Reciprocating Pump Failure Prediction via Total Energy Number
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Solution Overview
Problem
Reciprocating pump systems face issues with unpredictable failures due to inadequate monitoring, leading to unplanned downtime, costly maintenance, and lack of objective part life evaluation, especially in remote or hazardous locations.
Innovation Solution
A performance monitoring and prediction system that calculates a total energy number (TE) based on parameters like pulsation energy, temperature, solids, and chemical energy, allowing for imminent failure prediction and scheduling of maintenance, as well as objective comparison of competing parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If monitoring is implemented to predict failures, then reliability improves, but device complexity and cost increase
Solution Approach 1:
The monitoring system segments the complex pump operation into distinct measurable parameters (pressure, temperature, flow rate, power consumption). Each parameter is monitored separately through dedicated sensors, and the data is processed independently before being integrated into the overall failure prediction model. This segmentation reduces the complexity of the monitoring system while maintaining comprehensive monitoring capability.
Solution Approach 2:
The patent introduces an intermediary processing layer that collects data from multiple sensors and parameters, then transforms this raw data into a unified failure prediction index. This intermediary layer simplifies the relationship between complex sensor data and failure prediction, allowing the system to monitor pump health without requiring direct complex analysis of all operational parameters simultaneously.
2Measurement precision
If continuous monitoring is implemented, then failure prediction accuracy improves, but loss of time for maintenance increases
Solution Approach 1:
The system performs preliminary monitoring and analysis of pump parameters continuously, but only triggers detailed diagnostic actions when the failure prediction index indicates potential failure. This allows the system to maintain high detection accuracy through continuous data collection while avoiding unnecessary maintenance interruptions by using predictive indicators that can be checked without stopping the pump.
Solution Approach 2:
The monitoring system dynamically adjusts its response based on the current state of the pump. When parameters are within normal ranges, the system operates in a low-intensity monitoring mode that does not require maintenance intervention. When the failure prediction index exceeds thresholds, the system transitions to a high-intensity diagnostic mode that triggers maintenance actions. This dynamic approach optimizes between detection accuracy and maintenance time loss.
3Ease of operation
If traditional monitoring is used, then ease of operation is maintained, but loss of information about failure causes increases
Solution Approach 1:
The system continuously monitors pump parameters and provides feedback in the form of a failure prediction index that indicates the likelihood of failure. This feedback mechanism maintains ease of operation by presenting a single, easy-to-interpret indicator rather than requiring operators to analyze multiple parameters. Simultaneously, the feedback includes diagnostic information about which parameters are contributing to the failure risk, providing the necessary information about failure causes without complicating operation.
Data Source
AI summary
Performance parameters for a reciprocating pump including pulsation energy, temperature energy, solids, Miller number and chemical energy and the like are monitored and employed to at least periodically compute a total energy number over the operating life of the pump. The current computed value is compared to a predictive failure value empirically determined for the respective pump design, to determine when failure is likely to be imminent. Scheduling of maintenance with other pumping operations and objective rating of competing designs is possible based on the total energy number.