Detecting fluid leaks in pressurized systems of waterjet cutting systems

1. A waterjet cutting pressurization system, the system comprising:

a water pump: (i) having a pressurization chamber and (ii) having a high-pressure water seal maintaining water pressure within the chamber; and

a leak detector in fluid communication with the high-pressure water seal and configured to monitor a leak rate of a fluid from the high-pressure water seal, wherein the leak detector is configured to measure a temperature of the fluid.

2. The system of claim 1 , wherein the leak detector is configured to measure a number of discrete drops of the fluid leaking from the high pressure water seal.

3. The system of claim 1 , wherein the leak detector comprises an optical sensor.

4. The system of claim 1 , wherein the pressurization system comprises two or more leak detectors, each leak detector configured to monitor a leak rate of the fluid from a different seal.

5. The system of claim 4 , wherein the pressurization system comprises three or more leak detectors.

6. The system of claim 1 , further comprising a second leak detector coupled to the pressurization chamber.

7. The system of claim 1 , wherein the pressurization chamber is a first pressurization chamber and the water pump has a second pressurization chamber mechanically coupled to the first pressurization chamber.

8. The system of claim 7 , further comprising a second seal maintaining water pressure within the chamber within the second pressurization chamber and a second leak detector configured to monitor a leak rate of the fluid from the second seal within the second pressurization chamber.

9. The system of claim 1 , further comprising a leak collector tray that captures leaks from the water pump and directs them to the leak detector.

10. The system of claim 1 , wherein the leak detector determines a volumetric flow rate of the fluid from the seal.

11. The system of claim 1 , wherein the leak detector is in communication with a computerized controller.

12. The system of claim 1 , wherein the leak detector is in communication with a graphical user interface (GUI).

13. The system of claim 1 , further comprising a fluid flow path coupled to the water pump to convey the fluid from the high-pressure water seal to the leak detector.

14. The system of claim 1 , wherein the system is a high pressure liquid cutting system.

15. The system of claim 1 , wherein the leak detector being configured to monitor a leak rate of a fluid from the high-pressure water seal comprises being configured to detect an extended flow of fluid.

16. A waterjet cutting pressurization system comprising:

an intensifier water pump comprising:

(i) a first pressurization chamber and a first high-pressure seal disposed within the first pressurization chamber; and

(ii) a second pressurization chamber and a second high-pressure seal disposed within the second pressurization chamber; and

a first leak detector fluidly coupled to the first high-pressure seal and configured to monitor a first leak rate of a first fluid from the first high-pressure seal; and

a second leak detector fluidly coupled to the second high-pressure seal and configured to monitor a second leak rate of a second fluid from the second high-pressure seal,

wherein at least one of the first leak detector and the second leak detector is configured to measure a temperature of the first fluid or the second fluid.

17. The waterjet cutting pressurization system of claim 16 , further comprising a fluid flow component coupled to the first pressurization chamber and a third leak detector fluidly coupled to the fluid flow component.

18. The waterjet cutting pressurization system of claim 17 , wherein the first high-pressure seal comprises a high-pressure dynamic seal and the fluid flow component comprises a high-pressure static seal.

19. The waterjet cutting pressurization system of claim 18 , wherein the fluid flow component comprises one of: a check valve, tubing, or a high-pressure fitting.

20. The waterjet cutting pressurization system of claim 16 , further comprising a second fluid flow component coupled to the second pressurization chamber and a leak detector fluidly coupled to the second fluid flow component coupled to the second pressurization chamber.

21. The waterjet cutting pressurization system of claim 20 , wherein the second high-pressure seal comprises a high-pressure dynamic seal and the second fluid flow component coupled to the second pressurization chamber comprises a high-pressure static seal.

22. The waterjet cutting pressurization system of claim 21 , wherein the second fluid flow component coupled to the second pressurization chamber comprises one of: a check valve, tubing, or a high-pressure fitting.

23. An electronic method of determining a flow rate of a fluid leaking from a leaking member within a pressurized chamber of a pump, the method comprising:

providing a drop detector fluidly coupled to the pressurized chamber;

routing drops of the fluid from the leaking member within the pressurized chamber to the drop detector;

measuring, using the drop detector, a number of drops of the fluid expelled from the leaking member and passing by the drop detector;

measuring, using the drop detector, a temperature of the fluid;

sending an electronic signal indicating the number of drops from the drop detector to a computerized controller;

determining, using the computerized controller, an estimated flow rate of the fluid based on the measured number of drops; and

responsive to determining that the estimated flow rate of the fluid exceeds a threshold, issuing a fault signal.

24. The method of claim 23 , wherein the method is performed by a waterjet cutting system.

25. The method of claim 23 , wherein the drop detector comprises an optical sensor.

26. The method of claim 23 , further comprising collecting a series of drops of the fluid in a collection tray prior to the routing of individual drops to the drop detector.

27. The method of claim 23 , wherein the issuing the fault signal comprises providing a signal on a graphical user interface (GUI).

