SYSTEM FOR DETECTING WEAR IN FLUID END PACKING OF RECIPROCATING PUMPS

TECHNICAL FIELD

[0001] The present disclosure relates to reciprocating pumps. More particularly, the present disclosure relates to a system for detecting wear in a fluid end packing of a reciprocating pump.

BACKGROUND

[0002] Reciprocating pumps are widely used for applications such as drilling and hydraulic fracturing. A reciprocating pump typically has two sections, a fluid end that includes cylinders and plungers, and a power end that provide power to the plungers to reciprocate with respect to their corresponding cylinders to draw fluid into a fluid chamber (of the reciprocating pump) and then forcibly push out the fluid from the fluid chamber.

[0003] Fluid end packing may be used to seal the plunger against the cylinder to prevent leakage of frac fluid from around the plunger during pumping operations. However, during the pumping operations, the fluid end packing may experience wear and tear which may cause the fluid end packing to fail (e.g., cause the frac fluid to leak from the pump via the fluid end packing). Failure of the fluid end packing (due to wear and tear) may result in a reduction of operational efficiency of the reciprocating pump, and may further result in a failure resulting in downtime of the reciprocating pump or of entire hydraulic fracturing rig associated with the reciprocating pump.

[0004] US Patent Publication No. 10317875 discloses a method of monitoring a fluid pump that includes receiving time domain measurement data indicating vibrations occurring in a fluid pump, and filtering the measurement data to remove measurement data components having frequencies below a threshold frequency, the removed measurement data components associated with cyclical motions of the fluid pump. The method also includes dividing the filtered measurement data into a plurality of subsets, each subset corresponding to a pump cycle, and estimating a peak count for each subset, the peak count being a number of peaks having an amplitude that exceeds a selected amplitude threshold, the amplitude threshold associated with impacts between internal components of the pump. The method further includes comparing the peak count with an expected peak count, and determining whether the pump is in a condition selected from at least one of a wear condition and a failure condition based on the comparison.

SUMMARY OF THE INVENTION

[0005] In one aspect, the disclosure relates to a system for detecting wear in a fluid end packing of a reciprocating pump. The system includes an insert, a sensor, and a controller. The insert is associated with an annular seal ring of the fluid end packing. The annular seal ring defines a sealing interface with a plunger of the reciprocating pump. The sensor is configured to obtain vibration data associated with the fluid end packing. The controller configured to receive, from the sensor, the vibration data associated with the fluid end packing. Further, the controller is configured to determine, based on the vibration data being within a predefined range of vibration indicative of a contact of the plunger with the insert, that a wear level of the fluid end packing satisfies a wear threshold.

[0006] In another aspect, the disclosure is directed to a method of detecting wear in a fluid end packing of a reciprocating pump. The method includes disposing an insert at an annular seal ring of the fluid end packing. The annular seal ring defines a sealing interface with a plunger of the reciprocating pump. Further, the method includes receiving, by a controller, vibration data associated with the fluid end packing from a sensor. Furthermore, the method includes determining, by the controller, based on the vibration data being within a predefined range of vibration indicative of a contact of the plunger with the insert, that a wear level of the fluid end packing satisfies a wear threshold.

[0007] In yet another aspect, the disclosure relates to a reciprocating pump. The reciprocating pump includes a fluid end, a plunger, a fluid end packing, and a system. The fluid end housing defines a fluid chamber and a cylinder in fluid communication with the fluid chamber. The plunger is received within the cylinder and moveable with respect to the cylinder to facilitate an influx and an efflux of hydraulic fluid with respect to the fluid chamber. The fluid packing includes an annular seal ring that defines a sealing interface with the plunger. The system is configured to detect wear in the fluid end packing. The system includes an insert, a sensor, and a controller. The insert is associated with the annular seal ring. The sensor is configured to obtain vibration data associated with the fluid end packing. The controller is configured to receive, from the sensor, the vibration data associated with the fluid end packing. In addition, the controller is configured to determine, based on the vibration data being within a predefined range of vibration indicative of a contact of the plunger with the insert, that a wear level of the fluid end packing satisfies a wear threshold.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 illustrates a sectional view of a portion of a reciprocating pump showing a fluid end housing, a plunger, a fluid end packing, and a system for detecting wear in the fluid end packing, in accordance with an embodiment of the present disclosure;

