System and method for power pump performance monitoring and analysis
First Claim
1. A method for determining selected performance parameters of a reciprocating piston power pump, said pump comprising components including a housing providing at least one fluid chamber therein, a fluid inlet valve opening into said chamber, a fluid discharge valve for discharging fluid from said chamber, a rotatable crankshaft or eccentric, a reciprocating piston operably connected to said crankshaft and operable to displace fluid from said chamber, at least one pressure sensor in communication with said chamber for measuring pressure therein, at least one position sensor for sensing the position of said piston with respect to said chamber, and a signal processor operably connected to said sensors for receiving signals from said sensors, respectively, said method including:
- determining at least one performance parameter selected from a group consisting of pump hydraulic power per revolution of said crankshaft, pump hydraulic work performed per revolution of said crankshaft, chamber dynamic work performed per revolution of said crankshaft, total pump hydraulic work per revolution of said crankshaft, total chamber dynamic work per revolution of said crankshaft, average mechanical shock imposed on said housing, a cumulative stress cycle factor per revolution of said crankshaft, stress imposed on said housing for each chamber per revolution of said crankshaft, pump operating cycles in revolutions of said crankshaft to failure of at least one of said housing, said piston and said crankshaft, a stress factor to determine the number of equivalent stress cycles imposed on said housing per revolution of said crankshaft, housing life in months for each chamber per revolution of said crankshaft, crosshead load in a vertical direction, crosshead guide shock load and upper crosshead guide maximum shock load per revolution of said crankshaft; and
replacing one or more pump components prior to failure based on determining said at least one of said parameters.
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Accused Products
Abstract
A power pump performance analysis system and methods includes a signal processor connected to certain sensors for sensing pressures and stresses in the cylinder chambers and the inlet and discharge piping of a single or multicylinder pump. Pump speed and pump piston position may be determined by a crankshaft position sensor. Performance analyses for pump work performed, pump cylinder chamber stress, pump fluid end useful cycles to failure, and crosshead loading and shock analysis are provided for estimating pump component life and determining times for component replacement before failure.
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Citations
8 Claims
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1. A method for determining selected performance parameters of a reciprocating piston power pump, said pump comprising components including a housing providing at least one fluid chamber therein, a fluid inlet valve opening into said chamber, a fluid discharge valve for discharging fluid from said chamber, a rotatable crankshaft or eccentric, a reciprocating piston operably connected to said crankshaft and operable to displace fluid from said chamber, at least one pressure sensor in communication with said chamber for measuring pressure therein, at least one position sensor for sensing the position of said piston with respect to said chamber, and a signal processor operably connected to said sensors for receiving signals from said sensors, respectively, said method including:
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determining at least one performance parameter selected from a group consisting of pump hydraulic power per revolution of said crankshaft, pump hydraulic work performed per revolution of said crankshaft, chamber dynamic work performed per revolution of said crankshaft, total pump hydraulic work per revolution of said crankshaft, total chamber dynamic work per revolution of said crankshaft, average mechanical shock imposed on said housing, a cumulative stress cycle factor per revolution of said crankshaft, stress imposed on said housing for each chamber per revolution of said crankshaft, pump operating cycles in revolutions of said crankshaft to failure of at least one of said housing, said piston and said crankshaft, a stress factor to determine the number of equivalent stress cycles imposed on said housing per revolution of said crankshaft, housing life in months for each chamber per revolution of said crankshaft, crosshead load in a vertical direction, crosshead guide shock load and upper crosshead guide maximum shock load per revolution of said crankshaft; and replacing one or more pump components prior to failure based on determining said at least one of said parameters. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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Specification