Monitoring system for reciprocating pumps

Abstract

A reciprocating pump assembly includes a pump housing that houses a crankshaft. Pistons are mechanically connected to the crankshaft for pumping fluid through cylinders. Each cylinder has a fluid inlet and a fluid outlet. The pump also has a monitoring housing connected to the reciprocating pump. Within the monitoring housing is a computer with memory. Pressure sensor assemblies sense a pressure value of a fluid within the pump, and are in electrical communication with the memory. An accelerometer positioned on the pump measures vibrations of the pump and is also in electrical communication with the memory for storage of sensed vibrations or displacements during operations. A proximity sensor in electrical communication with the memory is located within the pump housing to determine the rotational velocity of the crankshaft.

1 - 24 . (canceled) 
     
     
         25 . A reciprocating pump assembly, comprising:
 a pump housing;   a crankshaft housed in the pump housing;   a piston connected to the crankshaft;   a cylinder connected to the pump housing and spaced therefrom in a first direction, the cylinder defining a chamber within which the piston is adapted to reciprocate so that a dynamic pressure within the chamber increases and decreases as the piston reciprocates within the chamber;   an inlet valve to control fluid flow into the chamber;   an outlet valve to control fluid flow out of the chamber;   a fluid inlet in fluid communication with the inlet valve;   a fluid outlet in fluid communication with the outlet valve;   a monitoring housing connected to the pump housing;   an accelerometer connected to the pump housing to sense vibrations of the reciprocating pump assembly;   at least one wire extending between the accelerometer and the monitoring housing;   a proximity sensor to determine a rotational velocity of the crankshaft;   a first pressure sensor assembly mounted to the fluid inlet to sense an overall fluid pressure of the fluid entering the pump, the first pressure sensor assembly comprising:
 a first plug member connected to the fluid inlet; 
 a first transducer located in the first plug member to sense an overall fluid pressure of fluid entering the reciprocating pump assembly; 
 a first plurality of prongs extending from the first transducer; and 
 a first plurality of wires extending from the first plurality of prongs, respectively; 
   a second pressure sensor assembly mounted to the cylinder to sense a dynamic pressure within the chamber, the second pressure assembly comprising:
 a second plug member connected to the cylinder; 
 a second transducer located in the second plug member to sense the dynamic pressure within the chamber; 
 a second plurality of prongs extending from the second transducer; and 
 a second plurality of wires extending from the second plurality of prongs, respectively; 
   a third pressure sensor assembly mounted to the fluid outlet to sense an overall fluid pressure of the fluid exiting the pump, the third pressure assembly comprising:
 a third plug member connected to the fluid outlet; 
 a third transducer located in the third plug member to sense the overall fluid pressure of the fluid exiting the reciprocating pump assembly; 
 a third plurality of prongs extending from the third transducer; and 
 a third plurality of wires extending from the third plurality of prongs, respectively; 
   a computer located within the monitoring housing, the computer comprising a memory, wherein the proximity sensor is in electrical communication with the memory,
 wherein the accelerometer is in electrical communication with the memory via at least the at least one wire extending between the accelerometer and the monitoring housing, 
 wherein the first transducer is in electrical communication with the memory via at least the first plurality of prongs and the first plurality of wires, 
 wherein the second transducer is in electrical communication with the memory via at least the second plurality of prongs and the second plurality of wires, 
 wherein the third transducer is in electrical communication with the memory via at least the third plurality of prongs and the third plurality of wires, and 
 wherein data, which is associated with the vibrations of the reciprocating pump assembly, the rotational velocity of the crankshaft, the overall fluid pressure of the fluid entering the reciprocating pump assembly, the dynamic pressure within the chamber, and the overall fluid pressure of the fluid exiting the reciprocating pump assembly, is adapted to be stored in the memory; and 
   a wire harness connected to the monitoring housing, the wire harness comprising at least one bundle of at least the following:
 the at least one wire extending between the accelerometer and the monitoring housing; 
 the first plurality of wires extending from the first plurality of prongs, respectively; 
 the second plurality of wires extending from the first plurality of prongs, respectively; and 
 the third plurality of wires extending from the first plurality of prongs, respectively; 
   wherein the monitoring housing is connected to the pump housing, and the wire harness is connected to the monitoring housing, so that the at least one wire, the first plurality of wires, the second plurality of wires, and the third plurality of wires, are all bundled together at a first bundle location adjacent the monitoring housing;   wherein the reciprocating pump assembly has opposing first and second portions spaced in a second direction that is perpendicular to the first direction;   wherein the monitoring housing is connected to the pump housing at the first portion of the reciprocating pump assembly; and   wherein the at least one wire, the first plurality of wires, the second plurality of wires, and the third plurality of wires, are all bundled together in the at least one bundle at a second bundle location that is:
 located, in the first direction, between the crankshaft and the cylinder; and 
 located, in the second direction, at the first portion of the reciprocating pump assembly. 
   
     
     
         26 . The reciprocating pump assembly of  claim 25 , further comprising:
 a piston rod housing extending, in the first direction, between the pump housing and the cylinder;   wherein the second bundle location is located on the piston rod housing.   
     
     
         27 . The reciprocating pump assembly of  claim 25 , wherein the second bundle location is located on the pump housing. 
     
     
         28 . The reciprocating pump assembly of  claim 25 , wherein each of the first, second and third pluralities of wires comprises:
 a first set of wires; and   a second set of wires selectively engaged with the first set of wires, respectively.   
     
     
         29 . The reciprocating pump assembly of  claim 28 , wherein the at least one bundle comprises:
 a first bundle, the first bundle comprising the respective first sets of wires of the first, second and third pluralities of wires;   a wire harness disconnect with which the first bundle is selectively engaged; and   a second bundle extending from the wire harness disconnect and to the monitoring housing, the second bundle comprising the respective second sets of wires of the first, second and third pluralities of wires;   wherein the second sets of wires are selectively engaged with the first sets of wires, respectively, via the selective engagement between the first bundle and the wire harness disconnect.   
     
     
         30 . The reciprocating pump assembly of  claim 29 , wherein the wire harness disconnect permits the first bundle to be selectively disengaged from the wire harness disconnect, and thus selectively disengaged from the second bundle, when at least the cylinder is disconnected from the pump housing. 
     
     
         31 . The reciprocating pump assembly of  claim 29 , further comprising:
 a piston rod housing extending, in the first direction, between the pump housing and the cylinder;   wherein the second bundle location is on the piston rod housing; and   wherein the wire harness disconnect is located at the second bundle location and thus on the piston rod housing.   
     
     
         32 . The reciprocating pump assembly of  claim 29 , wherein the second bundle location is on the pump housing; and
 wherein the wire harness disconnect is located at the second bundle location and thus on the pump housing.