Automated land truck pressure testing

Abstract

A method of determining the state of health of various components of pumping equipment on a pump unit may include an automatic diagnostic process performed on a unit controller with one or more diagnostic tests. One or more of the diagnostic tests may establish a flow path through a pipe network that includes a supply pump and a sensor valve. The diagnostic test may include positioning the sensor valve in a first position and a second position while operating the pump to deliver fluid via the flow circuit. The method includes comparing a set of results of the diagnostic test to a set of operational indicators, determining the state of health based on the comparison, and outputting a marker of the state of health of the pumping equipment.

Description

Background Art

[0001] In oil and gas wells, the primary purpose of barrier compositions such as cements or sealants is to isolate formation fluids between layers, also known as zonal isolation and zonal isolation barriers. Cement is also used to support the metal casing lining the well, and cement provides a barrier to prevent fluids from damaging the casing and to prevent fluids from migrating along the casing.

[0002] Typically, an oil well is drilled to a desired depth using a drill bit and a mud fluid system. Metal pipes (e.g., casing, liner, etc.) are lowered into the well to prevent the drilled formation from collapsing. Cement is placed between the casing and the formation through a primary cementing operation. One or more downhole tools may be connected to the casing to assist in the placement of cement.

[0003] In the initial cementing operation, a cement admixture customized for the environmental conditions of the wellbore is pumped into the wellbore. The pumping operation may utilize a pumping equipment that may include multiple components, such as valves and pumping equipment, controlled by a controller. The equipment and multiple components may require routine maintenance, and in some cases, one or more components may need to be repaired. Personnel may perform diagnostic tests on one or more of these components before work, although the data generated about the operation of these components may not necessarily be conclusive about the ability of these components to complete the intended work, nor may it necessarily be data indicating the operating condition of the equipment. An improved method for determining the operating condition of the pumping equipment is needed. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] For a more complete understanding of the present disclosure, reference is now made to the following brief description taken in conjunction with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

[0005] Figure 1 is a diagram of an operating environment at a wellsite according to one embodiment of the present disclosure.

[0006] Figure 2A is a diagram of a pump unit assembly according to one embodiment of the present disclosure.

[0007] Figure 2B is an illustration of a sensor valve having control and monitoring components undergoing diagnostic testing according to one embodiment of the present disclosure.

[0008] Figure 3 is an illustration of a fluid end and pressure manifold according to one embodiment of the present disclosure.

[0009] Figure 4 is a block diagram of a unit controller according to an embodiment of the present disclosure.

[0010] Figure 5A is a diagram of a communication system according to an embodiment of the present disclosure.

[0011] Figure 5B A block diagram of an application within a virtual network function on a network slice according to an embodiment of the present disclosure.

[0012] Fig. 6A is a block diagram of an exemplary communication system according to one embodiment of the present disclosure.

[0013] Figure 6B A block diagram of a 5G core network according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0014] It should be understood at the outset that although illustrative implementations of one or more embodiments are described below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The present disclosure should in no way be limited to the illustrative implementations, drawings, and techniques shown below, but may be modified within the scope of the appended claims and their full scope of equivalents.

[0015] Oil well construction can follow a series of construction phases, including drilling, cementing, and completion or stimulation. Each phase can be carried out using specialized equipment and materials to complete each phase.

[0016] Examples of equipment that can be used at these stages include pumping equipment of various configurations, types, and / or sizes. For example, during the drilling stage, an oil well can be drilled using a drill bit, a mud system, and a mud pump. As the drill bit penetrates the formation, drilling mud is pumped down the drill string to bring the drill cuttings back to the surface, examples of which include reciprocating (e.g., plunger) pumps. Mud pumping equipment may include a mixing system for blending a dry mud admixture with a liquid (e.g., water) to produce a mud slurry.

[0017] Also, for example, during the cementing stage, a cement pump may be used to introduce a cement slurry (e.g., a cement composition) into the annulus formed between the casing and the wellbore. Cement commonly used for cementing oil wells may be Portland cement composed of hydraulic cement having free lime and an alkali ion source, a calcium carbonate source, a calcium sulfate source, and an organic component. A mixing system may blend dry cement with water to produce a cement slurry.

[0018] In another example, during the completion and / or stimulation phase, a blender and a high pressure pump may be used to fracture the formation with a proppant slurry. The blender, also referred to as a blender unit, may include a mixing system for blending proppant (e.g., sand) and water with various additives (e.g., friction reducers) to produce a proppant slurry. The high pressure pump, also referred to as a fracturing unit, may deliver the proppant slurry into the wellbore with sufficient pressure to fracture the formation and deposit the proppant into the fractures.

[0019] The pumping equipment used in each well construction stage may include or be communicatively coupled to a unit controller. The unit controller may include a computer system having one or more processors, a memory, an input device, and an output device. The unit controller may be programmed with one or more pumping programs for mixing and placing for wellbore treatment. The unit controller may be communicatively connected to each component of the pumping equipment, including a mixing system and a main pump. For example, the unit controller may be communicatively coupled to a mixing barrel, a water pump, a plurality of valves, an additive system, a main pump, and a data acquisition system. The unit controller may establish control of each component (e.g., a mixing system) of the pumping equipment, and the data acquisition system provides feedback of the pumping operation. In some cases, the corresponding unit controller associated with two or more pumping equipment assemblies may be communicatively connected so that the pumping equipment assemblies work collaboratively. For example, an agitator and one or more high-pressure pumps may collaboratively deliver proppant slurry to the wellbore.

[0020] Delivery of a wellbore treatment (e.g., cement slurry) from a pumping equipment at a desired flow rate may depend on the health of the mixing system, main pump, control valves, and various components. The health of the pumping equipment may decline based on the cumulative volume of the treatment mixed, the amount of operating time, and / or the number of operations performed. For example, during normal operation of a continuous operation, various components of the mixing system may experience wear and a general decline in operating capacity. Maintenance personnel may perform diagnostic tests on pumping equipment (e.g., a mixing system) before or after work, however, in some cases, the diagnostic tests may be inconclusive, and / or the maintenance personnel may not be able to identify data indicating current or impending problems. Additionally or alternatively, the maintenance personnel may not be able to record or submit diagnostic test results for evaluation. Therefore, there is a need for an improved method for determining the health status of pumping equipment.

[0021] A solution to the problem of determining the state of pumping equipment may include a process for automatically determining the health state of pumping equipment executed in a unit controller. The automatic process may include multiple diagnostic methods (e.g., diagnostic tests) performed on various pumping equipment (e.g., mixing systems) by configuring various systems of the pumping unit to perform predetermined routines while automatically recording the results. In one embodiment, the automatic process can query pumps, valves, and sensors to determine the state. For example, the automatic process can determine whether a flow rate sensor is communicatively connected to the unit controller. In one embodiment, the automatic process can configure one or more pumping equipment components to establish a diagnostic test for at least one pumping equipment component. For example, the automatic process can configure a pipeline network in a pump unit, including setting at least one valve position through a mixing system, operating a pump so that a fluid is transmitted through a pipeline network at one or more predetermined flow rates, and recording data from a sensor during fluid transmission. In one embodiment, the automatic process can configure one or more pumping equipment components to perform diagnostic tests on a pressure manifold and a main pump. For example, the automatic process can isolate the pressure manifold from the mixing system to perform a pressure test on the pressure manifold and record data from a sensor during pressure application. The data from the sensor can be recorded in a data storage location on the unit controller and optionally displayed on a human-machine interface (HMI) (e.g., a display). The data can include pump speed values, valve position values, flow rate data, pressure data, or a combination thereof. The data can be processed to produce a result indicating the health status of the pumping equipment. For example, the result may indicate that the pumping equipment is operating normally, the mixing system or its components require maintenance, the flow rate of the supply pump is below the operating threshold, the pressure manifold cannot obtain the required operating pressure and should be stopped, or a combination thereof. The result can be displayed as a curve, a table, or a simple pass or fail (e.g., a pass / fail status), an error or warning message, or a combination thereof.

[0022] Additionally or alternatively, in one embodiment, the unit controller may cause data and / or results to be wirelessly transmitted between the system and a remote location (e.g., a remote service center). For example, in one embodiment, the unit controller may include or be communicatively coupled to a wireless communication assembly that is capable of wirelessly communicating with a remote service center, such as via a mobile network. In some embodiments, the data may be transmitted to the remote service center for processing to produce results indicative of the health of the hybrid system. Additionally or alternatively, in some embodiments, the results of the flow rate test may be transmitted to a remote location (e.g., a data storage location and / or a remote service center) for record keeping. The unit controller may automatically report the health of the hybrid system at the conclusion of the test.

[0023] In some embodiments, the unit controller may compare the diagnostic test results with a set of operating parameters to determine whether maintenance is required. The monitoring process performed on the unit controller may determine whether maintenance is required on one or more parts of the pumping equipment used for the pumping operation. In some embodiments, the monitoring process may track the type and duration of the wellbore treatment performed by the pumping unit. The diagnostic process may compare the diagnostic test results with a log of the well treatment pumping operation and the type and occurrence of maintenance performed on the pumping equipment. In some embodiments, the unit controller may determine when maintenance is recommended or required based on a predictive model. The predictive model may be based on a historical database of pumping operations. When maintenance is recommended for the pumping equipment, the unit controller may issue an alert to the field personnel via an interactive display. Alerts from the monitoring application may alert the remote service center of the type of maintenance required. The remote service center may place the pumping unit on a maintenance plan. In some embodiments, the remote service center may prompt the unit controller to perform additional diagnostic tests.

[0024] The present invention discloses a method for automating diagnostic testing of pumping equipment. The automated process can actuate and measure various components of the pumping equipment. The automated process can configure a pipeline network to perform diagnostic testing on one or more parts of the pumping equipment while recording data sets from sensors distributed around the network. The automated process can compare the data set log with one or more operating parameters to determine the health status of the pumping equipment. The data set can be transmitted to a service center. A monitoring application can provide a prediction of pumping equipment maintenance based on the diagnostic test and past pumping equipment utilization. The method for automating the diagnostic testing of pumping equipment can improve the reliability of the pumping equipment.

[0025] FIG. 1 illustrates a wellsite environment 10 according to one or more aspects of the disclosed subject matter. The wellsite environment 10 includes a drilling or servicing rig 12 extending above and around a wellbore 16 that penetrates a formation 18 for the purpose of recovering hydrocarbons. Any suitable drilling technique may be used to drill the wellbore 16 into the formation 18. Although the wellbore 16 is not limited to the wellbore 16 of FIG. 1 , the wellbore 16 is not limited to the wellbore 18 of FIG. 1 . Figure 1 14, but the wellbore 16 may also be deviated, horizontal, and / or curved over at least some portions of the wellbore 16. For example, the wellbore 16 or a lateral wellbore portion of the wellbore 16 may have a vertical portion 20, a deviated portion 22, and a horizontal portion 24. Some or all of the wellbore 16 may be cased, open hole, or a combination thereof. For example, a first portion extending from the ground may include a casing string 26, and a second portion may be a wellbore drilled into a formation 28. The main casing string 26 may be placed in the wellbore 16 and at least partially secured by cement 30.

[0026] The service rig 12 may be one of a drilling rig, a completion rig, a workover rig, or other structure, and supports operations in the wellbore 16. The service rig 12 may also include a derrick or other lifting device having a drill floor 32 through which the wellbore 16 extends downwardly from the service rig 12. In some cases, such as in an offshore location, the service rig 12 may be supported by piers extending downwardly to the seabed. Alternatively, the service rig 12 may be supported by columns located on a ballasted hull and / or pontoon below the water surface, which may be referred to as a semi-submersible platform or floating rig. In an offshore location, casing may extend from the service rig 12 to exclude seawater and contain drilling fluid return.

[0027] In one embodiment, the wellbore 16 can be completed by a cementing process, by which cement 30 is set in an annular space 40 between the casing string 26 and the wellbore 16. A pump unit 34, also referred to as a cement pumping device, can be fluidly connected to the wellhead 36 via a supply line 38. The wellhead 36 can be any type of pressure containment equipment connected to the top of the casing string 26, such as a surface Christmas tree, a production Christmas tree, a subsea Christmas tree, a lubricator connector, a blowout preventer, or a combination thereof. The wellhead 36 can anchor the casing string 26 at the ground 14. The wellhead 36 can include one or more valves for directing fluid flow from the wellbore and one or more sensors for collecting pressure, temperature, and / or flow rate data. In operation, the pump unit 34 can pump a volume of cement slurry through the supply line 38, through the wellhead 36, down the casing string 26, and into the annular space 40, and the cement slurry can be specifically customized for the wellbore.

[0028] Cement 30 can be Portland cement or a blend of Portland cement with various additives to customize cement for the wellbore environment. For example, retarders or accelerators can be added to the cement slurry to slow down or accelerate the curing process. In some embodiments, cement 30 can include a polymer designed for high temperatures. In some embodiments, the cement slurry can include additives such as fly ash to change the density of the cement slurry, such as reducing the density.

