SYSTEM AND METHOD FOR CONDITION MONITORING OF VERTICALLY SUSPENDED PUMPS

Abstract

A vertically suspended pump assembly configured to pump fluid from an open sump or a closed suction double casing, the vertically suspended pump assembly comprising: a motor disposed in a top portion; and one or more impellers disposed in a bottom portion and driven by the motor so that centrifugal forces are generated within a central passage way to pump fluid from the open sump or the closed suction double casing upwards through the central passage way; and a vibration sensor located at a bottom of the bowl casing or at an inlet casing of a first stage impeller; and a controller configured to receive, from the vibration sensor, a stream of data encoding one or more vibrational characteristics at the bottom of the bowl casing or at the inlet casing of the first stage impeller so that the vertically suspended pump assembly is monitored in real-time.

Description

TECHNICAL FIELD

This disclosure generally relates to condition monitoring of pumps.

BACKGROUND

A vertically suspended pump is a type of centrifugal pump often used in applications in, for example, the oil/gas exploration industry. Such pump can boost pressure of fluid to satisfy net positive suction head (NPSH) requirements before the fluid enters the inlets of the main pumps.

SUMMARY

In one aspect, implementations provide a system that includes: a vertically suspended pump assembly configured to pump fluid from an open sump or a closed suction double casing, the vertically suspended pump assembly comprising: a top portion located above-grade at a first end of the vertically suspended pump assembly; a bottom portion located below-grade at a second end of the vertically suspended pump assembly; a motor disposed in the top portion; one or more impellers disposed in the bottom portion and arranged in a stack within a bowl casing, wherein the one or more impellers are driven by the motor so that centrifugal forces are generated within a central passage way between the top portion and the bottom portion of the vertically suspended pump assembly to pump fluid from the open sump or the closed suction double casing upwards through the central passage way, wherein the one or more impellers comprise a first stage impeller at a bottom level of the stack; and a vibration sensor located at a bottom of the bowl casing or at an inlet casing of the first stage impeller; and a controller in communication with the vibration sensor and configured to receive, from the vibration sensor, a stream of data encoding one or more vibrational characteristics at the bottom of the bowl casing or at the inlet casing of the first stage impeller so that the vertically suspended pump assembly is monitored in real-time.

Implementations may include one or more of the following features.

The system may further include: a vibration cable that connects the vibration sensor to the controller. The system may further include: a pressurized pipe enclosing the vibration sensor and the vibration cable so that the vibration sensor and the vibration cable are insulated from the fluid. The system may further include: a pressure gauge attached to the pressurized pipe and configured to measure a pressure inside the pressurized pipe. The pressure inside the pressurized pipe may be higher than a pressure of the fluid outside the pressurized pipe. The system may further include: a flanged connection comprising two flanges facing each other and connected through a gasket, wherein the flanged connection is located on the pressurized pipe and by the vibration sensor such that, when the flanged connection is opened, the vibration sensor can be inspected. The system may further include: a pressurized hose enclosing the vibration sensor and the vibration cable so that the vibration sensor and the vibration cord are insulated from the fluid. The system may further include: a pressure gauge attached to the pressurized hose and configured to measure a pressure inside the pressurized hose. The pressure inside the pressurized hose may be higher than a pressure of the fluid outside the pressurized hose. The system may further include: a flanged connection comprising two flanges facing each other and connected through a gasket, wherein the flanged connection is located on the pressurized hose and by the vibration sensor such that, when the flanged connection is opened, the vibration sensor can be inspected. The one or more impellers are multi-stage impellers arranged in the stack within the shaft. The vertically suspended pump assembly may include: a vertically suspended open suction pump, and a vertically suspended closed suction pump.

In another aspect, implementations include a method for monitoring a vertically suspended pump assembly comprising one or more impellers arranged in a stack within a bowl casing, the method comprising: placing a vibration sensor at a bottom of the bowl casing or at an inlet casing of a first stage impeller of the one or more impellers; driving the one or more impellers using a motor so that centrifugal forces are generated within a central passage way of the vertically suspended pump assembly to pump fluid from the open sump or the closed suction double casing upwards through the central passage way; receiving, from the vibration sensor and on a controller in communication with the vibration sensor, a stream of data encoding one or more vibrational characteristics at the bottom of the bowl casing or at the inlet casing of the first stage impeller; and monitoring the vertically suspended pump assembly in real-time as fluid is from the open sump or the closed suction double casing upwards through the central passage way.

Implementations may include one or more of the following features.

The method may further include: connecting, using a vibration cord, the vibration sensor to the controller. The method may further include: enclosing, using a pipe or a hose, the vibration sensor and the vibration cable so that the vibration sensor and the vibration cable are insulated from the process fluid. The method may further include: pressurizing the pipe or hose so that a pressure inside is higher than a pressure of the process fluid. The method may further include: measuring, using a pressure gauge, the pressure inside the pipe or the hose. The method may further include: determining, based on, at least in part, the one or more vibrational characteristics, a condition of the vertically suspended pump assembly. The method may further include: in response to determining that the condition of the vertically suspended pump assembly is abnormal, causing the vertically suspended pump assembly to stop operation. The method may further include: opening a flanged connection by the vibration sensor; and inspecting the vibration sensor.

