Automated valve actuation for frac fluid ends using position and/or pressure sensors

Abstract

A pump includes a power end and a fluid end coupled to the power end. The power end includes a plunger, and the fluid end includes a crossbore in selective fluid communication with inlet and outlet bores. A suction valve controls fluid communication between the inlet bore and the crossbore, and a discharge valve controls fluid communication between the outlet bore and the crossbore. An actuation device is used to move the discharge valve between an open position and a closed position. A position sensor measures a position of the plunger. A pressure sensor measures a pressure of the crossbore, the inlet bore, or the outlet bore. A controller operates the discharge valve based on data from at least one of the position sensor or the pressure sensor.

1 . A plunger for use with a pump, the plunger comprising: 
 a pressure sensor;   a tubular body;   a chamber formed in the tubular body, wherein the pressure sensor is disposed in the chamber;   a plug coupled to the tubular body and disposed at an end of the chamber, the plug having a plug bore in fluid communication with the chamber; and   a plunger bore disposed through the tubular body and in fluid communication with the chamber; and   a wire disposed through the plunger bore and coupled to the pressure sensor.   
     
     
         2 . The plunger of  claim 1 , wherein the tubular body includes a circumferential recess adjacent a back end of the tubular body. 
     
     
         3 . The plunger of  claim 2 , wherein the plunger bore exits the tubular body at the circumferential recess. 
     
     
         4 . The plunger of  claim 2 , wherein a diameter of the back end of the tubular body is larger than a diameter of the circumferential recess. 
     
     
         5 . The plunger of  claim 2 , wherein a diameter of the back end of the tubular body is smaller than a diameter of a front end of the tubular body. 
     
     
         6 . The plunger of  claim 2 , wherein the plunger bore includes an angled section to direct the plunger bore toward the circumferential recess. 
     
     
         7 . The plunger of  claim 1 , wherein a sealing member is disposed between an outer surface of the plug and an inner surface of the tubular body. 
     
     
         8 . The plunger of  claim 1 , wherein an outer surface of the plug has a taper for engaging a corresponding taper formed on an inner surface of the tubular body. 
     
     
         9 . The plunger of  claim 1 , wherein the plug is threadedly coupled to the tubular body. 
     
     
         10 . The plunger of  claim 1 , wherein the plug is interference fit into the tubular body. 
     
     
         11 . The plunger of  claim 1 , wherein a front end of the plug bore is configured to receive a retrieval tool to facilitate removal of the plug from the tubular body. 
     
     
         12 . The plunger of  claim 11 , wherein the front end of the plug bore includes threads for mating with the retrieval tool. 
     
     
         13 . The plunger of  claim 1 , wherein the end of the chamber is open at a front end of the tubular body. 
     
     
         14 . The plunger of  claim 1 , further comprising a controller configured to measured data from the pressure sensor via the wire. 
     
     
         15 . The plunger of  claim 1 , wherein the wire is configured to transfer information between the pressure sensor and the controller. 
     
     
         16 . The plunger of  claim 1 , wherein the pressure sensor is configured to measure pressure within the pump. 
     
     
         17 . A plunger for use with a pump, the plunger comprising: 
 a pressure sensor;   a tubular body;   a chamber formed in the tubular body, wherein one end of the chamber is open at a front end of the tubular body, and wherein the pressure sensor is disposed in the chamber;   a plug coupled to the front end of tubular body at the one end of the chamber, the plug having a plug bore in fluid communication with the chamber; and   a plunger bore disposed through the tubular body and in fluid communication with the chamber, wherein the plunger bore exits through an outer diameter of the tubular body; and   a wire disposed through the plunger bore and coupled to the pressure sensor.   
     
     
         18 . The plunger of  claim 17 , wherein the tubular body includes a circumferential recess adjacent a back end of the tubular body. 
     
     
         19 . The plunger of  claim 18 , wherein the plunger bore includes an angled section to direct the plunger bore toward and exit through the circumferential recess. 
     
     
         20 . The plunger of  claim 19 , wherein an outer diameter of the back end of the tubular body is larger than an outer diameter of the circumferential recess, and wherein the outer diameter of the back end of the tubular body is smaller than an outer diameter of the front end of the tubular body.