[0029] The pump unit 34, also referred to as a wellbore pump unit, may include a mixing device 44, a pumping device 46, and a unit controller 48. The mixing device 44 may be in the form of a jet mixer, a circulating mixer, an intermittent mixer, a single-cylinder mixer, or a double-cylinder mixer having a mixing device and a liquid delivery system. The mixing device 44 may combine dry ingredients (e.g., cement) with a liquid (e.g., water) for pumping into the wellbore 16 via the pumping device 46. The liquid delivery system includes a supply pump, a flow control valve, and a sensor. The pumping device 46 may be a centrifugal pump, a piston pump, or a plunger pump. The unit controller 48 may establish control of the operation of the mixing device 44 and the pumping device 46. The unit controller 48 may operate the mixing device 44 and the pumping device 46 via one or more commands received from a maintenance personnel, as will be further described herein. Although the pump unit 34 is shown as a truck, it should be understood that the pump unit 34 may be skid-mounted or trailer-mounted. Although the pump unit 34 is shown as a single unit, it should be understood that there may be 2, 3, 4, or any number of pump units 34 fluidly coupled to the wellhead 36 , for example via a fluid manifold.

[0030] although Figure 1 The embodiments of the present invention describe the wellsite environment 10 in the context of cementing operations, but in additional or alternative embodiments, such as in the context of drilling or completion operations, the wellsite environment 10 may be used in conjunction with a wellbore. Figure 1 The pump unit 34 of the pump unit 34 is similarly arranged and can be a mud pump connected to the wellbore 16 by a supply line 38 to pump a drilling mud slurry or a water-based fluid such as a completion fluid (e.g., a brine completion fluid) into the wellbore 16. The mixing device 44 can be similarly used to blend or mix a dry mud admixture with a fluid such as water or an oil-based fluid. The pumping device 46 can include a piston pump or other suitable type or configuration. The drilling mud slurry or brine completion fluid can be referred to as a wellbore treatment.

[0031] In alternative embodiments, such as in the context of a well completion operation, Figure 1 The pump unit 34 of the embodiment of the present invention may be a blender fluidly connected to one or more high pressure pumping units, also referred to as "frac" pumps, fluidly connected to the wellbore 16 via a supply line 38 to pump wellbore treatments (e.g., fracturing mud) into the wellbore 16. For example Figure 1 The mixing device 44 of the mixing device can be similarly used to blend or mix the proppant (e.g., sand) with a water mixture including one or more additives (e.g., friction reducers or gels) into the fracturing slurry. The pumping device 46 can be a centrifugal pump or a plunger pump. Although in Figure 11, one pump unit 34 is shown, but it should be understood that two or more pump units may be coupled to the wellbore 16 and communicatively coupled through the unit controller 48 to cooperatively pump the wellbore treatment into the wellbore 16. For example, the blender may be fluidly coupled to the wellhead 36 via a fracturing pump. The blender and the fracturing pump may be communicatively coupled through the unit controller 48.

[0032] With reference to Fig. 2, a particular embodiment of the pump unit 34 is shown in more detail as a pump unit 200. In the embodiment of Fig. 2, the pump unit 200 includes a supply tank 202, a mixing system 220, a main pump 206, and at least one power supply 208. The main pump 206 can be a centrifugal pump or a plunger pump. The power supply 208 can include one or more electric, gas-driven or diesel-driven motors, which are coupled to the supply tank 202, the mixing system 220, the main pump 206, and various components such as feed pumps and valves. The power supply 208 can supply electricity to actuate the main pump 206. For example, the power supply 208 can be directly coupled to the main pump 206 by a drive shaft or such as indirectly coupled to the main pump 206 via a power supply. The mixing system 220 can blend a fluid composition of water, dry ingredients (e.g., cement, mud or sand) and other additives for delivery to the wellbore 16 via the main pump 206.

[0033] The pump unit 200 may include a unit controller 240, a data acquisition system (DAQ) card 242, and a display 244. The unit controller 240 may include a computer system including one or more processors, memory, input devices, and / or output devices, wherein one or more processes are executed in the memory and are configured to implement one or more of the methods or protocols disclosed herein, or a portion thereof. The unit controller 240 may be communicatively connected to the pumping device and mixing device of the pump unit 34. The DAQ card 242 may convert one or more analog and / or digital signals into signal data. In various embodiments, the DAQ card 242 may be an independent system having a microprocessor, a memory, and one or more applications executed in the memory, or may be combined or merged into a single assembly with the unit controller 240. For example, when combined into a single assembly, the DAQ card 242 may be combined with one of the input and output devices of the unit controller 240. The display 244 (e.g., an interactive display) may be a suitable configuration of a human-machine interface (HMI) providing an input device and an output device for the unit controller 240. Additional or alternative devices may also be used. The display 244 may include a selectable input screen including icons and selectable keyboard or keypad input for the unit controller 240. The display 244 may display data and information regarding the status and operation of the pump unit 200, including data from the DAQ card 242, to the user.

[0034] The supply tank 202 can store a certain volume of water or other liquids and provide water or liquids for mixing system 220. The supply tank 202 can be connected to a water supply unit, such as a water tank, by a supply line 212, a supply pump 214 and a sensor valve 216. The supply pump 214 can include a centrifugal pump, a piston pump or a plunger pump. The sensor valve 216 can include a flow control valve, such as a stop valve, a pinch valve or a needle valve, which can open, close or regulate the fluid flow inside. The unit controller 240 can provide power and / or control signals such as voltage and current to the sensor valve 216 and the supply pump 214. The supply tank 202 can have one or more sensors, such as a cylinder level sensor, that are communicatively connected to the unit controller 240 via a DAQ card 242.

[0035] The supply valve (eg, sensor valve 216) may be part of a sensor valve assembly. Turning now to Figure 2B , an example of a sensor valve assembly 250 may be shown. In some embodiments, the sensor valve assembly 250 includes a flow valve 252, a valve actuator 254, a flow rate sensor 256, an inlet 258, and an outlet 260. The flow valve 252 may be a stop valve, a pinch valve, a needle valve, a plug valve, or a sliding valve. The valve actuator 254 may be mechanically coupled to the flow valve 252, such as a throttle valve, and communicatively coupled to the unit controller 240. A position sensor on the valve actuator 254 may provide feedback, such as position feedback, to the unit controller 140 via the DAQ 142. In some embodiments, the sensor valve assembly 250 may have one or more sensors communicatively connected to the unit controller 140, including one or more pressure sensors, flow rate sensors, or a combination thereof. For example, the flow rate sensor 256 may be communicatively coupled to the unit controller 140 via the DAQ 242. The sensor valve assembly 250 may include an upstream pressure sensor 264, a downstream pressure sensor 266, or both. An upstream pressure sensor 264 may be located along the inlet 258 and a downstream pressure sensor 266 may be located along the outlet 260 of the flow control valve 150 . The sensor valve 216 may be an embodiment of a sensor valve assembly 250 .

[0036] The sensor can provide feedback of the state and operation of the valve to the unit controller 240. For example, the unit controller 240 can use the valve actuator 154 to open the flow valve 252 to a desired position of 0%, 25%, 50%, 100%, or any position between 0% and 100%. The sensor can provide pressure and / or flow rate measurements corresponding to the fluid flow (e.g., water flow) through the flow valve 252 at a given position. The flow rate sensor 256 can be a turbine flow meter or a Coriolis flow meter. The flow rate sensor 256 can transmit a periodic data set (e.g., a measurement of the flow rate) of the volume flow rate of the fluid passing through the sensor valve 216 to the unit controller 240 via the DAQ card 242.

[0037] In some embodiments, the sensor valve assembly may include a valve, a valve actuator, and a valve position sensor. For example, the sensor valve assembly may be referred to as an isolation valve with an open or closed position or a directional valve that changes a fluid flow path from a first fluid path to a second fluid path. In some embodiments, the sensor valve assembly may include a valve, a valve actuator with a position sensor, and at least one pressure sensor. For example, the sensor valve assembly may include a throttle valve that can inhibit flow when the valve is closed. In some embodiments, the sensor valve assembly may include a flow control valve, a valve actuator with a position sensor, at least one pressure sensor, and a flow control valve. For example, the sensor valve assembly may utilize feedback from a sensor to adjust the flow rate and / or pressure drop through the flow control valve. The term valve assembly may refer to a valve, a valve actuator, one or more valve position sensors, one or more pressure sensors, a flow control valve, or a combination thereof.

[0038] The mixing system 220 may include a mixing drum 204, one or more additive systems 222, and a liquid delivery system 234. The liquid delivery system may connect the supply tank 202 fluid to the mixing drum 204. One or more additive systems 222 may connect a certain volume of liquid additives (such as accelerators, retarders, extenders, fluid loss agents, and viscosity modifiers) to the mixing drum 204. The additive system 222 may include an additive pump 230, an additive valve 232, a flow meter, a volume measurement device, or a combination thereof. The additive pump 230 may be a diaphragm pump, a piston pump, or a centrifugal pump. The additive valve 232 may be a switch valve, such as a ball valve or a plug valve. Each additive pump 230 may be communicatively coupled to a corresponding flow meter and a unit controller 240 via a DAQ card 242. The unit controller 240 may dispense a predetermined volume of additives by controlling the additive pump 230 and the additive valve 232 using feedback from the flow meter. The liquid delivery system 234 includes a supply pump 224 and a sensor valve assembly 270, such as a flow control valve. Liquid delivery system 234 can supply liquid, such as water, of a predetermined flow rate to mixing drum 204. Unit controller 240 can change the volumetric rate of liquid (e.g., water) by using valve positions of supply pump 224 and sensor valve 270 in response to data from one or more sensors (e.g., flow meter). Mixing system 220 can include a mixing valve 226, such as a sensor valve, referred to as mixing valve 226, located between mixing drum 204 and main pump 206. Mixing valve 226 (e.g., sensor valve) can be a flow control valve or an isolation valve, such as a ball valve or a plug valve. In some embodiments, liquid delivery system 234 can supply water via supply pump 214 and supply line 212. Sensor valve 270 can be an embodiment of sensor valve assembly 250.

[0039] In some embodiments, the mixing system 220 includes a flow circuit 274. The flow circuit 274 may include a first sensor valve 272, a mixing pump 284, a return line 262, and a second sensor valve 268. The unit controller 240 may configure the flow circuit 274 by opening the first sensor valve 272 and the second sensor valve 268 to fluidly connect the return line 262 to the mixing drum 204. The mixing pump 284 (e.g., a supply pump) and at least one valve (e.g., a sensor valve 272) may be configured by the unit controller 240 to supply a desired fluid flow rate through the flow circuit 274. The sensor valve 272 may be an embodiment of the sensor valve assembly 250.

[0040] In some embodiments, the return line 278 can connect the mixing drum 204 fluid to the supply line 212. For example, the unit controller 240 uses the third sensor valve 276 and the fourth sensor valve 218 to configure the flow path to the supply line 212 via the return line 278. In some embodiments, the return line 278 can be part of the fluid manifold of the pump unit 200, such as a permanently installed high-pressure pipeline. In some embodiments, the return line 278 can be a temporary line installed by maintenance personnel, such as a flexible hose. The return line 278 can provide a flow path for returning or circulating the fluid flow through the pump unit 200.

[0041] The main pump 206 can be configured according to the operation in which it will be employed. For example, the main pump 206 can be a centrifugal pump, a piston pump, or a plunger pump. For example, in the context of cementing operations, the main pump 206 can be a centrifugal pump. In another scenario, the cementing operation can utilize a high pressure pump, such as a plunger pump, as the main pump 206. The slurry mixed in the mixing drum 204 can be transferred to the main pump 206 via the feed manifold for pressurization, and the main pump can deliver the treatment fluid through the discharge manifold. Now turn to Figure 3 , depicts a diagram of a pressure manifold 300 of a pump unit 200. In some embodiments, the pressure manifold 300 may include a feed manifold 310, a discharge manifold 312, a sensor valve 314, and a discharge hub 316. The feed manifold includes a high pressure line 326, a feed header 328, and a feed line 322 coupled to a fluid end 320 of the main pump 206. The fluid end 320 of the main pump 206 typically has three plungers, so there may be three feed lines coupled to the feed header 328, for example, feed lines 322A to 322C. Similarly, the discharge manifold 312 includes three discharge lines 324A to 324C coupled to a discharge header 332. The discharge manifold 312 may be coupled to a sensor valve 314 and a discharge hub 316. The sensor valve may be communicatively coupled to the unit controller 240.

[0042] Feed manifold 310 may be fluidly connected to mixing drum 204 via high pressure lines 326 and mixing valve 226. Feed manifold 310 may receive wellbore treatment fluid, such as cement slurry, from mixing drum 204 and distribute the fluid to each plunger / pressure chamber within fluid end 320 of main pump 206.

[0043] The discharge manifold 312 may receive pressurized fluid from the fluid end 320 via discharge lines 324A-324C and a discharge header 332. The pressurized fluid may travel through the discharge hub 316 to the high pressure line 336. In some embodiments, the high pressure line may be coupled to a wellhead. Return to Reference Figure 1 , the pumping equipment 46 of the pump unit 34 can deliver the pressurized fluid to the wellhead 36 via the supply line 38. Figure 3As shown, the high pressure line 336 can be coupled to a test block 340 and a sensor valve 342. The test block 340 can include a pressure transducer 344 communicatively coupled to the unit controller 240 for testing the pressure manifold 300, as will be described below. The sensor valve 342 can be communicatively connected to the unit controller 240. In some embodiments, the sensor valve 342 can be an isolation valve with or without a pressure sensor.