Implementations according to the present disclosure may be realized in computer implemented methods, hardware computing systems, and tangible computer readable media. For example, a system of one or more computers can be configured to perform particular actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. One or more computer programs can be configured to perform particular actions by virtue of including instructions that, when executed by data processing apparatus, cause the apparatus to perform the actions.

The details of one or more implementations of the subject matter of this specification are set forth in the description, the claims, and the accompanying drawings. Other features, aspects, and advantages of the subject matter will become apparent from the description, the claims, and the accompanying drawings.

DESCRIPTION OF DRAWINGS

FIG. 1A is a diagram illustrating an example according to some implementations of the present disclosure.

FIG. 1B is another diagram illustrating an example of a closed suction or double casing design used by some implementations of the present disclosure.

FIG. 2 illustrates an example of a controller used in some implementations of the present disclosure.

FIG. 3 is a flow chart illustrating an example according to some implementations of the present disclosure.

FIG. 4 is a block diagram illustrating an example of a computer system used to provide computational functionalities associated with described algorithms, methods, functions, processes, flows, and procedures, according to an implementation of the present disclosure.

Like reference numbers and designations in the various drawings indicate like elements.

DETAILED DESCRIPTION

The disclosed technology is directed to system and method for condition monitoring of rotating equipment such as vertical suspended design pumps, which are especially challenging in terms of early detection using vibration diagnosis. Although vibration patterns can be a significant indicator of equipment condition, the vibration data is typically acquired above grade on the pump discharge head and motor. A conventional installation would not place vibration sensors below-grade (or underground) in a vertically suspended pump because the pumped fluid can be hazardous, corrosive, or volatile in nature. In general, vibration sensors have been mounted on a stable surface that is free from movement, such as a concrete foundation or metal structure.

However, taken vibration data above-grade makes it especially difficult to detect failure mechanisms of the rotating equipment (such as a vertically suspended pump) that occur at the working end of the pump. The implementations may incorporate a vibration sensor at the 1^st stage impeller and bottom bearing/bushing locations. The implementations may further include a vibration cord connecting the vibration sensor to a monitoring system. The implementations may additionally include an isolating pipe (e.g. metallic or non-metallic), or a hose to protect the vibration sensor and the vibration cord. The implementations may particularly pressurize the pipe/hose internals to a pressure higher than surrounding pressure to prevent and monitor leakage from process side to the enclosing pipe. For vertically suspended open suction designs (e.g., API VS1-5 pumps), the sensor cabling in specific applications can be exposed to high temperatures, corrosive environments, etc., which can cause the cord or the sensor to malfunction. In various implementations, the sensor and the cord can be protected by the pressurized pipe or hose such that the processing fluid does not come in contact with the cord or sensor. The same isolation can be applied to other types of vertically suspended closed suction or canned pump designs (e.g., VS6-7 pumps). Additional details are provided below in association with FIGS. 1-4.

Referring to diagram 100 of FIG. 1A and diagram 120 of FIG. 1B, a vibration sensor 110 (or vibration sensor 130) is integrated into a specific section of a vertically suspended suction pump, which can be open (as shown in FIG. 1A) or closed (as shown in FIG. 1B). Specifically, the vibration sensor 110 (or vibration sensor 130) can be integrated to the bottom bowl assembly or 1^st stage impeller inlet casing of the pump. Integrating the sensor at this location, instead of the pump discharge head or motor, allows obtaining vibration data from the portion of the pump that actually vibrates during suction. In some cases, this portion corresponds to the first stage inlet of the pump where many of the failure modes can manifest. The sensor is connected to a vibration cord that transmits sensed vibration to a surface location or above the pump grade. The sensor and the cable (also known as cord in some cases) are enclosed by a pipe or a hose, which can be pressurized to protect the sensor and the cord. A flanged connection is used to connect the pipe or hose to the pump to facilitate connection/removal for inspection. The pressurized pipe can be connected to a pressure gauge or a monitoring system to continuous and online monitoring.

As illustrated, diagram 100 shows a vertically suspended pump vibration monitoring system configured to pump process fluid 109. In some embodiments, process fluid 109 can be a hydrocarbon fluid such as crude oil. Process fluid 109 can also be a non-hydrocarbon fluid. The vertically suspended pump includes a top or first end 101A and a bottom or second end 101B. As used within the present disclosure, the term “open or closed suction” refers to how the pump is designed to draw process fluid 109 into the pump. In an open suction pump, process fluid 109 is drawn into the pump through an open intake pipe or column that is submerged in the fluid. The pump impeller then uses centrifugal force to push the fluid out through the discharge pipe 105. Open suction pumps are often used in applications where the fluid being pumped is not hazardous and can be easily accessed. In a closed suction pump, process fluid 109 is drawn into the pump through a closed system that is sealed off from the surrounding environment. This closed suction system is typically accomplished using the double casing design, as illustrated in FIG. 1B (showing vibration sensor 130 located at the first stage impeller inlet casing 131, and pipe 132 that encloses vibration cable connecting vibration sensor 130 to controller 201). Open suction pumps directly from an open sump and directly into the liquid level. In comparison, a closed suction pump utilizes a canned design or a double casing design to contain the process fluid from the atmosphere. Closed suction pumps are often used in applications where the fluid being pumped is hazardous or difficult to access, and where a sealed system is necessary to prevent release of hazardous material to atmosphere.