[0009]FIG. 2 illustrates the fluid end packing, the plunger, and the system, in accordance with an embodiment of the present disclosure;

[0010]FIG. 3 illustrates the fluid end packing, and an insert of the system associated with the fluid end packing, in accordance with an embodiment of the present disclosure;

[0011]FIG. 4 illustrates the fluid end packing, and an insert of the system associated with the fluid end packing, in accordance with another embodiment of the present disclosure; and

[0012]FIG. 5 is a flowchart illustrating a method of detecting wear in the fluid end packing, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0013]Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Generally, corresponding reference numbers may be used throughout the drawings to refer to the same or corresponding parts, e.g., 1, 1`, 1``, 101 and 201 could refer to one or more comparable components used in the same and/or different depicted embodiments.

[0014] Referring to FIG. 1, a sectional view of a portion of a reciprocating pump 100 is shown. The reciprocating pump 100 may be used to supply pressurized frac fluid into subterranean rock formations, causing the formations to fracture. The frac fluid, which may be prepared onsite, may include water mixed with sand, ceramic particles, or other propellants. These propellants may assist in holding the fractures open after hydraulic pressure is removed. Oil and/or gas retained in the subterranean rock formations is thereby released, and may be recovered at the surface.

[0015] The reciprocating pump 100 defines a power end (not shown) for generating power, and a fluid end 104 operably coupled with the power end to perform operations of the reciprocating pump 100. The reciprocating pump 100 includes a fluid end housing 108 (associated with the fluid end 104), one or more inlet valves 112, one or more outlet valves 116, a plunger 120, and a fluid end packing 124.

[0016]The fluid end housing 108 defines multiple fluid chambers 128, and multiple cylinders 132 (or plunger bores 132) disposed in fluid communication with their respective fluid chambers 128, (only one fluid chamber 128 and its corresponding cylinder 132 is shown in FIG. 1). Further, the fluid end housing 108 may define an inlet passage 136 and an outlet passage 140. In an exemplary embodiment, as shown in FIG. 1, the inlet passage 136 and the outlet passage 140 may be axially aligned with respect to one another and/or the fluid chamber 128. The inlet passage 136 and the outlet passage 140 may be in fluid communication with the fluid chamber 128. For instance, during an operation of the reciprocating pump 100, frac fluid may enter the fluid chamber 128 via the inlet passage 136, for example, on an upstroke of the plunger 120 (i.e., when the plunger 120 moves away from the fluid chamber 128), and is driven out of the outlet passage 140, for example, on a downstroke of the plunger 120 (i.e., when the plunger 120 moves toward the fluid chamber 128).

[0017] The inlet valve 112 and the outlet valve 116 may be arranged within the inlet passage 136 and the outlet passage 140, respectively. The inlet valve 112 and the outlet valve 116 may be spring-loaded valves. However, it may be contemplated that, in other embodiments, the inlet valve 112 and the outlet valve 116 may be of any type known in the art. In operation, a differential pressure may drive movement of the inlet valve 112 and the outlet valve 116. For example, as the plunger 120 is on the upstroke, pressure at the inlet passage 136 may overcome the spring force of the inlet valve 112, thereby driving fluid (e.g., frac fluid) into the fluid chamber 128. However, on the downstroke, the inlet valve 112 may be driven to a closed position, while the spring force of the outlet valve 116 is overcome, thereby enabling the fluid (e.g., frac fluid) to exit via the outlet passage 140.