[0044] like Figure 3 As shown, the pump unit 200 can be a dual pump unit, which includes two mixing systems 220A to 220B, two supply tanks 202A to 202B, two mixing drums 204A to 204B and two main pumps 206A to 206B. The operation of the mixing system 220A can be independent of the mixing system 220B, and therefore the mixing drum 204A can be operated independently of the mixing drum 204B. The pressure manifold 300 can be configured to output only the maintenance fluid from the mixing system 220A or the maintenance fluid from the mixing system 220B using the operation of the sensor valves 314A and 314B. For example, the sensor valve 314B can be closed and the sensor valve 314A can be opened to guide the output of the mixing drum 204A via the main pump 206A through the discharge hub 316 so as to be delivered to the wellhead via the high pressure pipeline 336. Pressure manifold 300 may be configured with both sensor valves open to combine main pump 206A output with main pump 206B output at discharge hub 316 for delivery to a wellhead, such as wellhead 36 , via high pressure line 336 .

[0045] Although the pump unit 200 of FIG. 2 can be described as a cement pumping unit having a supply tank 202 (also referred to as a clean side) and a mixing drum (also referred to as a dirty side), the pump unit 200 can be configured as a dual mixing cylinder blender and / or a cementing unit. As a dual mixing cylinder blender, the mixing system 220 can be doubled by replacing the supply tank 202 with a second mixing drum 204B, a second flow loop 274B, and a second additive system 222B. The dual cylinder blender can mix or blend two volumes of wellbore treatments at the same time, or mix a portion of the treatments in one mixing tank so as to be transferred to a second mixing tank for blending additional materials into the treatment fluid. In some embodiments, the pump unit 200 can be a dual pump unit having a dual mixing cylinder blender with a total of four mixing drums or two mixing systems 200A to 200B with four mixing tanks 204A to 204D.

[0046] Although the pump unit 200 of FIG. 2 is described as a cement pumping unit, it should be understood that the pump unit 200 can be a mud pump, an admixture, a fracturing pump, or a water supply unit. Each type or configuration of the pump unit (e.g., a mud pump, a cement pump unit, an admixture, a fracturing pump, or a water supply device) can include a main pump (e.g., a main pump 206), a sensor valve (e.g., a sensor valve 270), and a unit controller (e.g., a unit controller 240). The unit controller (e.g., the unit controller 240) can receive periodic pumping data and can be communicatively connected to one or more main pumps 206. In some embodiments, the pump unit (e.g., the pump unit 200) can work in conjunction with at least one or more pump units. In some embodiments, the pump unit 200 can be communicatively connected to a control system at the well site and controlled by the control system.

[0047] In some embodiments, a wellbore servicing method may include providing a wellbore treatment via a pump unit, following a prescribed pumping procedure for placing the wellbore treatment at a target location within the wellbore. The wellbore treatment placed while performing the pumping procedure may include a treatment admixture (e.g., a cement admixture), a liquid admixture (e.g., water with additives), or a combination thereof, and may be placed via one or more downhole tools.

[0048] In one embodiment, a wellbore servicing method may include replacing a pump unit (e.g., Figure 1 The pump unit 34 may be transported to the wellsite environment 10. The pump unit 34 may be positioned at the wellsite environment 10 and a maintenance person may prepare the pump unit for pumping operations. Before coupling the pump unit 34 to the wellhead 36, a maintenance person may initiate an automated diagnostic process via the unit controller 48. In some embodiments, the unit controller 48 may initiate an automated diagnostic process as part of a startup process.

[0049] In some embodiments, diagnostic tests for determining the health of the pumping equipment may be initiated prior to a wellbore servicing operation, upon completion of a wellbore servicing operation, upon prompting by a service center, or a combination thereof. For example, the diagnostic test may be included in a startup procedure for the pump unit 34. When a diagnostic test is to be performed, the unit controller 48 may automatically initiate the diagnostic test or may prompt a user (e.g., a servicer) to initiate the diagnostic test. In one embodiment, for example, if the diagnostic test is not completed, the pumping unit 34 may be prohibited from completing a startup or shutdown procedure, such that the pumping unit 34 cannot be used to perform a wellbore servicing operation until the diagnostic test is completed.

[0050] In some embodiments, the results of the diagnostic test can be output, for example, as an alert provided to maintenance personnel, such as a pass / fail mark, a text message, or a combination thereof. For example, in one embodiment, a "fail" state can be notified to maintenance personnel, which can be the result of the diagnostic test. Additionally or alternatively, the fail state can be caused by the loss of a system performance file including the results of the diagnostic test, the corruption of the system performance file, or the inaccessibility of the system performance file. In various embodiments, the alert provided to the maintenance personnel can be generated by the unit controller 240, such as a remote computer executed at a network location, or a combination thereof, as will be further disclosed below. Additionally or alternatively, the results of the diagnostic test can form the basis for an action. For example, in the case where the pumping unit 200 has been assigned a fail state, the unit controller 240 can prohibit the operation of the pumping unit 200 until a diagnostic test has been performed and the pumping unit 200 has been assigned a pass state, until the pumping unit is repaired, and so on.

[0051] The automatic process may include multiple diagnostic methods for determining the health status of the pumping equipment of the pumping unit (e.g., pumping unit 200). In some embodiments, the automatic process may perform multiple diagnostic methods in a predetermined order. For example, a first diagnostic method (e.g., a diagnostic test) may be followed by a second diagnostic method and a third diagnostic method. The latter diagnostic method may include components tested during the previous diagnostic method. For example, the third diagnostic method (e.g., a diagnostic test) may include components tested during the first diagnostic method and the second diagnostic method, such as a valve. In some embodiments, the automatic process executed on the unit controller 240 may query the status of the communication device. Turning to Figure 5, the automatic process may perform a ready diagnostic method to determine the operating status of the connected components of the pumping equipment. The operating status may include a communication status, an operating status, and a calibration status. The ready diagnostic method of the automatic process may query the network device 588 and the long-range radio transceiver 590 to determine whether the unit controller 240 is communicatively connected to a network, such as a local area network and / or a wireless communication network. The unit controller 240 may be communicatively connected to a user device, such as a laptop, a second pumping unit, a control cart directing multiple pumping units, a computer system at a service center, a process at a remote location, a computer system at a remote location, a network location, or a combination thereof. If the readiness diagnostic method is unable to communicate with the network device 588 and / or the radio device 590, the readiness diagnostic method may return a fault for the communication status. If the network device 588 and / or the transceiver 590 is unable to communicatively connect to the local area network or the wireless communication network, the readiness diagnostic method may return a fault for the operational status.

[0052] In some embodiments, an automatic process executed on the unit controller may query the status of various components of the pumping equipment via DAQ 242. The automatic process may perform a readiness diagnostic method to determine the operating status of the connected components of the pumping equipment. The operating status may include a communication status, an operating status, and a calibration status. The readiness diagnostic method of the automatic process may query devices that are communicatively coupled to the analog input 594, the frequency input 596, and the Modbus input 598. For example, the readiness diagnostic method may query the tank level sensor on the mixing drum 204 and / or the supply tank 202 via the analog input 594. In another scenario, the diagnostic method may query multiple flow meters, such as the sensor valve 272 or the sensor valve 270, via the frequency input 596. In yet another scenario, the diagnostic method may query the valve actuator 254 and / or the position sensor via the Modbus input 198. If the readiness diagnostic method cannot communicate with the sensor (e.g., the valve sensor 272), the readiness diagnostic method may return a fault for the communication status. The readiness diagnostic method may actuate various components of the pumping equipment to determine the operating status. For example, the readiness diagnostic method can actuate the valve from a first position to a second position, for example, from a 100% open position to a 0% open position. If the data set from the valve position sensor is outside the expected or operational data set, the readiness diagnostic method can return a fault for the operational state. Some components of the pumping equipment can access calibration files during normal operation. For example, each flow meter can have a calibration data set based on fluid flow. In another example, the valve position sensor can have a calibration data set that associates the valve angle position (e.g., 3 degrees) with the valve operating position (e.g., 0% open or closed position). If the calibration file is not found, damaged or marked as a fault, the readiness diagnostic method can return a fault. The readiness diagnostic can return success or failure for the operational state of each component in the components of the pumping equipment. In some embodiments, the readiness diagnostic can record the operational state to a file in the memory 520 and / or the auxiliary storage device 522. In some embodiments, the operational state can be transmitted to a remote location, for example, a storage computer, via a transceiver 590 and / or a network device 588. The readiness diagnostics may provide maintenance personnel with an indication of the operational status of the various components of the pumping equipment via text, messaging, email alerts, display 244, or a combination thereof. A pass or fail result of the readiness diagnostics may be referred to as a readiness check.

[0053] In some embodiments, the readiness diagnostic method may be performed during a second or subsequent diagnostic method performed by an automated process. In some embodiments, the automated diagnostic method may perform a liquid supply diagnostic to determine the operating state of the liquid delivery system 234. The liquid supply diagnostic may determine the operating state of the supply pump 214, the supply pump 224, and the sensor valve 270 by circulating water through one or both supply pumps. The liquid supply diagnostic may establish a first flow path through a network of pipes within the pumping unit 200 to deliver water flow from the supply tank 202 through the sensor valve 270, and return the water to the supply tank 202 by setting the valves (e.g., positioning the plurality of valves to an open or closed position). For example, the liquid supply diagnostic may open (e.g., 100% open position) the sensor valves 216, 270, 226, and 276 while closing the sensor valves 272 and 268. This configuration of the sensor valves may be referred to as a first flow path position. The piping network can be configured to circulate water through the supply pump 214, the sensor valve 216, the supply tank 202, the sensor valve 270, the mixing drum 204, the mixing valve 226, the sensor valve 276, the return line 278 and back to the supply pump 214. In some embodiments, maintenance personnel may need to connect a temporary line, such as a flexible line, for the return line 278. The liquid supply diagnostic can operate the supply pump 214 to fill the supply tank 202 and the mixing drum 204 with a certain volume of water from the supply line 212. In some embodiments, the liquid supply diagnostic can prompt the maintenance personnel to supply water via operating the supply pump 214. The tank level sensor on the supply tank 202 can provide feedback to the unit controller 240 on the volume of water delivered by the supply pump 214. In some embodiments, the readiness diagnostic method can operate during or in coordination with the liquid supply diagnostic of filling the pump unit 200 with water. For example, the readiness diagnostic method can query the supply pump 214 at the beginning of the filling process. In another scenario, the readiness diagnostic method can query the valve before and / or during actuation to establish the piping network. The liquid supply diagnostic can actuate one or more valves (e.g., sensor valve 280) at the end of the filling process to establish a network of pipes that returns a volume of water flowing through the network to the supply tank. The liquid supply diagnostic can perform diagnostic tests on the health of the liquid delivery system 234 using the pump unit 200 supplied with a volume of water.

[0054] As used herein, the term "health" when used with reference to the supply pump 214, the supply pump 224, the mixing pump 284, the main pump 206, or a plurality of sensor valves may refer to the ability of the pumping equipment to transfer liquid to the mixing drum 204 for admixture of wellbore treatments and / or delivery to the wellhead according to a specified operating capacity. The operating capacity of the pumping equipment may be described as the fluid output, e.g., pressure and flow rate, from the supply tank 202 to the mixing drum 204, to the main pump 206, and to the wellhead via the various supply pumps and sensor valves. In one embodiment, the determination of the health of the mixing system 220 may include a determination that the mixing system 220 has achieved an operating capacity according to the needs of the current or expected pumping operation and / or a determination that the mixing system 220 has achieved at least a minimum operating capacity. In one embodiment, the determination of the health of the supply pump 224 may include a determination that the supply pump 224 has achieved an operating capacity according to the needs of the current or expected pumping operation and / or a determination that the supply pump 224 has achieved at least a minimum operating capacity. In one embodiment, the determination of the health of the hybrid system 220 may include a determination that the hybrid pump 284 has achieved operating capacity as required by current or anticipated pumping operations and / or a determination that the hybrid pump 284 has achieved at least a minimum operating capacity. In one embodiment, the determination of the health of the main pump 206 may include a determination that the main pump 206 has achieved operating capacity as required by current or anticipated pumping operations and / or a determination that the main pump 206 has achieved at least a minimum operating capacity.

[0055] In some embodiments, the liquid supply diagnostic can perform a diagnostic test on the health of the liquid delivery system 234 by circulating a volume of water through the pipe network as previously described. The liquid supply diagnostic can establish a water circulation through the pipe network at the maximum operating capacity of the supply pump 214 (e.g., full speed or 100% RPM) while bypassing the supply pump 224 (bypass not shown). The liquid supply diagnostic can receive a periodic data set indicating pumping operation from sensors (e.g., pressure sensors and flow sensors at sensor valve 216 and sensor valve 270). The liquid supply diagnostic can compare the pressure and flow rate of the water passing through the sensor valve 216 with a set of operating capacity thresholds. The liquid supply diagnostic can close the sensor valve 216 while operating the supply pump 214 at maximum capacity to determine the maximum pressure output of the supply pump 214. The diagnostic process can compare the pressure output with a set of operating capacity thresholds. The periodic data sets and comparisons of the data sets to the set of operating capacity thresholds may be i) saved to memory, ii) saved to secondary storage device 522, iii) transmitted to a remote location via transceiver 590 and / or network device 588, iv) sent as an alert to maintenance personnel, v) provided as a flag to maintenance personnel via display 244, or vi) a combination thereof.

