US20180223831A1 - Pump Monitoring and Notification System - Google Patents
Pump Monitoring and Notification System Download PDFInfo
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- US20180223831A1 US20180223831A1 US15/428,873 US201715428873A US2018223831A1 US 20180223831 A1 US20180223831 A1 US 20180223831A1 US 201715428873 A US201715428873 A US 201715428873A US 2018223831 A1 US2018223831 A1 US 2018223831A1
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Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/10—Other safety measures
- F04B49/103—Responsive to speed
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/25—Methods for stimulating production
- E21B43/26—Methods for stimulating production by forming crevices or fractures
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/25—Methods for stimulating production
- E21B43/26—Methods for stimulating production by forming crevices or fractures
- E21B43/2607—Surface equipment specially adapted for fracturing operations
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B1/00—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders
- F04B1/04—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement
- F04B1/053—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement with actuating or actuated elements at the inner ends of the cylinders
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B1/00—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders
- F04B1/04—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement
- F04B1/053—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement with actuating or actuated elements at the inner ends of the cylinders
- F04B1/0536—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement with actuating or actuated elements at the inner ends of the cylinders with two or more serially arranged radial piston-cylinder units
- F04B1/0538—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement with actuating or actuated elements at the inner ends of the cylinders with two or more serially arranged radial piston-cylinder units located side-by-side
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B17/00—Pumps characterised by combination with, or adaptation to, specific driving engines or motors
- F04B17/05—Pumps characterised by combination with, or adaptation to, specific driving engines or motors driven by internal-combustion engines
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B17/00—Pumps characterised by combination with, or adaptation to, specific driving engines or motors
- F04B17/06—Mobile combinations
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B19/00—Machines or pumps having pertinent characteristics not provided for in, or of interest apart from, groups F04B1/00 - F04B17/00
- F04B19/20—Other positive-displacement pumps
- F04B19/22—Other positive-displacement pumps of reciprocating-piston type
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B47/00—Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps
- F04B47/02—Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps the driving mechanisms being situated at ground level
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B51/00—Testing machines, pumps, or pumping installations
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B9/00—Piston machines or pumps characterised by the driving or driven means to or from their working members
- F04B9/02—Piston machines or pumps characterised by the driving or driven means to or from their working members the means being mechanical
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B2203/00—Motor parameters
- F04B2203/06—Motor parameters of internal combustion engines
- F04B2203/0605—Rotational speed
Definitions
- This application relates generally to a monitoring system and, more particularly, to a system and method of monitoring the performance of a hydraulic pump and generating a notification upon a failure of the pump.
- Hydraulic fracturing or fracking operations are often used during well development in the oil and gas industry. For example, in formations in which oil or gas cannot be readily or economically extracted from the earth, a hydraulic fracturing operation may be performed. Such a hydraulic fracturing operation typically includes pumping large amounts of fracking fluid at high pressure to induce cracks in the earth, thereby creating pathways via which the oil and gas may flow. Hydraulic fracturing or fracking pumps are typically relatively large positive displacement pumps. Fracking fluid often contains water, proppants and other additives and is pumped downhole by the fracking pump at a sufficient pressure to cause fractures and fissures to form within the well.
- fracking pumps may be at a relatively high risk of failure.
- Systems have been proposed for monitoring pump failures.
- U.S. Patent Publication No. 2016/0168976 discloses a system for detecting leakage in a fracking by monitoring the suction pressure, the discharge pressure, and a pump cylinder pressure. Each pressure may be measured by a different pressure sensor.
- a simplified system for monitoring a fracking pump would be desirable.
- a pump monitoring and notification system for a hydraulic pump includes a transmission speed sensor and a controller.
- the transmission speed sensor is associated with a transmission operatively connected to the hydraulic pump and generates transmission speed data indicative of an output speed of the transmission.
- the controller is configured to access a transmission threshold, with the transmission threshold being based upon variations in a rotational speed of the transmission, access a time threshold, and determine a rotational speed of the transmission based upon the transmission speed data from the transmission speed sensor.
- the controller is further configured to determine a variation in rotational speed of the transmission based upon the rotational speed, compare the variation in rotational speed of the transmission to the transmission threshold, and generate an alert signal when the variation in rotational speed of the transmission exceeds the transmission threshold for a time period exceeding the time threshold.
- a method of monitoring a hydraulic pump that is operatively connected to a transmission includes accessing a transmission threshold, with the transmission threshold being based upon variations in a rotational speed of the transmission, accessing a time threshold, and determining a rotational speed of the transmission based upon the transmission speed data from the transmission speed sensor associated with the transmission. The method further includes determining a variation in rotational speed of the transmission based upon the rotational speed, comparing the variation in rotational speed of the transmission to the transmission threshold, and generating an alert signal when the variation in rotational speed of the transmission exceeds the transmission threshold for a time period exceeding the time threshold.
- a pump system in still another aspect, includes a prime mover, a transmission operatively connected to and driven by the prime mover, and a hydraulic pump operatively connected to and driven by the transmission.
- the pump system further includes a state sensor for generating data indicative of whether the prime mover is operating at a steady-state, a transmission speed sensor associated with the transmission for generating transmission speed data indicative of an output speed of the transmission, and a controller.
- the controller is configured to access a transmission threshold, with the transmission threshold being based upon variations in a rotational speed of the transmission, access a time threshold, and determine a rotational speed of the transmission based upon the transmission speed data from the transmission speed sensor.
- the controller is further configured to determine a variation in rotational speed of the transmission based upon the rotational speed, compare the variation in rotational speed of the transmission to the transmission threshold, and generate an alert signal when the variation in rotational speed of the transmission exceeds the transmission threshold for a time period exceeding the time threshold.
- FIG. 1 is a perspective view of a pumping system supported on a trailer for transportation;
- FIG. 2 is a perspective view of a hydraulic pump of the pumping system depicted in FIG. 1 ;
- FIG. 3 is a sectional view of a portion of the fluid section of the hydraulic pump depicted in FIG. 2 ;
- FIG. 4 is a block diagram of a pump monitoring and notification system in accordance with the disclosure.