28. The method of claim 23 , wherein the leaking member comprises a chamber seal disposed within the pressurized chamber.

29. The method of claim 23 , wherein the measuring the number of drops includes measuring a change in voltage of an electronic signal generated by a sensor within the drop detector.

30. The method of claim 23 , wherein the fault signal comprises a watch warning in response to determining that the estimated flow rate exceeds a threshold of at least about 5 milliliters per minute.

31. The method of claim 23 , wherein the fault signal comprises an order to replace the leaking member in response to determining that the estimated flow rate exceeds a threshold of at least about 15 milliliters per minute.

32. The method of claim 23 , further comprising: providing a second leaking member disposed in a second pressurized chamber of the pump; providing a second drop detector fluidly coupled to the second pressurized chamber; routing drops of a second fluid from the second leaking member to the second drop detector; measuring, using the second drop detector, a number of drops of the fluid expelled from the second leaking member and passing by the second drop detector; sending an electronic signal indicating the number of drops from the second drop detector to the computerized controller; determining, using the computerized controller, an estimated flow rate of the fluid based on the measured number of drops; and responsive to determining that the estimated flow rate of the fluid exceeds a threshold, issuing a fault signal.

33. The method of claim 23 , wherein the fault signal corresponds to a remaining usable life of the leaking member.

34. The method of claim 23 , wherein the fault signal alerts a user that the leaking member has failed and needs to be replaced.

35. The method of claim 23 , wherein the estimated flow rate of the fluid corresponds to a remaining usable life of the leaking member.

36. A waterjet cutting pressurization system, the system comprising:

a water pump: (i) having a pressurization chamber and (ii) having a high-pressure water seal maintaining water pressure within the chamber; and

a leak detector in fluid communication with the high-pressure water seal and configured to monitor a leak rate of a fluid from the high-pressure water seal, wherein the leak detector is configured to detect a length of individual drops of the fluid.

37. A waterjet cutting pressurization system, the system comprising:

a water pump: (i) having a pressurization chamber and (ii) having a high-pressure water seal maintaining water pressure within the chamber;

a leak detector in fluid communication with the high-pressure water seal and configured to monitor a leak rate of a fluid from the high-pressure water seal; and

a controller configured to determine an estimated flow rate of the fluid based on an estimated volume of a drop of the fluid.

38. A waterjet cutting pressurization system comprising:

an intensifier water pump comprising:

(i) a first pressurization chamber and a first high-pressure seal disposed within the first pressurization chamber; and

(ii) a second pressurization chamber and a second high-pressure seal disposed within the second pressurization chamber; and

a first leak detector fluidly coupled to the first high-pressure seal and configured to monitor a first leak rate of a first fluid from the first high-pressure seal; and

a second leak detector fluidly coupled to the second high-pressure seal and configured to monitor a second leak rate of a second fluid from the second high-pressure seal,

wherein at least one of the first leak detector and the second leak detector is configured to detect a length of individual drops of the first fluid or the second fluid.

39. A waterjet cutting pressurization system comprising:

an intensifier water pump comprising:

(i) a first pressurization chamber and a first high-pressure seal disposed within the first pressurization chamber; and

(ii) a second pressurization chamber and a second high-pressure seal disposed within the second pressurization chamber; and

a first leak detector fluidly coupled to the first high-pressure seal and configured to monitor a first leak rate of a first fluid from the first high-pressure seal; and

a second leak detector fluidly coupled to the second high-pressure seal and configured to monitor a second leak rate of a second fluid from the second high-pressure seal,

wherein at least one of the first leak detector and the second leak detector is configured to determine an estimated flow rate based on an estimated volume of a drop of the first fluid or the second fluid.

40. An electronic method of determining a flow rate of a fluid leaking from a leaking member within a pressurized chamber of a pump, the method comprising:

providing a drop detector fluidly coupled to the pressurized chamber;

routing drops of the fluid from the leaking member within the pressurized chamber to the drop detector;

measuring, using the drop detector, a number of drops of the fluid expelled from the leaking member and passing by the drop detector and a length of individual drops;

sending an electronic signal indicating the number of drops from the drop detector to a computerized controller;

determining, using the computerized controller, an estimated flow rate of the fluid based on the measured number of drops; and

responsive to determining that the estimated flow rate of the fluid exceeds a threshold, issuing a fault signal.

41. An electronic method of determining a flow rate of a fluid leaking from a leaking member within a pressurized chamber of a pump, the method comprising:

providing a drop detector fluidly coupled to the pressurized chamber;

routing drops of the fluid from the leaking member within the pressurized chamber to the drop detector;

measuring, using the drop detector, a number of drops of the fluid expelled from the leaking member and passing by the drop detector;

sending an electronic signal indicating the number of drops from the drop detector to a computerized controller;

determining, using the computerized controller, an estimated flow rate of the fluid based on the measured number of drops and an estimated volume of a drop; and

responsive to determining that the estimated flow rate of the fluid exceeds a threshold, issuing a fault signal.