System and Method for Monitoring Valve Wear in a Fluid Pump

Abstract

A pump for pumping fluid includes a pressure sensor disposed in the discharge outlet that communicates with a plurality of pumping chambers. The pressure sensor monitors the discharge pressure and transmits the discharge pressure to a logic device. The logic device is configured to analyze the discharge pressure verses time, determine a peak-to-peak amplitude associated with the discharge pressure verses time, and to detect a pressure spike corresponding to the maximum or high peak-to-peak amplitude. The pressure spike may correspond to uncharacteristic operation of a discharge valve or a suction valve associated with the pump.

We claim: 
     
         1 . A pump for pumping fluid, the pump comprising:
 an intake manifold;   a discharge outlet;   a plurality of pumping chambers in fluid communication with the intake manifold and the discharge outlet;   a pressure sensor disposed in the discharge outlet; and   a logic device configured to receive discharge pressure data from the pressure sensor, to analyze the discharge pressure data verses time; and to determine a high peak-to-peak amplitude of the discharge pressure data verses time to detect a discharge pressure spike.   
     
     
         2 . The pump of  claim 1 , further comprising a discharge valve operatively disposed between one of the plurality of pumping chambers and the discharge outlet, wherein the discharge pressure spike is indicative of uncharacteristic operation of the discharge valve. 
     
     
         3 . The pump of  claim 2 , further comprising a piston disposed in each of the plurality of pumping chambers. 
     
     
         4 . The pump of  claim 3 , wherein the piston in each of the plurality of pumping chambers is configured to discharge fluid from the respective pumping chamber at different respective times. 
     
     
         5 . The pump of  claim 4 , wherein discharge of fluid from the plurality of pumping chambers is associated with a steady state discharge pressure. 
     
     
         6 . The pump of  claim 1 , wherein the logic device is further configured to receive a discharge pressure threshold value and to compare the discharge pressure threshold with the high peak-to-peak amplitude. 
     
     
         7 . The pump of  claim 6 , wherein the logic device is further configured to issue an alarm if the high peak-to-peak amplitude associated with the discharge pressure spike exceeds the discharge pressure threshold. 
     
     
         8 . The pump of  claim 1 , wherein the pump is a component of a fracking machine including a prime mover for operating the pump. 
     
     
         9 . The pump of  claim 8 , wherein the logic device is a dedicated component of a computer system operatively associated with the fracking machine. 
     
     
         10 . The pump of  claim 9 , wherein the logic device is a programmable logic device. 
     
     
         11 . A method of operating a pump, the method comprising:
 receiving electronic signals indicative of a discharge pressure associated with discharge of fluid from the pump;   analyzing discharge pressure verses time with a logic device dedicated at least in part to analysis of the discharge pressure;   determining a high peak-to-peak amplitude of the discharge pressure to detect a discharge pressure spike in the discharge pressure, the discharge pressure spike associated with uncharacteristic operation of a discharge valve or a suction valve associated with the pump.   
     
     
         12 . The method of  claim 11 , further comprising comparing the high peak-to-peak amplitude to a discharge pressure threshold and activating an alarm if the high peak-to-peak amplitude exceeds the discharge pressure threshold. 
     
     
         13 . The method of  claim 12 , wherein the pump includes a plurality of pumping chambers configured to discharge fluid at different respective times. 
     
     
         14 . The method of  claim 13 , wherein discharge of fluid from the plurality of pumping chambers is associated with a steady state discharge pressure. 
     
     
         15 . The method of  claim 14 , wherein the steady state discharge pressure is associated with a stable peak-to-peak amplitude. 
     
     
         16 . The method of  claim 15 , wherein the electronic signals indicative of the discharge pressure are transmitted from a pressure sensor disposed in a discharge outlet communicating with each of the plurality of pumping chambers. 
     
     
         17 . The method of  claim 11 , wherein the logic device is a programmable logic device. 
     
     
         18 . A system for monitoring operation of a pump discharging fluid, the system comprising:
 a pressure sensor disposed in a discharge outlet of the pump to measure a discharge pressure from a plurality of pumping chambers discharging fluid to the discharge outlet;   a logic device communicating with the pressure sensor to receive discharge pressure data reflecting the discharge pressure, the logic device configured to determine a high peak-to-peak amplitude associated with the discharge pressure, compare the high peak-to-peak amplitude with a discharge pressure threshold; and to issue an alarm if the high peak-to-peak amplitude exceeds the discharge pressure threshold.   
     
     
         19 . The system of  claim 18 , wherein the discharge of fluid from the plurality of pumping chambers provides a stable peak-to-peak amplitude, and the high peak-to-peak amplitude corresponds to a discharge pressure spike in the discharge pressure. 
     
     
         20 . The system of  claim 19 , wherein the discharge pressure spike indicates uncharacteristic operation of at least one of a suction valve or a discharge valve operatively associated with at least one of the plurality of pumping chambers.