- FIG. 5 is an exemplary graph of rotational speed of a hydraulic pump
- FIG. 6 is an exemplary graph of rotational speed of a transmission coupled to the hydraulic pump and corresponding to the rotational speed of the hydraulic pump depicted in FIG. 5 ;
- FIG. 7 is an exemplary graph of inlet pressure of the hydraulic pump corresponding to the rotational speed of the hydraulic pump depicted in FIG. 5 ;
- FIG. 8 is an enlarged view the portion identified as 8 in FIG. 5 ;
- FIG. 9 is an enlarged view the portion identified as 9 in FIG. 6 ;
- FIG. 10 is an enlarged view the portion identified as 10 in FIG. 7 ;
- FIG. 11 is a flowchart of a process of operating the pump monitoring and notification system.
- the pumping system 10 may include a prime mover such as an internal combustion engine 12 , a transmission 13 that is operatively connected to and driven by engine 12 , and a hydraulic pump 14 that is operatively connected to and driven by the transmission 13 .
- the engine 12 may be a compression ignition engine that combusts diesel fuel.
- the hydraulic pump 14 may be configured to pump hydraulic or fracking fluid into the ground to fracture rock layers during the fracturing process. Because the fracturing process may require introduction of hydraulic fluids at different locations about the fracturing site, the components of the pumping system 10 may be supported on a mobile trailer 15 disposed on wheels 16 to enable transportation of the system about the fracturing site.
- the transmission 13 may be configured with a plurality of gears operative between the engine 12 and the output shaft (not shown) of the transmission to alter the rotational speed of the output from the engine.
- a fixed gear mechanism or coupling depicted generally at 17 may be provided between the output shaft of the transmission 13 and the drive shaft 21 of the hydraulic pump 14 to further change or reduce the rotational speed between the engine 12 and the pump.
- hydraulic pump 14 includes a power section 20 and a fluid section 30 .
- the power section 20 may include an input or drive shaft 21 operatively connected to and driven by the transmission 13 .
- the drive shaft 21 may be operatively connected to an additional shaft 22 through gears (not shown) or other structure or mechanisms to convert rotational movement of the driveshaft into a linear movement at the fluid section 30 of the hydraulic pump 14 .
- the fluid section 30 may include an inlet end 31 and an outlet end 35 , spaced from the inlet end, with one or more cylinders 40 disposed between the inlet end and the outlet end.
- Each cylinder 40 may include a reciprocating member such as a piston 41 disposed for reciprocating sliding movement therein.
- an inlet conduit (not shown) may be fluidly connected to an inlet manifold 32 positioned at the inlet end 31 .
- the inlet manifold 32 may include a plurality of inlet lines 33 with each inlet line being fluidly connected to one of the cylinders 40 .
- the inlet end 31 may include a suction or inlet valve 42 ( FIG. 3 ) positioned along inlet wall 34 between each inlet line 33 and its associated cylinder 40 .
- the inlet valve 42 may be biased in a closed condition or position and moved to its open position to permit fracking fluid to pass therethrough upon the piston 41 generating a sufficient vacuum or negative pressure.
- a discharge or outlet conduit may be fluidly connected to an outlet manifold 36 positioned at the outlet end 35 .
- the outlet manifold may include a plurality of outlet lines 37 with each outlet line being fluidly connected to one of the cylinders 40 , such as at a location opposite the inlet lines 33 .
- the outlet end 35 may include a discharge or outlet valve 43 ( FIG. 3 ) positioned along outlet wall 38 between each outlet line 37 and its associated cylinder 40 .
- the outlet valve 43 may be biased in a closed condition or position and moved to its open position to permit fracking fluid to pass therethrough upon the piston 41 generating a sufficient or high enough pressure.
- operation of the engine 12 may drive rotation of the transmission 13 and ultimately rotation of the drive shaft 21 of the hydraulic pump 14 .
- Rotation of the drive shaft 21 causes reciprocating movement of the pistons 41 within cylinders 40 .
- the reciprocating movement of the pistons 41 may cause fracking fluid to be drawn through the inlet manifold 32 from the inlet conduit (not shown) and into the cylinders 40 through the inlet lines 33 and past the inlet valves 42 .
- Fracking fluid is driven by the pistons 41 past the outlet valves 43 through the outlet lines 37 and into outlet manifold 36 .
- the pumping system 10 may be controlled by the control system 60 as shown generally by an arrow in FIG. 1 indicating association with the pumping system.
- the control system 60 may include an electronic control module or controller 61 as shown generally by an arrow in FIG. 1 and a plurality of sensors.
- the controller 61 may control the operation of various aspects of the pumping system 10 .
- the controller 61 may be an electronic controller that operates in a logical fashion to perform operations, execute control algorithms, store, retrieve, and access data and other desired operations.
- the controller 61 may include or access memory, secondary storage devices, processors, and any other components for running an application.
- the memory and secondary storage devices may be in the form of read-only memory (ROM) or random access memory (RAM) or integrated circuitry that is accessible by the controller.
- ROM read-only memory
- RAM random access memory
- Various other circuits may be associated with the controller 61 such as power supply circuitry, signal conditioning circuitry, driver circuitry, and other types of circuitry.
- the controller 61 may be a single controller or may include more than one controller disposed to control various functions and/or features of the pumping system 10 .
- the term “controller” is meant to be used in its broadest sense to include one or more controllers and/or microprocessors that may be associated with the pumping system 10 and that may cooperate in controlling various functions and operations of the pumping system.
- the functionality of the controller 61 may be implemented in hardware and/or software without regard to the functionality.
- the controller 61 may rely on one or more data maps relating to the operating conditions and the operating environment of the pumping system 10 and the work site at which the pumping system is operating that may be stored in the memory of or associated with the controller. Each of these data maps may include a collection of data in the form of tables, graphs, and/or equations.
- the control system 60 and controller 61 may be located on the trailer 15 or may be distributed with components also located remotely from or off-board the trailer.
- Pumping system 10 may be equipped with a plurality of sensors that provide data indicative (directly or indirectly) of various operating parameters of elements of the system and/or the operating environment in which the system is operating.
- the term “sensor” is meant to be used in its broadest sense to include one or more sensors and related components that may be associated with the pumping system 10 and that may cooperate to sense various functions, operations, and operating characteristics of the element of the system and/or aspects of the environment in which the system is operating.
- An engine speed sensor 62 may be provided on or associated with the engine 12 to monitor the output speed of the engine.
- the engine speed sensor 62 may generate engine speed data indicative of the output speed of engine 12 .
- the engine speed sensor 62 may be used to determine whether the engine is operating at a steady state. Other manners (e.g., combinations of other sensors) may be used as a speed sensor to generate speed data indicative of the engine speed or whether the engine is operating at a steady state.
- a transmission speed sensor 63 ( FIG. 4 ) may be provided on or associated with the transmission 13 to monitor the output speed of the transmission.