[0018]The plunger 120 is received within the corresponding cylinder 132. The plunger 120 is moveable with respect to the cylinder 132 to facilitate an influx and an efflux of the fluid (e.g., frac fluid) with respect to the fluid chamber 128. For that, the plunger 120 is operably coupled with a crankshaft (not shown) in the power end of the reciprocating pump 100. The crankshaft may be driven to stroke the plunger 120 through the cylinder 132 and towards (i.e., downstroke) and away (i.e., upstroke) from the fluid chamber 128, along a cylinder axis 144, to alternatively draw the fluid (e.g., frac fluid) into the fluid chamber 128 and force the fluid out of the fluid chamber 128.

[0019] The fluid end packing 124 may be used to seal the plunger 120 against the cylinder 132 to prevent leakage of the frac fluid from around the plunger 120 during the pumping operations. For that, the fluid end packing 124 may be disposed between the plunger 120 and the cylinder 132. In an exemplary embodiment, the fluid end packing 124 may be disposed within an annular recess 148 that extends inward from an interior wall 152 of the cylinder 132. As shown in FIGS. 1, and 2, the fluid end packing 124 may be disposed between an outer peripheral surface 156 of the plunger 120 and an annular sleeve 160 mounted at an inner wall 164 of the annular recess 148.

[0020] The fluid end packing 124 includes multiple annular seal rings 168. In an exemplary embodiment, as shown in FIGS. 1-4, the fluid end packing 124 includes five annular seal rings 168, namely – a first annular seal ring 172, a second annular seal ring 176, a third annular seal ring 180, a fourth annular seal ring 184, and a fifth annular seal ring 188. In an example, as shown in FIG. 3, the first annular seal ring 172 is a header seal ring 172, the second annular seal ring 176 is a pressure seal ring 176, the third annular seal ring 180 is a secondary pressure seal ring 180, the fourth annular seal ring 184 is a first adapter ring 184, and the fifth annular seal ring 188 is a second adapter ring 188.

[0021]The first annular seal ring 172 may be formed of a soft elastomeric material such as hydrogenated nitrile butadiene rubber (HNBR) or the like, although other materials may be used. The first annular seal ring 172 (or the header seal ring 172) may define a forward side 192 facing towards the fluid chamber 128 (of the reciprocating pump 100), and a rearward side 196 facing away from the fluid chamber 128. The forward side 192 may have a flat profile. The rearward side 196 may define a protrusion 198 extending in a direction away from the forward side 192. Also, the first annular seal ring 172 may include an inner diameter cylindrical surface 200 and an outer diameter cylindrical surface 204. The inner diameter cylindrical surface 200 (hereinafter referred to as “first inner diameter cylindrical surface 200”) may extend between the forward side 192 and the rearward side 196, and may circumferentially surround a central axis 208 (shown in FIG. 1) (of the fluid end packing 124). The first inner diameter cylindrical surface 200 may bulge radially inward towards the central axis 208 of the fluid end packing 124 to define an extremity 212. The first inner diameter cylindrical surface 200 may have a first diameter. It should be noted that the term “first diameter” may refer to a longest distance between two imaginary points defined on the extremity 212 of the first inner diameter cylindrical surface 200 (of the first annular seal ring 172). The first inner diameter cylindrical surface 200 may be configured to define a sealing interface 216 with the outer peripheral surface 156 of the plunger 120.

[0022] The outer diameter cylindrical surface 204 (hereinafter referred to as “first outer diameter cylindrical surface 204”) may be defined opposite to the first inner dimeter cylindrical surface 200. The first outer diameter cylindrical surface 204 may extend between the forward side 192 and the rearward side 196 to circumferentially surround the first inner diameter cylindrical surface 200. The first outer diameter cylindrical surface 204 may be configured to contact the annular sleeve 160.

