Positive Displacement Pump Valve Monitoring via Pressure and Encoder Data
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Solution Overview
Problem
Existing valve condition monitoring in positive displacement pumps is inefficient and prone to premature failure due to wear and tear, leading to costly and premature pump replacements, with current acoustic monitoring techniques being complex and inaccurate.
Innovation Solution
A valve condition monitoring system using suction and discharge pressure sensors, an encoder, and acquisition hardware/software to monitor valve health in real-time, detecting inefficiencies and potential failures through data analysis and machine learning algorithms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If acoustic monitoring techniques are used to monitor valve conditions, then valve condition detection is attempted, but the system becomes complex and measurement accuracy deteriorates
Solution Approach 1:
The patent replaces complex acoustic monitoring systems with a simplified electrical sensing system. Instead of using acoustic sensors and complex signal processing, the invention uses electrical sensors to detect pressure differentials across the valve, providing accurate valve condition monitoring through straightforward electrical measurements rather than complex acoustic analysis
Solution Approach 2:
The patent extracts the essential monitoring function from the complex acoustic system by focusing solely on pressure differential measurement. Rather than attempting to monitor all acoustic parameters, the invention isolates and measures only the critical pressure differential across the valve, eliminating unnecessary system complexity while maintaining monitoring effectiveness
2Productivity
If pumps operate continuously for extended periods, then productivity increases, but valve seal deterioration accelerates leading to premature failure
Solution Approach 1:
The patent implements a feedback monitoring system that continuously measures pressure differentials across the valve and provides real-time information about valve condition. This feedback enables operators to detect early signs of valve seal deterioration and schedule maintenance before catastrophic failure occurs, allowing the pump to operate continuously at high productivity while maintaining reliability through proactive maintenance
Solution Approach 2:
The patent enables preliminary detection of valve seal deterioration by monitoring pressure differentials before actual failure occurs. By detecting early signs of seal wear through pressure measurements, maintenance can be scheduled in advance, preventing catastrophic failure and extending the useful continuous operation period of the pump
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 real-time detection of valve inefficiencies and potential failures, allowing for proactive maintenance, extending pump life and reducing downtime and costs by preventing catastrophic events.
Implementation Method 1
A suction pressure sensor is provided to monitor fluid pressure flowing to the fluid end
Implementation Method 2
a discharge pressure sensor is also provided to monitor fluid pressure flowing from the fluid end
Implementation Method 3
an encoder is provided to monitor reciprocation of the valve via a power end shaft
Data Source
AI summary
A technique for monitoring valve and pump efficiencies for positive displacement pumps. The techniques include utilizing a data acquisition system to attain intake and discharge pressure data in combination with real-time encoder position data. Thus, when combined, output from a pump may be monitored in real-time. As a result, pump life may be extended beyond an anticipated changeout schedule. By the same token, premature pump inefficiencies may also be detected for taking a pump offline in advance of expected life. In either circumstance, multi-pump operations may be substantially enhanced with cost and time savings realized.