- the transmission speed sensor 63 may generate transmission speed data indicative of the output speed of transmission 13 .
- the hydraulic pump 14 may not include a significant number of sensors.
- the trailer 15 may not include electrical connections adjacent the hydraulic pump 14 and therefore the pump may not include sensors that require electrical input.
- the nature of and operating environment associated with the operation of the engine 12 , the transmission 13 , and the hydraulic pump 14 may result in fewer sensors being associated with the pump.
- the hydraulic or fracking fluid may be abrasive and/or corrosive and thus the fluid section 30 of the hydraulic pump 14 may require maintenance substantially more frequently than the engine 12 or the transmission 13 . Accordingly, it may be desirable to reduce the number of sensors associated with the hydraulic pump 14 , when possible.
- the abrasive and/or corrosive nature of the fracking fluid being pumped may cause substantial wear on the components of the hydraulic pump 14 and, in particular, the fluid section 30 .
- Leaks are often more likely to occur at locations in which components of the hydraulic pump 14 move. More specifically, leaks may be likely to occur along the inlet wall or at the inlet valve 42 as indicated by the arrow 65 in FIG. 3 , along the outlet wall or at the outlet valve 43 as indicated by the arrow 66 , and/or along the path of the piston 41 through cylinder 40 as indicated by the arrow 67 . Such leaks may reduce the performance of the hydraulic pump 14 and may be indicative of more significant future failures.
- Cavitation may be caused by various conditions including leaks as described above as well as low pressure or low flow at the inlet end 31 . In addition to reduced performance of the hydraulic pump 14 , cavitation may also cause significant damage to the pump.
- the control system 60 may include a pump monitoring and notification system 68 as shown generally by an arrow in FIG. 1 that monitors aspects of the operation of the pumping system 10 .
- the pump monitoring and notification system 68 may monitor the operation of the engine 12 and the transmission 13 to determine whether the hydraulic pump 14 is leaking or experiencing cavitation. In doing so, upon the engine meeting specified operating conditions, the pump monitoring and notification system 68 may analyze variations in the rotational speed of the transmission 13 to determine whether its performance is within a desired operating window.
- variations in the rotational speed of the hydraulic pump 14 are approximately 3 RPM as depicted at 70 in FIG. 5
- variations in the rotational speed of the transmission 13 are approximately 5 RPM as depicted at 71 in FIG. 6
- variations in the inlet or suction pressure at or leading into the inlet lines 33 are approximately 100 kPa as depicted at 72 in FIG. 7 .
- vibrations will begin to occur within the pump. Such vibrations may result in and be evident as an increase in the variations in the rotational speed of the hydraulic pump 14 .
- the vibrations within the hydraulic pump 14 may be transferred to the transmission 13 through the coupling 17 between the pump and transmission and result in an increase in the variations in the rotational speed of the transmission.
- variations in the inlet or suction pressure at or leading into the inlet lines 33 have increased substantially to approximately 350 kPa as depicted at 73 as a result of a pump failure caused by a leak or cavitation.
- the vibrations within the hydraulic pump 14 increase due to the pump failure and, as depicted at 74 in FIG. 8 , result in an increase in the variations in the rotational speed of the hydraulic pump 14 to approximately 5 RPM as well as slightly increase the maximum rotational speed.
- Vibrations within the hydraulic pump 14 are transferred to the transmission 13 through the coupling 17 between the pump and transmission.
- the transferred vibrations results in an increase in the variations in the rotational speed of the transmission 13 to approximately 25 RPM as depicted at 75 .
- Leaks along the outlet line 37 such along outlet wall 38 or at outlet valve 43 or along the path of the piston 41 through the cylinder 40 may also cause similar changes in the variations in the rotational speed of the transmission 13 and the hydraulic pump 14 .
- the pump monitoring and notification system 68 may be configured to monitor the variations in the speed of rotation of the transmission 13 and generate an alert signal once the variations are equal to or greater than a predetermined transmission speed variation threshold.
- a predetermined transmission speed variation threshold When monitoring the variations in the speed of the transmission 13 , the speed of the transmission is measured relatively frequently, such as every millisecond. In order to determine the variation or difference between the maximum rotational speed of the transmission 13 and the minimum rotational speed of the transmission, the speeds may be measured over a predetermined period of time while operating the transmission at a steady state. As used herein, “steady state” refers to maintaining a constant or generally constant average speed.
- the transmission speed variation threshold may be defined as a difference between the maximum rotational speed of the transmission 13 and a minimum rotational speed of the transmission over a predetermined period of time while operating the transmission at a steady state.
- the transmission 13 may only be operating at steady state if the rotational input to the transmission from the engine 12 is operating at a steady state.
- the transmission speed variation threshold may be approximately 25 RPM.
- the pump monitoring and notification system 68 may utilize other variation in rotational speed thresholds.
- the pump monitoring and notification system 68 may be configured to use a smaller transmission speed variation threshold such as approximately 10, 15 or 20 RPM or a larger transmission speed variation threshold such as approximately 40 or 50 RPM.
- the transmission speed variation threshold may be between 10-60 RPM.
- the transmission speed variation threshold may be between 20-50 RPM.
- the transmission speed variation threshold may be at least 10 RPM or at least 15 RPM. Still other transmission speed variation thresholds are contemplated.
- the pump monitoring and notification system 68 may be configured to monitor the variations in the speed of rotation of the transmission 13 and generate an alert signal if the ratio between the current variation in the operational speed of the transmission 13 and the variation in rotational speed of the transmission during steady state operation exceeds a predetermined variation ratio threshold.
- the variation ratio threshold may be defined as a difference between a maximum rotational speed of the transmission and a minimum rotational speed of the transmission over a predetermined period of time while operating at a steady state divided by a variation in the rotational speed of the transmission while operating the transmission at a steady state and without a hydraulic pump failure.
- the variation in the rotational speed of the transmission 13 upon a leakage or cavitation is approximately 25 RPM and the variation in the rotational speed of the transmission at steady state is approximately 5 RPM.
- the variation ratio threshold may be set at approximately 5.
- the pump monitoring and notification system 68 may require a greater or lesser variation ratio threshold.
- the pump monitoring and notification system 68 may be configured to use a smaller variation ratio threshold such as approximately 2.5, 3 or 4 or a larger variation ratio threshold such as approximately 8 or 10.
- the variation ratio threshold may be between 2.5 and 12.
- the variation ratio threshold may be between 4 and 10.
