SENSOR SYSTEM FOR A POSITIVE DISPLACEMENT PUMP

Abstract

A positive displacement pump is provided that includes a pump housing having a pump chamber; a plunger mounted in the pump housing for reciprocating motion in the pump chamber; a suction valve positioned to allow a fluid to enter the pump chamber upon movement of the plunger in a first direction; a discharge valve positioned to discharge the fluid from the pump chamber upon movement of the plunger in a second direction; and at least one sensor enclosed by the pump housing for measuring at least one pump condition parameter.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

FIG. 1 is a schematic illustration of a pumping system for use in a well operation according to one embodiment of the present invention;

FIG. 2 is a schematic illustration of a various sensors coupled to a control system for use in the pumping system of FIG. 1;

FIG. 3 is a cross-sectional view of a positive displacement pump that can be used in the system illustrated in FIG. 1, according to an embodiment of the present invention;

FIG. 4 is close up view taken from detail 4 of FIG. 3, showing the interaction of a valve with a valve seat; and

FIG. 5 is close up view of the valve and valve seat of FIG. 4 shown with degradation of both the valve and the valve seat.

Claims

1. A positive displacement pump, comprising: a pump housing having a pump chamber;a plunger mounted in the pump housing for reciprocating motion in the pump chamber;a suction valve positioned to allow a fluid to enter the pump chamber upon movement of the plunger in a first direction;a discharge valve positioned to discharge the fluid from the pump chamber upon movement of the plunger in a second direction; andat least one sensor enclosed by the pump housing for measuring at least one pump condition parameter.

2. The pump of claim 1, further comprising a control system in communication with the at least one sensor to process the at least one pump condition parameter measured by the at least one sensor for evaluating a condition of the pump.

3. The pump of claim 2, wherein the communication between the control system and the at least one sensor is wireless.

4. The pump of claim 1, wherein the at least one sensor is self powered.

5. The pump of claim 1, wherein the at least one sensor comprises a chamber pressure sensor mounted on a face of the plunger at a position adjacent to the pump chamber.

6. The pump of claim 5, wherein the chamber pressure sensor measures at least one of pressure, temperature and vibration.

7. The pump of claim 5, wherein the chamber pressure sensor is powered by energy from the reciprocating motion of the plunger.

8. The pump of claim 1, wherein the at least one sensor comprises a plunger sensor carried by the plunger.

9. The pump of claim 8, wherein the plunger sensor measures a position of the plunger.

10. The pump of claim 8, wherein the plunger sensor is powered by energy from the reciprocating motion of the plunger.

11. The pump of claim 1, wherein the at least one sensor comprises a pump housing sensor carried by an interior wall of the pump housing at a position adjacent to the pump chamber.

12. The pump of claim 11, wherein the pump housing sensor measures at least one of pressure, temperature and vibration.

13. The pump of claim 11, wherein the pump housing sensor is powered by stress from the fluid within the pump chamber.

14. The pump of claim 1, wherein one of the suction valve and the discharge valve comprises a flexible valve insert, and wherein the at least one sensor comprises a valve insert sensor that measures a degradation of the valve insert.

15. The pump of claim 14, wherein the valve insert sensor is embedded within the flexible valve insert.

16. The pump of claim 14, wherein the valve insert sensor measures a conductivity between itself and a valve seat.

17. The pump of claim 14, wherein the valve insert sensor measures an integrity of itself.

18. The pump of claim 1, wherein the suction valve is movable into and out of contact with a suction valve seat; and wherein the discharge valve is movable into and out of contact with a discharge valve seat, and wherein the at least one sensor comprises a valve seat sensor that measures a degradation of one of the suction valve seat and the discharge valve seat.

19. The pump of claim 18, wherein the valve seat sensor is embedded within one of the suction valve seat and the discharge valve seat.

20. The pump of claim 18, wherein the valve seat sensor measures a conductivity between itself and one of the suction valve and the discharge valve.

21. The pump of claim 18, wherein the valve seat sensor measures an integrity of itself.

22. A positive displacement pump, comprising: a pump housing having a pump chamber;a plunger mounted in the pump housing for reciprocating motion in the pump chamber;a suction valve positioned to allow a fluid to enter the pump chamber upon movement of the plunger in a first direction;a discharge valve positioned to discharge the fluid from the pump chamber upon movement of the plunger in a second direction;at least one sensor enclosed by the pump housing for measuring at least one pump condition parameter; anda control system in communication with the at least one sensor to process the at least one pump condition parameter measured by the at least one sensor for evaluating a condition of the pump, wherein the communication between the control system and the at least one sensor is wireless.

23. The pump of claim 22, wherein the at least one sensor comprises a chamber pressure sensor mounted on a face of the plunger at a position adjacent to the pump chamber to measure at least one of pressure, temperature and vibration, and wherein the chamber pressure sensor is powered by energy from the reciprocating motion of the plunger.

24. The pump of claim 22, wherein the at least one sensor comprises a plunger sensor carried by the plunger to measure a position of the plunger, and wherein the plunger sensor is powered by energy from the reciprocating motion of the plunger.

25. The pump of claim 22, wherein the at least one sensor comprises a pump housing sensor carried by an interior wall of the pump housing at a position adjacent to the pump chamber to measure at least one of pressure, temperature and vibration, and wherein the pump housing sensor is powered by stress from the fluid within the pump chamber.

26. The pump of claim 22, wherein one of the suction valve and the discharge valve comprises a flexible valve insert, and wherein the at least one sensor comprises a valve insert sensor that measures a degradation of the valve insert.

27. The pump of claim 26, wherein the valve insert sensor is embedded within the flexible valve insert, and wherein the valve insert sensor measures a conductivity between itself and a valve seat.

28. The pump of claim 26, wherein the valve insert sensor measures an integrity of itself.

29. The pump of claim 22, wherein the suction valve is movable into and out of contact with a suction valve seat; and wherein the discharge valve is movable into and out of contact with a discharge valve seat, and wherein the at least one sensor comprises a valve seat sensor that measures a degradation of one of the suction valve seat and the discharge valve seat.

30. The pump of claim 28, wherein the valve seat sensor is embedded within one of the suction valve seat and the discharge valve seat, and wherein the valve seat sensor measures a conductivity between itself and one of the suction valve and the discharge valve.

31. The pump of claim 28, wherein the valve seat sensor measures an integrity of itself.