Apparatus and associated methods relate to monitoring health of a hydraulic system. A method includes monitoring pressure within the system and determining when a potential fatigue condition may occur based on counting the number of times pressure in the system has exceeded the at least one threshold. In some embodiments, strain cycle data is calculated based on a time sequence of signals generated by a hydraulic fitting, which is indicative of strain of the hydraulic fitting. An output signal indicative of the fatigue condition determined is generated. In some embodiments, the strain data includes a number of strain cycles that the time sequence of signals crosses from below a strain threshold to above the strain threshold.

Apparatus and associated methods relate to monitoring health of a hydraulic system. A method includes monitoring pressure within the system and determining when a potential fatigue condition may occur based on counting the number of times pressure in the system has exceeded the at least one threshold. In some embodiments, strain cycle data is calculated based on a time sequence of signals generated by a hydraulic fitting, which is indicative of strain of the hydraulic fitting. An output signal indicative of the fatigue condition determined is generated. In some embodiments, the strain data includes a number of strain cycles that the time sequence of signals crosses from below a strain threshold to above the strain threshold.

Aspects are provided for positive displacement pumps and methods and systems for controlling such pumps to provide alerts based on user configurable tubing usage limits. A pump may include a user interface, a memory storing processor executable instructions, and a processor coupled with the user interface and the memory and configured to execute the instructions to receive a configuration of a tubing usage limit via the user interface. The processor may be configured to operate the pump according to a program. The processor may be configured to measure a tubing usage during pump operation. The processor may be configured to generate an alert when the tubing usage reaches the tubing usage limit.

Apparatus and methods for determining operational health of a pump. An example method may include commencing operation of a processing device to monitor operational health of a pump for pumping a fluid at a wellsite, wherein the pump may be a reciprocating pump. During pumping operations of the pump, the processing device may receive pressure measurements of the fluid at a fluid inlet manifold and/or a fluid outlet manifold of the pump, receive position measurements of fluid displacing members of the pump, detect irregular pressure measurements based on the received pressure measurements, determine operational phase of the pump based on the received position measurements, and determine which of fluid inlet and outlet valves of the pump is leaking based on operational phase during which the irregular pressure measurements are detected.

Apparatus and methods for determining operational health of a pump. An example method may include commencing operation of a processing device to monitor operational health of a pump for pumping a fluid at a wellsite, wherein the pump may be a reciprocating pump. During pumping operations of the pump, the processing device may receive pressure measurements of the fluid at a fluid inlet manifold and/or a fluid outlet manifold of the pump, receive position measurements of fluid displacing members of the pump, detect irregular pressure measurements based on the received pressure measurements, determine operational phase of the pump based on the received position measurements, and determine which of fluid inlet and outlet valves of the pump is leaking based on operational phase during which the irregular pressure measurements are detected.

A pumping system includes a first variable displacement pump having a first inlet and a first outlet. The first outlet is fluidically connected to a system outlet. A first actuator is mechanically coupled to a first displacement mechanism of the first variable displacement pump A second variable displacement pump includes a second inlet and a second outlet. The second outlet is fluidically connected to the system outlet. The pumping system also includes a second actuator mechanically coupled to a second displacement mechanism of the second variable displacement pump. An electrohydraulic servo valve is hydraulically connected to the first and second actuators. An electronic engine controller is in communication with the electrohydraulic servo valve and is configured to send electrical current to the electrohydraulic servo valve to drive the first actuator and the second actuator.

Systems and methods for controlling downhole linear motors to minimize connections to surface equipment. In one embodiment, an ESP system is coupled by a power cable to equipment at the surface of a well. The ESP system includes a linear motor and a reciprocating pump. The motor has a set of position sensors that sense the position of a mover in the motor. Combining circuitry (E.G., XOR gate) combines the outputs of the position sensors into a single composite signal in which signal components corresponding to the position sensors are indistinguishable. A single channel carries the composite signal from the ESP system to the surface equipment. A control system determines a starting position of the motor and determines its subsequent position based on transitions in the composite signal. The motor is then operated based on the position determined from the composite signal.

Systems and methods for controlling downhole linear motors to minimize connections to surface equipment. In one embodiment, an ESP system is coupled by a power cable to equipment at the surface of a well. The ESP system includes a linear motor and a reciprocating pump. The motor has a set of position sensors that sense the position of a mover in the motor. Combining circuitry (E.G., XOR gate) combines the outputs of the position sensors into a single composite signal in which signal components corresponding to the position sensors are indistinguishable. A single channel carries the composite signal from the ESP system to the surface equipment. A control system determines a starting position of the motor and determines its subsequent position based on transitions in the composite signal. The motor is then operated based on the position determined from the composite signal.

A method of controlling a gas compression system includes comparing an engine load of an engine of the gas compression system during operation to a load threshold and controlling a suction valve coupled to an intake of a reciprocating compressor. The suction valve is controlled based at least in part on the comparison of the engine load to the load threshold. Controlling the suction valve includes incrementing the suction valve toward a closed position to reduce flow of a gas into the intake when the engine load is greater than or equal to the load threshold.

A method of controlling a gas compression system includes comparing an engine load of an engine of the gas compression system during operation to a load threshold and controlling a suction valve coupled to an intake of a reciprocating compressor. The suction valve is controlled based at least in part on the comparison of the engine load to the load threshold. Controlling the suction valve includes incrementing the suction valve toward a closed position to reduce flow of a gas into the intake when the engine load is greater than or equal to the load threshold.