating pressure, peak-to-peak pressures, fluid flow rate
induced peak-to-peak pressure, fluid flow induced peak-to-peak
pressure as a percentage of average operating pressure, pump
volumetric efficiency and pump mechanical efficiency. The display
456 also indicates discharge valve seal delay in degrees of
rotation of the crankshaft from a so called piston zero or top dead
center (maximum displacement) starting point with respect to the
respective cylinder chambers of the pump, as well as piston seal
pressure variation during fluid compression and suction valve seal
delay in degrees of rotation of the crankshaft or eccentric from
the top dead center position of the respective cylinder chambers.
Still further, the pump type may be displayed as well as suction
piping pressures, as indicated. The parameters displayed are
determined by the system of the invention which utilizes the
various sensors.
[0046] Various pressure sensors 452 sense pressure in the
respective pump chambers associated with each of the pistons and
pressure signals are transmitted to the processor. These pressure
signals may indicate when valves are opening and closing. For
example, if the pressure sensed in a pump chamber does not rise
essentially instantly, after the piston for that chamber passes
bottom dead center by 0 degrees to 10 degrees of crankshaft
rotation, then it is indicated that the inlet or suction valve is
delayed in closing or is leaking. In situations like this, the
display may show that a discharge valve is not closed for 16.7
degrees of rotation after piston top dead center position.
Accordingly, pressure changes, or the lack thereof, are sensed by
cylinder chamber pressure sensors.
[0047] Software embedded in the computer 450 processor is operable
to correlate the angle of rotation of the crankshaft with respect
to pressure sensed in the respective cylinder chambers to determine
any delay in pressure changes which could be attributable to delays
in the respective suction or discharge valves reaching their fully
seated and sealed positions. These delays can, of course, affect
volumetric efficiency of the respective cylinder chambers and the
overall volumetric efficiency of the pump. In this regard, total
volumetric efficiency is determined by calculating the average
volumetric efficiency based on the angular delay in chamber
pressure increase or pressure decrease, as the case may be, with
respect to the position of the pistons in the respective
chambers.
[0048] The volumetric efficiency of the pump is a combination of
normal pump timed events and the sealing condition of the piston
seal and the inlet and discharge valves. Pump volumetric efficiency
and component status is determined by determining the condition of
the components and calculating the degree of fluid bypass. Pump
volumetric efficiency (VE) is computed by performing a
computational fluid material balance around each pump chamber.
[0049] Pump chamber pressures, as sensed by the sensors may be used
to determine pump timing events that affect performance, such as
volumetric efficiency, and chamber maximum and minimum pressures,
as well as fluid compression delays. Still further, fluid pressures
in the pump chambers may be sensed during a discharge stroke to
determine, through variations in pressure, whether or not there is
leakage of a piston packing or seal, such as the packing seal.
Still further, maximum and minimum chamber fluid pressures may be
used to determine fatigue limits for certain components of a pump,
such as the fluid end housing, the valves and virtually any
component that is subject to cyclic stresses induced by changes in
pressure in the pump chambers and the pump discharge piping.
[0050] As mentioned previously, the computer 450 processor may be
adapted with a suitable computer program to provide for determining
pump volumetric efficiency which is the arithmetic average of the
volumetric efficiency of the individual pump chambers as determined
by the onset of pressure rise as a function of crankshaft position
(delay in suction valve closing and seating) and the delay in
pressure drop after a piston has reached top dead center (delay in
discharge valve closing and seating).
[0051] Additional parameters which may be measured and calculated
in accordance with the invention are the so-called delta volumes
for the suction or inlet stabilizer and the discharge pulsation
dampener. The delta volume is the volume of fluid that must be
stored and then returned to the fluid flowstream to make the pump
suction and discharge fluid flow rate substantially constant. This
volume varies as certain pump operating parameters change. A
significant increase in delta volume occurs when timing delays are
introduced in the opening and closing of the suction and discharge
valves. The delta volume is determined by applying actual angular
degrees of rotation of the crankshaft with respect the suction and
discharge valve closure delays to a mathematical model that
integrates the difference between the actual fluid flow rate and
the average flow rate.
