Mud Pump Pressure Switch Backup Safety System

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Solution Overview

Problem

Mud pumping systems face catastrophic failures due to pressure buildup when pressure relief valves fail to operate effectively, posing risks to equipment and personnel safety.

Innovation Solution

A pressure switch safety system that includes a pressure switch, alarm, timer, and shut down control module, which activates an alarm and automatically shuts down the mud pumping system if excessive pressure is detected and not relieved within a preset time, ensuring safety by preventing over-pressurization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a pressure relief valve is installed to prevent excessive pressure, then system safety is improved, but the system remains vulnerable to catastrophic failure if the relief valve fails

Engineering Contradiction:

Improvepressure relief reliabilityVSAvoidcatastrophic failure risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent implements a backup pressure switch safety system that activates when the primary pressure relief valve fails. The pressure switch is calibrated to trigger at a higher pressure threshold than the relief valve, providing a secondary safety mechanism that cushions against catastrophic failure before it occurs.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The pressure switch acts as an intermediary safety device between the primary pressure relief valve and the catastrophic failure mode. It monitors pressure independently and triggers an alarm and shutdown sequence when the relief valve fails to operate properly, mediating the protection gap.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a pressure switch safety system with alarm and timer is added, then system safety is improved, but device complexity increases

Engineering Contradiction:

Improvesafety system reliabilityVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The safety system is segmented into distinct functional modules: pressure switch, alarm device, timer, and shutdown control. Each component performs a specific function, making the overall complex system manageable through functional segmentation and independent troubleshooting of each module.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system implements automatic shutdown control that activates without human intervention when pressure exceeds safe limits. The timer and alarm work autonomously to provide warnings and execute shutdown sequences, reducing the need for continuous manual monitoring and simplifying operator tasks.

Inventive Principle:

Principle #25Self-service

3Reliability

If automatic shutdown control is implemented, then system safety is improved, but loss of time in resetting the system increases

Engineering Contradiction:

Improvepressure management safetyVSAvoidsystem shutdown and reset time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The alarm provides advance warning before automatic shutdown occurs, allowing operators to take preliminary actions to safely reduce pressure or address the underlying issue. This preliminary alert period minimizes unnecessary shutdowns and allows for faster recovery when pressure excursions are corrected before the timer expires.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively mitigates the risk of equipment damage and personnel harm by automatically shutting down the mud pumping system when pressure relief fails, providing a timely warning and ensuring pressure is managed within safe limits.

Implementation Method 1

a pressure switch for mounting to a mud pumping system. The pressure switch can be moved from a pressure switch open position to a pressure switch closed position when the pressure within the mud pumping system reaches an excess trigger pressure

Methodology Applied

Scientific EffectPressure detection:

Implementation Method 2

Each first relay contact is moveable from a first relay normal open position to a first relay closed position when the pressure switch is in the pressure switch closed position

Methodology Applied

Scientific EffectElectrical activation:

Data Source

PatentUS10041600B2Mud pump pressure switch

Publication Date: 2018.08.07 SAUDI ARABIAN OIL CO

AI summary

A pressure switch safety system includes a pressure switch for mounting to a mud pumping system. The pressure switch can be moved from a pressure switch open position to a pressure switch closed position when the pressure within the mud pumping system reaches an excess trigger pressure. The excess trigger is greater than the pressure required to activate a pressure relief valve system of the mud pumping system. An alarm and a timer are actuated when the pressure switch is moved from the pressure switch open position to the pressure switch closed position. The timer has a preset time interval. The system has a mud pump shut down control module that will shut down the mud pumping system after the preset time interval has elapsed.