- the variation ratio threshold may be at least 2.5 or 3. Still other variation ratio thresholds are contemplated.
- the pump monitoring and notification system 68 may monitor the variations in the rotational speed of the transmission 13 by measuring the rotational speed at predetermined intervals. For example, the rotational speed of the transmission 13 may be measured once every millisecond. Other measurements intervals are contemplated.
- the pump monitoring and notification system 68 may be configured to require the transmission speed variation threshold or variation ratio threshold to be met or exceeded for a predetermined length of time. In one example, the pump monitoring and notification system 68 may require the transmission speed variation threshold or variation ratio threshold to be met or exceeded for 60 seconds before generating an alert signal.
- the pump monitoring and notification system 68 may require the threshold to be met or exceed for longer or shorter periods of time.
- the time threshold may be 30 seconds, 120 seconds, or any other desired time period.
- the pump monitoring and notification system 68 may include, in addition or in the alternative, an accumulator function to account for the extent or degree to which the relevant transmission threshold (e.g., transmission speed variation threshold or variation ratio threshold) is exceeded.
- the accumulator function may integrate the extent to which the threshold is exceeded and establish an additional or accumulator threshold for the accumulator function.
- the accumulator function may sum the amount by which the threshold is exceeded and the sum or accumulated result compared to the accumulator threshold. Upon exceeding the accumulator threshold, the alert signal may be generated.
- the pump monitoring and notification system 68 may be configured to permit the hydraulic pump 14 to operate for a relatively long period of time before generating an alert signal if the transmission speed variation threshold or variation threshold ratio is exceeded by a relatively small amount (e.g., 10%). However, the pump monitoring and notification system 68 may generate an alert signal relatively quickly if the transmission speed variation threshold or variation threshold ratio is exceeded by a relatively large amount (e.g., 75%).
- Alert signals generated by the pump monitoring and notification system 68 may take any desired form.
- an alert signal may provide a notice or warning to personnel or systems at the work site and/or remote from the work site.
- an alert signal may, in addition or in the alternative, include a command to shutdown or reduce the operation of the pumping system 10 in order to reduce the likelihood of further damage to the hydraulic pump 14 .
- the pump monitoring and notification system 68 may be configured so that the controller 61 receives information from various sensors and systems of the pumping system 10 and processes the information to determine when pump leakage or cavitation is occurring without directly using or requiring the operating characteristics of the hydraulic pump 14 (e.g., input pressure, output pressure, rotational speed of the pump). As such, the pump monitoring and notification system 68 may determine that pump leakage or cavitation is occurring without sensors directly monitoring the operating characteristics of the hydraulic pump 14 .
- the controller 61 may receive data from the engine speed sensor 62 to determine the rotational speed of the engine 12 and receive data from the transmission speed sensor 63 to determine the rotational speed of the transmission 13 .
- the pump monitoring and notification system 68 may generate an alert signal 77 when the variation in the rotational speed of the transmission 13 exceeds the transmission speed variation threshold or variation ratio threshold.
- the pump monitoring and notification system 68 may be configured to require the variation in the rotational speed of the transmission 13 to exceed the transmission speed variation threshold or variation ratio threshold for a predetermined time threshold.
- the pump monitoring and notification system 68 may be used with pumping systems 10 that include a prime mover, such as an engine 12 , operatively connected to drive transmission 13 , and with the transmission operatively connected to drive the hydraulic pump 14 .
- the pump monitoring and notification system 68 may determine whether the hydraulic pump 14 is experiencing leakage or cavitation based upon variations in the rotational speed of the transmission 13 without monitoring additional aspects or operating characteristics of the pump.
- FIG. 11 depicts one example of the operation of the pump monitoring and notification system 68 .
- a plurality of thresholds may be set or stored.
- the thresholds may include any type of transmission threshold based upon variations in rotational speed of the transmission 13 , such as a transmission speed variation threshold of the transmission speed, an engine speed variation threshold, and a time threshold or period of time that the variation in rotational speed of the transmission 13 must exceed the transmission speed variation threshold.
- the transmission threshold may be a variation ratio threshold of the transmission speed may be set or stored.
- the pumping system 10 may be operated at block 81 .
- Data from the engine speed sensor 62 and the transmission speed sensor 63 may be received at block 82 .
- the controller 61 may determine the engine speed based upon the engine speed data received from the engine speed sensor 62 .
- the controller 61 may determine at decision block 84 whether the engine 12 is operating at a steady state so that the pump monitoring and notification system 68 may be operated in an accurate manner.
- the pumping system 10 may continue to be operated and blocks 81 - 84 repeated.
- the controller 61 may determine at block 85 the speed of the transmission 13 based upon the transmission speed data received from the transmission speed sensor 63 . Based upon the transmission speed, the controller 61 may determine at block 86 the magnitude of the variation in the transmission speed.
- the controller 61 may access the transmission speed variation threshold and compare the magnitude of the variation in transmission speed to the transmission speed variation threshold. If the variation in transmission speed does not exceed the transmission speed variation threshold at decision block 87 , the pumping system 10 may continue to be operated and blocks 81 - 87 repeated. If the variation in transmission speed does exceed the transmission speed variation threshold, the controller 61 may access the time threshold and determine at decision block 88 whether the time during which the variation in transmission speed exceeds the transmission speed variation threshold also exceeds the time threshold. If the time threshold has not been reached, the pumping system 10 may continue to be operated and blocks 81 - 88 repeated. If the time threshold has been reached, an alert signal may be generated by controller 61 at block 89 . In some instances, the pumping system 10 may continue to be operated and blocks 81 - 89 repeated. In other instances, the alert signal may also include a command to shut down or reduce the operation of the pumping system 10 .
- a variation ratio threshold may be set or stored that defines a threshold ratio between the magnitude of steady state operation of the transmission and the magnitude of the variation in transmission speed during a pump failure.
- An example using the variation ratio threshold may operate generally in accordance with the example depicted in FIG. 11 except that the magnitude of the variation of the transmission speed during steady state operation must be determined or otherwise set or stored within the controller 61 .
- the magnitude of the variation in transmission speed during steady state operation may be set or stored by an operator or other personnel.
- the magnitude of the variation in transmission speed during steady state operation may be determined during steady state operation of the pumping system 10 .
- the controller 61 may determine after block 86 the variation ratio threshold by dividing the magnitude of the variation of the transmission speed based upon the transmission speed as determined at block 85 by the variation of the transmission speed during steady state operation. Further, decision block 87 is modified to determine whether the ratio determined by the controller 61 exceeds the variation ratio threshold.
