System and Method for Comprehensive Fracturing Pump Operation Monitoring

Abstract

A system for monitoring a hydraulic fracturing pump includes a first sensor configured to measure a discharge fluid pressure of the pump, a second sensor configured to sense a displacement of a crankshaft of the pump, a processor communicatively coupled to the first and second sensors and configured to analyze the sensor data and determine a cycle count, duty cycle, and operating hour value for the positive displacement pump, and a display coupled to the processor configured to display the cycle count, duty cycle, and operating hour value.

What is claimed is: 
     
         1 . A system for monitoring a hydraulic fracturing pump, comprising:
 a first sensor configured to measure a discharge fluid pressure of the pump;   a second sensor configured to sense a displacement of a crankshaft of the pump;   a processor communicatively coupled to the first and second sensors and configured to analyze the sensor data and determine a cycle count, duty cycle, and operating hour value for the pump; and   a display coupled to the processor configured to display the cycle count, duty cycle, and operating hour value.   
     
     
         2 . The system of  claim 1 , wherein the processor is configured to determine a number of operating hours that the pump is operating at a speed equal or above a predetermined threshold. 
     
     
         3 . The system of  claim 1 , wherein the processor is configured to determine the number of hours the pump is operating within certain fluid discharge pressure ranges. 
     
     
         4 . The system of  claim 1 , wherein the processor is configured to determine the number of cycles the pump is operating within certain fluid discharge pressure ranges. 
     
     
         5 . The system of  claim 1 , wherein the first and second sensor is selected from the group consisting of pressure transducer, strain gauge, pressure sensor, accelerometer, vibration sensor, piezoelectric element, proximity sensor, linear variable displacement transducer, load cell, and flow meter. 
     
     
         6 . The system of  claim 1 , further comprising a wireless communication interface coupled to the processor. 
     
     
         7 . The system of  claim 1 , further comprising a data communication port coupled to the processor. 
     
     
         8 . A system for monitoring a hydraulic fracturing pump having a crankshaft, comprising:
 at least one sensor configured to measure at least one of a discharge fluid pressure of the pump, and a second sensor configured to sense a displacement of a crankshaft of the pump; and   a processor communicatively coupled to the at least one sensor and configured to analyze the sensor data and determine a cycle count, duty cycle, and operating hour value for the pump.   
     
     
         9 . The system of  claim 8 , wherein the at least one sensor is mounted in at least an interior and exterior of the pump and is selected from the group consisting of pressure transducer, strain gauge, pressure sensor, accelerometer, vibration sensor, piezoelectric element, proximity sensor, linear variable displacement transducer, load cell, and flow meter. 
     
     
         10 . The system of  claim 8 , further comprising a display coupled to the processor configured to display the cycle count, duty cycle, and operating hour value. 
     
     
         11 . The system of  claim 8 , wherein the processor is configured to determine a number of operating hours that the pump is operating at a speed equal or above a predetermined threshold. 
     
     
         12 . The system of  claim 8 , wherein the processor is configured to determine the number of hours the pump is operating within certain fluid discharge pressure ranges. 
     
     
         13 . The system of  claim 8 , wherein the processor is configured to determine the number of cycles the pump is operating within certain fluid discharge pressure ranges. 
     
     
         14 . The system of  claim 8 , further comprising at least one wireless communication interface coupled to the processor. 
     
     
         15 . The system of  claim 8 , further comprising a data communication port coupled to the processor. 
     
     
         16 . A method for a comprehensive monitoring of operations of a hydraulic fracturing pump, comprising:
 receiving sensor data from at least one sensor configured to measure at least one of a discharge fluid pressure of the pump and a displacement of a crankshaft of the pump;   analyzing the sensor data and determine a cycle count, duty cycle, and operating hour value for the positive displacement pump;   storing the cycle count, duty cycle, and operating hour value; and   wirelessly communicating the cycle count, duty cycle, and operating hour value to an external device.   
     
     
         17 . The method of  claim 16 , further comprising determining a number of operating hours that the pump is operating at a speed equal or above a predetermined threshold. 
     
     
         18 . The method of  claim 16 , further determining the number of hours the pump is operating within certain fluid discharge pressure ranges. 
     
     
         19 . The method of  claim 16 , further determining the number of cycles the pump is operating within certain fluid discharge pressure ranges. 
     
     
         20 . The method of  claim 16 , wherein receiving sensor data comprises receiving sensor data from at least one sensor selected from the group consisting of pressure transducer, strain gauge, pressure sensor, accelerometer, vibration sensor, piezoelectric element, proximity sensor, linear variable displacement transducer, load cell, and flow meter.