Regardless of whether the pump is open or closed suction, the vertically suspended pump generally includes motor 102, an impeller in enclosure 108, casings 103 and 104, and shaft 107. The motor 102 drives the impeller, which can include multiple stages and rotates at high speed inside the casing. As the impeller rotates, the impeller creates a low-pressure zone in the center of the casing, which draws fluid into the pump. The fluid is then pushed out through the discharge pipe 105 by the high-pressure zone created by the impeller blades.

As illustrated, the pump assembly can extend from a top portion that includes first end 101A to a bottom portion that includes second end 101B. The top portion can house motor 102, which can be electric motor or another suitable motor. Motor 102 is connected to shaft 107 disposed within a central passageway of casings 103 and 104 that extend into ground level 106. Within the bottom portion, the bottom end of shaft 107 is connected to one or more impellers (e.g, a multi-stage impeller) disposed within respective bowl casings. The bottom portion of some implementations can include three such impellers: lower impeller, intermediate impeller, and upper impeller, disposed in a stacking manner with the lower impeller situated the lowest. Some implementations can include a different number of impellers and corresponding bowl casings, such as, for example, only one impeller and corresponding bowl casing, or, four or a greater number of impellers and corresponding bowl casings. The implementations can include top bushing, line-shaft bushings, and bottom bushing for alignment and bearing surfaces for shaft 107 at varying depths.

As illustrated, implementations can incorporate a vibration sensor 100 located at the bottom bowl assembly at the 1^st stage impeller casing of the vertically suspended pump. This location can provide sufficient sensitivity to effectively diagnose these vibration responses in terms of early detection. Vibration cord 112 connects vibration sensor 100 to vibration monitoring system connection 114, which connects to controller 201. Implementations can enclose vibration sensor 100 and vibration cord 112 in isolating pipe/hose 113. As discussed above, isolating pipe/hose can isolate the vibration sensor and the vibration cable from press fluid 109 so that the sensor and the cord are not in contact with the process liquid. Moreover, isolating pipe/hose 113 is pressurized to prevent leakage of the process fluid inside. The implementations can include pressure gauge 115 to monitor the internal pressure during operation. The pressure readings can also be provided to controller 201. This arrangement can effectively prevent sensor and/or cord malfunction, especially when the process fluid exhibits high temperature or corrosive characteristics. The implementations can further include a flanged connection 111 at the sensor location to facilitate the removal of the pipe/hose 113 so that vibration sensor can be inspected. In these implementations, the flanged connection 111 is insulated at the connection between the two flanges by a suitable gasket.

Rotating equipment vibration can lead to several failure modes related to a vertically suspended pump. The early indicators can include, for example, increased vibration amplitude. Examples of failure mechanisms can include mechanical looseness, rotor imbalance, resonance, worn bearings/bushings, and compromised suction conditions from obstructions or compromised Net Positive Suction Head Available (NPSHA). Vertical suspended design pumps can be especially challenging in terms of early detection using vibration diagnosis. Due to the inherent vertically suspended design, the vibration source is buried under ground. Vibration data is typically acquired above grade on the pump discharge head and motor, thus rendering it especially difficult to detect these failure mechanisms when dominant vibrations occur at the working end of the pump. By installing a vibration sensor on the bottom bowl assembly or 1^st stage impeller casing location, implementations can capabilities for early detection of these types of failures, due to the enhanced proximity of the measurement location. In the case of vertically suspended open suction designs (e.g., API VS1 to VS5 pumps), the sensor cabling in specific applications can be exposed to high temperatures and/or corrosive environments. This reality can lead to malfunction of the vibration sensor and the connecting cord when high temperature liquids (such as molten sulfur) or corrosive liquids (such as sulfuric acid) are often encountered. By enclosing the sensor and the cord in a suitable pipe or hose that is pressurized and extended from the sensor location at the bottom up to the vibration monitoring system connection 114, the sensor and cord can be isolated from the press fluid and harsh underground environments. The pipe material can be metallic steel or non-metallic, which is lighter and have less structural support requirements. A hose configuration can likewise have enough strength to withstand the fluid hydraulic forces. The hose configuration can be more flexible and lighter than the pipe configuration. In other words, the hose configuration can create smaller additional weight to the pump so that the hose configuration will not transmit vibrational forces that might cause cyclic stresses leading to sensor failure. These arrangements are equally applicable to vertically suspended closed suction or canned pump designs (e.g., VS6-VS7 pumps), as opposed to “open suction” design used by VS1-VS5 pumps.

FIG. 2 shows an example of an example of a user-interactive graphical user interface (GUI) 220 on controller 201. Like the cockpit of an aircraft, or the instrument panel on a vehicle, the interactive GUI 220 presents a panel that allows the user to visualize real-time and in-situ measurements of the vibration pattern at the level of the 1^st impeller of a selected vertically suspended pump (e.g., corresponding to a chosen ID 230) while the pump operates at a depth range (e.g., indicated by depth 240). The panel can allow real-time measurements from multiple sensors (e.g., measurements 250a, 250b, 250c) on the selected pump to be streamed and projected to the user, e.g., as a rolling curve (such as bar 260), a usage bar, a progress bar, or a speedometer layout. These measured parameters can include temperature, vibration amplitude, and strain. For example, the user-interactive GUI 220 can project trend information and forecast a behavior of a measured parameter (e.g., time left before next maintenance or replacement of a pump component). In this example, the panel may receive measurements, and predict the well-being of the pump component using these measurements and past history. Additionally, the modeling may factor in fluid properties of the fluid in which the pump is operating. Moreover, the interactive GUI 220 can provide operational guidance or real-time alert (e.g., attention 270) on the panel based on the real-time measurements, much like navigational guidance on a GPS device. The real-time alert can include both visually popping the attention flag, and sounding an alarm on controller 201.