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Abstract
Description
- This application relates generally to a monitoring system and, more particularly, to a system and method of monitoring the performance of a hydraulic pump and generating a notification upon a failure of the pump.
- Hydraulic fracturing or fracking operations are often used during well development in the oil and gas industry. For example, in formations in which oil or gas cannot be readily or economically extracted from the earth, a hydraulic fracturing operation may be performed. Such a hydraulic fracturing operation typically includes pumping large amounts of fracking fluid at high pressure to induce cracks in the earth, thereby creating pathways via which the oil and gas may flow. Hydraulic fracturing or fracking pumps are typically relatively large positive displacement pumps. Fracking fluid often contains water, proppants and other additives and is pumped downhole by the fracking pump at a sufficient pressure to cause fractures and fissures to form within the well.
- As a result of the abrasive and sometimes corrosive nature of the fracking fluid and the high pressures to which the fracking pumps are subjected, fracking pumps may be at a relatively high risk of failure. Systems have been proposed for monitoring pump failures. For example, U.S. Patent Publication No. 2016/0168976 discloses a system for detecting leakage in a fracking by monitoring the suction pressure, the discharge pressure, and a pump cylinder pressure. Each pressure may be measured by a different pressure sensor. A simplified system for monitoring a fracking pump would be desirable.
- The foregoing background discussion is intended solely to aid the reader. It is not intended to limit the innovations described herein, nor to limit or expand the prior art discussed. Thus, the foregoing discussion should not be taken to indicate that any particular element of a prior system is unsuitable for use with the innovations described herein, nor is it intended to indicate that any element is essential in implementing the innovations described herein. The implementations and application of the innovations described herein are defined by the appended claims.
- In one aspect, a pump monitoring and notification system for a hydraulic pump includes a transmission speed sensor and a controller. The transmission speed sensor is associated with a transmission operatively connected to the hydraulic pump and generates transmission speed data indicative of an output speed of the transmission. The controller is configured to access a transmission threshold, with the transmission threshold being based upon variations in a rotational speed of the transmission, access a time threshold, and determine a rotational speed of the transmission based upon the transmission speed data from the transmission speed sensor. The controller is further configured to determine a variation in rotational speed of the transmission based upon the rotational speed, compare the variation in rotational speed of the transmission to the transmission threshold, and generate an alert signal when the variation in rotational speed of the transmission exceeds the transmission threshold for a time period exceeding the time threshold.
- In another aspect, a method of monitoring a hydraulic pump that is operatively connected to a transmission includes accessing a transmission threshold, with the transmission threshold being based upon variations in a rotational speed of the transmission, accessing a time threshold, and determining a rotational speed of the transmission based upon the transmission speed data from the transmission speed sensor associated with the transmission. The method further includes determining a variation in rotational speed of the transmission based upon the rotational speed, comparing the variation in rotational speed of the transmission to the transmission threshold, and generating an alert signal when the variation in rotational speed of the transmission exceeds the transmission threshold for a time period exceeding the time threshold.
- In still another aspect, a pump system includes a prime mover, a transmission operatively connected to and driven by the prime mover, and a hydraulic pump operatively connected to and driven by the transmission. The pump system further includes a state sensor for generating data indicative of whether the prime mover is operating at a steady-state, a transmission speed sensor associated with the transmission for generating transmission speed data indicative of an output speed of the transmission, and a controller. The controller is configured to access a transmission threshold, with the transmission threshold being based upon variations in a rotational speed of the transmission, access a time threshold, and determine a rotational speed of the transmission based upon the transmission speed data from the transmission speed sensor. The controller is further configured to determine a variation in rotational speed of the transmission based upon the rotational speed, compare the variation in rotational speed of the transmission to the transmission threshold, and generate an alert signal when the variation in rotational speed of the transmission exceeds the transmission threshold for a time period exceeding the time threshold.
-
FIG. 1 is a perspective view of a pumping system supported on a trailer for transportation; -
FIG. 2 is a perspective view of a hydraulic pump of the pumping system depicted inFIG. 1 ; -
FIG. 3 is a sectional view of a portion of the fluid section of the hydraulic pump depicted inFIG. 2 ; -
FIG. 4 is a block diagram of a pump monitoring and notification system in accordance with the disclosure; -
FIG. 5 is an exemplary graph of rotational speed of a hydraulic pump; -
FIG. 6 is an exemplary graph of rotational speed of a transmission coupled to the hydraulic pump and corresponding to the rotational speed of the hydraulic pump depicted inFIG. 5 ; -
FIG. 7 is an exemplary graph of inlet pressure of the hydraulic pump corresponding to the rotational speed of the hydraulic pump depicted inFIG. 5 ; -
FIG. 8 is an enlarged view the portion identified as 8 inFIG. 5 ; -
FIG. 9 is an enlarged view the portion identified as 9 inFIG. 6 ; -
FIG. 10 is an enlarged view the portion identified as 10 inFIG. 7 ; and -
FIG. 11 is a flowchart of a process of operating the pump monitoring and notification system. - Referring to
FIG. 1 , an example of apumping system 10 is illustrated that is particularly suited for use with geological fracturing processes to recover oil and/or natural gas from the earth. Thepumping system 10 may include a prime mover such as aninternal combustion engine 12, atransmission 13 that is operatively connected to and driven byengine 12, and ahydraulic pump 14 that is operatively connected to and driven by thetransmission 13. In one example, theengine 12 may be a compression ignition engine that combusts diesel fuel. Thehydraulic pump 14 may be configured to pump hydraulic or fracking fluid into the ground to fracture rock layers during the fracturing process. Because the fracturing process may require introduction of hydraulic fluids at different locations about the fracturing site, the components of thepumping system 10 may be supported on amobile trailer 15 disposed onwheels 16 to enable transportation of the system about the fracturing site. - The
transmission 13 may be configured with a plurality of gears operative between theengine 12 and the output shaft (not shown) of the transmission to alter the rotational speed of the output from the engine. In some instances, a fixed gear mechanism or coupling depicted generally at 17 may be provided between the output shaft of thetransmission 13 and thedrive shaft 21 of thehydraulic pump 14 to further change or reduce the rotational speed between theengine 12 and the pump. - As depicted in
