Automated pump truck confirmation test

Abstract

A method of determining a health status of the various components of the pumping equipment on a pump unit may comprise an automatic diagnostic process with one or more diagnostic tests executing on a unit controller. One or more of the diagnostic tests can establish a flow path through the piping network comprising a supply pump and a sensor valve. The diagnostic test can include positioning the sensor valve in a first and second position while operating the pump to communicate a fluid via the flow loop. The method includes comparing a set of results of the diagnostic test to an operational indicator set, determining the health status based upon the comparison, and outputting indicia of the health status of the pumping equipment.

What is claimed is: 
     
         1 . A wellbore servicing method comprising:
 transporting a pump unit to a wellsite, wherein the pump unit comprises a unit controller configured to perform a diagnostic test, wherein the unit controller comprises a processor, a non-transitory memory, and an input output device;   initiating, by the unit controller, a start-up procedure comprising an automatic diagnostic process further comprising at least one diagnostic test selected from the group consisting of a readiness diagnostic test, a liquid supply diagnostic test, and a mix water diagnostic test;   performing the diagnostic test;   determining a set of results of the diagnostic test;   comparing a set of results of the diagnostic test to an operational indicator set,   determining a health status of one or more components of the pump unit based upon the comparison of the set of results of the diagnostic test and the operational indicator set;   initiating a repair and scheduling maintenance of the one or more components of the pump unit in response to a fail status within the health status; or   pumping a wellbore treatment into the wellbore in response to a passing status of the health status of one or more components of the pump unit.   
     
     
         2 . The method of  claim 1 , wherein the readiness diagnostic test comprises a communication check, an operation check, a calibration check, or combinations thereof, wherein the communication check comprises communicating with various components of the pump unit, wherein the operation check comprises actuating the various components, and wherein the calibration check comprises access a calibration file of the various components. 
     
     
         3 . The method of  claim 1 , wherein the liquid supply diagnostic test comprises:
 configuring a flow path comprising a sensor valve and a supply pump, wherein the supply pump provides a flow rate through the sensor valve;   performing the diagnostic test, wherein the diagnostic test comprises:
 positioning the sensor valve in a first, a second, and a third position; 
 operating the supply pump to communicate a fluid via the flow path at full speed; 
 measuring, by the sensor valve, a first periodic dataset while the fluid is communicated via the flow path with the sensor valve in the first position which is a full open position; 
 measuring, by the sensor valve, a second periodic dataset while the fluid is communicated via the flow path with the sensor valve in the second position which is a closed position; and 
 measuring, by the sensor valve, a third periodic dataset while the fluid is communicated via the flow path with the sensor valve in the third position which is a test valve position. 
   
     
     
         4 . The method of  claim 1 , wherein the mix water diagnostic test comprises:
 configuring a flow loop comprising a sensor valve and a supply pump, wherein the flow loop provides a flow rate through the sensor valve;   performing the diagnostic test, wherein the diagnostic test comprises:
 positioning the sensor valve in a first, second, and third position; 
 operating the supply pump to communicate a fluid via the flow loop at full speed; 
 measuring, by the sensor valve, a first periodic dataset while the fluid is communicated via the flow loop with the sensor valve in a first position which is a full open position; 
 measuring, by the sensor valve, a second periodic dataset while the fluid is communicated via the flow loop with the sensor valve in a second position which is a closed position; and 
 measuring, by the sensor valve, a third periodic dataset while the fluid is communicated via the flow loop with the sensor valve in a third position which is a test valve position. 
   
     
     
         5 . The method of  claim 1 , further comprising determining, by the unit controller, a probability of a future maintenance event in response to the set of results of the diagnostic test, a pump usage log, a pump maintenance log, or combinations thereof, and wherein the probability of a future maintenance event is determined by a predictive maintenance model. 
     
     
         6 . The method of  claim 5 , further comprising assigning, by the unit controller, the pump unit to a maintenance schedule at a service center in response to the probability of a future maintenance event. 
     
     
         7 . A computer-implemented method of determining a health status of a pumping equipment system within a wellbore pump unit, the method comprising:
 initiating, by a unit controller, a diagnostic process comprising at least one diagnostic test, and wherein the unit controller comprises a processor, a non-transitory memory, and an input output device;   performing, by the unit controller, the at least one diagnostic test;   determining, by the diagnostic process, a set of results of the diagnostic test;   comparing the set of results of the diagnostic test to an operational indicator set;   determining the health status of the pumping equipment system based upon the comparison; and   outputting, by the unit controller, indicia of the health status of the pumping equipment via the input output device, wherein the indicia of the health status of the pumping equipment comprises a visual cue, and audible cue, or both.   
     
     
         8 . The method of  claim 7 , wherein the at least one diagnostic test comprises:
 configuring a plurality of sensor valves to configure a piping network;   filling the piping network with a volume of water;   operating a pump to establish 1) a flowrate of water, 2) a target pressure value, or 3) both;   measuring, by at least one sensor, a periodic dataset; and   storing the periodic dataset, wherein the periodic dataset is associated with the operation of the pump and the configuration of the piping network.   
     