FIG. 3 is a flow chart 300 illustrating an example of a process according to some implementations of the present disclosure. The process may install a vibration sensor at the location of the first stage impeller of a vertically suspended pump (301). As illustrated in FIGS. 1A to 1B and explained above, this location can refer to a depth level location (e.g., bottom bearing/bushing locations on the perimeter of the shaft). The location of interest can be a rigid surface inside the pump where the vibration sensor can be attached. The vibration sensor can be encapsulated for easy mounting. The vertically suspended pumps can include vertically suspended open suction designs (e.g., API VS1-5 pumps), as well as vertically suspended closed suction or canned pump designs (e.g., VS6-7 pumps). In various implementations, the sensor can be placed at the 1^st stage impeller inlet casing or the bottom bowl assembly. For example, the sensor can be stud-mounted to the casing. The pipe enclosing the vibration cable can be routed vertically and supported to the remaining bowl assemblies or column, then routed up through the discharge head, as illustrated in FIGS. 1A and 1B.

As outlined in U.S. application Ser. No. 17/333,572 (published as US 2022/0381254), U.S. application Ser. No. 17/333,612 (published as US 2022/0381134), Ser. No. 17/333,597 (published as US 2022/0381704), U.S. Provisional Application No. 63/380,014, and U.S. application Ser. No. 17/984,807, all of which are incorporated herein by reference, vibration sensor 100 can be based on Radio Frequency (RF) resonance response and constructed using responsive nanomaterials patches (such as silver nanoparticles or carbon nanotubes) for condition monitoring of vertical crude charge pumps. For example, sensor 100 can monitor mechanical strain, stress, and vibration based on the impact these mechanical perturbations have on the nano effect of electrostatic capacitive molecular coupling in-between carbon nanotube (CNT) polymer composites. Vibration and strain conditions can be correlated to the frequency resonance shift of the resonating structure, and therefore to the health status of the pump. In other words, the sensing mechanism can be described in terms of the surface current distribution on the resonating patches, which is directly related to the resonance and frequency shift. Sensor 100 may also incorporate a Miro-Electro Mechanical system-based (MEMS) piezoelectric accelerometer sensor that produces electric charge or output under acceleration, strain, or vibration. Such MEMS sensor can include a high-temperature accelerometer with a temperature range up to 250° C. Piezoelectric and elastomeric composite materials can be utilized to create a sensor stack design enabling effective vibrational transfer and transduction to piezoelectric signals, which can then be filtered and amplified by an external circuit to accurately evaluate the vibration frequencies during operation. Designs can factor in environmental performance requirements of the pumping system so that the frequency responses exhibited by anomalous behaviors can reveal an onset of failure. MEMS sensor configuration can utilize micro machined silicon, thin film deposition, and microfabrication patterning. The main components can include an anchor, a proof mass, a flexible/spring-like membrane, and a piezoelectric material that converts strain or vibrations to voltage as the proof mass flexes the piezoelectric thin film. In this manner, strain loading or vibration can be readily converted to output voltage signals and when coupled to an appropriate amplifier circuit design, the output signal can be designed to produce a sharp resonant peak at very specific frequencies. Using this approach, precision accelerometers have been demonstrated for a wide range of applications. A simpler approach is to utilize thin-film piezoelectric materials fabricated on a flexible substrate.

The implementations may attach a vibration cord 112 to connect the vibration sensor 100 with controller 201 (e.g., through monitoring system connection 114), as shown in box 302. As illustrated in FIGS. 1A to 1B, and explained above, vibration cord 112 can be a co-axial cable that provides driving signals (e.g., interrogation pulses) for the vibration sensor 100. The cord can also be a fiber, or a waveguide. For example, a resonant layer on vibration sensor 100 can include an electrically conductive nanomaterial so that the resonant layer can resonate at a resonant frequency in response to receiving the interrogation pulses. The resonating response can thus exhibit a phase, amplitude, and resonance shift in comparison to the original interrogation pulse based on the composition and dimensions of the construction of the vibration sensor 100. By measuring the phase, amplitude, and resonance shifts and scattering parameters (S-parameters) of the resonating response, implementations can infer the vibration behavior of the pump (e.g., at the 1^st stage impeller).

Implementations may install a pressurized pipe (or hose) that enclose the vibration cord 112 and the vibration sensor 100, as shown in box 303. As illustrated in FIGS. 1A to 1B and explained above, the harsh environment (e.g., high temperature (such as 150 degree Celsius or above) and potentially corrosive fluid) can cause malfunction of the vibration sensor and the vibration cord, if exposed. By enclosing the vibration sensor and the vibration cable in a pipe (or hose) and pressurizing the pipe (or hose), the implementations can effectively isolate the vibration sensor and vibration cord from the underground harsh environment. Moreover, the implementations may incorporate a pressure gauge to monitor the internal pressure of the pipe (or hose). Additionally, implementations may incorporate a flanged connection at the sensor location. This flanged connection can a suitable gasket between the two flanges for insulation. Through this flanged connection, implementations can allow for removal of the pipe/hose to inspect the sensor and conduct maintenance.