FIG. 2 ,hydraulic pump 14 includes apower section 20 and afluid section 30. Thepower section 20 may include an input ordrive shaft 21 operatively connected to and driven by thetransmission 13. Thedrive shaft 21 may be operatively connected to anadditional shaft 22 through gears (not shown) or other structure or mechanisms to convert rotational movement of the driveshaft into a linear movement at thefluid section 30 of thehydraulic pump 14. - Referring to
FIG. 3 , thefluid section 30 may include aninlet end 31 and anoutlet end 35, spaced from the inlet end, with one ormore cylinders 40 disposed between the inlet end and the outlet end. Eachcylinder 40 may include a reciprocating member such as apiston 41 disposed for reciprocating sliding movement therein. - Referring to
FIG. 2 , an inlet conduit (not shown) may be fluidly connected to aninlet manifold 32 positioned at theinlet end 31. Theinlet manifold 32 may include a plurality ofinlet lines 33 with each inlet line being fluidly connected to one of thecylinders 40. Theinlet end 31 may include a suction or inlet valve 42 (FIG. 3 ) positioned alonginlet wall 34 between eachinlet line 33 and its associatedcylinder 40. In one embodiment, theinlet valve 42 may be biased in a closed condition or position and moved to its open position to permit fracking fluid to pass therethrough upon thepiston 41 generating a sufficient vacuum or negative pressure. - A discharge or outlet conduit (not shown) may be fluidly connected to an
outlet manifold 36 positioned at theoutlet end 35. The outlet manifold may include a plurality ofoutlet lines 37 with each outlet line being fluidly connected to one of thecylinders 40, such as at a location opposite theinlet lines 33. Theoutlet end 35 may include a discharge or outlet valve 43 (FIG. 3 ) positioned alongoutlet wall 38 between eachoutlet line 37 and its associatedcylinder 40. In one embodiment, theoutlet valve 43 may be biased in a closed condition or position and moved to its open position to permit fracking fluid to pass therethrough upon thepiston 41 generating a sufficient or high enough pressure. - During a pumping process, operation of the
engine 12 may drive rotation of thetransmission 13 and ultimately rotation of thedrive shaft 21 of thehydraulic pump 14. Rotation of thedrive shaft 21 causes reciprocating movement of thepistons 41 withincylinders 40. The reciprocating movement of thepistons 41 may cause fracking fluid to be drawn through theinlet manifold 32 from the inlet conduit (not shown) and into thecylinders 40 through theinlet lines 33 and past theinlet valves 42. Fracking fluid is driven by thepistons 41 past theoutlet valves 43 through theoutlet lines 37 and intooutlet manifold 36. - The
pumping system 10 may be controlled by thecontrol system 60 as shown generally by an arrow inFIG. 1 indicating association with the pumping system. Thecontrol system 60 may include an electronic control module orcontroller 61 as shown generally by an arrow inFIG. 1 and a plurality of sensors. Thecontroller 61 may control the operation of various aspects of thepumping system 10. - The
controller 61 may be an electronic controller that operates in a logical fashion to perform operations, execute control algorithms, store, retrieve, and access data and other desired operations. Thecontroller 61 may include or access memory, secondary storage devices, processors, and any other components for running an application. The memory and secondary storage devices may be in the form of read-only memory (ROM) or random access memory (RAM) or integrated circuitry that is accessible by the controller. Various other circuits may be associated with thecontroller 61 such as power supply circuitry, signal conditioning circuitry, driver circuitry, and other types of circuitry. - The
controller 61 may be a single controller or may include more than one controller disposed to control various functions and/or features of thepumping system 10. The term “controller” is meant to be used in its broadest sense to include one or more controllers and/or microprocessors that may be associated with thepumping system 10 and that may cooperate in controlling various functions and operations of the pumping system. The functionality of thecontroller 61 may be implemented in hardware and/or software without regard to the functionality. Thecontroller 61 may rely on one or more data maps relating to the operating conditions and the operating environment of thepumping system 10 and the work site at which the pumping system is operating that may be stored in the memory of or associated with the controller. Each of these data maps may include a collection of data in the form of tables, graphs, and/or equations. - The
control system 60 andcontroller 61 may be located on thetrailer 15 or may be distributed with components also located remotely from or off-board the trailer. - Pumping
system 10 may be equipped with a plurality of sensors that provide data indicative (directly or indirectly) of various operating parameters of elements of the system and/or the operating environment in which the system is operating. The term “sensor” is meant to be used in its broadest sense to include one or more sensors and related components that may be associated with thepumping system 10 and that may cooperate to sense various functions, operations, and operating characteristics of the element of the system and/or aspects of the environment in which the system is operating. - An engine speed sensor 62 (
FIG. 4 ) may be provided on or associated with theengine 12 to monitor the output speed of the engine. Theengine speed sensor 62 may generate engine speed data indicative of the output speed ofengine 12. Theengine speed sensor 62 may be used to determine whether the engine is operating at a steady state. Other manners (e.g., combinations of other sensors) may be used as a speed sensor to generate speed data indicative of the engine speed or whether the engine is operating at a steady state. A transmission speed sensor 63 (FIG. 4 ) may be provided on or associated with thetransmission 13 to monitor the output speed of the transmission. Thetransmission speed sensor 63 may generate transmission speed data indicative of the output speed oftransmission 13. - In some instances, the
hydraulic pump 14 may not include a significant number of sensors. In one example, thetrailer 15 may not include electrical connections adjacent thehydraulic pump 14 and therefore the pump may not include sensors that require electrical input. In addition, the nature of and operating environment associated with the operation of theengine 12, thetransmission 13, and thehydraulic pump 14 may result in fewer sensors being associated with the pump. For example, the hydraulic or fracking fluid may be abrasive and/or corrosive and thus thefluid section 30 of thehydraulic pump 14 may require maintenance substantially more frequently than theengine 12 or thetransmission 13. Accordingly, it may be desirable to reduce the number of sensors associated with thehydraulic pump 14, when possible. - The abrasive and/or corrosive nature of the fracking fluid being pumped may cause substantial wear on the components of the
hydraulic pump 14 and, in particular, thefluid section 30. Leaks are often more likely to occur at locations in which components of thehydraulic pump 14 move. More specifically, leaks may be likely to occur along the inlet wall or at theinlet valve 42 as indicated by thearrow 65 inFIG. 3 , along the outlet wall or at theoutlet valve 43 as indicated by thearrow 66, and/or along the path of thepiston 41 throughcylinder 40 as indicated by thearrow 67. Such leaks may reduce the performance of thehydraulic pump 14 and may be indicative of more significant future failures. - In addition to avoiding leaks in the
hydraulic pump 14, it is desirable to avoid cavitation within the pump. Cavitation may be caused by various conditions including leaks as described above as well as low pressure or low flow at theinlet end 31. In addition to reduced performance of thehydraulic pump 14, cavitation may also cause significant damage to the pump. - The