[0056] In some embodiments, the liquid supply diagnostic can utilize the supply pump 224 and the sensor valve 270 to perform the previously described diagnostic tests. By establishing a flow bypass (not shown) around the supply pump 214, the flow path through the pipe network can bypass the supply pump 214. The liquid supply diagnostic can establish a water circulation that circulates through the pipe network at the maximum operating capacity of the supply pump 224 while receiving periodic data sets indicative of pumping operation from sensors located at the sensor valve 270 and various other locations (e.g., the mixing valve 226). The liquid supply diagnostic can close (e.g., 0% open) the sensor valve 270 with the supply pump 224 operating at maximum capacity to determine the maximum pressure output of the supply pump 224. The liquid supply diagnostic can compare the pressure and flow rate of the water through the sensor valve 216 and the maximum pressure output to a set of operating capacity thresholds. The periodic data sets and comparisons of the data sets to the set of operating capacity thresholds may be i) saved to memory, ii) saved to secondary storage device 522, iii) transmitted to a remote location via transceiver 590 and / or network device 588, iv) sent as an alert to maintenance personnel, v) provided as a flag to maintenance personnel via display 244, or vi) a combination thereof.

[0057] In some embodiments, the liquid supply diagnostics may actuate one or more sensor valves to various valve positions while circulating water with the supply pump 224. For example, when the supply pump 224 is operated at maximum capacity and / or maximum revolutions per minute (RPM), the liquid supply diagnostics may position the sensor valves to 25% open, 50% open, 75% open, and 100% open. In some embodiments, the liquid supply diagnostics may actuate the sensor valve 270 between the supply tank 202 and the mixing drum 204 to various positions while receiving periodic data sets indicating pumping operations from the sensor valve 270. In some embodiments, the liquid supply diagnostics may actuate the mixing valve 226 between the mixing drum 204 and the return line 278 to various positions while receiving periodic data sets indicating pumping operations from the mixing valve 226 (e.g., the sensor valve). The diagnostic process may compare the pressure and flow rate outputs of the sensors to a set of operating capacity thresholds. The periodic data sets and comparisons of the data sets to the set of operating capacity thresholds may be i) saved to memory, ii) saved to secondary storage device 522, iii) transmitted to a remote location via transceiver 590 and / or network device 588, iv) sent as an alert to maintenance personnel, v) provided as a flag to maintenance personnel via display 244, or vi) a combination thereof.

[0058] Although the fluid supply diagnostics are described as actuating the sensor valve 270 and the mixing valve 226 , it should be appreciated that the diagnostic process may perform diagnostic routines on any number of valves (eg, the sensor valve 216 ).

[0059] In some embodiments, the mixed water diagnostic process can perform diagnostic tests on the health of the mixed water system 286 by circulating a certain volume of water through the flow loop 274. The diagnostic process can configure multiple valves to establish the flow loop 274 and isolate the flow loop 274 from the liquid delivery system 234. For example, the diagnostic process can close (e.g., set the valve to 0% open) the sensor valve 270 and the mixing valve 226, and open (e.g., 100% open) the sensor valve 272 and the sensor valve 268. This configuration of multiple sensor valves can be referred to as a flow loop position. The mixed water diagnostic can establish the circulation of water through the flow loop 274 at the maximum operating capacity of the mixing pump 284. The mixed water diagnostic process can receive periodic data sets indicating pumping operation from sensors (e.g., pressure and flow rate sensors at the sensor valve 272 and the sensor valve 268). The diagnostic process can compare the pressure and flow rate of water passing through the sensor valve 272 and / or the sensor valve 268 with a set of operating capacity thresholds. The liquid supply diagnostic may close the sensor valve 268 while operating the mixing pump 284 at maximum capacity to determine the maximum pressure output of the mixing pump 284. The diagnostic process may compare the pressure output to a set of operating capacity thresholds. The periodic data set and the comparison of the data set to the set of operating capacity thresholds may be i) saved to memory, ii) saved to the auxiliary storage device 522, iii) transmitted to a remote location via the transceiver 590 and / or the network device 588, iv) sent as an alert to maintenance personnel, v) provided as a flag to maintenance personnel via the display 244, or vi) a combination thereof.

[0060] In some embodiments, a method for determining the health status of pumping equipment (e.g., a liquid delivery system or a mixing water system) may generally include the following steps: preparing the pumping equipment (e.g., mixing system 220) for diagnostic testing, running the diagnostic test and collecting multiple periodic data sets, evaluating the multiple periodic data sets, and determining the health status of the pumping equipment based on the results of the evaluated data sets.

[0061] In some embodiments, the diagnostic process can prepare various components of the pumping equipment for diagnostic testing by filling or otherwise providing fluid to the pipe network. For example, the unit controller 240 can control the components of the pumping unit 200 to fill the pipe network by placing a certain volume of water in the supply tank 202 and / or the mixing drum 204 via the supply pipeline 212. For example, the unit controller 240 can open the sensor valve 216 and operate the supply pump 214 to fill the supply tank 202 and the mixing drum 204 until the cylinder level sensor in one or both locations indicates that the supply tank 202 or the mixing drum 204 is filled with water. For example, the unit controller 240 can fill the supply tank 202 and the mixing drum 204 until at least one cylinder level sensor indicates that one or both tanks are 40%, 45%, 50%, 55%, 60% or any portion of the water level between 15% and 100% of the cylinder's fill capacity. The unit controller 240 can stop the supply pump 214 and configure one or more valves so that the pumping unit such as Figure 2A In some embodiments, a readiness diagnostic process may be performed on various components of the pumping equipment prior to or in coordination with filling the pipe network with a volume of water.

[0062] In some embodiments, running the diagnostic test may include operating the mixing system 220, the liquid delivery system 234, and / or the mixing water system 286 to circulate a fluid (e.g., water) through the pipe network and / or the flow loop 274 at multiple flow rates and / or pressures to generate multiple periodic data sets (which generally include data indicative of the performance of the pumping equipment or its components). In various embodiments, any suitable protocol suitable for generating multiple periodic data sets may be employed, although examples of protocols are disclosed herein.

[0063] The pumping of wellbore maintenance fluid may cause leakage by eroding the sealing ability of the seal and fatigue the installed connection, thereby slowly degrading the pumping equipment. Leakage can cause loss of pump pressure, reduced operating capacity, and in some cases, leakage of the treatment fluid from the pump unit. The automatic process can include a leak detection diagnostic process for the pipeline network, the main pump 206, the high pressure manifold coupled to the main pump 206, or a combination thereof. In some embodiments, the hybrid system leakage diagnostic process can perform diagnostic tests on the health of the mixed water system 286 by applying a static pressure level and monitoring the hybrid system 220 within a predetermined time period. The diagnostic test can determine the pressure value used in the test based on the nominal operating valve, the maximum operating valve, or the pending operating value, for example, the target test pressure. For example, the pending operating value can be based on the need for the current or expected pumping operation of the pump unit 200. In some embodiments, the hybrid system leakage diagnostic process can access the pumping program including the steps (also referred to as stages) of the current pumping operation to determine the pending operating value. In some embodiments, the diagnostic process can prompt the maintenance personnel with the expected pumping pressure of the current and / or expected pumping operation, for example, the pending operating value. The diagnostic process can determine the target test pressure by identifying the maximum pumping pressure from the pumping program or maintenance personnel and applying a safety factor. For example, the diagnostic process can determine the target test pressure by adding a safety factor (e.g., 1,000 psi) to the pending operating value.

[0064] In some embodiments, the ready diagnostic process can be performed before or in coordination with the mixed system leak diagnostic. In some embodiments, the diagnostic process can establish a flow path through the pipe network and fill the mixed system 220 with a certain volume of water, as previously described. In some embodiments, the mixed system leak diagnostic process can circulate water through the pipe network for a predetermined period of time. In some embodiments, the diagnostic process can close the sensor valve 276 to isolate the return line 278 and open the supply line 212 leading to the water source. In some embodiments, the mixed system leak diagnostic can utilize the supply pump 214 to apply a predetermined pressure value (e.g., test pressure) to the mixed system 220. In this scenario, the leak diagnostic can apply a test pressure to the inlet manifold of the supply tank 202, the liquid delivery system 234, the mixing drum 204, the mixed water system 286, and the main pump 206, as described below. In some embodiments, the leak diagnostic process can close the mixing valve 226 to exclude the inlet manifold of the main pump 206 from the mixed system 220. In some embodiments, the leak diagnostic can utilize the supply pump 224 to apply a test pressure to exclude the supply tank 202 from the mixed system 220 pressure test.

[0065] The hybrid system leak diagnostics can determine the health of the hybrid system 220 by identifying the presence or absence of a leak using a pressure detection protocol. The leak diagnostics can identify a pending operating value, a target test pressure, and an emergency release value. The pending operating value can be an expected working pressure. The target test pressure can be the expected working pressure plus a safety factor, for example, 1,000 psi. The emergency release value (ERV) can be based on the target test pressure or the maximum operating pressure. For example, the ERV can be the target test pressure plus a safety factor, for example, 1,500 psi. The leak diagnostics can stop a pump (e.g., a supply pump), open a valve (e.g., a sensor valve 276), or a combination thereof in response to the measured pressure within the hybrid system 220 reaching or exceeding the ERV. In some embodiments, the pending operating value can be a nominal operating value, for example, an average operating pressure of the pump unit 200. In some embodiments, the pending operating value can be a maximum allowable operating pressure, for example, a maximum working pressure. In some embodiments, the target test pressure can be the maximum test pressure of the pumping unit 200. In some embodiments, the ERV value can be a target test pressure or a maximum test pressure of the pumping unit 200.

[0066] The hybrid system leak diagnostic can apply pressure to the hybrid system 220 using a valve configured as described above. The leak diagnostic can set the ERV to a pressure value consisting of a target test pressure plus a safety factor. In some embodiments, the leak diagnostic can increase the pressure level within the hybrid system 220 in step values. For example, the leak diagnostic can increase the pressure level to 25%, 50%, or 75% of the target pressure valve and maintain the step value for a predetermined period of time. In another scenario, the leak diagnostic can increase the pressure level within the hybrid system 220 to 50% of the target pressure and maintain the step pressure for 10 minutes. The application of the step pressure hold can determine a leak at a pressure lower than the target test pressure, for example, a health condition. The leak diagnostic can increase the pressure level within the hybrid system 220 to the test pressure value. The hybrid system diagnostic can receive a periodic data set indicating the health condition of the hybrid system 220 during a predetermined target pressure hold time. The diagnostic process can determine the health condition of the hybrid system 220 by comparing the pressure response to a pressure test threshold, also known as a pass / fail criterion. The pressure response of the hybrid system 220 can be a reduction in the pressure value within a certain period of time (e.g., the target pressure hold time). It can be expected that there will be an initial pressure loss because the seals in the pumping equipment will move and / or deflect when in contact with the sealing surface. For example, due to the applied pressure (e.g., target pressure), the seals on the access port of the supply tank 202 can deflect 10% to 80% when in contact with the sealing surface. The diagnostic process can actuate the supply pump 214 to compensate for the initial pressure loss. The diagnostic process can monitor the pressure response via a periodic data set from the sensor valve 216, 270, 226 or other pressure sensors. The pressure response can be stable, for example, zero pressure change, or pressure change within the target pressure holding time. The diagnostic process can compare the pressure response with a predetermined pressure test threshold. The predetermined pressure test threshold can be based on the volume of liquid loss, the reduction of pressure, or the rate of reduction of pressure. For example, the predetermined pressure test threshold can be a total pressure loss of 100psi. In another scenario, the test threshold can reach 100psi within 60 minutes. In another scenario, the test threshold can be a pressure loss of 20% within 60 minutes. The diagnostic process can determine the health of the hybrid system 220 based on the comparison of the pressure response with the predetermined pressure test threshold. The periodic data sets and determination of the health status of the hybrid system 220 may be i) saved to memory, ii) saved to auxiliary storage 522, iii) transmitted to a remote location via transceiver 590 and / or network device 588, iv) sent as an alert to maintenance personnel, v) provided as a flag to maintenance personnel via display 244, or vi) a combination thereof.

[0067] Now turn to Figure 3, the automated process may include a leak detection diagnostic process for the main pump 206 and the high pressure manifold. In some embodiments, the high pressure manifold leak diagnostic process (also referred to as manifold leak diagnostic) may perform a diagnostic test on the health of the high pressure manifold 300 by applying a target test pressure and monitoring the pressure manifold 300 for a predetermined period of time.

[0068] In some embodiments, the readiness diagnostic process can be performed before or in coordination with the manifold leak diagnostic. In some embodiments, the diagnostic process can open the mixing valve 226 coupled to the mixing drum 204A to fill the high pressure line 326 and the feed manifold 310 with water. The diagnostic process can isolate one side of the discharge manifold 312 by closing the sensor valve 314. For example, the diagnostic process can close the sensor valve 314B to isolate the discharge manifold 312A and the high pressure line 336 from the other side or the discharge manifold 312B. In some embodiments, the manifold leak diagnostic process can circulate water through the mixing system 220 before opening the mixing valve 226 to supply water to the feed manifold 310A.