[0023]The second annular seal ring 176 (or the pressure seal ring 176) may define a forward surface 220 facing towards the fluid chamber 128 and a rearward surface 224 facing away from the fluid chamber 128. The forward surface 220 may have a curved profile. The forward surface 220 may define a recess 228. The rearward surface 224 may have a curved profile. Further, the second annular seal ring 176 may define a second inner diameter cylindrical surface 232 and a second outer diameter cylindrical surface 236. The second inner diameter cylindrical surface 232 may extend between the forward surface 220 and the rearward surface 224, and may circumferentially surround the central axis 208 (of the fluid end packing 124). The second inner diameter cylindrical surface 232 may have a second diameter. It should be noted that the term “second diameter” may refer to a longest distance between two imaginary innermost points (one innermost point 240 shown in FIG. 3) defined on the second inner diameter cylindrical surface 232 (of the second annular seal ring 176). The second diameter may be greater than the first diameter. Further, the second outer diameter cylindrical surface 232 may be defined opposite to the first inner dimeter cylindrical surface 200, and configured to contact the annular sleeve 160.

[0024] The second annular seal ring 176 may be formed of a soft elastomeric material such as hydrogenated nitrile butadiene rubber (HNBR) or the like, although other materials may be used. The second annular seal ring 176 may be disposed towards the rearward side 196 of the first annular seal ring 172 (or the header seal ring 172). In an exemplary embodiment, as shown in FIG. 3, the second annular seal ring 176 may abut the rearward side 196 (of the first annular seal ring 172) such that the protrusion 198 (of the first annular seal ring 172) is received within the recess 228 of the second annular seal ring 176.

[0025] The third annular seal ring 180 (or the secondary pressure seal ring 180) may have a structure and configuration similar to that of the second annular seal ring 176. For instance, the third annular seal ring 180 may define a forward surface 244 (similar to the forward surface 220) facing towards the fluid chamber 128 and configured to abut against the rearward surface 224 of the second annular seal ring 176, a rearward surface 248 (similar to the rearward surface 224) facing away from the fluid chamber 128, a third inner diameter cylindrical surface 252 having a third diameter, and a third outer diameter cylindrical surface 256 opposite to the third inner diameter cylindrical surface 252 and configured to contact the annular sleeve 160. The third diameter (of the third inner diameter cylindrical surface 252) may be greater than the first diameter (of the first inner diameter cylindrical surface 200, of the first annular seal ring 172).

[0026]The fourth annular seal ring 184 (or the first adapter ring 184) may abut against the rearward surface 248 (of the third annular seal ring 180) at its one end, and against a threaded retainer nut (not shown) at its other end. The fourth annular seal ring 184 may define a fourth inner diameter cylindrical surface 260 circumferentially surrounding the central axis 208 (of the fluid end packing 124), and a fourth outer diameter cylindrical surface 264 opposite to the fourth inner diameter cylindrical surface 260. The fourth inner diameter cylindrical surface 260 may define a fourth diameter greater than the first diameter of the first inner diameter cylindrical surface 200 (of the first annular seal ring 172). The fourth outer diameter cylindrical surface 264 may contact the annular sleeve 160. Additionally, the fourth annular seal ring 184 may define a groove 268 proximate to a lubricant passage 272 defined by the fluid end housing 108. The groove 268 and the lubricant passage 272 may be in fluid communication with one another to facilitate passage of a lubricant through the fluid end housing 108 for distribution in the cylinder 132 and the outer peripheral surface 156 of the plunger 120. In an exemplary embodiment, the fourth annular seal ring 184 (or the first adapter ring 184) may be fabricated from metal, such as brass.