control system 60 may include a pump monitoring andnotification system 68 as shown generally by an arrow inFIG. 1 that monitors aspects of the operation of thepumping system 10. The pump monitoring andnotification system 68 may monitor the operation of theengine 12 and thetransmission 13 to determine whether thehydraulic pump 14 is leaking or experiencing cavitation. In doing so, upon the engine meeting specified operating conditions, the pump monitoring andnotification system 68 may analyze variations in the rotational speed of thetransmission 13 to determine whether its performance is within a desired operating window. - Referring to
FIGS. 5-7 , in one example, under steady state operating conditions with no leakage or cavitation, variations in the rotational speed of thehydraulic pump 14 are approximately 3 RPM as depicted at 70 inFIG. 5 , variations in the rotational speed of thetransmission 13 are approximately 5 RPM as depicted at 71 inFIG. 6 , and variations in the inlet or suction pressure at or leading into the inlet lines 33 are approximately 100 kPa as depicted at 72 inFIG. 7 . - As leakage or cavitation begins to occur within the
hydraulic pump 14, vibrations will begin to occur within the pump. Such vibrations may result in and be evident as an increase in the variations in the rotational speed of thehydraulic pump 14. In addition, the vibrations within thehydraulic pump 14 may be transferred to thetransmission 13 through thecoupling 17 between the pump and transmission and result in an increase in the variations in the rotational speed of the transmission. As depicted inFIG. 10 , variations in the inlet or suction pressure at or leading into the inlet lines 33 have increased substantially to approximately 350 kPa as depicted at 73 as a result of a pump failure caused by a leak or cavitation. At approximately the same time, the vibrations within thehydraulic pump 14 increase due to the pump failure and, as depicted at 74 inFIG. 8 , result in an increase in the variations in the rotational speed of thehydraulic pump 14 to approximately 5 RPM as well as slightly increase the maximum rotational speed. Vibrations within thehydraulic pump 14 are transferred to thetransmission 13 through thecoupling 17 between the pump and transmission. As depicted inFIG. 9 , the transferred vibrations results in an increase in the variations in the rotational speed of thetransmission 13 to approximately 25 RPM as depicted at 75. Leaks along theoutlet line 37 such alongoutlet wall 38 or atoutlet valve 43 or along the path of thepiston 41 through thecylinder 40 may also cause similar changes in the variations in the rotational speed of thetransmission 13 and thehydraulic pump 14. - In one embodiment, the pump monitoring and
notification system 68 may be configured to monitor the variations in the speed of rotation of thetransmission 13 and generate an alert signal once the variations are equal to or greater than a predetermined transmission speed variation threshold. When monitoring the variations in the speed of thetransmission 13, the speed of the transmission is measured relatively frequently, such as every millisecond. In order to determine the variation or difference between the maximum rotational speed of thetransmission 13 and the minimum rotational speed of the transmission, the speeds may be measured over a predetermined period of time while operating the transmission at a steady state. As used herein, “steady state” refers to maintaining a constant or generally constant average speed. Accordingly, the transmission speed variation threshold may be defined as a difference between the maximum rotational speed of thetransmission 13 and a minimum rotational speed of the transmission over a predetermined period of time while operating the transmission at a steady state. In some instances, thetransmission 13 may only be operating at steady state if the rotational input to the transmission from theengine 12 is operating at a steady state. - In one example, the transmission speed variation threshold may be approximately 25 RPM. In other examples, the pump monitoring and
notification system 68 may utilize other variation in rotational speed thresholds. For example, the pump monitoring andnotification system 68 may be configured to use a smaller transmission speed variation threshold such as approximately 10, 15 or 20 RPM or a larger transmission speed variation threshold such as approximately 40 or 50 RPM. In another example, the transmission speed variation threshold may be between 10-60 RPM. In still another example, the transmission speed variation threshold may be between 20-50 RPM. In a further example, the transmission speed variation threshold may be at least 10 RPM or at least 15 RPM. Still other transmission speed variation thresholds are contemplated. - In another embodiment, the pump monitoring and
notification system 68 may be configured to monitor the variations in the speed of rotation of thetransmission 13 and generate an alert signal if the ratio between the current variation in the operational speed of thetransmission 13 and the variation in rotational speed of the transmission during steady state operation exceeds a predetermined variation ratio threshold. The variation ratio threshold may be defined as a difference between a maximum rotational speed of the transmission and a minimum rotational speed of the transmission over a predetermined period of time while operating at a steady state divided by a variation in the rotational speed of the transmission while operating the transmission at a steady state and without a hydraulic pump failure. - In the example depicted in
FIGS. 5-10 , the variation in the rotational speed of thetransmission 13 upon a leakage or cavitation is approximately 25 RPM and the variation in the rotational speed of the transmission at steady state is approximately 5 RPM. Accordingly, for such an example, the variation ratio threshold may be set at approximately 5. In other examples, the pump monitoring andnotification system 68 may require a greater or lesser variation ratio threshold. For example, the pump monitoring andnotification system 68 may be configured to use a smaller variation ratio threshold such as approximately 2.5, 3 or 4 or a larger variation ratio threshold such as approximately 8 or 10. In another example, the variation ratio threshold may be between 2.5 and 12. In still another example, the variation ratio threshold may be between 4 and 10. In a further example, the variation ratio threshold may be at least 2.5 or 3. Still other variation ratio thresholds are contemplated. - The pump monitoring and
notification system 68 may monitor the variations in the rotational speed of thetransmission 13 by measuring the rotational speed at predetermined intervals. For example, the rotational speed of thetransmission 13 may be measured once every millisecond. Other measurements intervals are contemplated. In order to reduce the likelihood of false warnings or alerts, the pump monitoring andnotification system 68 may be configured to require the transmission speed variation threshold or variation ratio threshold to be met or exceeded for a predetermined length of time. In one example, the pump monitoring andnotification system 68 may require the transmission speed variation threshold or variation ratio threshold to be met or exceeded for 60 seconds before generating an alert signal. - In other examples, the pump monitoring and
notification system 68 may require the threshold to be met or exceed for longer or shorter periods of time. For example, the time threshold may be 30 seconds, 120 seconds, or any other desired time period. - If desired, the pump monitoring and
notification system 68 may include, in addition or in the alternative, an accumulator function to account for the extent or degree to which the relevant transmission threshold (e.g., transmission speed variation threshold or variation ratio threshold) is exceeded. The accumulator function may integrate the extent to which the threshold is exceeded and establish an additional or accumulator threshold for the accumulator function. The accumulator function may sum the amount by which the threshold is exceeded and the sum or accumulated result compared to the accumulator threshold. Upon exceeding the accumulator threshold, the alert signal may be generated. - As an example, the pump monitoring and
