Reciprocating Pump Valve Leak Detection via Phase-Pressure Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Reciprocating mud pumps in well drilling operations often experience valve wear and erosion due to high pressures and abrasive fluids, leading to late detection of leaks and pump failures, which disrupt drilling efficiency.
Innovation Solution
A monitoring system comprising a pressure sensor, position sensor, and processing device is used to detect irregular pressure measurements and determine the operational phase of reciprocating pumps, identifying which inlet or outlet valves are leaking by analyzing sensor data during pumping operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If reciprocating pumps operate under high pressure with abrasive fluids, then pumping capability is improved, but valve wear and erosion increase leading to leaks and pump failures
Solution Approach 1:
The monitoring system performs preliminary detection of valve leaks by continuously analyzing pressure measurements and operational phase data before actual pump failures occur. This allows early identification of wear and erosion issues, enabling preventive maintenance actions that preserve valve durability while maintaining pumping capability under high pressure conditions
Solution Approach 2:
The system implements feedback by continuously monitoring pressure measurements during different operational phases and comparing them against expected values. When deviations indicate valve leaks, the system provides feedback signals for maintenance intervention, creating a closed-loop control that maintains reliability while preserving the high-power pumping capability
2Duration of action of moving object
If valve wear is detected late, then pump operation continues longer, but pump failures and severe damage occur
Solution Approach 1:
The monitoring system performs preliminary detection of valve wear and leak conditions by analyzing pressure measurement patterns before they progress to severe damage. This early detection extends the safe operational duration of the pump by enabling timely maintenance interventions that prevent catastrophic failures
3Reliability
If pump failures occur, then operational continuity is maintained longer, but drilling efficiency is reduced
Solution Approach 1:
The system provides continuous feedback on pump operational health through pressure monitoring and analysis. By detecting valve leaks early and providing timely alerts, the system enables maintenance scheduling that maintains operational continuity while minimizing interruptions to drilling efficiency through planned rather than reactive maintenance
Data Source
AI summary
Apparatus and methods for determining operational health of a pump. An example method may include commencing operation of a processing device to monitor operational health of a pump for pumping a fluid at a wellsite, wherein the pump may be a reciprocating pump. During pumping operations of the pump, the processing device may receive pressure measurements of the fluid at a fluid inlet manifold and/or a fluid outlet manifold of the pump, receive position measurements of fluid displacing members of the pump, detect irregular pressure measurements based on the received pressure measurements, determine operational phase of the pump based on the received position measurements, and determine which of fluid inlet and outlet valves of the pump is leaking based on operational phase during which the irregular pressure measurements are detected.