[0027]The fifth annular seal ring 188 (or the second adapter ring 188) may define a front surface 276 facing towards the fluid chamber 128 and a rear surface 280 facing away from the fluid chamber 128. The front surface 276 may define a planar profile. The rear surface 280 may define a planar profile. When the fifth annular seal ring 188 is disposed within the annular recess 148, the front surface 276 may abut against a shoulder 284 of the annular recess 148 and the rear surface 280 may abut against the forward side 192 of the first annular seal ring 172. Further, the fifth annular seal ring 188 may define a fifth inner diameter cylindrical surface 288 extending around the central axis 208 (of the fluid end packing 124) and defining a fifth diameter greater than the first diameter of the first inner diameter cylindrical surface 200 (of the first annular seal ring 172). Furthermore, the fifth annular seal ring 188 may define a fifth outer diameter cylindrical surface 292 opposite to the fifth inner diameter cylindrical surface 288 and contacting the annular sleeve 160. In an exemplary embodiment, the fifth annular seal ring 188 (or the second adapter ring 188) may be fabricated from metal, such as brass.

[0028] It should be noted that, in other embodiments, the first annular seal ring 172, the second annular seal ring 176, the third annular seal ring 180, the fourth annular seal ring 184, and the fifth annular seal ring 188 may be any other type of seal rings known in the art. Further, the fluid end packing 124 may have more or less than five annular seal rings based on the configuration of the reciprocating pump 100.

[0029]During the pumping operations, the fluid end packing 124 may experience wear and tear which may cause the fluid end packing 124 to fail. To detect wear in the fluid end packing 124, in one or more aspects of the present disclosure, a system 300 is provided on the reciprocating pump 100. The system 300 is configured to determine whether a wear level of the fluid end packing 124 satisfies a predefined wear threshold. The system 300 includes an insert 304, a sensor 308, and a controller 312. Each of the insert 304, the sensor 308, and the controller 312 is now discussed in detail.

[0030]The insert 304 is associated with the annular seal ring 168 of the fluid end packing 124. For instance, the insert 304 is associated with the first annular seal ring 172 (or the header seal ring 172) of the fluid end packing 124. In another embodiment, the insert 304 may be associated with any other annular seal ring 168, such as, the second annular seal ring 176, or the third annular seal ring 180, and so on. The insert 304 may be a fabricated from a metallic material. In an example, the insert 304 may be formed of a metallic material that is harder than a material of the first annular seal ring 172 (e.g., the header seal ring 172). For example, the insert 304 may be fabricated from brass. In another example, the insert 304 may be fabricated from steel.

[0031]The insert 304 defines a contact tip 316. In an example, the insert 304 may include a continuous ring-shaped body 320 defining a center axis (not shown). The ring-shaped body 320 may define a first portion 324 and a second portion 328. The first portion 324 may extend longitudinally along the center axis of the ring-shaped body 320 to define an outer wall 332 of the insert 304. The second portion 328 may extend radially inwardly from the first portion 324 (towards the central axis) to define an inner wall 336 of the insert 304. The contact tip 316 is defined at the inner wall 336 of the insert 304, as shown in FIG. 3. The contact tip 316 may be exposed when the first inner diameter cylindrical surface 200 of the first annular seal ring 172 is worn down enough (e.g., due to contact with the outer peripheral surface 156 of the plunger 120) to be flattened from one end to the other.

[0032]Further, the insert 304 may be embedded within the annular seal ring 168. In an exemplary embodiment, as shown in FIGS. 2 and 3, the insert 304 is embedded within the first annular seal ring 172 (or the header seal ring 172). The insert 304 is embedded within the first annular seal ring 172 (or the header seal ring 172) in a manner that the contact tip 316 is positioned closer to the first inner diameter cylindrical surface 200 than the first outer diameter cylindrical surface 204 of the first annular seal ring 172. In addition, the insert 304 is embedded within the first annular seal ring 172 (or the header seal ring 172) in a manner that the contact tip 316 (of the insert 304) is located at a diameter (measured as two times a distance between the contact tip 316 and the central axis 208 of the fluid end packing 124) greater than the first diameter (associated with the first annular seal ring 172) and less than the second diameter (associated with the second annular seal ring 176). That is, the contact tip 316 of the insert 304 is located between the extremity 212 (defined at the first inner diameter cylindrical surface 200 of the first annular seal ring 172) and the innermost point 240 (defined at the second inner diameter cylindrical surface 232 of the second annular seal ring 176).