[0069] In some embodiments, the manifold leak diagnostic can apply pressure to the high pressure manifold 300. The manifold leak diagnostic can set the ERV to a pressure value consisting of a target test pressure plus a safety factor. In this scenario, the ERV can stop the main pump 206A, disengage the power end from the fluid end, engage a brake on the drive shaft of the power end, or a combination thereof. In some embodiments, the manifold leak diagnostic can utilize the main pump 206A to apply a predetermined pressure value, such as a test pressure, to the pressure manifold 300. In this scenario, the manifold leak diagnostic can engage the main pump 206A to pressurize the water from the feed manifold 310A, thereby applying a test pressure to the exhaust manifold 312A, the exhaust hub 316, the high pressure line 336, and the test block 340. In some embodiments, the leak diagnostic process can keep the sensor valve 314B open, for example, 100% open, to apply the test pressure to the exhaust manifold 312B. In some embodiments, the manifold leak diagnostic may utilize both main pumps 206A and 206B to apply a test pressure to both exhaust manifolds 312A, 312B and the high pressure line 336 .

[0070] In some embodiments, the manifold leak diagnostics can increase the pressure level in a step value. For example, the manifold leak diagnostics can increase the pressure level to 25%, 50%, or 75% of the target pressure valve, and maintain the step value for a predetermined period of time. The manifold leak diagnostics can increase the pressure level in the pressure manifold 300 to the test pressure value. The manifold leak diagnostics can receive a periodic data set indicating the health of the high-pressure manifold 300 during the predetermined target pressure holding time. The diagnostic process can determine the health of the high-pressure manifold by comparing the pressure response with the pressure test threshold value also referred to as the pass / fail standard. The pressure response of the high-pressure manifold can be a decrease in the pressure value within a certain period of time (e.g., the target pressure holding time). An initial pressure loss can be expected because the seals in the pumping equipment will move and / or deflect when in contact with the sealing surface. The diagnostic process can actuate the main pump 206A to compensate for the initial pressure loss. The diagnostic process can monitor the pressure response via a periodic data set from the pressure transducer 344 on the sensor valve 314A, 314B, 342, the test block 340, or other pressure sensors. The pressure response can be stable, for example, zero pressure change, or pressure change within the target pressure holding time. The diagnostic process can compare the pressure response with a predetermined pressure test threshold. The predetermined pressure test threshold can be based on the volume of liquid loss, the reduction in pressure, or the rate of pressure reduction. For example, the predetermined pressure test threshold can be a total pressure loss of 100psi. In another scenario, the test threshold can reach 100psi within 60 minutes. In another scenario, the test threshold can be a pressure loss of 20% within 60 minutes. The diagnostic process can determine the health of the high pressure manifold 300 based on the comparison of the pressure response with the predetermined pressure test threshold. The periodic data set and the determination of the health of the high pressure manifold 300 can be i) saved to memory, ii) saved to auxiliary memory 522, iii) transmitted to a remote location via transceiver 590 and / or network device 588, iv) sent to maintenance personnel as an alert, v) provided to maintenance personnel as a mark via display 244, or vi) a combination thereof.

[0071] The automatic process can complete a variety of diagnostic methods configured to determine the health of the pumping equipment of a pumping unit (e.g., pumping unit 200) and provide a maintenance personnel with an indication of the end of the automatic process. The automatic process can provide at least one report, warning, or display of an indication that the health of the pumping equipment is "good" or sufficient for the current pumping operation. The automatic process can indicate the "good" health and return control of the pumping unit 200 to the maintenance personnel.

[0072] In some embodiments, a servicer may provide wellbore service operations at the conclusion of the automated process. The fluid and / or treatment admixture may be added to the pump unit (e.g., Figure 134) as a wellbore treatment (e.g., cement slurry). A pump unit (e.g., Figure 1 34) can be used in a mixing device (e.g., Figure 1 The treatment blend and the liquid blend are mixed in the mixing drum 204 of the mixing system 220 to form a treatment slurry and the treatment slurry is pumped into the wellbore 16 via the supply line 38 using the pumping device 46. The pumping unit 34 can deliver the treatment slurry into the wellbore 16 at a desired flow rate according to the pumping program. Returning to Figure 2, the flow rate of the blended mud from the pump unit 200 to the wellbore 16 can be controlled by the unit controller 240. The liquid delivery system 234 can deliver liquid (e.g., water) from the supply tank 202 and / or the supply line 212 to the mixing drum 204 according to the pumping program at a predetermined flow rate to produce a blended slurry in the mixing system 220 for delivery to the wellbore 16 via the main pump 206. The operating capacity of the liquid delivery system 234 to deliver fluid at a desired or predetermined flow rate may depend on the health of the mixing system 220.

[0073] As will be appreciated by those skilled in the art after reading this disclosure, current or anticipated pumping operations may require that the mixing system 220 be able to provide certain operating performance values, e.g., combined pressure and flow rate, that are less than the minimum operating capacity of the mixing equipment. However, changes in wellbore conditions may require that the mixing system 220 be operated at higher operating performance values ​​that may include the minimum operating capacity. Therefore, it is important to understand the operating capacity of the liquid delivery system 234 before commencing wellbore servicing operations at the wellsite.

[0074] In another scenario, the automated process may provide for display of at least one report, alert, or indication that the health of the pumping equipment is "poor" or insufficient for the current pumping operation. The automated process may indicate a health level below the operational requirements for the current pumping operation, provide an indication of a failure mode, and return control of the pumping unit 200 to maintenance personnel.

[0075] In some embodiments, the health of the pumping equipment (e.g., pressure manifold 300) can be determined based on the results of at least one of the diagnostic tests. In some embodiments, the results or a set of results of the diagnostic test can include one or more averages, multiple averages, system performance curves, system mathematical functions, or combinations thereof. In some embodiments, the diagnostic process can include data processing of the periodic data set after the diagnostic test is completed. The diagnostic process can generate a post-processed periodic data set from the periodic data set by applying one or more data reduction techniques to smooth the periodic data set (e.g., data cleaning, numerical reduction, or a combination thereof) to remove out-of-range values ​​and mark missing values ​​in the data set. Data processing can include averaging the post-processed periodic data set to generate an average or a set of averages representing each set of periodic data. The average can be a single value representing multiple values ​​within a given duration. The average can be determined by applying one or more mathematical techniques, such as arithmetic mean, median, geometric median, mode, geometric mean, harmonic mean, generalized mean, moving average, or a combination thereof. In some embodiments, the average can be determined when each of the multiple periodic data sets is generated (e.g., in real time or alternatively at a later time). The result or set of results of the at least one diagnostic test may be determined by data processing of the periodic data set.

[0076] In some embodiments, the health of the pumping equipment can be determined by comparing the results of at least one diagnostic test to the minimum operating capacity of the pumping equipment (e.g., mixing system 220). Additionally or alternatively, the results of the diagnostic test can be compared to the maintained operating capacity (e.g., expected capacity based on previous use and maintenance of the pumping equipment (e.g., mixing system 220)). Additionally or alternatively, the results of the diagnostic test can be compared to a historical database (e.g., a capacity based on historical data from multiple pump units (e.g., pump unit 200, master pump, mixing system, and various components)).

[0077] In some embodiments, the results of at least one of the diagnostic tests may be compared to a set of operational indicators (which may include a readiness check, a minimum operating capacity, a nominal operating capacity, a list of failure modes, or a combination thereof).

[0078] In some embodiments, the nominal operating capacity may include one or more values ​​that indicate the normal operating capacity of a well-maintained or recently serviced portion of the pump unit 200 (e.g., the mixing system 220). The values ​​of the readiness diagnostics, liquid supply diagnostics, mixing water diagnostics, mixing system leak diagnostics, manifold leak diagnostics, or combinations thereof may indicate the nominal operating capacity of the pumping equipment of the pumping unit 200.

[0079] In some embodiments, the failure mode may include one or more values ​​indicating one or more failure modes (e.g., bearing failure) of the pumping equipment. The value of the failure mode may indicate one or more failures of the pumping equipment (e.g., mixing system 220) or its components. For example, the failure of the supply pump 224 to achieve a pressure value during a diagnostic test may indicate an impending seal failure.

[0080] The result of the comparison between the result from at least one of the diagnostic tests and the set of operating indicators can produce a status of the pumping equipment. For example, in the case where the diagnostic test result meets or exceeds the value of the pending operating capacity, the hybrid system 220 can have a "pass" or "acceptable" status; in the case where it is not, the hybrid system can have a "fail" or unacceptable status. Additionally or alternatively, in the case where the diagnostic test result meets or exceeds the value of the minimum operating capacity, the hybrid system 220 can have a "pass" or "acceptable" status; in the case where it is not, the hybrid system can have a "fail" or unacceptable status. Additionally or alternatively, in the case where the diagnostic test result meets or exceeds the value of the nominal operating capacity, the hybrid system 120 can have a "pass" or "acceptable" status; in the case where it is not, the hybrid system can have a "fail" or unacceptable status. Additionally or alternatively, in the case where the diagnostic test result meets or exceeds the value of the nominal operating capacity, the hybrid system 120 can have a "pass" or "acceptable" status; in the case where it is not, the hybrid system can have a "fail" or unacceptable status. Additionally or alternatively, in the case where the diagnostic test result meets or exceeds a series of failure modes, the hybrid system 220 can have a "pass" or "acceptable" status; in the case where it is not, the hybrid system can have a "fail" or unacceptable status.

[0081] In some embodiments, the method for determining the health of the pumping equipment may further include the steps of creating one or more outputs in response to the status of the pumping equipment. The output may include an indication of the health of the pumping equipment (e.g., the pressure manifold 300), such as a visual prompt (e.g., an indicator light), a text message or message indicating the status of the mixing system 300, an audible prompt such as an alarm or buzzer, or a combination thereof.

[0082] For example, referring again to FIG. 2 , the unit controller 240 can display an alert on the interactive display 244. The alert can be displayed as a curve, a table, or a simple pass or fail (e.g., a pass / fail status) on the interactive display 244. For example, the pass / fail status can be a color indicator that includes green for a pass status, and a fail status can be red. The pass / fail status can include a multi-color indicator for indicating a range such as green, yellow, and red. For example, yellow can be a warning at the bottom of a range value. When the result is a fail, a pass / fail message, such as a text message, can be included.

[0083] In some embodiments, the pump unit 34 can monitor at least one pump (e.g., Figure 1 The unit controller 48 may load one or more processes into a memory to track the pumping equipment usage. One or more processes may be applications loaded when the unit controller 48 is started or before the pumping program begins. The management process executed on the unit controller 48 may load a current pump data set, which includes a pump usage log for each pump in the pump (e.g., the mixing pump 284). The pump maintenance log may be created and / or maintained by one or more diagnostic processes and / or management processes. The pump maintenance log includes at least one value indicating a past maintenance event, such as a pump identification, a repair performed, a location, or a date. The pump usage log and the pump maintenance log may also be referred to as a historical data set. The pump usage log includes pump usage values ​​indicating a wellbore pumping operation, such as a pump flow rate, a pump pressure, a fluid volume, or a combination thereof. The unit controller 48 may update the pump usage log with pump usage values ​​including periodic sensor data indicating a pumping operation. For example, the unit controller 48 may initiate a pumping program that includes a sequential series of steps, including wellbore treatment fluid admixtures, pump pressures, pump flow rates, fluid volumes, or combinations thereof, to place the wellbore treatment into the wellbore, and the management process may update the pump usage log based on the time period and / or treatment volume pumped.

[0084] In some embodiments, the automatic process can determine the probability of future maintenance events. The diagnostic process can input one or more of the diagnostic test results into the pump usage log and the pump maintenance log into the predictive maintenance model. The predictive maintenance model can access a historical database of pumping operations of the type of pumping unit (e.g., pump unit 34). The predictive maintenance model can output the probability of future maintenance events by using the results of the current diagnostic test, the past results of the diagnostic test, the historical database of pumping operations, the pump usage log, the pump maintenance log, or a combination thereof as input. Future maintenance events may include performance degradation, impending equipment failure, precursory equipment failure, or a combination thereof. As the accumulation of pump usage values ​​approaches the usage threshold of future maintenance events, the performance of pumping equipment (e.g., pumping equipment 46) may decline. Pump performance degradation may include deterioration of pumping capacity (e.g., reduction in pressure or flow rate capacity), and / or catastrophic failure. Future maintenance events can be solved by performing preventive maintenance on the pump equipment, including adjustment, replacement of components, overhaul, or a combination thereof. The predictive maintenance model can provide a pump equipment life value including the remaining pump usage value before future maintenance events. The diagnostic process may provide the probability of future maintenance events for the pressure manifold 300, main pump 206, mixing pump 284, supply pumps 224 and 214, mixing water system 286, mixing system 220, liquid delivery system 234, and all of their various components.

[0085] In some embodiments, one or more of evaluating a plurality of periodic data sets, determining the health of the pumping equipment, and creating one or more outputs in response to the state of the mixing system may be performed via operation of the unit controller 240 .