The implementations may then operate the pump and obtain vibration signature from the vibration sensor (304). As illustrated in FIGS. 1A, 1B, and 2 and explained above, the implementations can perform real-time measurements using vibration sensor 110 (or vibration sensor 130) and project the measurement results on a user-interactive interface on controller 201. In many cases, the characteristics of the resonating pulse (e.g., from resonating layers on the sensor) in response to the interrogating pulse are correlated to vibrational characteristics of the operating pump (e.g., at the location of the 1^st stage impeller), which can reveal the mechanical properties of the operating pump. These mechanical properties can indicate the condition and health status of the pump.

The implementations may then compare the vibration amplitude to a pre-defined alarm level amplitude (305). Based on the comparison, the implementations may determine whether the vibration amplitudes exceed an alarm level set point (306). In response to determining that the vibration amplitudes do not exceed the alarm level set point, the implementations may continue to operate the vibration sensor to monitor the pump (304). In response determining that the vibration amplitudes have exceeded the alarm level set point, the implementations may investigate and troubleshoot, e.g., by using vibration signatures and other process data (307). For example, the implementations may determine whether other discrete frequency are appearing, but below alert level (308). In response to determining no, the implementations may continue to operate the vibration sensor to monitor the pump (304). In response to determining that other discrete frequency are appearing, and above the alert level, the implementations may further investigate and perform troubleshooting (309). For example, the implementations may change operations condition such as the flow rate, or shut down the motor of the pump. In many cases, the implementations can generate audio and visual feedback on the user-interactive interface of controller 201 to alert an operator of the pump, as illustrated in FIG. 2 and explained above.

FIG. 4 is a block diagram 400 illustrating an example of a computer system 400 used to provide computational functionalities associated with described algorithms, methods, functions, processes, flows, and procedures, according to an implementation of the present disclosure. The illustrated computer 402 is intended to encompass any computing device such as a server, desktop computer, laptop/notebook computer, wireless data port, smart phone, personal data assistant (PDA), tablet computing device, one or more processors within these devices, another computing device, or a combination of computing devices, including physical or virtual instances of the computing device, or a combination of physical or virtual instances of the computing device. Additionally, the computer 402 can comprise a computer that includes an input device, such as a keypad, keyboard, touch screen, another input device, or a combination of input devices that can accept user information, and an output device that conveys information associated with the operation of the computer 402, including digital data, visual, audio, another type of information, or a combination of types of information, on a graphical-type user interface (UI) (or GUI) or other UI.

The computer 402 can serve in a role in a computer system as a client, network component, a server, a database or another persistency, another role, or a combination of roles for performing the subject matter described in the present disclosure. The illustrated computer 402 is communicably coupled with a network 430. In some implementations, one or more components of the computer 402 can be configured to operate within an environment, including cloud-computing-based, local, global, another environment, or a combination of environments.

The computer 402 is an electronic computing device operable to receive, transmit, process, store, or manage data and information associated with the described subject matter. According to some implementations, the computer 402 can also include or be communicably coupled with a server, including an application server, e-mail server, web server, caching server, streaming data server, another server, or a combination of servers.

The computer 402 can receive requests over network 430 (for example, from a client software application executing on another computer 402) and respond to the received requests by processing the received requests using a software application or a combination of software applications. In addition, requests can also be sent to the computer 402 from internal users, external or third-parties, or other entities, individuals, systems, or computers.

Each of the components of the computer 402 can communicate using a system bus 403. In some implementations, any or all of the components of the computer 402, including hardware, software, or a combination of hardware and software, can interface over the system bus 403 using an application programming interface (API) 412, a service layer 413, or a combination of the API 412 and service layer 413. The API 412 can include specifications for routines, data structures, and object classes. The API 412 can be either computer-language independent or dependent and refer to a complete interface, a single function, or even a set of APIs. The service layer 413 provides software services to the computer 402 or other components (whether illustrated or not) that are communicably coupled to the computer 402. The functionality of the computer 402 can be accessible for all service consumers using this service layer. Software services, such as those provided by the service layer 413, provide reusable, defined functionalities through a defined interface. For example, the interface can be software written in JAVA, C++, another computing language, or a combination of computing languages providing data in extensible markup language (XML) format, another format, or a combination of formats. While illustrated as an integrated component of the computer 402, alternative implementations can illustrate the API 412 or the service layer 413 as stand-alone components in relation to other components of the computer 402 or other components (whether illustrated or not) that are communicably coupled to the computer 402. Moreover, any or all parts of the API 412 or the service layer 413 can be implemented as a child or a sub-module of another software module, enterprise application, or hardware module without departing from the scope of the present disclosure.

The computer 402 includes an interface 404. Although illustrated as a single interface 404 in FIG. 4, two or more interfaces 404 can be used according to particular needs, desires, or particular implementations of the computer 402. The interface 404 is used by the computer 402 for communicating with another computing system (whether illustrated or not) that is communicatively linked to the network 430 in a distributed environment. Generally, the interface 404 is operable to communicate with the network 430 and comprises logic encoded in software, hardware, or a combination of software and hardware. More specifically, the interface 404 can comprise software supporting one or more communication protocols associated with communications such that the network 430 or interface's hardware is operable to communicate physical signals within and outside of the illustrated computer 402.

