Systems and methods for monitoring, detecting, and/or intervening with respect to cavitation and pulsation events during hydraulic fracturing operations may include a supervisory controller. The supervisory controller may be configured to receive pump signals indicative of one or more of pump discharge pressure, pump suction pressure, pump speed, or pump vibration associated with operation of the hydraulic fracturing pump. The supervisory controller also may be configured to receive blender signals indicative of one or more of blender flow rate or blender discharge pressure. Based on one or more of these signals, the supervisory controller may be configured to detect a cavitation event and/or a pulsation event. The supervisory controller may be configured to generate a cavitation notification signal indicative of detection of cavitation associated with operation of the hydraulic fracturing pump, and/or a pulsation notification signal indicative of detection of pulsation associated with operation of the hydraulic fracturing pump.

Aspects of the subject technology relate to systems and methods for optimizing multi-unit pumping operations at a well site. Systems and methods are provided for receiving sensor data from a hydraulic fracturing fleet equipment at an equipment system, designating an event as being flagged based on the sensor data from the hydraulic fracturing fleet equipment, determining a physical action based on the flagged event and a priority list of actions, and providing instructions to a first pump of the hydraulic fracturing fleet equipment to perform the physical action based on the flagged event and the priority list of actions.

Aspects of the subject technology relate to systems and methods for optimizing multi-unit pumping operations at a well site. Systems and methods are provided for receiving sensor data from a hydraulic fracturing fleet equipment at an equipment system, designating an event as being flagged based on the sensor data from the hydraulic fracturing fleet equipment, determining a physical action based on the flagged event and a priority list of actions, and providing instructions to a first pump of the hydraulic fracturing fleet equipment to perform the physical action based on the flagged event and the priority list of actions.

A fixture has a body that connects to a motor, the body having a bore. The body has a piston in the bore, separating the bore into a pressure chamber and a lubricant chamber in fluid communication with lubricant in the motor. A technician applies pressure to the pressure chamber, which causes the piston to increase pressure of the lubricant in the lubricant chamber and in the motor. The technician monitors a distance of movement of the piston, indicating a presence of residual air in the lubricant. If the movement meets a amount, the technician applies a vacuum to the lubricant chamber and bleeds out residual air from the lubricant in the motor.

A system and method for predicting failures of rod pumps using a scaled load ratio is configured to: optimize the size of a rolling window, the upper and lower bounds of the normal range of the scaled load ratio, an alert period, and an alert frequency ratio; receive data of a current maximum/minimum loads on a surface rod, and a current speed; remove outliers showing an abnormality; scale the current maximum/minimum loads on the surface rod using the maximum/minimum loads on the surface rod in normal operation; calculate a scaled load ratio; calculate the average of scaled load ratios in the rolling window; determine whether the average of scaled load ratios is in the normal range, and classify the values as normal and abnormal events; calculate the ratio of the abnormal events in the alert period, and generate an alert when the calculated ratio exceeds the alert frequency ratio; and monitor a pump state using the pump failure prediction system.

A system and method for predicting failures of rod pumps using a scaled load ratio is configured to: optimize the size of a rolling window, the upper and lower bounds of the normal range of the scaled load ratio, an alert period, and an alert frequency ratio; receive data of a current maximum/minimum loads on a surface rod, and a current speed; remove outliers showing an abnormality; scale the current maximum/minimum loads on the surface rod using the maximum/minimum loads on the surface rod in normal operation; calculate a scaled load ratio; calculate the average of scaled load ratios in the rolling window; determine whether the average of scaled load ratios is in the normal range, and classify the values as normal and abnormal events; calculate the ratio of the abnormal events in the alert period, and generate an alert when the calculated ratio exceeds the alert frequency ratio; and monitor a pump state using the pump failure prediction system.

A power end assembly includes a crankshaft section, a crosshead section, and a connector section coupled together by one, two, or more sets of stay rods. The power end may include one or more support plates that are coupled to the crankshaft section and/or crosshead section. The crosshead section includes a plurality of individual crosshead frames. The connector section may include a plurality of individual connector plates or may be a unitary connector plate. The power end is configured to be coupled to a fluid end assembly by coupling the fluid end assembly to the connector plates.

A variable frequency drive system and a method of controlling a pump driven by a motor with the pump in fluid communication with a fluid system is provided. The method includes monitoring a pressure in the fluid system, monitoring and adjusting an operating frequency of the motor to maintain the pressure at a pressure set point, and, based on the monitored operating frequency, causing the pump to temporarily boost the pressure in the fluid system to a temporary boost set point for a first time period. The method also includes determining whether the temporarily boosted pressure in the fluid system stays above the pressure set point for a second time period and causing the pump to enter a sleep mode when the temporarily boosted pressure stays above the pressure set point through the second time period.

Disclosed embodiments include a reconfigurable multi-stage gas compressor having a first-stage compression cylinder, a second-stage compression cylinder, and two stepped cylinders. Each of the stepped cylinders include first and second compression cylinders. The gas flow paths through the stepped cylinders are configured in a user-selectable configuration to be in series or in parallel so that the reconfigurable multi-stage gas compressor functions as one of: a three-stage compressor, as a four-stage compressor, and as a hybrid three/four stage compressor. In first and second configurations, the system generates four stages of compression and outputs 4-stage compressed gas through a single exit port, and through dual exit ports, respectively. In a third configuration, the system outputs hot and cooled 3-stage compressed gas through first and second ports and 4-stage compressed gas through a third port. In a fourth configuration, the system outputs hot and cooled 3-stage compressed gas with no 4-stage compressed gas.

A fixture has a body that connects to a motor, the body having a bore. The body has a piston in the bore, separating the bore into a pressure chamber and a lubricant chamber in fluid communication with lubricant in the motor. A technician applies pressure to the pressure chamber, which causes the piston to increase pressure of the lubricant in the lubricant chamber and in the motor. The technician monitors a distance of movement of the piston, indicating a presence of residual air in the lubricant. If the movement meets a amount, the technician applies a vacuum to the lubricant chamber and bleeds out residual air from the lubricant in the motor.