[0052] Another parameter associated with determining component life
for a pump, is pump hydraulic power output for each pump working
cycle or 360 degrees of rotation of the crankshaft. Still further,
pump component life cycles may be determined by using a multiple
regression analysis to determine parameters which can project the
actual lives of pump components. The factors which affect life of
pump components are absolute maximum pressure, average maximum
pressure, maximum pressure variation and frequency, pump speed,
fluid temperature, fluid lubricity and fluid abrasivity.
[0053] As mentioned previously, pressure variation during fluid
"compression" is an indication of the condition of a piston or
plunger packing seal. This variation is defined as an absolute
maximum deviation of actual pressure data from a linear value
representative of the compression pressure and is an indication of
the condition of seals. A leaking seal results in a longer
compression cycle because part of the fluid being displaced is
bypassing or leaking through the seal. A pump chamber
"decompression" cycle is also shorter because, after the discharge
valve completely closes and seals against its seat, part of the
fluid to be decompressed is bypassing a plunger seal or packing.
The difference in volume required to reach discharge operating
pressure over a "compression" cycle for each pump chamber
determines an average leakage rate. This leakage rate is adjusted
for a leak rate at discharge operating pressures by calculating a
leak velocity based on standard orifice plate pressure drop
calculations.
[0054] Suction valve leak rate results in a longer decompression
cycle because part of the fluid being displaced by the pressurizing
element is returning to the pump inlet or suction fluid flowline.
The difference in volume required to reach discharge operating
pressure over a compression cycle determines an average leakage
rate. This compression leak rate is then adjusted for a leak rate
at discharge operating pressures by calculating a leak velocity
based on standard orifice plate pressure drop calculations. The
leak rate is then applied to the duration of the discharge valve
open cycle. So-called pump intake or suction acceleration head
response is an indicator of the suction piping configuration and
operating conditions which meet the pump's demand for fluid. This
is defined as the elapsed time between the suction valve opening
and the first chamber or suction piping or manifold pressure peak
following the opening.
[0055] Still further, the system of the present invention is
operable to determine fluid cavitation which usually results in
high pressure "spikes" occurring in the pumping chamber during the
suction stroke. Generally, the highest pressure spikes occur at the
first pressure spike following the opening of a suction valve. Both
minimum and maximum pressures are monitored to determine the extent
and partial cause of cavitation.
[0056] The system is also operable to provide signals indicating
valve design and operating conditions which can result in excessive
peak pressures in the pumping chambers before the discharge valve
opens, for example. These peaks or so-called overshoot pressures
can result in premature pump component failure and excessive
hydraulic forces in the discharge piping. For purposes of such
analysis, the overshoot pressure is defined as peak chamber
pressure minus the average discharge fluid pressure.
[0057] The system of the present invention is also operable to
analyze operating conditions in the pump suction and discharge flow
lines, such as in the piping. A normally operating multiplex power
pump will induce pressure variations at both one and two times the
crankshaft speed multiplied by the number of pump pistons. Flow
induced pressure variation is defined as the sum of the
peak-to-peak pressure resulting from these two frequencies. Also,
acceleration induced pressure spikes are created when the pump
valves open and close. Acceleration pressure variation for purposes
of the methodology of the invention is defined as the total
peak-to-peak pressure variation.
[0058] Hydraulic resonance occurs when a piping system has a
hydraulic resonant frequency that is excited by forces induced by
operation of a pump. Fluid hydraulic resonance is determined by
analysis of the pressure waves created by the pump to determine how
close the pressure response matches a true sine wave. The computer
450 is programmed to activate an alarm when the flow induced
pressure variation exceeds a predetermined limit. Alternatively the
computer 450 monitoring software can be programmed to trigger the
reset relief valve that is operably connected and controlled by the
processor.
[0059] Those skilled in the art will appreciate that the system,
including pressure sensors together with the reset relief valve and
its associated sensors provides information which may be used to
analyze a substantial number of system operating conditions for a
pump. The processor is adapted to provide a visual display 456
which may be displayed on the monitor, providing graphical display
of pressure versus crankshaft position for each cylinder chamber
and other parameters.