The computer 402 includes a processor 405. Although illustrated as a single processor 405 in FIG. 4, two or more processors can be used according to particular needs, desires, or particular implementations of the computer 402. Generally, the processor 405 executes instructions and manipulates data to perform the operations of the computer 402 and any algorithms, methods, functions, processes, flows, and procedures as described in the present disclosure.

The computer 402 also includes a database 406 that can hold data for the computer 402, another component communicatively linked to the network 430 (whether illustrated or not), or a combination of the computer 402 and another component. For example, database 406 can be an in-memory, conventional, or another type of database storing data consistent with the present disclosure. In some implementations, database 406 can be a combination of two or more different database types (for example, a hybrid in-memory and conventional database) according to particular needs, desires, or particular implementations of the computer 402 and the described functionality. Although illustrated as a single database 406 in FIG. 4, two or more databases of similar or differing types can be used according to particular needs, desires, or particular implementations of the computer 402 and the described functionality. While database 406 is illustrated as an integral component of the computer 402, in alternative implementations, database 406 can be external to the computer 402. As illustrated, the database 406 holds data 416 including, for example, data from vibration sensor 100 and pressure gauge 115, as explained in more detail in association with FIGS. 1-3.

The computer 402 also includes a memory 407 that can hold data for the computer 402, another component or components communicatively linked to the network 430 (whether illustrated or not), or a combination of the computer 402 and another component. Memory 407 can store any data consistent with the present disclosure. In some implementations, memory 407 can be a combination of two or more different types of memory (for example, a combination of semiconductor and magnetic storage) according to particular needs, desires, or particular implementations of the computer 402 and the described functionality. Although illustrated as a single memory 407 in FIG. 4, two or more memories 407 or similar or differing types can be used according to particular needs, desires, or particular implementations of the computer 402 and the described functionality. While memory 407 is illustrated as an integral component of the computer 402, in alternative implementations, memory 407 can be external to the computer 402.

The application 408 is an algorithmic software engine providing functionality according to particular needs, desires, or particular implementations of the computer 402, particularly with respect to functionality described in the present disclosure. For example, application 408 can serve as one or more components, modules, or applications. Further, although illustrated as a single application 408, the application 408 can be implemented as multiple applications 408 on the computer 402. In addition, although illustrated as integral to the computer 402, in alternative implementations, the application 408 can be external to the computer 402.

The computer 402 can also include a power supply 414. The power supply 414 can include a rechargeable or non-rechargeable battery that can be configured to be either user- or non-user-replaceable. In some implementations, the power supply 414 can include power-conversion or management circuits (including recharging, standby, or another power management functionality). In some implementations, the power-supply 414 can include a power plug to allow the computer 402 to be plugged into a wall socket or another power source to, for example, power the computer 402 or recharge a rechargeable battery.

There can be any number of computers 402 associated with, or external to, a computer system containing computer 402, each computer 402 communicating over network 430. Further, the term “client,” “user,” or other appropriate terminology can be used interchangeably, as appropriate, without departing from the scope of the present disclosure. Moreover, the present disclosure contemplates that many users can use one computer 402, or that one user can use multiple computers 402.

Implementations of the subject matter and the functional operations described in this specification can be implemented in digital electronic circuitry, in tangibly embodied computer software or firmware, in computer hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Software implementations of the described subject matter can be implemented as one or more computer programs, that is, one or more modules of computer program instructions encoded on a tangible, non-transitory, computer-readable computer-storage medium for execution by, or to control the operation of, data processing apparatus. Alternatively, or additionally, the program instructions can be encoded in/on an artificially generated propagated signal, for example, a machine-generated electrical, optical, or electromagnetic signal that is generated to encode information for transmission to a receiver apparatus for execution by a data processing apparatus. The computer-storage medium can be a machine-readable storage device, a machine-readable storage substrate, a random or serial access memory device, or a combination of computer-storage mediums. Configuring one or more computers means that the one or more computers have installed hardware, firmware, or software (or combinations of hardware, firmware, and software) so that when the software is executed by the one or more computers, particular computing operations are performed.

The term “real-time,” “real time,” “realtime,” “real (fast) time (RFT),” “near(ly) real-time (NRT),” “quasi real-time,” or similar terms (as understood by one of ordinary skill in the art), means that an action and a response are temporally proximate such that an individual perceives the action and the response occurring substantially simultaneously. For example, the time difference for a response to display (or for an initiation of a display) of data following the individual's action to access the data can be less than 1 millisecond (ms), less than 1 second (s), or less than 5 s. While the requested data need not be displayed (or initiated for display) instantaneously, it is displayed (or initiated for display) without any intentional delay, taking into account processing limitations of a described computing system and time required to, for example, gather, accurately measure, analyze, process, store, or transmit the data.

The terms “data processing apparatus,” “computer,” or “electronic computer device” (or equivalent as understood by one of ordinary skill in the art) refer to data processing hardware and encompass all kinds of apparatus, devices, and machines for processing data, including by way of example, a programmable processor, a computer, or multiple processors or computers. The apparatus can also be, or further include special purpose logic circuitry, for example, a central processing unit (CPU), an FPGA (field programmable gate array), or an ASIC (application-specific integrated circuit). In some implementations, the data processing apparatus or special purpose logic circuitry (or a combination of the data processing apparatus or special purpose logic circuitry) can be hardware- or software-based (or a combination of both hardware- and software-based). The apparatus can optionally include code that creates an execution environment for computer programs, for example, code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of execution environments. The present disclosure contemplates the use of data processing apparatuses with an operating system of some type, for example LINUX, UNIX, WINDOWS, MAC OS, ANDROID, IOS, another operating system, or a combination of operating systems.

