Instrumented Fracturing Pumps for Wear Detection and Predictive Maintenance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fracturing pumps lack effective monitoring and predictive maintenance capabilities, leading to potential equipment failure and inefficiencies during fracturing operations.
Innovation Solution
Incorporating sensors such as load washers, crankshaft encoders, accelerometers, RFID sensors, optical fibers, and flowmeters into fracturing pumps to measure and estimate pump parameters, detect wear, and optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are incorporated into fracturing pumps to enable monitoring and predictive maintenance, then reliability and maintenance efficiency are improved, but device complexity increases
Solution Approach 1:
The patent implements feedback mechanisms through sensors that continuously monitor pump operating parameters (pressure, temperature, vibration, flow rate) and provide real-time data to the control system. This feedback enables predictive maintenance by detecting anomalies before they lead to equipment failure, thereby improving reliability while managing complexity through automated monitoring rather than manual inspection
Solution Approach 2:
The patent replaces traditional mechanical monitoring systems with electronic sensors and digital measurement systems. Instead of using mechanical gauges and manual inspection procedures, the system employs electronic sensors (pressure transducers, temperature sensors, vibration sensors, flow meters) that convert physical parameters into electrical signals for automated analysis, reducing mechanical complexity while enhancing reliability
2Measurement precision
If multiple sensors are added to measure and estimate pump parameters, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent employs multi-functional sensors and measurement systems that can detect multiple pump parameters simultaneously. For example, vibration sensors not only measure mechanical vibrations but also provide information about bearing condition, alignment issues, and overall equipment health. This multi-functionality approach improves measurement precision across multiple parameters while avoiding the complexity of installing separate dedicated sensors for each measurement
Solution Approach 2:
The patent combines multiple measurement functions into integrated sensor systems and centralized data acquisition units. Instead of having separate independent measurement systems for each parameter, the system merges sensor data collection, signal processing, and analysis into a unified platform, thereby improving comprehensive measurement precision while reducing overall system complexity through consolidation
Data Source
AI summary
Certain embodiments of the present disclosure generally relate to pumps for conveying fluid at a wellsite. More specifically, some embodiments relate to pumps, such as fracturing or other stimulation pumps, instrumented with sensors to measure or estimate pump parameters. In some instances, pump sensors are used to detect wear or failure or assess remaining useful life of pump components. The sensors can also or instead be used to assess, and in some cases optimize, pump performance. Various additional systems, devices, and methods are also disclosed.