[0060] The system's computer 450 controller, hard drive or other
digital storage device and display 456 can be used for predictive
analysis of the pump and component parts providing data to the
operator to reveal conditions and maintenance related required
tasks including but not limited to: [0061] Hidden Failure--A
functional failure whose effects are not apparent to the operating
crew under normal circumstances if the failure mode occurs on its
own. [0062] Lubrication Task--The periodic application of a
lubricant to items that require lubrication for proper operation or
to prevent premature functional failures. [0063] Non-significant
Function (NSF)--A function whose failure will have no adverse
safety, environmental, operational, or economic effects. [0064] On
Condition Task--A periodic or continuous inspection designed to
detect a potential failure condition and allow correction prior to
functional failure. [0065] Other Action--A term used to indicate
that some action (other than PM) is either required or desired to
most effectively deal with the consequences of a failure mode.
[0066] Potential Failure--A definable and detectable condition that
indicates that a functional failure will occur. [0067] Preventive
Maintenance (PM)--Actions performed prior to functional failure
(multiple failures or demand requirements for hidden failures) to
achieve the desired level of safety and reliability for an item.
[0068] Servicing Task--The replenishment of consumable materials
that are depleted during normal operations. [0069] Severity
Classification--A category assigned to a failure mode based on the
impacts of its potential effects. [0070] Significant Function
(SF)--A function whose failure will have adverse effect with regard
to Safety, Environment, Operations, and Economics.
[0071] In conjunction with the pump, is a fully controlled and
monitored pressure relief valve that is situated to set off with
excessive mud flow pressures. Turning now to FIG. 5, there is a
partially exploded cross sectional view of a reset relief valve
showing chamber 500 and in fluid communication therewith and
pressure sensor assembly 502 of the relief valve. A break is shown
in FIG. 5 between the upper and lower portion of the valve where
the pressure sensor assembly 502 is placed for ease of
illustration. Transducer 506 is positioned in a sealed ring 504
that is in fluid communication with the hydraulic fluid that moves
between chambers 500 and 512 during operation. On the bottom of
ring 504 are ports 514 that permit fluid flow from chamber 500 into
the ring whereby the transducer 506 can sense pressure in the
fluid. Pressure is sensed by the transducer 506 which is capable of
sensing the pressure on the fluid which in turn transmits that
pressure reading to a gauge 516 and electronically to a computer
control system. Gauge 516 may be analog or digital depending on the
application. As pressure is being monitored and data points stored,
the user is capable of controlling the valve and making sure its
operation is within desired operating limits before during and
after the valve is activated. Further, the computer parameters can
be set for high pressures to shut down the pump before the reset
valve is set off.
[0072] By storing data on a recurring basis, the operator can
design the system with greater degrees of control and can analyze
the data associated with an activation of the valve to better
utilize the valve and other pumps in the system. Set screw 520
permits access to the system for bleeding off pressure. Other ports
are positioned around the pressure sensor assembly for insertion of
oil or other hydraulic fluid.
[0073] One of the advantages of having a relief valve that is
computer monitored and controlled is that upon set-off the operator
obtains valuable real time information about the pump just prior to
and during set-off. The system is capable of storing data about the
operation of the pump such as the time of set-off, the exact
pressure that caused the relief valve to activate and speed and
pressure associated with the pump.
[0074] The graphic display of the computer system may also show the
discharge pressure parameters including discharge manifold
pressure, total peak-to-peak pressure, flow induced peak-to-peak
pressure, flow induced peak-to-peak pressure as a percent of
average manifold pressure, the primary (largest) peak-to-peak
pressure which is occurring at a particular frequency, the primary
peak-to-peak pressure as a percent of average manifold
pressure.
[0075] The processor may show pressure variation versus pump speed
as determined by the system based on measuring chamber pressure and
crankshaft position and speed.
[0076] The system may further display information showing
crankshaft angle versus pump speed in strokes per minute showing
discharge valve sealing delays in degrees of crankshaft rotation
from piston top dead center. Suction valve sealing delays, from
piston bottom dead center, may also be indicated.
[0077] The system of the invention may also be adapted to provide
graphic displays such as a diagram of pump discharge pressure
versus crankshaft angle showing the variation in pump discharge
piping pressure, as well as the frequency and amplitude of pressure
pulsations. Another display which may be provided by the system
comprises a diagram of pump discharge piping pressure as measured
by a pressure sensor versus pump speed in piston strokes per minute
as calculated by the system. Still further, the system is operable
to display fluid pressure conditions in the pump suction manifold,
such as the manifold or piping. The system could also aid in
de-synchronizing multiple pumps to decrease pulsation on the piping
system.