A computer program, which can also be referred to or described as a program, software, a software application, a unit, a module, a software module, a script, code, or other component can be written in any form of programming language, including compiled or interpreted languages, or declarative or procedural languages, and it can be deployed in any form, including, for example, as a stand-alone program, module, component, or subroutine, for use in a computing environment. A computer program can, but need not, correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data, for example, one or more scripts stored in a markup language document, in a single file dedicated to the program in question, or in multiple coordinated files, for example, files that store one or more modules, sub-programs, or portions of code. A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network.

While portions of the programs illustrated in the various figures can be illustrated as individual components, such as units or modules, that implement described features and functionality using various objects, methods, or other processes, the programs can instead include a number of sub-units, sub-modules, third-party services, components, libraries, and other components, as appropriate. Conversely, the features and functionality of various components can be combined into single components, as appropriate. Thresholds used to make computational determinations can be statically, dynamically, or both statically and dynamically determined.

Described methods, processes, or logic flows represent one or more examples of functionality consistent with the present disclosure and are not intended to limit the disclosure to the described or illustrated implementations, but to be accorded the widest scope consistent with described principles and features. The described methods, processes, or logic flows can be performed by one or more programmable computers executing one or more computer programs to perform functions by operating on input data and generating output data. The methods, processes, or logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, for example, a CPU, an FPGA, or an ASIC.

Computers for the execution of a computer program can be based on general or special purpose microprocessors, both, or another type of CPU. Generally, a CPU will receive instructions and data from and write to a memory. The essential elements of a computer are a CPU, for performing or executing instructions, and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to, receive data from or transfer data to, or both, one or more mass storage devices for storing data, for example, magnetic, magneto-optical disks, or optical disks. However, a computer need not have such devices. Moreover, a computer can be embedded in another device, for example, a mobile telephone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a global positioning system (GPS) receiver, or a portable memory storage device.

Non-transitory computer-readable media for storing computer program instructions and data can include all forms of media and memory devices, magnetic devices, magneto optical disks, and optical memory device. Memory devices include semiconductor memory devices, for example, random access memory (RAM), read-only memory (ROM), phase change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), and flash memory devices. Magnetic devices include, for example, tape, cartridges, cassettes, internal/removable disks. Optical memory devices include, for example, digital video disc (DVD), CD-ROM, DVD+/−R, DVD-RAM, DVD-ROM, HD-DVD, and BLURAY, and other optical memory technologies. The memory can store various objects or data, including caches, classes, frameworks, applications, modules, backup data, jobs, web pages, web page templates, data structures, database tables, repositories storing dynamic information, or other appropriate information including any parameters, variables, algorithms, instructions, rules, constraints, or references. Additionally, the memory can include other appropriate data, such as logs, policies, security or access data, or reporting files. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

To provide for interaction with a user, implementations of the subject matter described in this specification can be implemented on a computer having a display device, for example, a CRT (cathode ray tube), LCD (liquid crystal display), LED (Light Emitting Diode), or plasma monitor, for displaying information to the user and a keyboard and a pointing device, for example, a mouse, trackball, or trackpad by which the user can provide input to the computer. Input can also be provided to the computer using a touchscreen, such as a tablet computer surface with pressure sensitivity, a multi-touch screen using capacitive or electric sensing, or another type of touchscreen. Other types of devices can be used to interact with the user. For example, feedback provided to the user can be any form of sensory feedback. Input from the user can be received in any form, including acoustic, speech, or tactile input. In addition, a computer can interact with the user by sending documents to and receiving documents from a client computing device that is used by the user.

The term “graphical user interface,” or “GUI,” can be used in the singular or the plural to describe one or more graphical user interfaces and each of the displays of a particular graphical user interface. Therefore, a GUI can represent any graphical user interface, including but not limited to, a web browser, a touch screen, or a command line interface (CLI) that processes information and efficiently presents the information results to the user. In general, a GUI can include a plurality of user interface (UI) elements, some or all associated with a web browser, such as interactive fields, pull-down lists, and buttons. These and other UI elements can be related to or represent the functions of the web browser.

Implementations of the subject matter described in this specification can be implemented in a computing system that includes a back-end component, for example, as a data server, or that includes a middleware component, for example, an application server, or that includes a front-end component, for example, a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described in this specification, or any combination of one or more such back-end, middleware, or front-end components. The components of the system can be interconnected by any form or medium of wireline or wireless digital data communication (or a combination of data communication), for example, a communication network. Examples of communication networks include a local area network (LAN), a radio access network (RAN), a metropolitan area network (MAN), a wide area network (WAN), Worldwide Interoperability for Microwave Access (WIMAX), a wireless local area network (WLAN) using, for example, 802.11 a/b/g/n or 802.20 (or a combination of 802.11x and 802.20 or other protocols consistent with the present disclosure), all or a portion of the Internet, another communication network, or a combination of communication networks. The communication network can communicate with, for example, Internet Protocol (IP) packets, Frame Relay frames, Asynchronous Transfer Mode (ATM) cells, voice, video, data, or other information between networks addresses.

