Plunger Pump Packing Leakage Detection via Hydraulic Pressure Feedback
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Solution Overview
Problem
Existing plunger pumps in oilfield operations suffer from delayed detection of packing leakage, which can lead to operating inefficiencies and safety hazards due to undetected failures.
Innovation Solution
A packing leakage detection system incorporating a pressure sensor and control system to monitor pressure values within the hydraulic end of the plunger pump, providing real-time alerts for shutdown or overhaul when abnormal pressure thresholds are exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional plunger pumps are used without detection systems, then device complexity is reduced, but packing leakage detection is delayed causing safety hazards and operating inefficiencies
Solution Approach 1:
The patent replaces manual inspection and traditional mechanical detection methods with electronic pressure sensing and automated control systems. The pressure sensor continuously monitors hydraulic end pressure, and the control system automatically analyzes pressure changes to detect packing leakage, substituting human judgment with electronic detection and calculation systems.
Solution Approach 2:
The patent implements a closed-loop feedback system where the pressure sensor continuously monitors pressure values, the control system receives and analyzes this data, and when abnormal pressure changes indicating packing leakage are detected, the system provides real-time alerts and warnings. This continuous feedback loop enables timely detection and response to packing degradation.
2Measurement precision
If pressure sensors and control systems are added to detect packing leakage, then detection accuracy is improved, but device complexity increases
Solution Approach 1:
The patent introduces a control system as an intermediary between the pressure sensor and the alert mechanism. The control system receives pressure data from the sensor, calculates pressure change rates, compares them against thresholds, and triggers alerts only when abnormal conditions are detected. This intermediary layer enables precise detection while maintaining system manageability.
Solution Approach 2:
The patent monitors changes in pressure parameters over time, specifically the rate of pressure change (dp/dt). By analyzing how pressure parameters evolve rather than just static pressure values, the system can detect packing leakage conditions that manifest as abnormal pressure change patterns, improving measurement precision for detecting degradation trends.
3Reliability
If real-time pressure monitoring is implemented, then operational safety is enhanced, but energy consumption increases
Solution Approach 1:
The pressure sensor and control system operate in periodic cycles, continuously monitoring pressure but only triggering full alert sequences when abnormal conditions are detected. The system periodically samples pressure data, calculates changes, and compares against thresholds, enabling real-time safety monitoring while allowing energy-saving modes during normal operation when no anomalies are present.
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
Enables timely detection of packing failures, preventing safety accidents and damage to the valve box by promptly alerting operators to perform maintenance, thereby enhancing operational safety and efficiency.
Implementation Method 1
a pressure sensor is configured to detect a pressure value inside a hydraulic end of the plunger pump
Data Source
AI summary
This application relates to the field of oil and gas devices, systems, and methods, and particularly relates to a packing leakage detection system and method. The packing leakage detection system includes a plunger pump, a pressure sensor and a control system, where the pressure sensor is configured to detect a pressure value inside a hydraulic end of the plunger pump, and send the detected pressure value to the control system; and the control system is configured to acquire the pressure value sent by the pressure sensor, and send prompt information according to the pressure value, where the prompt information includes at least one of alarm information and information for prompting shutdown and overhaul. This application is used for solving the problem that a leakage anomaly caused by a packing failure is not discovered in time.