Systems and methods for monitoring a condition of a fracturing component section of a hydraulic fracturing unit

Abstract

Systems and methods to monitor a condition of a fracturing component section including a section frame and a hydraulic fracturing component of a hydraulic fracturing unit to pump fracturing fluid connected to the section frame may include a condition monitoring controller configured to receive one or more signals from one or more sensors configured to be connected to the fracturing component section and generate signals indicative of operating parameters associated with operation of the fracturing component. The condition monitoring controller may be configured to generate, based at least in part on the signals, condition signals indicative of approaching maintenance due to be performed, predicted component damage, predicted component failure, existing component damage, existing component failure, irregularities of component operation, and/or operation exceeding rated operation. The systems and methods also may include exchanging the fracturing component for another fracturing component based at least in part on the condition signals.

1 . A component condition monitoring system to connect to a fracturing component section of a high power hydraulic fracturing unit to pump fracturing fluid into a subterranean formation, the component condition monitoring system comprising:
 a fracturing component section configured to be mounted to a high power hydraulic fracturing unit to pump fracturing fluid, the fracturing component section including a section frame;   a hydraulic fracturing component connected to and supported by the section frame, the section frame including a base that supports the fracturing component section, and one or more guide rails that assist with alignment of the fracturing component section with another fracturing component section;   a plurality of sensors connected to the fracturing component section and positioned to generate one or more signals indicative of operating parameters associated with operation of the fracturing component section; and   a condition monitoring controller connected to the section frame and positioned to:   receive the one or more signals from one or more of the plurality of sensors; and   generate, based at least in part on the one or more signals, condition signals indicative of one or more of approaching maintenance due to be performed, predicted component damage, predicted component failure, existing component damage, existing component failure, irregularities of component operation, or operation exceeding rated operation.   
     
     
         2 . The component condition monitoring system of  claim 1 , wherein:
 the plurality of sensors comprises one or more of a pressure sensor, a vibration sensor, a temperature sensor, or a fluid condition sensor, and the condition monitoring controller is configured to receive signals from the one or more of the pressure sensor, the vibration sensor, the temperature sensor, or the fluid condition sensor; and   identify one or more of excessive pressure, excessive vibration, excessive temperature, fluid contamination, or fluid degradation associated with the fracturing component section.   
     
     
         3 . The component condition monitoring system of  claim 1 , wherein the component condition monitoring system further comprises one or more of:
 an output device configured to communicate with an on-site operator of the fracturing component section; or   a transmitter configured to transmit signals to a location remote from the fracturing component section indicative of the one or more of approaching maintenance due to be performed, predicted component damage, predicted component failure, existing component damage, existing component failure, irregularities of component operation, or operation exceeding rated operation.   
     
     
         4 . The component condition monitoring system of  claim 1 , wherein the high power hydraulic fracturing unit is positioned to receive power from an electrical power source, and the system further comprising the electrical power source being configured also to supply electrical power to the condition monitoring controller, the electrical power source including one or more of one or more batteries, one or more alternators, one or more electrical power generators, or one or more solar panels. 
     
     
         5 . The component condition monitoring system of  claim 1 , wherein the fracturing component section of the high power hydraulic fracturing unit facilitates exchanging the hydraulic fracturing component for another hydraulic fracturing component of the high power hydraulic fracturing unit responsive to the generated condition signals. 
     
     
         6 . A component condition monitoring system to connect to a fracturing component section including a section frame and a hydraulic fracturing component connected to the section frame, the component condition monitoring system comprising:
 a plurality of sensors positioned to connect to the fracturing component section and generate one or more signals indicative of operating parameters associated with operation of the hydraulic fracturing component; and   a condition monitoring controller configured to:   receive the one or more signals from one or more of the plurality of sensors; and   generate, based at least in part on the one or more signals, condition signals indicative of one or more of approaching maintenance due to be performed, predicted component damage, predicted component failure, existing component damage, existing component failure, irregularities of component operation, or operation exceeding rated operation, the section frame including a base that supports the fracturing component section, and one or more guide rails that assist with alignment of the fracturing component section with another fracturing component section.   
     
     
         7 . The component condition monitoring system of  claim 6 , wherein:
 the plurality of sensors comprises one or more of a pressure sensor, a vibration sensor, a temperature sensor, or a fluid condition sensor, and the condition monitoring controller is configured to receive signals from the one or more of the pressure sensor, the vibration sensor, the temperature sensor, or the fluid condition sensor; and   identify one or more of excessive pressure, excessive vibration, excessive temperature, fluid contamination, or fluid degradation associated with the fracturing component section.   
     
     
         8 . The component condition monitoring system of  claim 6 , wherein the component condition monitoring system further comprises one or more of:
 an output device configured to communicate with an on-site operator of the fracturing component section; or   a transmitter configured to transmit signals to a location remote from the fracturing component section indicative of the one or more of approaching maintenance due to be performed, predicted component damage, predicted component failure, existing component damage, existing component failure, irregularities of component operation, or operation exceeding rated operation.   
     
     
         9 . The component condition monitoring system of  claim 8 , wherein the condition monitoring controller is configured to receive electrical power from an electrical power source comprising one or more of one or more batteries, one or more alternators, one or more electrical power generators, or one or more solar panels. 
     
     
         10 . The component condition monitoring system of  claim 6 , wherein the fracturing component section further comprises a section frame to which the hydraulic fracturing component and the condition monitoring controller are attached, and wherein the fracturing component section facilitates exchanging the hydraulic fracturing component of the hydraulic fracturing unit for another hydraulic fracturing component.