A method for determining a flow volume of a fluid delivered by a pump, wherein the flow volume is determined as a function of predefined pump information depending on a pump geometry, rotation speed information, which correlates with the rotation speed of the pump, and pressure information, which correlates with a differential pressure at the pump.

The method serves for operating at least one pump assembly (1, 1a, 5) of a multitude of pump assemblies (1, 1a, 5) which each comprise a programmable electronic motor (4, 4a, 6) control for individual pumps or groups or pumps, and which are at least temporarily data-connected to a server (8) via a network, with which data, in particular parameters and/or operating data of the multitude of pump assemblies (1, 1a, 5) is transferred via the network to a server (8) and is stored there in a data base. The stored data is processed according to defined typically statistical computation rules, whereupon the at least one pump assembly is then adapted in its programming via the network, on the basis of the processed data.

A signal processor is provided comprising one or more signal processor modules configured to: compare signaling containing information about historical data related to the performance of a pump; and provide corresponding signaling containing information about predicted maintenance needs of the pump on a real time basis based at least partly on the signaling compared containing information about the historical data related to the performance of the pump. The one or more signal processor modules may be configured to compare over time the hydraulic power generated by the pump and electric power consumed by a motor driving the pump, including tracking a ratio of hydraulic to electric power. The one or more signal processor modules may be configured to predict maintenance needs based on an algorithm that takes into account a trade-off between the cost of power consumed by a motor driving the pump and the cost associated with the pump maintenance in order to substantially minimize the total cost of operating the pump.

A method, system, and apparatus for testing mobile pumps and mobile fire pumps. Exemplary embodiments described herein can reduce or eliminate the discharge of water used for testing pumps to the ground or other ambient environments. Further, exemplary embodiments can reduce or eliminate the potential for contamination of water bodies and reduce or eliminate need for large transportable reservoirs as a source of water. Exemplary embodiments can include attachment of hose valves to pump outlets for controlling a flow rate of water as well as water pressure. A hose may further be coupled to each hose valve and looped to a pump inlet, allowing for the recycling of water. Flow meters may further be provided on the looped lines to measure water flow. A low flow capacity water source and discharge may be utilized to provide further control of or adjustment to test system temperature, water flow and pressure.

A pump controller features a signal processor configured to respond to signaling containing information about three corresponding discrete arrays with respect to a discrete motor speed for each system position at a motor speed derived from 3D discrete distribution surfaces of motor power, pump differential pressure and flow rate by respective numerical interpolations; and determine corresponding signaling containing information to control a pump, or pumps in a system of pumps, or a system of pumps based upon a corresponding pump differential pressure and flow rate at the motor speed for a corresponding power reading value determined using a numerical interpolation of the three corresponding discrete arrays, the signaling received. The signal processor is configured to provide the corresponding signaling as control signaling to control the pump, or the pumps in the system of pumps, or the system of pumps.

A pumping system having a pump includes a pump controller having a signal processor or processing module configured at least to: receive signaling containing information about pump differential pressure, flow rate and corresponding power data at motor maximum speed published by pump manufacturers, as well as instant motor power and speed; and determine corresponding signaling containing information about instant pump differential pressure and flow rate using a combined affinity equation and numerical interpolation algorithm to control the pump in the pumping system, based upon the signaling received.

Apparatus, including a pump system controller, features a signal processor or processing module configured at least to: receive signaling containing information about pump differential pressure, flow rate and corresponding power data at motor maximum speed published by pump manufacturers, as well as instant motor power and speed, for a system of pumps arranged in a multiple pump configuration; and determine corresponding signaling containing information about instant pump differential pressure and flow rate for the system of pumps arranged in the multiple pump configuration using a combined affinity equation and numerical interpolation algorithm, based upon the signaling received.

A rig management system is disclosed. The rig management system may be configured to receive information to be used to control shifting of a transmission to prevent cavitation during use of the hydraulic fracturing rig. The rig management system may be configured to determine a flow rate for a pump based on the information. The rig management system may be configured to determine an output torque of the transmission based on the flow rate. The rig management system may be configured to determine a transmission gear for the transmission based on the output torque and a fuel consumption map, wherein the fuel consumption map identifies a respective fuel consumption rate for different combinations of transmission gears and output torques. The rig management system may be configured to cause the transmission to shift into the transmission gear after determining the transmission gear.

A method for operating a pump includes establishing a pump limit characteristics diagram by mapping a first system parameter (P1) as a function of a second system parameter (P2) to identify a permissible operating region of the pump; for each first system parameter value (P1.sub.0), identifying a minimum allowable second system parameter value (P2.sub.0); monitoring the first system parameter (P1) and identifying a minimum allowable second system parameter value (P2.sub.0) corresponding to the monitored first system parameter value (P1.sub.m); monitoring the second system parameter (P2) and comparing the monitored second system parameter value (P2.sub.m) with the identified minimum allowable second system parameter value (P2.sub.0); and regulating a control valve that controls fluid flow through a return line connecting the suction and discharge sides of the pump so that the monitored second system parameter value (P2.sub.m) does not fall below the minimum allowable second system parameter value (P2.sub.0).

A system, method, and computer-readable medium for determining the flow rate and fluid density in an electrical submersible pump (ESP) and controlling the ESP based on the flow rate and density. In one implementation, an ESP system includes an ESP, drive circuitry, a current sensor, a voltage sensor, and a processor. The ESP includes an electric motor. The drive circuitry is electrically coupled to the ESP and is configured to provide an electrical signal to power the ESP. The current sensor is configured to measure a current of the electrical signal. The voltage sensor is configured to measure a voltage of the electrical signal. The processor is configured to calculate speed of a shaft of the electric motor based on a frequency induced by rotation of the motor detected in the current. The processor is also configured to calculate a density of fluid in the ESP based on the speed.