Online monitoring system for five-cylinder pump

Abstract

The utility model discloses a five-cylinder pump on-line monitoring system, and relates to the field of drilling five-cylinder pump intelligent monitoring, in particular to a five-cylinder pump on-line monitoring system which comprises a five-cylinder pump and a data sensing unit, and the data sensing unit is arranged on the five-cylinder pump and used for monitoring data in cylinders. The five-cylinder pump comprises five independent hydraulic cylinders, and each hydraulic cylinder is provided with an independent suction valve and an independent discharge valve; the data sensing unit comprises an angle sensor, a vibration sensor, a strain sensor and a pressure sensor. The method has the advantages that the early warning capability is improved, the maintenance decision is optimized, the safety is enhanced, the operation and maintenance efficiency is improved, the service life of equipment is prolonged, and digital transformation and environmental protection are promoted.

Description

TECHNICAL FIELD

[0001] The utility model relates to the field of drilling five cylinder pump intelligent monitoring, concretely relates to a five cylinder pump on -line monitoring system. BACKGROUND

[0002] As the core component of the drilling rig, the stability and reliability of the five cylinder pump are crucial to the entire production process. During the drilling process, the five cylinder pump is responsible for high-pressure mud delivery, which is used to flush the well bottom, cool the drill bit, and carry out the cuttings. However, due to the high-pressure delivery of mud and the cuttings carried back, the various components of the five cylinder pump, especially the discharge valve and the suction valve, are easily affected by physical and chemical corrosion, leading to mild or severe damage to the valves. This damage can affect the working condition of the five cylinder pump, and further cause mechanical equipment failure, even causing downtime. Once the five cylinder pump fails and stops, it may not only cause production interruption, but also bring safety hazards.

[0003] Currently, the monitoring system for the five cylinder pump has many shortcomings. In the work site, whether the five cylinder pump is damaged mainly depends on the experience of the maintenance personnel. This experience-based detection method is not conducive to accurately determining the fault type and determining the maintenance plan, and lacks real-time measurement of state data for online fault diagnosis and evaluation, which cannot quickly handle the fault. In addition, the on-site working environment is noisy and located in a high-pressure area, and the detection position is dangerous, which brings safety hazards to the detection personnel.

[0004] Therefore, a system capable of real-time monitoring of the running state of the five cylinder pump is needed, which enables the staff to timely and accurately grasp the working state of the five cylinder pump, reduces the work intensity of the on-site maintenance personnel, reduces the risk of inspection in the dangerous working area, reduces the number of downtime due to unplanned failures, and provides strong protection for the safe, stable and efficient operation of the five cylinder pump. UTILITY MODEL CONTENTS

[0005] The utility model aims at the above-mentioned problem, and provides a five cylinder pump on-line monitoring system.

[0006] The technical scheme adopted by the utility model is as follows: a five cylinder pump on-line monitoring system, comprising: a five cylinder pump and a data perception unit, the data perception unit is arranged on the five cylinder pump for monitoring the running data of the five cylinder pump;

[0007] The five cylinder pump comprises a power system, a crankshaft, a connecting rod, a piston, a discharge valve, a discharge pipe, a liquid cylinder, a suction valve and a suction pipe; the power system is connected and drives the crankshaft, the crankshaft is connected with one end of the connecting rod, the crankshaft drives the connecting rod to move, the other end of the connecting rod is connected with the piston, the piston is driven to move linearly, and positive pressure and negative pressure are formed in the liquid cylinder, the liquid cylinder is provided with the discharge valve and the suction valve, and the discharge valve and the suction valve are respectively connected with the discharge pipe and the suction pipe;

[0008] The five-cylinder pump comprises five independent liquid cylinders, each of which is provided with an independent suction valve and a discharge valve.

[0009] The data sensing unit comprises a rotation angle sensor and / or a vibration sensor and / or a strain sensor and / or a pressure sensor.

[0010] Further, the rotation angle sensor is arranged at the rotation axis of the crankshaft.

[0011] Further, the vibration sensor is arranged at the outer surface of the suction valve.

[0012] Further, the strain sensor is arranged at the outer surface of the suction valve.

[0013] Further, the pressure sensor is arranged at the outer surface of the suction valve and connected with the inside of the liquid cylinder through a through hole.

[0014] Further, the data acquisition device is electrically connected with the data sensing unit for data acquisition.

[0015] Further, the data acquisition device is electrically connected with the system machine.

[0016] Further, the system machine is provided with a communication device.

[0017] Further, the system machine is electrically connected with a power system.

[0018] Further, the pressure sensor and / or the vibration sensor and / or the strain sensor are arranged in multiple corresponding to the number of liquid cylinders.

