Halliburton Energy Services, Inc.

Joseph A Beisel

Stanley Vernon Stephenson

Justin Lee Hurst

James Alan Olis

Harold Grayson Walters

Glenn Howard Weightman

David Mark Stribling

Dick Charles Headrick

Lawrence A Herndon

Shahab Jamali Ghare Tape

Jim Basuki Surjaatmadja

Timothy Holiman Hunter

Thomas M Logan

Stan V Stephenson

The life of internal components of a frack pump is affected by the frack fluid being pumped. The disclosure evaluates pump components and identifies parameters of frack pumps that may affect the remaining life of pump components based on pump models generated using flow type histories of the frack pumps. Pump related factors can also be used to identify the pump parameters. In one example, a method of evaluating pump components of a frack pump includes: (1) comparing a flow type history of the frack pump to at least one pump model, wherein the flow type history is automatically determined and is based on a proppant concentration of frack fluid pumped by the frack pump, (2) evaluating a condition of at least one component of the pump based on the comparing, and (3) changing a parameter of the pump based on the evaluating.

Automatically detecting a key parameter affecting pump components

A pump comprising a bore pump fluid end having a reciprocating element bore, a discharge valve assembly comprising a discharge valve seat and a discharge valve body, and a suction valve assembly comprising a suction valve seat and a suction valve body; a hollow, cylindrical reciprocating element; a hollow reciprocating element adapter comprising a first end having a fluid inlet opposite a second end having a fluid outlet, wherein the second end of the reciprocating element adapter is connected to and in fluid communication with the fluid intake end of the reciprocating element; a pump power end having a push rod connected to the first end of the reciprocating element adapter; and a movable manifold comprising a reciprocating element end and a fluid intake end, wherein the reciprocating element end of the movable manifold is connected to and in fluid communication with the fluid inlet of the reciprocating element adapter.

Flexible manifold for reciprocating pump

The life of internal components of a frack pump is affected by the frack fluid being pumped. Manually trying to keep track of the frack fluid type being pumped is a tedious task that is susceptible to incorrect data or missing data. As such, the disclosure provides automated tracking of the amount of time or fluid volume that frack pumps pump the different fluid types and managing usage of the frack pumps using a history of the pumping. An example method of managing usage of a frack pump includes: (1) obtaining, for a time period or fluid volume, a proppant presence for a frack fluid being pumped by a frack pump, (2) automatically determining a flow type history for the frack pump over the time period or fluid volume based at least on the proppant presence, and (3) controlling a usage of the frack pump using the flow type history.

Automatically determining flow type histories for frack pumps and managing usage thereof using the flow type histories

A pump monitoring system for use in wellbore operations can determine whether an indication of a failure is due to an actual pump issue or a failed sensor. The pump monitoring system includes a sensor on a fluid end of a pump to measure properties associated with the pump and a vibration detector. A computing device executes instructions to receive the sensor signal and the vibration signal and identify an irregularity in the sensor signal. The processor then determines whether an operational signal component is present in the vibration signal, and displays an indication that the sensor has failed when the operational signal component is not present in the vibration signal. If the operational signal component is present in the vibration signal, the irregularity is likely caused by a pump problem such as a failed valve.

Sensor failure diagnosis in a pump monitoring system

A monitoring system may include a strain gauge, a position sensor, and a torque sensor. The strain gauge may measure strain in a chamber of the pressure pump and generate a strain signal representing the strain measurement. The position sensor may measure a position of a rotating member and generate a position signal representing the position measurement. The torque sensor may measure torque in a component of the pressure pump and generate a torque signal representing the torque measurement. The torque measurement may be used with the strain measurement and the position measurement to determine a condition of the pressure pump.

Pressure pump performance monitoring system using torque measurements

A system may include multiple strain gauges and multiple position sensors positioned on multiple pressure pumps. The strain gauges may measure strain in chambers of the pressure pumps. The position sensors may measure positions of rotating members of the pressure pumps. One or more computing devices may be communicatively couplable to the strain gauges and the position sensors to determine an adjustment to a flow rate of fluid through at least one pump using a strain measurement and a position measurement for the at least one pump such that a timing of changes in composition of the fluid delivered to into a first manifold at an input for the pressure pumps matches the timing of the changes in composition of the fluid delivered from a second manifold at an output for the pressure pumps.