[0033]Referring to FIG. 4, an insert 304`, in accordance with another embodiment of the present disclosure, is now discussed. The insert 304` may be fabricated from a metallic material similar to that of the insert 304. Further, the insert 304` may define a contact tip 316`. In an example, the insert 304` may include a continuous ring-shaped body 320` defining a center axis (not shown). The ring-shaped body 320` may define a first portion 324`, a second portion 328`, and a third portion 330` extending between the first portion 324` and the second portion 328`. The first portion 324` may define an outer wall 332` of the insert 304`. The second portion 328` may define an inner wall 336` of the insert 304`. The contact tip 316` is defined at the inner wall 336` of the insert 304`.

[0034] Further, the insert 304` may be disposed at an interface between any two annular seal rings 168. For instance, as shown in FIG. 4, the insert 304` is disposed at an interface between the first annular seal ring 172 (or the header seal ring 172) and the second annular seal ring 176 (or the pressure seal ring 176). For that, the first portion 324` and the second portion 328` may have profiles complementary to profiles of the rearward side 196 (of the first annular seal ring 172) and the forward surface 220 (of the second annular seal ring 176), and the third portion 330` may have a profile complementary to profiles of the protrusion 198 (of the first annular seal ring 172) and the recess 228 (of the second annular seal ring 176).

[0035] Further, the insert 304` is disposed at the interface between the first annular seal ring 172 and the second annular seal ring 176 in a manner that the contact tip 316` is positioned closer to the first and second inner diameter cylindrical surfaces 200, 232 than their corresponding first and second outer diameter cylindrical surfaces 204, 236. In addition, the insert 304` is disposed at the interface between the first annular seal ring 172 and the second annular seal ring 176 in a manner that the contact tip 316` (of the insert 304`) is located at a diameter (measured as two times a distance between the contact tip 316` and the central axis 208 of the fluid end packing 124) greater than the first diameter (associated with the first annular seal ring 172) and less than the second diameter (associated with the second annular seal ring 176). That is, the contact tip 316` of the insert 304` is located between the extremity 212 (defined at the first inner diameter cylindrical surface 200 of the first annular seal ring 172) and the innermost point 240 (defined at the second inner diameter cylindrical surface 232 of the second annular seal ring 176).

[0036] The sensor 308 may be a vibration sensor 340 which may be installed in association with the fluid end packing 124. In an exemplary embodiment, as shown in FIG. 2, the vibration sensor 340 is an accelerometer 344 attached to a body (i.e., fluid end housing 108) of the reciprocating pump 100 at a location proximate to the fluid end packing 124. In some examples, a position of the sensor 308 is vertically overlapping with a position of at least a portion of the fluid end packing 124, a portion of the insert 304, a portion of the first annular seal ring 172, and/or a portion of any other annular seal ring 168, such as a portion of the second annular seal ring 176 or a portion of the third annular seal ring 180. Although only one sensor 308 (or accelerometer 344) is shown (in FIGS. 1 and 2) attached to the fluid end housing 108 of the reciprocating pump 100, it may be contemplated that, in other embodiments, more than one sensor (similar to the sensor 308) may be installed at different locations of the fluid end housing 108 of the reciprocating pump 100.

[0037] The sensor 308 is configured to obtain vibration data associated with the fluid end packing 124. It may be noted that vibration data may be related to vibration (frequency) of the fluid end packing 124 during operation of the reciprocating pump 100. The vibration data may be measured in units of gravity (g), may indicate a force of a vibration (e.g., of the fluid end packing 124), and/or may indicate a pattern of the vibration. Additionally, or alternatively, the vibration data may be time-series data (e.g., may identify a vibration over time). Further, the sensor 308 may be configured to correspondingly generate signals that may be processed and analyzed to determine vibrational behavior of the fluid end packing 124.