[0019] In summary, due to the adoption of the above technical scheme, the beneficial effects of the present application are:

[0020] 1. Improved early warning capability: By continuously monitoring the key operating parameters of the five-cylinder pump, the system can timely detect abnormal signs and issue early warnings to prevent sudden failures, thereby ensuring the continuity and stability of production.

[0021] 2. Optimized maintenance decision: Based on real-time data and historical trend analysis, the maintenance team can more accurately develop maintenance plans and implement predictive maintenance rather than traditional periodic maintenance, reducing unnecessary maintenance costs while ensuring that the equipment is always in optimal working condition.

[0022] 3. Enhanced safety: Reduces safety risks caused by unexpected equipment downtime, especially for five-cylinder pumps operating in high-temperature, high-pressure, and corrosive environments. Real-time monitoring can effectively prevent accidents and protect personnel and equipment safety.

[0023] 4. Improve operational efficiency: Automated data collection and analysis reduce the need for manual inspections, reducing labor intensity, allowing maintenance personnel to be freed from heavy field detection and focus on more complex analysis and maintenance work.

[0024] 5. Extend equipment life: Continuous optimization and timely intervention of five-cylinder pump operation can reduce component wear and extend the overall service life of the equipment, saving the cost of replacing equipment for enterprises.

[0025] 6. Promote digital transformation: The implementation of the system is part of Industry 4.0 and smart manufacturing, helping enterprises achieve digital transformation, improve overall operational efficiency and management level, and lay the foundation for future higher-level automation and intelligence.

[0026] 7. Environmental protection: Effective monitoring and management of five-cylinder pump operation reduces energy waste and environmental pollution caused by failures, meeting the requirements of green and sustainable development.

[0027] In summary, the online monitoring system for the five-cylinder pump not only improves the reliability and safety of the equipment, but also promotes the modernization of operation and maintenance management, bringing economic and social benefits to enterprises. BRIEF DESCRIPTION OF DRAWINGS

[0028] Figure 1 is a structural schematic diagram of the utility model,

[0029] Figure 2 is a system composition diagram of the monitoring system of the utility model,

[0030] Figure 3 is a work flow diagram of the monitoring system of the utility model.

[0031] Marked in the figure: 1 - power system, 2 - crankshaft, 3 - connecting rod, 4 - piston, 5 - liquid cylinder, 6 - discharge valve, 7 - discharge pipe, 8 - suction valve, 9 - suction pipe, 10 - angle sensor, 11 - vibration sensor, 12 - strain sensor, 13 - pressure sensor, 14 - data acquisition device, 15 - system machine. DETAILED DESCRIPTION

[0032] The utility model will be described in detail below in combination with the drawings.

[0033] In order to make the purpose, technical scheme and advantages of the utility model more clear and obvious, the utility model will be further described in detail below in combination with the drawings and examples. It should be understood that the specific examples described here are only used to explain the utility model, and are not used to limit the utility model.

[0034] In this embodiment, as Figure 1As shown, a five-cylinder pump online monitoring system includes: a five-cylinder pump and a data sensing unit, wherein the data sensing unit is installed on the five-cylinder pump to monitor the operating data of the five-cylinder pump;

[0035] The five-cylinder pump includes a power system 1, a crankshaft 2, a connecting rod 3, a piston 4, a discharge valve 6, a discharge pipe 7, a hydraulic cylinder 5, a suction valve 8, and a suction pipe 9. The power system 1 is connected to and drives the crankshaft 2. The crankshaft 2 is connected to one end of the connecting rod 3, which drives the connecting rod 3 to move. The other end of the connecting rod 3 is connected to the piston 4, which drives the piston 4 to make linear reciprocating motion and forms positive and negative pressure in the hydraulic cylinder 5. The hydraulic cylinder 5 is equipped with a discharge valve 6 and a suction valve 8, which are respectively connected to the discharge pipe 7 and the suction pipe 9.

[0036] The five-cylinder pump includes five independent liquid cylinders 5, each of which is equipped with an independent suction valve 8 and discharge valve 6;

[0037] The data sensing unit includes an angle sensor and / or a vibration sensor 11 and / or a strain sensor 12 and / or a pressure sensor 13.

[0038] The technical problem to be solved by this utility model is: in order to overcome the shortcomings of the existing technology, to realize the systematic monitoring of the five-cylinder pump, reduce the difficulty of operation and maintenance, reduce safety hazards, and avoid unplanned downtime.

[0039] To achieve the above objectives, such as Figure 2 , 3 As shown, this utility model is an online monitoring system for a five-cylinder pump, including a data sensing unit, a data acquisition and communication unit, and a system unit 15; the data sensing unit is used to measure the operating status parameters of the five-cylinder pump in real time, and is composed of an angle sensor 10, a vibration sensor 11, a strain sensor 12, and a pressure sensor 13, so as to realize the real-time monitoring of the operating status of the five-cylinder pump.

