Apparatus and method for diagnosing the status of specific components in high-pressure fluid pumps

A high-pressure pump head, comprising:

• a pressurization chamber;
• a pressurizing member at least partially received in the pressurization chamber, the pressurizing member being moveable within the pressurization chamber to draw fluid into the pressurization chamber with an intake action and to compress a fluid in the pressurization chamber with a pressurizing action;
• an inlet fluid control assembly coupled to the pressurization chamber to allow fluid to enter the pressurization chamber through an inlet port during the intake action and to prevent back flow through the inlet port during the pressurizing action;
• a pressurized fluid control assembly coupled to the pressurization chamber to selectively allow pressurized fluid to pass from the pressurization chamber to an outlet chamber during at least a portion of the pressurizing action and to prevent back flow from the outlet chamber to the pressurization chamber;
• and
• a diagnostic system having a first temperature sensor coupled to the pump head and a second temperature sensor coupled to the pump head, the first temperature sensor being positioned on the pump head to sense a beat flux produced by a specific component and identify that the specific component is malfunctioning, wherein the first temperature sensor is coupled to the pump head upstream from the inlet fluid control assembly with respect to a fluid flow direction through the pump, and the second temperature sensor is coupled to the pump head downstream from the pressurized fluid control assembly with respect to the fluid flow direction, the first and second temperature sensors together indicating an individual operational status of each of the inlet fluid control assembly, the pressurized fluid control assembly and a component of the pump head upstream from the inlet fluid control assembly.

A high-pressure pump head, comprising:

• a pressurization chamber;
• a plunger having a first end received in the pressurization chamber and a second end adapted to be operatively attached to a motor, the first end of the plunger being moveable within the pressurization chamber along an intake stroke to draw fluid into the pressurization chamber and along a pressurizing stroke to compress fluid in the pressurization chamber;
• an inlet check valve coupled to the pressurization chamber to allow fluid to enter the pressurization chamber during the intake stroke and to prevent back flow through an inlet port during the pressurizing stroke;
• an outlet check valve coupled to the pressurization chamber to selectively allow pressurized fluid to pass from the pressurization chamber into an outlet chamber during the pressurizing stroke and to prevent back flow from the outlet chamber into the pressurization chamber;
• a seal around the plunger toward the second end of the plunger;
• a first temperature sensor coupled to the pressurization chamber proximate to the seal;
• and
• a second temperature sensor coupled to an end cap housing the outlet chamber, wherein the first and second temperature sensors indicate the operational status of the inlet check valve, the outlet check valve and the seal.

A high-pressure pump head, comprising:

• a pressurization chamber;
• a plunger at least partially received in the pressurization chamber, the plunger being moveable within the pressurization chamber along an intake stroke to draw fluid into the pressurization chamber and along a pressurizing stroke to compress fluid in the pressurization chamber;
• an inlet fluid control assembly coupled to the pressurization chamber to allow fluid to enter the pressurization chamber through an inlet port during the intake stroke and to prevent back flow through the inlet port during the pressurizing stroke;
• a pressurized fluid control assembly coupled to the pressurization chamber to selectively allow pressurized fluid to pass from the pressurization chamber to an outlet chamber during at least a portion of the pressurizing stroke and to prevent back flow from the outlet chamber to the pressurization chamber;
• a seal around the plunger to seal the pressurization chamber;
• and
• a diagnostic system having a first temperature sensor coupled to the pressurization chamber upstream from the inlet fluid control assembly with respect to a fluid flow direction through the pump, a second temperature sensor coupled to the pump head downstream from the pressurized fluid control assembly with respect to the fluid flow direction, and a processor operatively coupled to the first and second temperature sensors to receive first and second temperature signals, respectively, wherein the processor specifically identifies whether the inlet fluid control assembly, the outlet fluid control assembly, or the seal is malfunctioning by comparing the first and second temperature signals with first and second reference signals, respectively.

A diagnostic system for monitoring an inlet valve assembly of a high-pressure pump, an outlet valve assembly of the high-pressure pump and a seal around a plunger of the high pressure pump, comprising:

• a first temperature sensor coupled to the pump at a location affected by a heat flux at the seal and a temperature of fluid in the pressurization chamber;
• a second temperature sensor coupled to the pump at a location downstream from the outlet check valve assembly with respect to a flow of fluid through the pump;
• and
• a processor operatively coupled to the first and second temperature sensors to receive first and second temperature input signals, wherein the processor specifically identifies whether the inlet check valve, the outlet check valve or the seal is malfunctioning by comparing the first and second input signals with first and second reference levels, respectively.