[0038]The controller 312 may be an electronic controller that operates in a logical fashion to perform operations, execute control algorithms, store, and retrieve data and other desired operations. The controller 312 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 312. Various other circuits may be associated with the controller 312 such as power supply circuitry, signal conditioning circuitry, driver circuitry, and other types of circuitry.

[0039]The controller 312 may be a single controller or may include more than one controller disposed to control various functions and/or features of the reciprocating pump 100 (or the hydraulic fracturing rig). 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 reciprocating pump 100, and that may cooperate in controlling various functions and operations of the reciprocating pump 100. The functionality of the controller 312 may be implemented in hardware and/or software without regard to the functionality. The controller 312 may rely on one or more predefined data relating to the operating conditions and the operating environment of the reciprocating pump 100 and/or the hydraulic fracturing rig that may be stored in a memory of or associated with the controller 312.

[0040]The controller 312 is communicably coupled with the sensor 308. By way of the controller’s 312 communicable coupling with the sensor 308, the controller 312 is configured to receive the vibration data (e.g., frequency) (e.g., in the form of signals) associated with the fluid end packing 124, from the sensor 308. Further, the controller 312 is configured to process the vibration data (received from the sensor 308) to determine if a wear level of the fluid end packing 124 satisfies a wear threshold. It should be noted that the wear threshold may be associated with a wear condition of the fluid end packing 124 (or the first annular seal ring 172) in which the outer peripheral surface 156 of the plunger 120 contacts with the contact tip 316 of the insert 304. In an embodiment, the controller 312 may determine whether the vibration data associated with the fluid end packing 124 stays within the predefined range of vibration for a predefined time period to determine that the wear level of the fluid end packing 124 satisfies the wear threshold. Upon determining the wear level of the fluid end packing 124 satisfying the wear threshold, the controller 312 may be configured to provide an alert indicating that the fluid end packing 124 needs maintenance.

INDUSTRIAL APPLICABILITY

[0041]Referring to FIG. 5, an example method of detecting wear in the fluid end packing 124 of the reciprocating pump 100 is now discussed. The method is discussed by way of a flowchart 500 that illustrates example steps (i.e., from 504 to 512) associated with the method. The example method is also discussed in conjunction with FIGS. 1, 2, 3, and 4.

[0042]At step 504, the insert 304 (or 304`) is disposed at the annular seal ring 168 of the fluid end packing 124. In an example, as shown in FIG. 3, the insert 304 is embedded within the first annular seal ring 172 (e.g., the header seal ring 172) of the fluid end packing 124. In another example, as shown in FIG. 4, the insert 304` is disposed at the interface between the first annular seal ring 172 and the second annular seal ring 176 (e.g., the pressure seal ring 176). The insert 304 (or 304`) may be disposed at the annular seal ring 168 in a manner such that the contact tip 316 (or 316`) of the insert 304 (or 304`) is located at the diameter (measured as two times the distance between the contact tip 316 and the central axis 208 of the fluid end packing 124) between the first diameter (associated with the first annular seal ring 172, as discussed above) and the second diameter (associated with the second annular seal ring 176, as discussed above). Further, the fluid end packing 124 with the insert 304 is installed within the annular recess 148 of the fluid end housing 108 such that the fluid end packing 124 forms the sealing interface with the outer peripheral surface 156 of the plunger 120.

[0043]During the pumping operation, components of the reciprocating pump 100, such as the fluid end packing 124, may be subjected to vibrations. The sensor 308 mounted at the portion of the fluid end housing 108 proximate to the fluid end packing 124 (along with the insert 304, or 304`) may obtain the vibration data (e.g., frequency) associated with the vibration of the fluid end packing 124, and may correspondingly generate signals to be transmitted to the controller 312. The controller 312 may receive the vibration data (signals) associated with the vibration of the fluid end packing 124, from the sensor 308, at step 508.