Pressure pump balancing system

A pump monitoring system for use in wellbore operations includes a strain gauge that can be positioned on a fluid end of a pump and at least one pressure transducer to measure relative pressure. A computing device can be connected to the strain gauge and the pressure transducers. The computing device executes programming instructions to identify failures of specific valves by correlating the strain signal to an actual pressure associated with the specific valve in the pump section. The processor then determines whether a pump pressure corresponds to the actual pressure associated with the specific valve, and if so, displays an indication that the specific valve in the pump section has failed.

Valve failure determination in a pump monitoring system

A hose for a reciprocating pump, the hose comprising: a first end and a second end separated by a length (L) along a centerline of the hose, wherein the first end reciprocates with a reciprocating element of the reciprocating pump during operation of the reciprocating pump; an inner surface and an outer surface separated by a thickness; and a variable bend radius wherein a bend radius of a first section of the hose is different from a bend radius of at least one second section of the hose, such that, during operation of the reciprocating pump, a stress on the first end of the hose, the second end of the hose, or both the first end of the hose and the second end of the hose is reduced relative to that of a hose that does not contain the variable bend radius.

A valve seat comprising a primary retention component to retain the valve seat in a valve seat housing upon seating of the valve seat in the valve seat housing, and a secondary retention component to at least temporarily retain the valve seat in the valve seat housing during seating of the valve seat in the valve seat housing, whereafter the valve seat is primarily retained in the valve seat housing via the primary retention component.

Pump valve seat with supplemental retention

A monitoring system may include strain gauges and position sensors corresponding to multiple pressure pumps. The strain gauge for each pressure pump may measure the strain in a respective chamber of each pump. The position sensor for each pump may measure the position of a rotating member of each pump. The monitoring system may also include one or more computing devices for determining actuation delays associated with valves corresponding to the respective chamber of each pump using expected actuation points and actual actuation points of the valves. The computing devices may compare the actuation points for the valves of all of the pressure pumps to determine a condition of a valve in one of the pressure pumps.

Multiple-pump valve monitoring system

A monitoring system may include at least a strain gauge and a computing device for determining a bulk modulus of a fluid system of a pressure pump using strain measurements. The strain gauge may determine strain in a chamber of the pressure pump. The computing device may receive a strain signal generated by the strain gauge and may correlate the strain signal to pressure to determine a change in pressure during a period in which fluid is isolated in the chamber. The computing device may use the change in pressure during this period to determine a bulk modulus of the fluid system.

Bulk modulus monitoring system

A monitoring system for a plurality of pressure pumps may include, for each pump, a strain gauge, a position sensor and a pressure transducer. A strain gauge may be positionable on each pump to generate a strain measurement corresponding to strain in each pump. A position sensor may be positionable on each pump to generate a position measurement corresponding to a position of a rotating member corresponding of each pump. A pressure transducer is positionable on each pump to generate a boost pressure measurement that is usable with the strain measurement and the position measurement to determine a cavitation threshold for each pump.

Cavitation avoidance system

A monitoring system can include a position sensor coupled to a pump to sense a position of a rotating assembly member of the pump and generate an associated position signal. The position signal can be used to determine a position of a displacement member in a chamber in a fluid end of the pump. The monitoring system can include a strain gauge to measure strain in the chamber and generate an associated strain signal. The strain signal can be used to determine an actuation point for a valve in the chamber. A computing device can determine an actuation delay of the valve by correlating the position of the displacement member in the chamber with the actuation point for the valve. The actuation delay can represent the actuation point relative to the position of the displacement member during operation of the pump.

Critical valve performance monitoring system

A monitoring system may include a position sensor, strain gauges, and a computing device for monitoring valves in a wellbore pressure pump having multiple chambers to determine cavitation in the fluid end of the wellbore pressure pump using strain measurements for each chamber. The strain gauges may determine strain in each chamber of the pressure pump. The position sensor may determine the position of a crankshaft mechanically coupled to a plunger in each chamber. The computing device may receive signals generated by the strain gauges and the position sensor related to the strain in each chamber and the position of the crankshaft, respectively, and may process the signals to determine delays in the actuation of the valves for identifying cavitation and distinguishing cavitation conditions from alternative conditions in the fluid end.

Growing community of inventors

Duncan, OK, United States of America

Joseph A Beisel