A multiple head high-pressure pump, comprising:

• a first pump head having a first pressurization chamber, a first plunger received in the first pressurization chamber, a first inlet check valve coupled to the first pressurization chamber, a first outlet check valve coupled between the first pressurization chamber and a first outlet chamber, and a first seal around the first plunger;
• a second pump head having a second pressurization chamber, a second plunger received in the second pressurization chamber, a second inlet check valve coupled to the second pressurization chamber, a second outlet check valve coupled between the second pressurization chamber and a second outlet chamber, and a second seal around the second plunger;
• a third pump head having a third pressurization chamber, a third plunger received in the third pressurization chamber, a third inlet check valve coupled to the third pressurization chamber, a third outlet check valve coupled between the third pressurization chamber and a third outlet chamber, and a third seal around the third plunger;
• and
• a diagnostic system having a first temperature sensor coupled to the first pump head upstream from the first inlet check valve, a second temperature sensor coupled to first pump head downstream from the first outlet check valve, a third temperature sensor coupled to the second pump head upstream from the second inlet check valve, a fourth temperature sensor coupled to the second pump head downstream from the second outlet check valve, a fifth temperature sensor coupled to the third pump head upstream from the third inlet check valve, a sixth temperature sensor coupled to the third pump head downstream from the third outlet check valve, and a processor coupled to each temperature sensor, the processor comparing input signals from the temperature sensors to specifically identify whether one of the first inlet check valve, the first outlet check valve, the first seal, the second inlet check valve, the second outlet check valve, the second seal, the third inlet check valve, the third outlet check valve, or the third seal is malfunctioning.

A high-pressure fluid system, comprising

• a high-pressure pump;
• a component coupled to the pump to receive pressurized fluid from the pump;
• a temperature sensor attached to at least one of the pump and the component at a location at which a heat flux produced by a leak in the one of the pump and the component can be sensed, wherein the component is a dynamic tool operated by the high-pressure fluid and the temperature sensor is coupled to the tool;
• and
• a processor operatively coupled to the temperature sensor, the processor comparing a sensed temperature from the temperature sensor to a reference temperature, and the processor indicating that the one of the pump and the component is malfunctioning when the sensed temperature is above the reference temperature for a predetermined period.

A high-pressure fluid system, comprising:

• a high-pressure pump;
• a component coupled to the pump to receive pressurized fluid from the pump;
• a temperature sensor attached to at least one of the pump and the component at a location at which a heat flux produced by a leak in the one of the pump and the component can be sensed;
• and
• a processor operatively coupled to the temperature sensor, the processor comparing a sensed temperature from the temperature sensor to a reference temperature, and the processor indicating that the one of the pump and the component is malfunctioning when the sensed temperature is above the reference temperature for a predetermined period, wherein the pump has an inlet check valve, an outlet check valve and a plunger seal, and wherein the temperature sensor comprises a first temperature probe coupled to the pump proximate to the plunger seal and a second temperature probe coupled to an outlet chamber of the pump proximate to the outlet check valve.

A high-pressure fluid system, comprising:

• a high-pressure pump;
• a component coupled to the pump to receive pressurized fluid from the pump;
• a temperature sensor attached to at least one of the pump and the component at a location at which a heat flux produced by a leak in the one of the pump and the component can be sensed;
• and
• a processor operatively coupled to the temperature sensor, the processor comparing a sensed temperature from the temperature sensor to a reference temperature, and the processor indicating that the one of the pump and the component is malfunctioning when the sensed temperature is above the reference temperature for a predetermined period;
• wherein the component comprises a swivel coupled to the pump via a high-pressure fluid line and nozzle coupled to the pump via a valve and the high-pressure fluid line;
• wherein the pump comprises a pressurization chamber, a plunger received in the pressurization chamber, a plunger seal between the plunger and the pressurization chamber, an outlet chamber for pressurized fluid, and a pump valve assembly having an inlet check valve and an outlet check valve between the pressurization chamber and the outlet chamber;
• and
• wherein the temperature sensor comprises a plurality of individual temperature probes coupled to the processor, wherein an individual probe is coupled to each of the swivel, the nozzle valve, the pressurization chamber proximate to the plunger seal and the outlet chamber.

A method of predicting failure of a component in a high-pressure pump having a pressurization chamber, an inlet check valve coupled to the pressurization chamber, and an outlet check valve coupled to the pressurization chamber, the method comprising:

• measuring a first temperature of a first pump component upstream from the inlet check valve with respect to a flow of fluid through the pump;
• measuring a second temperature of a second pump component downstream from the outlet check valve with respect to the fluid flow through the pump;
• comparing the first and second measured temperatures with first and second reference temperatures, respectively;
• and
• diagnosing that one of the inlet check valve, the outlet check valve or a component upstream of the inlet check valve with respect to the fluid flow through the pump is malfunctioning.