notification system 68 may be configured to permit thehydraulic pump 14 to operate for a relatively long period of time before generating an alert signal if the transmission speed variation threshold or variation threshold ratio is exceeded by a relatively small amount (e.g., 10%). However, the pump monitoring andnotification system 68 may generate an alert signal relatively quickly if the transmission speed variation threshold or variation threshold ratio is exceeded by a relatively large amount (e.g., 75%). - Alert signals generated by the pump monitoring and
notification system 68 may take any desired form. In one example, an alert signal may provide a notice or warning to personnel or systems at the work site and/or remote from the work site. In another example, an alert signal may, in addition or in the alternative, include a command to shutdown or reduce the operation of thepumping system 10 in order to reduce the likelihood of further damage to thehydraulic pump 14. - The pump monitoring and
notification system 68 may be configured so that thecontroller 61 receives information from various sensors and systems of thepumping system 10 and processes the information to determine when pump leakage or cavitation is occurring without directly using or requiring the operating characteristics of the hydraulic pump 14 (e.g., input pressure, output pressure, rotational speed of the pump). As such, the pump monitoring andnotification system 68 may determine that pump leakage or cavitation is occurring without sensors directly monitoring the operating characteristics of thehydraulic pump 14. - As depicted in
FIG. 4 , thecontroller 61 may receive data from theengine speed sensor 62 to determine the rotational speed of theengine 12 and receive data from thetransmission speed sensor 63 to determine the rotational speed of thetransmission 13. Upon theengine 12 operating at a steady state condition, the pump monitoring andnotification system 68 may generate analert signal 77 when the variation in the rotational speed of thetransmission 13 exceeds the transmission speed variation threshold or variation ratio threshold. In some instances, the pump monitoring andnotification system 68 may be configured to require the variation in the rotational speed of thetransmission 13 to exceed the transmission speed variation threshold or variation ratio threshold for a predetermined time threshold. - The industrial applicability of the system described herein will be readily appreciated from the foregoing discussion. The pump monitoring and
notification system 68 may be used with pumpingsystems 10 that include a prime mover, such as anengine 12, operatively connected to drivetransmission 13, and with the transmission operatively connected to drive thehydraulic pump 14. The pump monitoring andnotification system 68 may determine whether thehydraulic pump 14 is experiencing leakage or cavitation based upon variations in the rotational speed of thetransmission 13 without monitoring additional aspects or operating characteristics of the pump. -
FIG. 11 depicts one example of the operation of the pump monitoring andnotification system 68. Atblock 80, a plurality of thresholds may be set or stored. The thresholds may include any type of transmission threshold based upon variations in rotational speed of thetransmission 13, such as a transmission speed variation threshold of the transmission speed, an engine speed variation threshold, and a time threshold or period of time that the variation in rotational speed of thetransmission 13 must exceed the transmission speed variation threshold. In another embodiment described below, the transmission threshold may be a variation ratio threshold of the transmission speed may be set or stored. - The
pumping system 10 may be operated atblock 81. Data from theengine speed sensor 62 and thetransmission speed sensor 63 may be received atblock 82. Atblock 83, thecontroller 61 may determine the engine speed based upon the engine speed data received from theengine speed sensor 62. Thecontroller 61 may determine atdecision block 84 whether theengine 12 is operating at a steady state so that the pump monitoring andnotification system 68 may be operated in an accurate manner. - If the
engine 12 is not operating in a steady state manner, analysis of the variations in the transmission speed may not provide reliable data. Accordingly, when theengine 12 is not operating in a steady state manner, thepumping system 10 may continue to be operated and blocks 81-84 repeated. - If the
engine 12 is operating in a steady state manner, thecontroller 61 may determine atblock 85 the speed of thetransmission 13 based upon the transmission speed data received from thetransmission speed sensor 63. Based upon the transmission speed, thecontroller 61 may determine atblock 86 the magnitude of the variation in the transmission speed. - The
controller 61 may access the transmission speed variation threshold and compare the magnitude of the variation in transmission speed to the transmission speed variation threshold. If the variation in transmission speed does not exceed the transmission speed variation threshold atdecision block 87, thepumping system 10 may continue to be operated and blocks 81-87 repeated. If the variation in transmission speed does exceed the transmission speed variation threshold, thecontroller 61 may access the time threshold and determine atdecision block 88 whether the time during which the variation in transmission speed exceeds the transmission speed variation threshold also exceeds the time threshold. If the time threshold has not been reached, thepumping system 10 may continue to be operated and blocks 81-88 repeated. If the time threshold has been reached, an alert signal may be generated bycontroller 61 atblock 89. In some instances, thepumping system 10 may continue to be operated and blocks 81-89 repeated. In other instances, the alert signal may also include a command to shut down or reduce the operation of thepumping system 10. - Other configurations of the operation of the pump monitoring and
notification system 68 are contemplated. For example, rather than setting or storing a transmission speed variation threshold atblock 80, a variation ratio threshold may be set or stored that defines a threshold ratio between the magnitude of steady state operation of the transmission and the magnitude of the variation in transmission speed during a pump failure. An example using the variation ratio threshold may operate generally in accordance with the example depicted inFIG. 11 except that the magnitude of the variation of the transmission speed during steady state operation must be determined or otherwise set or stored within thecontroller 61. In one embodiment, the magnitude of the variation in transmission speed during steady state operation may be set or stored by an operator or other personnel. In another embodiment, the magnitude of the variation in transmission speed during steady state operation may be determined during steady state operation of thepumping system 10. - In another aspect of the second example that is different from the example depicted in
FIG. 11 , thecontroller 61 may determine afterblock 86 the variation ratio threshold by dividing the magnitude of the variation of the transmission speed based upon the transmission speed as determined atblock 85 by the variation of the transmission speed during steady state operation. Further,decision block 87 is modified to determine whether the ratio determined by thecontroller 61 exceeds the variation ratio threshold. - It will be appreciated that the foregoing description provides examples of the disclosed system and technique. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated.
- Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.
- Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.
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