[0040] The data acquisition and communication unit is used to acquire sensor signals at high speed. It is implemented by an embedded circuit based on a microcontroller or FPGA (specifically, a Siemens 1500 series PLC (Programmable Logic Controller)) to ensure real-time data acquisition and transmission communication. The system unit 15 is used to receive data, further analyze and process the data, and then output the analyzed and processed monitoring results.

[0041] As preferred, the five-cylinder pump mainly comprises a crank or crankshaft 2, a connecting rod 3, a crosshead, a piston 4, a cylinder liner, an exhaust valve 6, an exhaust four-way, an exhaust air tank, an exhaust pipe 7, a liquid cylinder 5, an intake valve 8, an intake pipe 9, and a driving shaft. The crankshaft 2 is driven to rotate by the motor through the gear transmission system of the power system 1, drives the connecting rod 3 to move, and the connecting rod 3 rotates synchronously with the crankshaft 2, drives the crosshead to move reciprocatingly in the straight line between the upper and lower guide plates, and drives the piston 4 to move reciprocatingly in the horizontal straight line, so that the intake valve 8 is opened and the exhaust valve 6 is closed, and the exhaust valve 6 is opened and the intake valve 8 is closed, so that the five-cylinder pump continuously circulates and transports the medium;

[0042] The five-cylinder pump comprises five independent pump cylinders, each liquid cylinder 5 comprises one intake valve 8 and one exhaust valve 6, and a total of 10 valves; the data sensing unit comprises a rotation angle sensor 10, a vibration sensor 11, a strain sensor 12, and a pressure sensor 13. The rotation angle sensor 10 is used for monitoring the position information of the five-cylinder pump, measuring the rotation angle of the crankshaft 2 of the power end of the pump, realizing the periodical recording of the pump stroke, and is installed on the rotation center of the crankshaft 2 of the power end of the five-cylinder pump. The vibration sensor 11 is used for monitoring the vibration signal of the five-cylinder pump and is installed on the outer surface of the intake liquid cylinder 5 of the liquid end of the five-cylinder pump. The strain sensor 12 is used for monitoring the strain signal of the five-cylinder pump and is installed on the outer surface of the intake liquid cylinder 5 of the liquid end of the five-cylinder pump. The pressure sensor 13 is used for monitoring the pressure of the five-cylinder pump and is installed on the outer surface of the intake valve 8 of the liquid end of the five-cylinder pump.

[0043] As preferred, the number of the pressure sensor 13, the vibration sensor 11, the strain sensor 12, and the rotation angle sensor 10 is five, corresponding to the number of the liquid cylinder 5 of the five-cylinder pump.

[0044] As preferred, the rotation angle sensor 10 is an angle encoder of an angle encoder E6CP-A, and the range is 0-360 degrees.

[0045] As preferred, the vibration sensor 11 is a vibration sensor 11 of S31 D20, and the range is 0-20 mm / s.

[0046] As preferred, the strain sensor 12 is a strain sensor 12 of CPR610-S01, and the range is 0-100 με.

[0047] As preferred, the pressure sensor 13 is a pressure sensor 13 of WIKA990.36, and the range is 0-70 MPa.

[0048] As preferred, the data acquisition device 14 is an embedded circuit based on a single-chip microcomputer or FPGA (specifically, a PLC (programmable logic controller) of the Siemens 1500 series), and the data acquisition frequency is 1 KHz.

[0049] As a preferred, the system machine 15 is a computer equipped with diagnostic software.

[0050] As a preferred, the system machine 15 communication device has communication function, can connect external equipment for data exchange.

[0051] As a preferred, the pressure sensor 13, vibration sensor 11, strain sensor 12, corner sensor 10 are electrically connected to the data acquisition device 14, and the data acquisition device 14 is electrically connected to the system machine 15.

[0052] As a preferred, the corner sensor 10 is arranged on the rotation center of the crankshaft 2 of the five-cylinder pump; the vibration sensor 11 is arranged on the outer surface of the suction cylinder 5 of the five-cylinder pump; the strain sensor 12 is arranged on the outer surface of the suction cylinder 5 of the five-cylinder pump; the pressure sensor 13 is arranged on the outer surface of the discharge cylinder 5 of the five-cylinder pump.

[0053] Specifically, in the maintenance process:

[0054] 1. Data sensing unit installation

[0055] Corner sensor 10: installed on the rotation center of the crankshaft 2, real-time monitoring of the angle change of the crankshaft 2. This helps to understand the working state and running period of the pump.

[0056] Vibration sensor 11: installed on the outer surface of the suction valve 8, used to detect the vibration during pump operation. Abnormal vibration may indicate equipment failure or wear.

[0057] Strain sensor 12: also installed on the outer surface of the suction valve 8, used to measure the deformation caused by pressure change, so as to evaluate the stress state of the equipment.