The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what can be claimed, but rather as descriptions of features that can be specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented, in combination, in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations, separately, or in any sub-combination. Moreover, although previously described features can be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination can be directed to a sub-combination or variation of a sub-combination.

Particular implementations of the subject matter have been described. Other implementations, alterations, and permutations of the described implementations are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations can be considered optional), to achieve desirable results. In certain circumstances, multitasking or parallel processing (or a combination of multitasking and parallel processing) can be advantageous and performed as deemed appropriate.

Moreover, the separation or integration of various system modules and components in the previously described implementations should not be understood as requiring such separation or integration in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.

Furthermore, any claimed implementation is considered to be applicable to at least a computer-implemented method; a non-transitory, computer-readable medium storing computer-readable instructions to perform the computer-implemented method; and a computer system comprising a computer memory interoperably coupled with a hardware processor configured to perform the computer-implemented method or the instructions stored on the non-transitory, computer-readable medium.

Claims

1. A system comprising:

a vertically suspended pump assembly configured to pump fluid from an open sump or a closed suction double casing, the vertically suspended pump assembly comprising: a top portion located above-grade at a first end of the vertically suspended pump assembly; a bottom portion located below-grade at a second end of the vertically suspended pump assembly; a motor disposed in the top portion; one or more impellers disposed in the bottom portion and arranged in a stack within a bowl casing, wherein the one or more impellers are driven by the motor so that centrifugal forces are generated within a central passage way between the top portion and the bottom portion of the vertically suspended pump assembly to pump fluid from the open sump or the closed suction double casing upwards through the central passage way, wherein the one or more impellers comprise a first stage impeller at a bottom level of the stack; and

a vibration sensor located at a bottom of the bowl casing or at an inlet casing of the first stage impeller; and

a controller in communication with the vibration sensor and configured to receive, from the vibration sensor, a stream of data encoding one or more vibrational characteristics at the bottom of the bowl casing or at the inlet casing of the first stage impeller so that the vertically suspended pump assembly is monitored in real-time.

2. The system of claim 1, further comprising:

a vibration cable that connects the vibration sensor to the controller.

3. The system of claim 2, further comprising:

a pressurized pipe enclosing the vibration sensor and the vibration cable so that the vibration sensor and the vibration cable are insulated from the fluid.

4. The system of claim 3, further comprising:

a pressure gauge attached to the pressurized pipe and configured to measure a pressure inside the pressurized pipe.

5. The system of claim 4, wherein the pressure inside the pressurized pipe is higher than a pressure of the fluid outside the pressurized pipe.

6. The system of claim 3, further comprising:

a flanged connection comprising two flanges facing each other and connected through a gasket, wherein the flanged connection is located on the pressurized pipe and by the vibration sensor such that, when the flanged connection is opened, the vibration sensor can be inspected.

7. The system of claim 2, further comprising:

a pressurized hose enclosing the vibration sensor and the vibration cable so that the vibration sensor and the vibration cord are insulated from the fluid.

8. The system of claim 7, further comprising:

a pressure gauge attached to the pressurized hose and configured to measure a pressure inside the pressurized hose.

9. The system of claim 8, wherein the pressure inside the pressurized hose is higher than a pressure of the fluid outside the pressurized hose.

10. The system of claim 7, further comprising:

a flanged connection comprising two flanges facing each other and connected through a gasket, wherein the flanged connection is located on the pressurized hose and by the vibration sensor such that, when the flanged connection is opened, the vibration sensor can be inspected.

11. The system of claim 1, wherein the one or more impellers are multi-stage impellers arranged in the stack.

12. The system of claim 1, wherein the vertically suspended pump assembly comprises: a vertically suspended open suction pump, and a vertically suspended closed suction pump.

13. A method for monitoring a vertically suspended pump assembly comprising one or more impellers arranged in a stack within a bowl casing, the method comprising:

placing a vibration sensor at a bottom of the bowl casing or at an inlet casing of a first stage impeller of the one or more impellers;

driving the one or more impellers using a motor so that centrifugal forces are generated within a central passage way of the vertically suspended pump assembly to pump fluid from the open sump or the closed suction double casing upwards through the central passage way;

receiving, from the vibration sensor and on a controller in communication with the vibration sensor, a stream of data encoding one or more vibrational characteristics at the bottom of the bowl casing or at the inlet casing of the first stage impeller; and

monitoring the vertically suspended pump assembly in real-time as fluid is from the open sump or the closed suction double casing upwards through the central passage way.

14. The method of claim 13, further comprising:

connecting, using a vibration cord, the vibration sensor to the controller.

15. The method of claim 14, further comprising:

enclosing, using a pipe or a hose, the vibration sensor and the vibration cable so that the vibration sensor and the vibration cable are insulated from the process fluid.

16. The method of claim 15, further comprising:

pressurizing the pipe or hose so that a pressure inside is higher than a pressure of the process fluid.

17. The method of claim 16, further comprising:

measuring, using a pressure gauge, the pressure inside the pipe or the hose.

18. The method of claim 13, further comprising:

determining, based on, at least in part, the one or more vibrational characteristics, a condition of the vertically suspended pump assembly.

19. The method of claim 18, further comprising:

in response to determining that the condition of the vertically suspended pump assembly is abnormal, causing the vertically suspended pump assembly to stop operation.

20. The method of claim 13, further comprising:

opening a flanged connection by the vibration sensor; and

inspecting the vibration sensor.