[0086] Unit controller (e.g. Figure 1 2 or 240 of FIG. 2) can be a computer system suitable for communication and control of the various components of the pumping unit. In one embodiment, the unit controller (e.g., Figure 12 or the unit controller 240 of FIG. 2) is shown in FIG. 5 as a computer system 510. In the embodiment of FIG. 5, the computer system 510 includes one or more processors 512 (which may be referred to as a central processor unit or CPU) that communicate with a memory 520, an auxiliary storage device 522, an input-output device 524, a DAQ card 532, and a network device 528. The computer system 510 can continuously monitor the state of the input device and change the state of the output device based on a plurality of programming instructions. The programming instructions may include one or more application programs retrieved from the memory 520 for execution by the processor 578 in the non-transitory memory within the memory 520. The input-output device may include an HMI (e.g., the interactive display 244 in FIG. 2) having a display screen and / or the ability to receive conventional input from a maintenance person, such as a button, a touch screen, a keyboard, a mouse, or any other such device or element that a maintenance person can use to input commands to the computer system 510. The auxiliary storage device 522 may include a solid-state memory, a hard drive, or any other type of memory suitable for data storage. The auxiliary storage device 522 may include a removable memory storage device such as a solid-state memory or a removable memory medium such as a magnetic medium and an optical medium (i.e., a CD-ROM). The computer system 510 may communicate with various networks using a network device 528, including: a wired network, such as Ethernet or fiber optic communications; and a short-range wireless network, such as Wi-Fi (i.e., IEEE 802.11), Bluetooth or other low-power wireless signals (such as ZigBee, Z-Wave, 6LoWPan, Thread, and WiFi-ah). The computer system 510 may include a long-range radio transceiver 590 for communicating with a mobile network provider, as will be further disclosed herein.

[0087] The computer system 510 may include a DAQ card 532 for communicating with one or more sensors. The DAQ card 532 may be a stand-alone system having a microprocessor, memory, and one or more application programs executed in the memory. As shown, the DAQ card 532 may be a card or device within the computer system 510. In one embodiment, the DAQ card 532 may be combined with an input-output device 584. The DAQ card 532 may receive one or more analog inputs 534, one or more frequency inputs 536, and one or more Modbus inputs 538. For example, the analog input 594 may include a cylinder level sensor. For example, the frequency input 536 may include a flow meter, i.e., from a Figure 2B For example, Modbus input 538 may include a pressure transducer, i.e., from Figure 2BDAQ card 532 can convert signals received via analog input 534, frequency input 536, and Modbus input 538 into corresponding sensor data. For example, DAQ card 532 can convert signals received via analog input 534, frequency input 536, and Modbus input 538 into corresponding sensor data. Figure 2B The frequency input 596 of the flow rate sensor 256 is shown converted to flow rate data measured in gallons per minute (GPM).

[0088] Additionally or alternatively, in one embodiment, one or more of the following steps of evaluating multiple periodic data sets, determining the health of the pumping equipment, and / or creating one or more outputs in response to the state of the hybrid system may be performed via operation of a computer located at a remote location (e.g., a remote service center). Additionally or alternatively, in one embodiment, one or more of the following steps of evaluating multiple periodic data sets, determining the health of the pumping equipment, and / or creating one or more outputs in response to the state of the hybrid system may be performed collaboratively via operation of the unit controller 240 and a computer located at a remote location (e.g., a remote service center). For example, in one embodiment, the unit controller 240 may transmit data from a diagnostic test (e.g., a pressure manifold 300 leak diagnostic) to the remote service center, such as via a data communications system, as will be further described herein.

[0089] For example, data may be transmitted via a data communication system and received by various wired or wireless means between the pump unit 200 at the well site and the remote service center, and used for further processing. Referring to FIG. 6 , a data communication system 600 is described. The data communication system 600 includes a pump unit 34 disposed at a well site 602, an access node 610 (e.g., a cellular site), a mobile operator network 654, a network 634, a storage computer 636, a service center 638, and a plurality of user devices 652. The pump unit 34 may include a communication device 606 (e.g., the transceiver 590 of FIG. 5 ), which may transmit and / or receive via any suitable communication device (wired or wireless), such as wirelessly connecting to the access node 610 to transmit data (e.g., system performance files) to the storage computer 636. The storage computer 636 may also be referred to as a data server, a data storage server, or a remote server. The storage computer 636 may include a database that may be used to store system performance files and / or diagnostic test results. Wireless communications may include various types of radio communications, including cellular, satellite 630, or any other form of long-range radio communications. The communication device 606 may transmit some or all of the data to a storage computer 636 via a wired connection. The communication device 606 may communicate via a combination of wireless and wired communications. For example, the communication device 606 may be wirelessly connected to an access node 610 that is communicatively connected to a network 634 via a mobile operator network 654.

[0090] In one embodiment, the communication device 606 on the pump unit 34 is communicatively connected to the mobile operator network 654, which may include the access node 610, the 5G edge site 612, the 5G core network 620, and the network 634. The communication device 606 may be a transceiver 590 connected to the computer system 676 of FIG. 5. The computer system 510 may be the unit controller 240 of FIG. 2 or Figure 1 unit controller 48, so the communication device 606 can be communicatively connected to the unit controller 240 and / or 48.

[0091] Access node 610 may also be referred to as a cellular site, cell tower, cell site, or in the case of 5G technology, a Gigabit Node B. Access node 610 provides a wireless communication link to communication devices 606 (e.g., cell controller 240 and / or cell controller 48) in accordance with 5G, Long Term Evolution (LTE), Code Division Multiple Access (CDMA), or Global System for Mobile Communications (GSM) wireless telecommunications protocols.

[0092] The communication device 606 can establish a wireless link with the mobile operator network 654 (e.g., 5G core network 620) using a long-range radio transceiver (e.g., 590 of FIG. 5) to receive data, communication, and in some cases, voice and / or video communication. The communication device 606 may also include a display and input device (e.g., interactive display 144 or HMI), a camera (e.g., video, photo, etc.), a speaker for audio, or a microphone for audio input by a user. The long-range radio transceiver (e.g., transceiver 590) of the communication device 606 may be able to establish wireless communication with the access node 610 based on 5G, LTE, CDMA or GSM telecommunication protocols. The communication device 606 may be able to support two or more different wireless telecommunication protocols, and therefore may be referred to as a multi-protocol device in some contexts. The communication device 606 (e.g., device 606A) can communicate with another communication device (e.g., device 606B) on a second pump truck (e.g., pump unit 34B) via a wireless link provided by the access node 610 and via a wired link provided by the mobile operator network 654 (e.g., 5G edge site 612 or 5G core network 620). Although the pump unit 34 and the communication device 606 are shown as a single device, the pump unit 34 can be part of a pump unit system (e.g., a fracturing group). For example, the pump unit 34A can communicate with the pump units 34B, 34C, 34D, 34E, and 34F at the same well site (e.g., well site 602 of FIG. 6) or at multiple well sites. In one embodiment, the pump units 34A to 34E can be different types of pump units at the same well site or at multiple well sites. For example, pump unit 34A can be a fracturing pump, pump unit 34B can be an admixer, pump unit 34C can be a water supply unit, pump unit 34D can be a cementing unit, and pump unit 34E can be a mud pump. Pump units 34A to 34F can be communicatively coupled together at the same well site by one or more communication methods. Pump units 34A to 34F can be communicatively coupled using a combination of wired communication methods and wireless communication methods. For example, a first group of pump units 34A to 34C can be communicatively coupled with wired communication (e.g., Ethernet). A second group of pump units 34D to 34E can be communicatively coupled to a first group of pump units 34A to 34C using low-power wireless communication (e.g., WIFI). A third group of pump units 34F can be communicatively coupled to one or more of the first or second group of pump units by a long-range radio communication method (e.g., mobile communication network 654).

[0093] 5G edge site 612 can be communicatively coupled to access node 610. 5G edge site 612 can also be referred to as a regional data center (RDC) and can include a virtual network in the form of a cloud computing platform. The cloud computing platform can create a virtual network environment from standard hardware such as servers, switches, and storage devices. The total amount of computing availability 614 of 5G edge site 612 is shown by a pie chart, a portion of which is shown as a network slice 618 and the rest is computing availability 616. Network slice 618 represents the amount of computing that can be used to store data or for processing data. Network slice 618 can be referred to as a network location. The cloud computing environment will be further described in more detail below. Although 5G edge site 612 is shown as being communicatively coupled to access node 610, it should be understood that 5G edge site 612 can be communicatively coupled to multiple access nodes (e.g., node 610). 5G edge site 612 can receive all or part of voice and data communications from one or more access nodes (e.g., node 610). The 5G edge site 612 may process all or part of the voice and data communications, or may pass all or part of the voice and data communications to the 5G core network 620, as will be further described below. Although the virtual network is described as being created from a cloud computing network, it should be understood that the virtual network may be formed from network function virtualization (NFV). NFV creates a virtual network environment from standard hardware such as servers, switches, and storage devices. ETSI GS NFV 002v1.2.1 (2014-12) describes NFV more fully.

[0094] The 5G core network 620 can be communicatively coupled to the 5G edge site 612 and provide a mobile communication network via the 5G edge site 612 and one or more access nodes 610. Although the access node 610 is shown as being communicatively connected to the 5G edge site 612, it should be understood that one or more access nodes (e.g., 610) can be communicatively connected to the 5G core network 620. The 5G core network 620 may include a virtual network in the form of a cloud computing platform. The cloud computing platform can create a virtual network environment from standard hardware such as servers, switches, and storage devices. The total amount of computing availability 622 of the 5G core network 620 is shown by a pie chart, a portion of which is shown as a network slice 626, and the rest is computing availability 624. The network slice 626 may be referred to as a network location. The network slice 626 represents the amount of computing that can be used to store or process data. The cloud computing environment will be further described in more detail below. Although the 5G core network 620 is shown as being communicatively coupled to the 5G edge site 612, it should be understood that the 5G core network 620 can be communicatively coupled to multiple access nodes (e.g., node 610) in addition to one or more 5G edge sites (e.g., edge site 612). The 5G core network 620 can be communicatively coupled to one or more mini data centers (MDCs). The MDC can generally be described as a smaller version or self-contained 5G edge site, which includes an access node (e.g., node 610) with a cloud computing platform (e.g., a virtual network environment) created from standard computer system hardware (e.g., processors, switches, and storage devices). The 5G core network 620 can receive all or part of voice and data communications via the 5G edge site 612, one or more MDC nodes, and one or more access nodes (e.g., node 610). The 5G core network 620 can process all or part of voice and data communications, as will be further described below. Although the virtual network is described as being created from a cloud computing network, it should be understood that the virtual network can be formed from network function virtualization (NFV). NFV creates a virtual network environment from standard hardware such as servers, switches, and storage devices.

[0095] Storage computer 636 can be communicatively coupled to a 5G network, such as mobile operator network 654, via network 634. Storage computer 636 can be a computer, a server, or any other type of storage device. Storage computer 636 can be referred to as a network location. Network 634 can be one or more public networks, one or more private networks, or a combination thereof. A portion of the Internet can be included in network 634.

[0096] The service center 638 can be used as a base of operations for multiple pump units, for example, to provide maintenance for the pump unit 34. Maintenance operations can include repair, replacement, modification, upgrade, or a combination thereof of equipment on the pump unit 34, the equipment including: referring back to FIG. 2 , the unit controller 240, the DAQ card 242, the interactive display 244 (i.e., HMI), the power supply 208, the supply tank 202, the mixing system 220, the additive system 222, the main pump 206, multiple pumps (e.g., the supply pump 224), multiple valves (e.g., the sensor valve 270), multiple sensors (e.g., the flow rate sensor 256), or a combination thereof.

[0097] The service center 638 can have a central computer 640 that executes one or more applications (e.g., a maintenance application 642). The maintenance application 642 can assign a pump unit (e.g., a pump unit 34) for maintenance to one or more components (e.g., a main pump 206) on the pump unit according to a maintenance plan 648. In one embodiment, the maintenance application 642 can receive or retrieve diagnostic test results associated with the pump unit 34 from a historical database on a storage computer 636. The central computer 640 can access the diagnostic test results and determine whether the results of the diagnostic test are below a threshold or whether the results include an alert indicating that the diagnostic test generates a fault value, an error value, or at least one data point below an operating threshold. In some embodiments, the central computer 640 (e.g., the maintenance application 642) can send one or more alerts to one or more user devices 652 that are communicatively connected to the maintenance application 642 via the network 634. Additionally or alternatively, the central computer 640 can arrange for service (e.g., at the service center 638) to diagnose or remedy a problem with the pump unit 34 based on the results of the diagnostic test, such as replacing one or more seals within the supply pump 224. Additionally or alternatively, the unit controller 48 may dispatch the unit for maintenance and / or schedule maintenance, such as at a service center 638 , to diagnose or remedy a problem with the pump unit 34 based on the results of the diagnostic tests, such as to replace one or more seals within the pumping equipment 46 .

[0098] Although the maintenance application 642 is described as executing on the central computer 640, it should be understood that the central computer 640 can be any form of computer system in a computer system or cloud computing environment, such as a server, workstation, desktop computer, laptop computer, tablet computer, smart phone, or any other type of computing device. The central computer 640 (e.g., computer system) can include one or more processors, memory, input devices, and output devices, as described in more detail further below. Although the service center 638 is described as having the maintenance application 642 executing on the central computer 640, it should be understood that the service center 638 can have 2, 3, 4, or any number of computers 640 (e.g., computer systems), where 2, 3, 4, or any number of maintenance applications 642 are executed on the central computer 640.

