Mud Pump Valve Seal Life Forecasting via Optical Detection

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Solution Overview

Problem

Mud pump valves in oil and gas drilling rigs face challenges with seal wear, leading to inefficiencies and increased costs due to the difficulty in determining when seals are worn, resulting in premature or late replacements.

Innovation Solution

A method and system that utilize sensors to determine baseline and in-use behaviors of valves, comparing these to forecast the remaining useful life of the seals, incorporating pressure, vibration, stress, light passage, and marker detection to accurately assess seal condition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If seals are replaced at standard intervals based on estimated lifecycle, then seal reliability is maintained, but pump productivity decreases due to premature replacements and drilling delays

Engineering Contradiction:

Improveseal reliabilityVSAvoidpump productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the mechanical/time-based seal replacement system with an optical detection and data processing system. Sensors monitor light passage through seals, and a processor analyzes the data to determine actual seal condition, enabling replacements based on real seal health rather than predetermined intervals.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements continuous feedback by monitoring light transmission through seals during operation. The sensors provide real-time data about seal degradation, and the processor uses this feedback to assess current seal condition and predict remaining useful life, allowing dynamic adjustment of replacement timing.

Inventive Principle:

Principle #23Feedback

2Quantity of substance

If seals are replaced based on rough estimation of lifecycle, then replacement costs are controlled, but loss of time increases due to both premature and late replacements

Engineering Contradiction:

Improvereplacement costsVSAvoiddrilling delays

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs preliminary detection of seal degradation before actual failure occurs. By continuously monitoring light transmission and analyzing trends, the system predicts remaining useful life and schedules replacements optimally, preventing both premature and late replacements.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If multiple sensors and detection methods are implemented to accurately monitor seal condition, then measurement precision improves, but device complexity increases

Engineering Contradiction:

Improveseal condition detection accuracyVSAvoiddetection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent employs a multi-functional detection approach where a single optical system performs multiple functions: measuring light transmission intensity, detecting light passage timing, and monitoring seal position. This universal optical platform reduces overall system complexity compared to using separate specialized sensors for each measurement type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This approach allows for timely and cost-effective replacement of worn seals, enhancing pump efficiency and reducing downtime by accurately predicting seal lifespan.

Implementation Method 1

emitting a light from one side of at least one of the one or more valves toward an opposite side of the at least one of the one or more valves

Methodology Applied

Scientific EffectLight passage detection: Light

Implementation Method 2

causing a vibration response to fluid flow past at least one of the one or more valves

Methodology Applied

Scientific EffectVibration detection: Vibration

Implementation Method 3

measuring a pressure in the chamber in response to a position of the piston

Methodology Applied

Scientific EffectPressure measurement: Pressure Increase

Data Source

PatentUS20240044328A1Mud pump valve leak detection and forecasting

Publication Date: 2024.02.08 SCHLUMBERGER TECH CORP

AI summary

A system and method for controlling a pump in a drilling system, of which the method includes determining a plurality of baseline behaviors for one or more valves of the pump, determining a plurality of in-use behaviors for the one or more valves of the pump. Each of the plurality of in-use behaviors are determined based on one or more measurements from one or more sensors. The method also includes comparing the in-use behaviors and the baseline behaviors, and forecasting, based on the comparison of the in-use behaviors and the baseline behaviors, a remaining useful life of the at least one of the one or more valves.