     
         9 . The method of  claim 7 , wherein the at least one diagnostic test is a liquid supply diagnostic test, wherein the liquid supply diagnostic test comprises:
 configuring a flow path through a piping network by positioning a plurality of sensor valves into a first flow path position;   operating a supply pump at full speed to communicate a fluid via the flow path;   measuring, by at least one sensor, a first periodic dataset of pressure and flowrate while the fluid is communicated via the flow path with the sensor valve in a first position that is fully open; and   measuring, by the at least one sensor, a second periodic dataset of pressure and flowrate with the sensor valve in a second position that is fully closed.   
     
     
         10 . The method of  claim 9 , wherein the liquid supply diagnostic test further comprises:
 operating the supply pump to communicate the fluid via the flow path at full speed; and   measuring, by at least one sensor, a third periodic dataset of pressure and flowrate while the fluid is communicated via the flow path with the sensor valve in a third position.   
     
     
         11 . The method of  claim 8 , wherein the at least one diagnostic test is a mix water diagnostic test, wherein the mix water diagnostic test comprises:
 configuring a flow loop through a piping network by positioning a plurality of sensor valves into a flow loop position;   operating a mix pump at full speed to communicate a fluid via the flow loop;   measuring, by at least one sensor, a first periodic dataset of pressure and flowrate while the fluid is communicated via the flow loop with the sensor valve in a first position that is fully open; and   measuring, by the at least one sensor, a second periodic dataset of pressure and flowrate with the sensor valve in a second position that is fully closed.   
     
     
         12 . The method of  claim 11 , wherein the mix water diagnostic test further comprises:
 operating the mix pump to communicate the fluid via the flow loop at full speed; and   measuring, by at least one sensor, a third periodic dataset of pressure and flowrate while the fluid is communicated via the flow loop with the sensor valve in a third position.   
     
     
         13 . The method of  claim 8 , wherein the operational indicator set comprises a configuration check, a minimum operational capacity, a nominal operational capacity, and a series of failure modes. 
     
     
         14 . The method of  claim 8 , wherein the set of results of the diagnostic test comprises data processing of a periodic dataset to produce a set of averaged values, and wherein one or more of:
 generating the set of results from the data processed periodic datasets,   comparing the set of results of the diagnostic test to the operational indicator set, and   determining the health status of the pumping equipment based upon the comparison of the set of results of the diagnostic test and the operational indicator set is performed via the unit controller.   
     
     
         15 . The method of  claim 14 , wherein one or more of:
 data processing the periodic datasets,   generating the set of results from the data processed periodic datasets,   comparing the set of results of the diagnostic test to the operational indicator set, and   determining the health status of the pumping equipment based upon the comparison of the set of results of the diagnostic test and the operational indicator set is performed via a remote computer.   
     
     
         16 . The method of  claim 15 , wherein the remote computer is disposed in a network location, wherein the network location is one of i) a VNF on a network slice within a 5G core network, ii) a VNF on a network slice within a 5G edge network, iii) a storage computer communicatively coupled to a network via a mobile communication network, or iv) a computer system communicatively coupled to the network via the mobile communication network. 
     
     
         17 . The method of  claim 16 , wherein the network location comprises a database, a storage device, the remote computer, a virtual network function, or combination thereof. 
     
     
         18 . A system of a wellbore pumping unit, comprising:
 a wellbore pumping unit comprising a mixing system;   a unit controller comprising a processor, a non-transitory memory, and an automatic diagnostic process executing in memory, configured to:
 establish a flow path through the mixing system to route fluid communication through a sensor valve via a supply pump; 
 perform a diagnostic test, wherein the diagnostic test comprises:
 selectively positioning the sensor valve in a first position, a second position, and a third position; 
 operating the supply pump to communicate a fluid via the flow path at full speed; 
 measuring, by the sensor valve, a first periodic dataset while the fluid is communicated via the flow path with the sensor valve in the first position; 
 measuring, by the sensor valve, a second periodic dataset while the fluid is communicated via the flow path with the sensor valve in the second position; and 
 measuring, by the sensor valve, a third periodic dataset while the fluid is communicated via the flow path with the sensor valve in the third position; 
 
 compare, by the unit controller or a remote computer, a result of the diagnostic test to an operational indicator set, 
 determine, by the unit controller or the remote computer, a health status of the mixing system based upon the comparison of the result of the diagnostic test and the operational indicator set; and 
 output, by the unit controller, of the health status of the mixing system, wherein the health status of the mixing system a visual cue, and audible cue, or both. 
   
     
     
         19 . The system of  claim 18 , wherein:
 the sensor valve comprises a set of sensors comprising a plurality of pressure sensors, a flowrate sensor, at least one valve position sensors, a tub level sensor, or combinations thereof.   
     
     
         20 . The system of  claim 18 , wherein the wellbore pumping unit is a mud pump, a cement pumping unit, a blender unit, a water supply unit, or a fracturing pump.