[0099] In some embodiments, the mobile operator network 654 includes a 5G core network 620 and a 5G edge site 612 with virtual servers in a cloud computing environment. One or more servers of the type disclosed herein (e.g., storage computers 636 and central computers 640) can be provided by virtual network functions (VNFs) executed within the 5G core network. The pump unit 34 on the well site 602 can be communicatively coupled to the 5G edge site 612 via an access node 610 (e.g., a Gigabit Node B), including the 5G core network 620, and can therefore be communicatively coupled to one or more VNFs with virtual servers, as will be described more fully below. Turning now to FIG. 7, a representative example of a network slice 618 and / or 626 is described. The computing services executed on the network slice 618 and / or 626 may include a first virtual network function (VNF) 658, a second VNF 660, and an unallocated portion 662. The computing service may include a first application 664A executed on the first VNF ​​658 and a second application 666A executed on the second VNF 660. The first application 664A and the second application 666A can be computing service applications commonly referred to as remote applications. The total computing amount can include the first VNF ​​658, the second VNF 660, and the unallocated portion 662. The unallocated portion 662 can represent the computing amount reserved for future use. The first VNF ​​658 can include the first application 664A and the additionally allocated computing amount 664B. The second VNF 660 can include the second application 666A and the additionally allocated computing amount 666B. Although two VNFs are shown, the network slice 618 and / or 626 can have a single VNF, two VNFs, or any number of VNFs. Although the first VNF ​​658 and the second VNF 660 are shown as having equal computing amounts, it should be understood that the computing amounts may not be equal and may vary according to the computing amount requirements of each application. The first application 664A executed in the first VNF ​​658 can be configured to communicate or share data with the second application 666A executed in the second VNF 660. The first application 664A and the second application 666A may be independent and do not share data or communication with each other. Although the network slice 618 and / or 626 is shown as having two VNFs and an unallocated portion 662, the network slice 618 and / or 626 may be configured without the unallocated portion 662. Although only one application (the first application 664A) is described as executing within the first VNF ​​658, two or more applications may execute within the first VNF ​​658 and the second VNF 660. In one embodiment, the network slice 618 and / or 626 may be a network slice 618 on a 5G edge site 612.In one embodiment, the network slice 626 may be a network slice 626 on the 5G core network 620. In one embodiment, the first application 664A and / or the second application 666A executed on the first VNF ​​658 and / or the second VNF 660 may be a maintenance application 642, a maintenance plan 648, a storage computer 636, a historical database of system performance files, or a combination thereof.

[0100] Turning now to FIG. 8A , an embodiment of a communication system 550 is described as being suitable for implementing one or more embodiments disclosed herein, such as implementing communications or messaging as disclosed herein, including but not limited to wireless communications between the communication device 606 on FIG. 6 and the mobile operator network 654; communications with computing components and networks associated with FIG. 5 (e.g., long-range radio transceiver 190); and the like. In general, the communication system 550 includes a plurality of access nodes: a first access node 554a, a second access node 554b, and a third access node 554c (collectively referred to as access nodes 554), which are configured to provide coverage in which a plurality of user equipment (UE) 552 (such as mobile phones, tablet computers, machine-type communication devices, unit controllers, tracking devices, embedded wireless modules, and / or other wirelessly equipped communication devices (whether or not operated by a user)) can operate. The access nodes 554 can be considered to establish an access network 556. In some contexts, the access network 556 can be referred to as a radio access network (RAN). In the 5G technology generation, the access nodes 554 can be referred to as gigabit nodes B (gNB). In 4G technology (e.g., Long Term Evolution (LTE) technology), access node 554 may be referred to as an enhanced Node B (eNB). In 3G technology (e.g., Code Division Multiple Access (CDMA) and Global System for Mobile Communications (GSM)), access node 554 may be referred to as a base transceiver station (BTS) combined with a base station controller (BSC). In some contexts, access node 554 may be referred to as a cell site or cell tower. In some implementations, a pico cell may provide some functionality of access node 554, albeit with a limited coverage area. Each of these different embodiments of access node 554 may be considered to provide substantially similar functionality in different technology generations.

[0101] It should be understood that the access network 556 may include any number of access nodes 554. In addition, each access node 554 may be coupled to a core network 558 that provides connections to various application servers 559 and / or networks 560. In one embodiment, at least some of the application servers 559 may be located near the edge of the network (e.g., geographically close to UE 552 and end users) to deliver so-called "edge computing". The network 560 may be one or more private networks, one or more public networks, or a combination thereof. The network 560 may include a public switched telephone network (PSTN). The network 560 may include the Internet. With this arrangement, a UE 552 within the coverage of the access network 556 may participate in air interface communications with the access node 554, and thereby may communicate with various application servers and other entities via the access node 554.

[0102] The communication system 550 may operate according to a particular radio access technology (RAT), wherein communications from the access node 554 to the UE 552 define the downlink or forward link, and communications from the UE 552 to the access node 554 define the uplink or reverse link. Over the years, the industry has developed various generations of RATs in an ongoing effort to increase the available data rates and quality of service for end users. These generations range from "1G" (which used simple analog frequency modulation to facilitate basic voice call services) to "4G" such as Long Term Evolution (LTE), which now uses technologies such as orthogonal frequency division multiplexing (OFDM) and multiple-input multiple-output (MIMO) to facilitate mobile broadband services.

[0103] Turning now to FIG. 8B, other details of the core network 558 are described. In one embodiment, the core network 558 is a 5G core network. The 5G core network technology is based on a service-based architecture paradigm. Instead of building the 5G core network as a series of dedicated communication nodes (e.g., HSS nodes, MME nodes, etc.) running on a dedicated server computer, the 5G core network is provided as a service or network function set. These services or network functions can be executed on a virtual server in a cloud computing environment that supports dynamic expansion and avoids long-term capital expenditures (usage fees can replace capital expenditures). These network functions may include, for example, a user plane function (UPF) 579, an authentication server function (AUSF) 575, an access and mobility management function (AMF) 576, a session management function (SMF) 577, a network exposure function (NEF) 570, a network storage function (NRF) 571, a policy control function (PCF) 572, a unified data management (UDM) 573, a network slice selection function (NSSF) 574 and other network functions. In some contexts, a network function may be referred to as a virtual network function (VNF).

[0104] Network functions can be formed by a combination of small software called microservices. Some microservices can be reused to form different network functions, thereby fully utilizing the utility of such microservices. Network functions can provide services to other network functions by extending application programming interfaces (APIs) to those other network functions that call their services via APIs. The 5G core network 558 can be divided into a user plane 580 and a control plane 582, thereby promoting independent scalability, evolution, and flexible deployment.

[0105] The NEF 570 securely exposes the services and capabilities provided by the network functions. The NRF 571 supports service registration of network functions and network function discovery of other network functions. The PCF 572 supports policy control decisions and flow-based charging control. The UDM 573 manages network user data and can be paired with a user data repository (UDR) that stores user data such as customer profile information, customer authentication numbers, and encryption keys for information. The application function 592, which can be located outside the core network 558, exposes the application layer for interaction with the core network 558. In one embodiment, the application function 592 can be executed on an application server 559 that is geographically close to the UE 552 in an "edge computing" deployment mode. The core network 558 can provide a subscriber (e.g., an enterprise customer) with a network slice consisting of multiple 5G network functions that are configured to provide customized communication services to the subscriber, such as providing communication services according to a communication policy defined by the customer. The NSSF 574 can help the AMF 576 select a network slice instance (NSI) for use with the UE 552.

[0106] The systems and methods disclosed herein may be advantageously employed in the context of wellbore servicing operations, particularly in connection with the use of the wellbore servicing apparatus disclosed herein.

[0107] In one embodiment, the diagnostic tests disclosed herein can identify equipment failures or reduced operability that might otherwise go unidentified. For example, a reduction in pump output of a pump (e.g., supply pump 224) can be gradual and difficult to quantify or identify. The diagnostic tests disclosed herein (wherein a partially closed sensor valve 270 can increase head pressure while reducing the flow rate of supply pump 224) can apply additional stress and can reveal a reduction in pump output, and therefore a reduction in the operating capacity of liquid delivery system 234.

[0108] Additionally or alternatively, the diagnostic tests disclosed herein may be performed automatically prior to initiation of a wellbore servicing operation, upon completion of a wellbore servicing operation, or both. The unit controller 240 may automatically initiate a diagnostic test upon startup or shutdown of the pump unit 200, or may prompt a servicer to initiate a diagnostic test. The unit controller 240 may prevent operation of the pump unit 200 until the diagnostic test is complete.

[0109] Additionally or alternatively, the diagnostic tests disclosed herein may determine whether the pumping unit 200 can complete the wellbore servicing operation without interruption. The diagnostic tests may determine whether one or more components of the pumping equipment (e.g., the mixing system 220) can operate within the operating limits of the pumping unit 200. Additionally, the diagnostic tests may determine whether the operating capacity of one or more components of the pumping equipment (e.g., the mixing system 220) has dropped below a threshold.

[0110] Other public content

[0111] The following are non-limiting specific embodiments according to the present disclosure:

[0112] In a first embodiment, a computer-implemented method for determining a health status of a hybrid system associated with a wellbore pump unit, the method comprising: initiating a diagnostic process including at least one diagnostic test by a unit controller, and wherein the unit controller comprises a processor, a non-volatile memory, and an input-output device; performing the at least one diagnostic test by the unit controller; determining a set of results of the diagnostic test through the diagnostic process; comparing the set of results of the diagnostic test with a set of operating indicators; determining the health status of the pumping equipment system based on the comparison; and outputting a mark of the health status of the pumping equipment by the unit controller via the input-output device, wherein the mark of the health status of the pumping equipment comprises a visual prompt and an auditory prompt or both.

[0113] A second embodiment, according to the method of the first embodiment, wherein the at least one diagnostic test includes: configuring multiple sensor valves to configure a pipe network; filling the pipe network with a certain volume of water; operating a pump to establish 1) a flow rate of water, 2) a target pressure value, or 3) both; measuring a periodic data set by at least one sensor; and storing the periodic data set, wherein the periodic data set is associated with the operation of the pump and the configuration of the pipe network.

[0114] A third embodiment, a method according to the first embodiment, wherein the at least one diagnostic test is a feed manifold diagnostic test, wherein the feed manifold diagnostic test includes: configuring a flow path through a pipe network by positioning a plurality of sensor valves into a first flow path position, wherein the flow path includes a feed manifold located between a high pressure line and a fluid end; operating a supply pump at full speed to deliver fluid through the flow path, and closing a valve coupled to a return line; and measuring a first periodic data set of pressure and flow rate by at least one sensor when the fluid is delivered through the flow path and the valve on the return line is closed with the sensor valve in a first position that is fully open.

[0115] A fourth embodiment, a method according to the first embodiment, wherein the at least one diagnostic test is a discharge manifold diagnostic test, wherein the discharge manifold test includes: coupling a high pressure supply line between a discharge hub and a test block with a shutoff valve; setting an emergency release value (ERV); operating a plunger pump to pump a certain volume of water and apply a target pressure value to the test block via the high pressure supply line; and measuring a first periodic data set of pressure by at least one sensor.

[0116] A fifth embodiment, according to the method described in the fourth embodiment, wherein the diagnostic process is configured to stop the plunger pump, disengage the power end from the fluid end, engage the brake on the drive shaft of the power end, open the pressure relief valve, or a combination thereof when the plunger pump exceeds the ERV value.

[0117] A sixth embodiment, according to the method of any one of the first to fifth embodiments, 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 a combination thereof.

[0118] A seventh embodiment, according to the method of the sixth embodiment, wherein the probability of future maintenance events is determined by a predictive maintenance model.

[0119] An eighth embodiment, a method according to the sixth embodiment or the seventh embodiment, further comprising: assigning, by the unit controller, the wellbore pump unit to a maintenance plan at a service center in response to the probability of a future maintenance event.

[0120] A ninth embodiment, according to the method according to any one of the first to eighth embodiments, wherein the set of operating indicators includes configuration check, minimum operating capacity, nominal operating capacity and a series of failure modes.

[0121] A tenth embodiment, according to any one of the first to ninth embodiments, wherein the set of results of the diagnostic test includes data processing a periodic data set to generate a set of average values.

[0122] An eleventh embodiment, according to the method described in the tenth embodiment, wherein one or more of the following items are performed via the unit controller: generating the group of results from the periodic data set processed by data; comparing the group of results of the diagnostic test with the set of operating indicators; and determining the health status of the pumping equipment based on the comparison of the group of results of the diagnostic test with the set of operating indicators.

[0123] A twelfth embodiment, according to the method described in the eleventh embodiment, wherein one or more of the following items are performed via a remote computer: data processing is performed on the periodic data set; the group of results is generated from the data processed periodic data set; the group of results of the diagnostic test is compared with the operating indicator set; and the health status of the pumping equipment is determined based on the comparison of the group of results of the diagnostic test with the operating indicator set.

[0124] A thirteenth embodiment, according to the method described in any one of the second to twelfth embodiments, further comprising: transmitting the periodic data set to a remote computer via a wireless communication protocol.

[0125] A fourteenth embodiment, according to the method described in the thirteenth embodiment, wherein the wireless communication protocol is at least one of 5G, Long Term Evolution (LTE), Code Division Multiple Access (CDMA) or Global System for Mobile Communications (GSM) telecommunication protocols.

[0126] A fifteenth embodiment, according to the method described in the thirteenth embodiment, wherein the network location is one of the following: 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 the network via a mobile communication network, or iv) a computer system communicatively coupled to the network via the mobile communication network.