[0078] A typical installation of a system for temporary or
permanent performance monitoring and/or analysis requires that all
of the pressure transducers be preferably on the horizontal center
line of the pump piping or pump chambers, respectively, to minimize
gas and sediment entrapment.
[0079] The system of the invention is also operable to determine
pump piping hydraulic resonance and mechanical frequencies excited
by one or more pumps connected thereto for both fixed and variable
speed pumps. Preferably, a test procedure would involve
instrumenting the pump, where plural pumps are used, that is
furthest from the system discharge flowline or manifold. A
vibration sensor, could be located at the position of the most
noticeable piping vibration. The piping system should be configured
for the desired flow path and all block valves to pumps not being
operated should be open as though they were going to be operating.
The instrumented pump or pumps should be started and run at maximum
speed for fifteen minutes to allow stabilization of the system. A
data acquisition system should then be operated to collect one
minute of pumping system data. Alternatively, data may be continued
to be collected while changing pump speed at increments of five
strokes per minute every thirty seconds until minimum operating
speed is reached. Data may be continued to be collected while
changing suction or discharge pressures. The displays provided by
the processor could be reviewed for pump operating problems as well
as hydraulic and mechanical resonance. If a hydraulic resonant
condition is observed, this may require the installation of wave
blockers or orifice plates in the system piping.
[0080] The system is operable to provide displays comprising
simulated three dimensional charts displaying peak-to-peak
pressures occurring at respective frequencies for a given pump
speed in strokes per minute. For a triplex pump, the normal
excitation frequency is three and six times the pump speed. As pump
speed increases, the excitation frequencies increase.
[0081] The software developed for the pump and valve is a method of
acquiring multiple streams of analog data as real time occurrences
and simultaneously displaying and storing them via digital
interface using an interface system for later analysis. Using an
application developed for this system, the control computer can
monitor and record from 1 to 4 simultaneous analog pressure
readings at a rate of 1 sample/sec per channel or faster. In
addition a secondary capacity to monitor 4 digital only inputs is
extant in the current system, with desired inputs undetermined. The
data acquisition and its interaction and use with the software acts
as a control system to the overal pump and its various operating
compenents and attachments.
[0082] The computer system of a preferred embodiment may be of any
of a variety of known systems with associated input and output
devices, having adequate processing speed and storage capacity to
analyze and process data associated with the operation of the pump.
The system may also have wireless capability and preferably is
capable of operating in temperature ranges of: 0 to 40.degree. C.;
Storage: -20 to 65.degree. C., with Relative Humidity: 30% to 80%.
It may use data processing of [0083] 4 channels of 14-bit analog
input [0084] Up to 200 kS/s single-channel sampling [0085] Up to
132 kS/s multichannel (aggregate) sampling [0086] 4 digital I/O
lines (3.3 V) Further, a variety of sensors may be employed
including preferably pressure transducers, with 0-10,000 PSI
pressure sensitivity, 6-30 vdc input excitation voltage, 1-5 vdc
output signal, and simple 3 wire connections (plus ground).
[0087] The software application employed preferably is a data
acquisition and storage system with a 90 day continuous storage
capacity. The computer software permits real time evaluation of
ambient pressure in the system and control of the valve according
to the user's preferences. Due to the recurrent sensing of the
system, when the valve is set off, data has been stored for later
analysis of the cause of the pressure spike that may have set off
the valve.
[0088] The present invention combines a computer controlled
monitoring system for a pump and a reset relief valve with
increased power characteristics and longevity by use of
poly-fluorocarbon treated or infused materials and an integrally
forged crank. By having the pump responsive to ambient conditions
that are monitored real time, the reset valve, which is
interconnected through sensors that sense operating conditions of
the pump system, can send feedback to the motor to reduce pressure
buildup before the valve is set off. Further, in certain conditions
the reset valve can trip in advance of catastrophic failure of the
pump through the computer control and feedback system of the
present invention.
[0089] While the invention has been described in connection with a
preferred embodiment, it is not intended to limit the scope of the
invention to the particular form set forth, but on the contrary, it
is intended to cover such alternatives, modifications, and
equivalents as may be included within the spirit and scope of the
invention as defined by the claims.
* * * * *