System for detecting wear in fluid end packing of reciprocating pumps

A method of detecting wear in a fluid end packing of a reciprocating pump, the method comprising:

• disposing an insert at an annular seal ring of the fluid end packing, the annular seal ring defining a sealing interface with a plunger of the reciprocating pump;
• receiving, by a controller, vibration data associated with the fluid end packing from a sensor;
• and
• 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.

A reciprocating pump comprising:

• a fluid end housing defining a fluid chamber and a cylinder in fluid communication with the fluid chamber;
• a plunger 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;
• a fluid end packing including an annular seal ring defining a sealing interface with the plunger;
• and
• a system for detecting wear in the fluid end packing, the system including:
• an insert associated with the annular seal ring;
• a sensor configured to obtain vibration data associated with the fluid end packing;
• and
• a controller configured to:
• receive, from the sensor, the vibration data associated with the fluid end packing;
• and
• 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.