[0127] A sixteenth embodiment, according to the method of the fifteenth embodiment, wherein the network location includes a database, a storage device, the remote computer, a virtual network function, or a combination thereof.

[0128] A seventeenth embodiment, according to the method of the fifteenth embodiment, further comprising: accessing, by the remote computer, a historical database at the network location, the historical database comprising data associated with a plurality of pump units.

[0129] An eighteenth embodiment, a method for wellbore maintenance, comprising: transporting a pump unit to a well site, wherein the pump unit comprises a unit controller configured to perform diagnostic tests, wherein the unit controller comprises a processor, a non-volatile memory and an input-output device; initiating, by the unit controller, a startup procedure comprising an automatic diagnostic process, wherein the automatic diagnostic process further comprises at least one diagnostic test selected from the group consisting of: a readiness diagnostic test, a feed manifold test and a discharge manifold test; performing the diagnostic test; determining a set of results of the diagnostic test; comparing the set of results of the diagnostic test with a set of operating indicators, and determining a health status of one or more components of the pump unit based on the comparison of the set of results of the diagnostic test with the set of operating indicators; in response to a failure state within the health status, initiating repair and planned maintenance of the one or more components of the pump unit; or pumping a wellbore treatment into the wellbore in response to a pass state of the health status of one or more components of the pump unit.

[0130] A nineteenth embodiment, according to the method described in the eighteenth embodiment, wherein the readiness diagnostic test includes a communication check, an operation check, a calibration check or a combination thereof, wherein the communication check includes communicating with various components of the pump unit, wherein the operation check includes actuating the various components, and wherein the calibration check includes accessing calibration files of the various components.

[0131] A twentieth embodiment, according to a method described in accordance with the eighteenth embodiment, wherein the feed manifold diagnostic test comprises: configuring a flow path including 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 fully open position; operating the supply pump at full speed to deliver fluid through the flow path; closing the valve on the return line; and measuring a first periodic data set by the sensor valve when the fluid is delivered through the flow path with the sensor valve in the fully open position and the valve on the return line is in the fully closed position.

[0132] A twenty-first embodiment, according to the method of the eighteenth embodiment, wherein the exhaust manifold diagnostic test includes: coupling a high-pressure supply line between the exhaust hub and a test block with a shut-off valve; setting an emergency release value (ERV); operating a plunger pump to pump a certain volume of water and apply a target pressure value to the test block via the high-pressure supply line; and measuring a first periodic data set of pressure by at least one sensor.

[0133] A twenty-second embodiment, according to the method described in any one of the eighteenth to twenty-first embodiments, further comprising: determining, by the unit controller, the probability of future maintenance events in response to the set of results of the diagnostic test, the pump usage log, the pump maintenance log, or a combination thereof.

[0134] A twenty-third embodiment, according to the method of the twenty-second embodiment, wherein the probability of future maintenance events is determined by a predictive maintenance model.

[0135] A twenty-fourth embodiment, a method according to the twenty-second embodiment or the twenty-third embodiment, further comprising: assigning, by the unit controller, the pump unit to a maintenance plan at a service center in response to the probability of a future maintenance event.

[0136] The twenty-fifth embodiment, a system of a wellbore pumping unit, comprising: a wellbore pumping unit, the wellbore pumping unit comprising a discharge manifold coupled to a plunger pump; a unit controller, the unit controller comprising a processor, a non-volatile memory and an automatic diagnostic process executed in the memory, the unit controller being configured to: perform a discharge manifold diagnostic test, wherein the diagnostic test comprises: operating the plunger pump to pump a certain volume of water and applying a target pressure value to the test block via the high-pressure supply line; and a first periodic data set of pressure measured by at least one sensor; comparing the result of the diagnostic test with a set of operating indicators by the unit controller or a remote computer; determining the health status of the discharge manifold by the unit controller or the remote computer based on the comparison of the result of the diagnostic test with the set of operating indicators; and outputting the health status of the discharge manifold by the unit controller, wherein the health status of the discharge manifold is a visual prompt and an auditory prompt or both.

[0137] A twenty-sixth embodiment, according to the system described in the twenty-fifth embodiment, further comprising: the sensor valve is selectively positioned in a first position or a second position by the unit controller, wherein the first position fluidly couples the first exhaust manifold with the second exhaust manifold, and wherein the second position decouples the first exhaust manifold from the second exhaust manifold.

[0138] A twenty-seventh embodiment. The system of the twenty-sixth embodiment, wherein the exhaust manifold diagnostic test is applied to the first exhaust manifold and the second exhaust manifold in response to the unit controller positioning the sensor valve in the first position.

[0139] A twenty-eighth embodiment, according to the system of any one of the twenty-fifth to twenty-seventh embodiments, further comprising: a remote computer, which communicates with the unit controller via a wireless communication protocol.

[0140] The twenty-ninth embodiment is a system according to the twenty-eighth embodiment, wherein the wireless communication protocol is at least one of 5G, Long Term Evolution (LTE), Code Division Multiple Access (CDMA) or Global System for Mobile Communications (GSM) telecommunication protocols.

[0141] A 30th embodiment, according to any one of the 25th to 29th embodiments, wherein the wellbore pumping unit is a mud pump, a cement pumping unit, a blender unit, a water supply unit or a fracturing pump.

[0142] Although embodiments have been shown and described, those skilled in the art may make modifications thereto without departing from the spirit and teachings of the present disclosure. The embodiments described herein are merely illustrative and are not intended to be limiting. Many variations and modifications of the embodiments disclosed herein are possible and within the scope of the present disclosure. Where numerical ranges or limitations are expressly specified, such expression ranges or limitations should be understood to include iterative ranges or limitations of similar magnitudes falling within the expressly specified ranges or limitations (e.g., from about 1 to about 10 including 2, 3, 4, etc.; greater than 0.10 including 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range having a lower limit R1 and an upper limit Ru is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R1+k*(Ru-R1), wherein k is a variable ranging from 1% to 100% in 1% increments, i.e., k is 1%, 2%, 3%, 4%, 5%, ... 50%, 51%, 52%, ..., 95%, 96%, 97%, 98%, 99% or 100%. In addition, any numerical range defined by the two R numbers defined above is also specifically disclosed. The use of the term "optionally" relative to any element in the claims is intended to mean that the subject element is required or alternatively not required. Both alternatives are intended to be within the scope of the claims. The use of broad terms such as "including", "comprising", "having", etc. should be understood to provide support for narrower terms such as "consisting of", "mainly consisting of", "substantially consisting of", etc.

[0143] Therefore, the scope of protection is not limited by the description set forth above, but only by the following claims, which scope includes all equivalents of the subject matter of the claims. Each claim is incorporated into this specification as an embodiment of the present disclosure. Therefore, the claims are another description and are an addition to the embodiments of the present invention. The discussion of references herein is not an admission that they are prior art, especially any reference that may have a publication date after the priority date of the present application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference to the extent that they provide illustrative, procedural or other details supplementary to those set forth herein.

Claims

1. A wellbore maintenance method, comprising: transporting a pump unit to a wellsite, wherein the pump unit includes a unit controller configured to perform a diagnostic test, wherein the unit controller includes a processor, a non-transitory memory, and an input-output device; initiating, by the unit controller, a startup routine including an automatic diagnostic process, the automatic diagnostic process further including at least one diagnostic test selected from the group consisting of: a readiness diagnostic test, a feed manifold test, and an exhaust manifold test; performing said diagnostic test; determining a set of results of said diagnostic test; comparing a set of results of the diagnostic tests to a set of operational indicators, determining a health state of one or more components of the pump unit based on the comparison of the set of results of the diagnostic tests with the set of operating indicators; initiating repair or planned maintenance of the one or more components of the pump unit in response to a failure condition within the health state; or In response to a passing status of the health status of one or more components of the pump unit, a wellbore treatment is pumped into the wellbore.

2. The method of claim 1 , wherein the readiness diagnostic test comprises a communication check, an operational check, a calibration check, or a combination thereof, wherein the communication check comprises communicating with various components of the pump unit, wherein the operational check comprises actuating the various components, and wherein the calibration check comprises accessing calibration files for the various components.

3. The method of claim 1 , wherein the feed manifold diagnostic test comprises: configuring a flow path including 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 fully open position; operating the supply pump at full speed to deliver fluid through the flow path; Close the valve on the return line; and A first periodic data set is measured by the sensor valve when the fluid is communicated via the flow path with the sensor valve in the fully open position and the valve on the return line is in a fully closed position.

4. The method of claim 1 wherein said exhaust manifold diagnostic test comprises: coupling a high pressure supply line between the discharge hub and a test block with a shutoff valve; Set the emergency release value (ERV); operating a plunger pump to pump a volume of water and apply a target pressure value to the test block via the high pressure supply line; as well as A first periodic data set of pressure is measured by at least one sensor.

5. The method according to claim 1, further comprising: A probability of a future maintenance event is determined by the unit controller in response to the set of results of the diagnostic test, a pump usage log, a pump maintenance log, or a combination thereof. The method of claim 5 , wherein the probability of a future maintenance event is determined by a predictive maintenance model.

7. The method according to claim 5, further comprising: The pump unit is assigned, by the unit controller, to a maintenance plan at a service center in response to the probability of a future maintenance event.

8. A system of a wellbore pumping unit, comprising: a wellbore pumping unit comprising a discharge manifold coupled to a plunger pump; A unit controller comprising a processor, a non-transitory memory, and an automatic diagnostic process executed in the memory, the unit controller being configured to: Perform an exhaust manifold diagnostic test, which includes: operating a plunger pump to pump a volume of water and apply a target pressure value to the test block via the high pressure supply line; and a first periodic data set of pressure measured by at least one sensor; comparing the results of the diagnostic test to a set of operating indicators by the unit controller or a remote computer, determining, by the unit controller or the remote computer, a health status of the exhaust manifold based on the comparison of the results of the diagnostic test to the set of operating indicators; and The health status of the exhaust manifold is output by the unit controller, wherein the health status of the exhaust manifold is a visual prompt and an audible prompt or both.

9. The system of claim 8, further comprising: The sensor valve is selectively positioned by the unit controller in a first position or a second position, wherein the first position fluidly couples a first exhaust manifold with a second exhaust manifold, and wherein the second position decouples the first exhaust manifold from the second exhaust manifold.

10. The system of claim 9 wherein the exhaust manifold diagnostic test is applied to the first exhaust manifold and the second exhaust manifold in response to the unit controller positioning the sensor valve in the first position.

11. The system of claim 8, further comprising: A remote computer is in communication with the unit controller via a wireless communication protocol.

12. The system of claim 11, wherein the wireless communication protocol is at least one of 5G, Long Term Evolution (LTE), Code Division Multiple Access (CDMA), or Global System for Mobile Communications (GSM) telecommunication protocols.

13. The system of claim 8, wherein the wellbore pumping unit is a mud pump, a cement pumping unit, a blender unit, a water supply unit, or a fracturing pump.

14. A computer-implemented method of determining a health status of a pumping equipment system within a wellbore pump unit, the method comprising: initiating a diagnostic process including at least one diagnostic test by a unit controller, and wherein the unit controller includes a processor, a non-transitory memory, and an input-output device; performing, by said unit controller, said at least one diagnostic test; determining a set of results of said diagnostic test by said diagnostic process; comparing the set of results of the diagnostic test to a set of operational indicators; determining the health status of the pumping equipment system based on the comparison; as well as An indicia of the health status of the pumping equipment is output by the unit controller via the input-output device, wherein the indicia of the health status of the pumping equipment includes a visual prompt and an audible prompt or both.

15. The method of claim 14, wherein the at least one diagnosis comprises: Configure multiple sensor valves to configure the pipe network; filling the network of pipes with a volume of water; operating the pump to establish 1) a flow rate of water, 2) a target pressure value, or 3) both; measuring a periodic data set by at least one sensor; and The periodic data set is stored, wherein the periodic data set is associated with operation of the pump and configuration of the pipe network.

16. The method of claim 14, wherein the at least one diagnostic test is a feed manifold diagnostic test, wherein the feed manifold diagnostic test comprises: configuring a flow path through the piping network by positioning a plurality of sensor valves into a first flow path position, wherein the flow path includes a feed header between a high pressure line and a fluid end; operating the supply pump at full speed to deliver fluid via the flow path and closing the valve coupled to the return line; as well as A first periodic data set of pressure and flow rate is measured by at least one sensor while the fluid is communicated via the flow path with the sensor valve in a first position that is fully open and the valve on the return line is closed.

17. The method of claim 14, wherein the at least one diagnostic test is an exhaust manifold diagnostic test, wherein the exhaust manifold test comprises: coupling a high pressure supply line between the discharge hub and a test block with a shutoff valve; Set the emergency release value (ERV); operating a plunger pump to pump a volume of water and apply a target pressure value to the test block via the high pressure supply line; as well as A first periodic data set of pressure is measured by at least one sensor.

18. The method of claim 17, wherein the diagnostic process is configured to stop the plunger pump, disengage the power end from the fluid end, engage a brake on a drive shaft of the power end, open a pressure relief valve, or a combination thereof if the plunger pump exceeds the ERV value.

19. The method of claim 14, further comprising: A probability of a future maintenance event is determined by the unit controller in response to the set of results of the diagnostic test, a pump usage log, a pump maintenance log, or a combination thereof.

20. The method of claim 19, wherein the probability of a future maintenance event is determined by a predictive maintenance model.

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