[0058] Pressure sensor 13: installed on the outer surface of the suction valve 8, monitors the suction pressure to ensure that the pump works within the normal pressure range.

[0059] 2. Data acquisition and transmission

[0060] Data acquisition is carried out using data acquisition device, the frequency is set to 1KHz, ensuring high frequency and high precision data reading.

[0061] The data acquisition device transmits the collected data to the system machine 15, and realizes real-time communication and processing of data through internal network.

[0062] 3. Data analysis and monitoring

[0063] The system machine 15 receives data from the data acquisition device, and processes the data using special analysis software.

[0064] Analysis includes trend analysis, threshold comparison, etc., to identify any possible anomalies or failure patterns.

[0065] The system can generate reports and alarms, automatically notify maintenance personnel for inspection or intervention when detecting abnormalities.

[0066] 4. Maintenance decision support

[0067] According to the analysis results, the system can provide maintenance suggestions such as replacing parts, adjusting operating parameters, etc.

[0068] Maintenance teams can develop more effective maintenance plans and strategies based on the information provided by the system.

[0069] 5. Regular inspection and calibration

[0070] Regularly check and calibrate sensors and data acquisition equipment to ensure measurement accuracy.

[0071] Check the connection lines and interfaces to prevent data transmission problems caused by poor contact or damage.

[0072] 6. Training and updates

[0073] Regular training for operators and maintenance personnel to familiarize them with the use of the system and troubleshooting skills.

[0074] According to the development of technology and the needs of the site, constantly update the software and hardware of the system to improve the monitoring ability and efficiency.

[0075] Through the above steps, the five-cylinder pump online monitoring system not only can monitor the equipment status in real time, but also can effectively prevent the occurrence of faults, prolong the service life of the equipment and reduce the maintenance cost.

[0076] The above is only the preferred embodiment of the present application, and is not intended to limit the present application. Any modification, equivalent replacement and improvement within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A five-cylinder pump online monitoring system, characterized in that: Includes: a five-cylinder pump and a data sensing unit, wherein the data sensing unit is installed on the five-cylinder pump to monitor the operating data of the five-cylinder pump; the five-cylinder pump includes a power system (1), a crankshaft (2), a connecting rod (3), a piston (4), a discharge valve (6), a discharge pipe (7), a hydraulic cylinder (5), a suction valve (8), and a suction pipe (9); the power system (1) is connected to and drives the crankshaft (2), the crankshaft (2) is connected to one end of the connecting rod (3), the crankshaft (2) drives the connecting rod (3) to move, the other end of the connecting rod (3) is connected to the piston (4), driving the piston (4) to make linear reciprocating motion, and forming positive pressure and negative pressure in the hydraulic cylinder (5), the hydraulic cylinder (5) is provided with a discharge valve (6) and a suction valve (8), the discharge valve (6) and the suction valve (8) are respectively connected to the discharge pipe (7) and the suction pipe (9); The five-cylinder pump includes five independent liquid cylinders (5), each of which is equipped with an independent suction valve (8) and discharge valve (6); The data sensing unit includes an angle sensor (10) and / or a vibration sensor (11) and / or a strain sensor (12) and / or a pressure sensor (13).

2. The online monitoring system for a five-cylinder pump as described in claim 1, characterized in that: The rotation angle sensor (10) is located at the rotation axis of the crankshaft (2).

3. The online monitoring system for a five-cylinder pump as described in claim 1, characterized in that: The vibration sensor (11) is located on the outer surface of the suction valve (8).

4. The online monitoring system for a five-cylinder pump as described in claim 1, characterized in that: The strain sensor (12) is disposed on the outer surface of the suction valve (8).

5. The online monitoring system for a five-cylinder pump as described in claim 1, characterized in that: The pressure sensor (13) is disposed on the outer surface of the suction valve (8), and the outer surface of the suction valve is provided with a through hole communicating with the inside of the liquid cylinder. The pressure sensor (13) communicates with the inside of the liquid cylinder through the through hole.

6. The online monitoring system for a five-cylinder pump as described in claim 1, characterized in that: It includes a data acquisition device (14), which is electrically connected to a data sensing unit and is used to acquire data.

7. The online monitoring system for a five-cylinder pump as described in claim 6, characterized in that: Includes a system unit (15), and the data acquisition device (14) is electrically connected to the system unit (15).

8. The online monitoring system for a five-cylinder pump as described in claim 7, characterized in that: The system unit (15) is equipped with a communication device.

9. The online monitoring system for a five-cylinder pump as described in claim 7, characterized in that: The system (15) is electrically connected to the power system (1).

10. The online monitoring system for a five-cylinder pump as described in claim 1, characterized in that: The number of pressure sensors (13) and / or vibration sensors (11) and / or strain sensors (12) corresponding to the hydraulic cylinders (5) is set to multiple.

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