Instrumented fracturing pump systems and methods

Abstract

Certain embodiments of the present disclosure generally relate to pumps for conveying fluid at a wellsite. More specifically, some embodiments relate to pumps, such as fracturing or other stimulation pumps, instrumented with sensors to measure or estimate pump parameters. In some instances, pump sensors are used to detect wear or failure or assess remaining useful life of pump components. The sensors can also or instead be used to assess, and in some cases optimize, pump performance. Various additional systems, devices, and methods are also disclosed.

1 - 11 . (canceled) 
     
     
         12 . A method for reducing consumable component wear of at least one fracturing pump, comprising:
 establishing a pump operating envelope, the envelope comprising a plurality of ranges of values of pump operational measurements;   operating the pump;   obtaining, with a processor, an operating value for each of the pump operational measurements;   analyzing, with the processor, the pump operational measurements with respect to the pump operating envelope;   performing, with the processor, at least one action to alter the operation of the pump to ensure the operational measurements are within the operating envelope and thereby reduce the wear of at least one consumable component of the pump.   
     
     
         13 . The method of  claim 12  wherein the at least one fracturing pump comprises a plurality of fracturing pumps each connected to a common supply and discharge. 
     
     
         14 . The method of  claim 12  wherein the values of the pump operating envelope are selected to increase the operational life of a plurality of consumable components of the pump. 
     
     
         15 . The method of  claim 12  wherein the values of the pump operating envelope include an upper limit and a lower limit of discharge pressure, a pump flow rate, a revolutions per minute (RPM) of the pump, a pump plunger size, and a pump output horsepower. 
     
     
         16 . The method of  claim 12  wherein the consumable components of the pump comprises at least one of a ball bearing, a roller bearing, and a sliding bearing. 
     
     
         17 . The method of  claim 12  further comprising calculating, with the processor, a wear rate of at least one of the consumable components. 
     
     
         18 . The method of  claim 12  wherein the pump comprises at least one sensor configured to detect the pump and provide the operating value of at least one of the pump operational measurements. 
     
     
         19 . The method of  claim 18  wherein the at least one sensor comprises an RFID sensor positioned within a housing of the pump. 
     
     
         20 . The method of  claim 19  wherein the RFID sensor at least one passive RFID sensor. 
     
     
         21 . The method of  claim 20  wherein the pump further comprises an RFID access point that is configured to wirelessly power the at least one passive RFID sensor. 
     
     
         22 . The method of  claim 13 , wherein performing at least one action comprises selecting at least one of the plurality of pumps as a reserve pump and not operating the selected reserve pump. 
     
     
         23 . The method of  claim 12  further comprising calculating, with the processor, a wear rate of at least one of the consumable components of the pump. 
     
     
         24 . The method of  claim 23 , wherein performing the at least one action reduces the wear rate of at least one of the consumable components of the pump.