[0044]Further, the controller 312 may process the vibration data (received from the sensor 308) to determine if the wear level of the fluid end packing 124 satisfies the wear threshold (associated with a wear condition of the fluid end packing 124 (or the first annular seal ring 172) in which the outer peripheral surface 156 of the plunger 120 directly contacts with the contact tip 316 of the insert 304). The controller 312 may determine that the wear level of the fluid end packing 124 satisfies the wear threshold based on the vibration data being within the predefined range of vibration indicative of the contact of the plunger 120 with the insert 304 (or 304`), at step 512. In further embodiments, to determine that the wear level of the fluid end packing 124 satisfies the wear threshold, the controller 312 may determine whether the vibration data associated with the fluid end packing 124 stays within the predefined range of vibration for the predefined time period. Upon determining the wear level of the fluid end packing 124 satisfying the wear threshold, the controller 312 may provide an alert indicating that the fluid end packing 124 needs maintenance.

[0045] In an exemplary embodiment, upon receipt of the vibration data, the controller 312 may identify a vibration frequency associated with the vibration of the fluid end packing 124. Upon determining the vibration frequency (associated with the fluid end packing 124) to be within the predefined range of vibration frequency indicative of a contact of the outer peripheral surface 156 of the plunger 120 with the contact tip 316 of the insert 304, the controller 312 may determine that the wear level of the fluid end packing 124 satisfies the wear threshold. Additionally, in embodiments, the controller 312 may determine whether the vibration frequency (of the fluid end packing 124) is within the predefined range of vibration frequency for the predefined time period to determine that the wear level of the fluid end packing 124 satisfies the wear threshold. It should be noted that the predefined range of vibration frequency may be prestored in the memory associated with the controller 312. Once the controller 312 determines that the wear level of the fluid end packing 124 satisfies the wear threshold, the controller 312 may provide an alert (e.g., audio or visual alert) to an operator associated with the reciprocating pump 100 (or the hydraulic fracturing rig) indicating that the fluid end packing 124 needs maintenance or be replaced with a new fluid end packing (similar to the fluid end packing 124 with insert 304).

[0046] The system 300 allows the operator to quickly and efficiently identify a fluid end packing failure. The operator then can determine a preferred time to repair or replace the fluid end packing (e.g., immediately if the wear level of the fluid end packing 124 satisfies the wear threshold for the predefined time period, or at a later time if the wear level of the fluid end packing 124 satisfies the wear threshold for a time period lower than the predefined time period) and therefore minimize an amount of time that reciprocating pump 100 (or the hydraulic fracturing rig) is down during a fracturing operation. Further, because the system 300 provides alert to the operator indicating the fluid end packing 124 needs maintenance, the operator may timely schedule a time to repair or replace the fluid end packing 124. As a result, an amount of time that the reciprocating pump 100 is operating with a leaking packing is minimized. This may reduce a likelihood that one or more other components of the reciprocating pump 100, such as the plunger 120 or the remaining annular seal rings 168 (e.g., metallic first and second adapter rings 184, 188), are damaged and therefore improves a performance and/or longevity of the reciprocating pump 100 and the one or more other components of the reciprocating pump 100.

[0047] Unless explicitly excluded, the use of the singular to describe a component, structure, or operation does not exclude the use of plural such components, structures, or operations or their equivalents. The use of the terms “a” and “an” and “the” and “at least one” or the term “one or more,” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B” or one or more of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B; A, A and B; A, B and B), unless otherwise indicated herein or clearly contradicted by context. Similarly, as used herein, the word "or" refers to any possible permutation of a set of items. For example, the phrase "A, B, or C" refers to at least one of A, B, C, or any combination thereof, such as any of: A; B; C; A and B; A and C; B and C; A, B, and C; or multiple of any item such as A and A; B, B, and C; A, A, B, C, and C; etc.

[0048] It will be apparent to those skilled in the art that various modifications and variations can be made to the system, the reciprocating pump, and/or the method of the present disclosure without departing from the scope of the disclosure. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the enclosure, the system, the reciprocating pump, and/or the method disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalent.