Monitoring lubricant in hydraulic fracturing pump system

A monitoring apparatus adapted to monitor a hydraulic fracturing pump system comprising a reciprocating pump assembly whereby a crankshaft is configured to be rotated via a transmission attached to an engine, to drive the reciprocating pump assembly, the monitoring apparatus comprising:

• a gateway, comprising one or more processors and a non-transitory computer readable medium operably coupled thereto;
• a crankshaft rotation sensor configured to be in communication with the gateway;
• and an element configured to rotate along with the crankshaft and defining first and second outer-diameter transition regions;
• wherein the crankshaft rotation sensor is configured to count a number of times the crankshaft rotates;
• wherein the crankshaft rotation sensor comprises a proximity sensor, the proximity sensor comprising a distal end configured to be proximate the element when the element rotates along with the crankshaft;
• wherein the first and second outer-diameter transition regions are circumferentially spaced;
• wherein the proximity sensor is configured to detect each of the two outer-diameter transition regions as it rotates past the distal end of the proximity sensor;
• and
• wherein the element comprises a collar, the collar comprising first and second arcuate sections defining first and second outer diameters, respectively;
• wherein the first and second diameters are different in that the first outer diameter is greater than the second outer diameter;
• and
• wherein the difference between the first and second outer diameters defines the first and second outer-diameter transition regions.

A method of monitoring lubricant in a hydraulic fracturing pump system positioned at a location, the hydraulic fracturing pump system comprising an engine, a transmission operably coupled to the engine, and a reciprocating pump assembly operably coupled to the transmission, the reciprocating pump assembly comprising a crankshaft via which the transmission is operably coupled to the reciprocating pump so that the engine is configured to rotate the crankshaft, via the transmission, to drive the reciprocating pump assembly, and an element configured to rotate along with the crankshaft, the element defining first and second outer-diameter transition regions spaced circumferentially, the method comprising:

• detecting, using a gateway and a proximity sensor comprising a distal end proximate the element when the element rotates along with the crankshaft, the two outer-diameter transition regions as the element rotates past the distal end of the proximity sensor to determine a RPM of the crankshaft;
• detecting, using the gateway and the RPM of the crankshaft, one or more events;
• activating, using the gateway and/or a computing device in communication therewith, one or more alarms to indicate the existence of the detected one or more events;
• and
• wherein the first and second outer-diameter transition regions are circumferentially spaced by about 180 degrees.

A method of monitoring lubricant in a hydraulic fracturing pump system positioned at a location, the hydraulic fracturing pump system comprising an engine, a transmission operably coupled to the engine, and a reciprocating pump assembly operably coupled to the transmission, the reciprocating pump assembly comprising a crankshaft via which the transmission is operably coupled to the reciprocating pump so that the engine is configured to rotate the crankshaft, via the transmission, to drive the reciprocating pump assembly, and an element configured to rotate along with the crankshaft, the element defining first and second outer-diameter transition regions spaced circumferentially, the method comprising:

• detecting, using a gateway and a proximity sensor comprising a distal end proximate the element when the element rotates along with the crankshaft, the two outer-diameter transition regions as the element rotates past the distal end of the proximity sensor to determine a RPM of the crankshaft;
• detecting, using the gateway and the RPM of the crankshaft, one or more events;
• activating, using the gateway and/or a computing device in communication therewith, one or more alarms to indicate the existence of the detected one or more events;
• wherein the element comprises a collar, the collar comprising first and second arcuate sections defining first and second outer diameters, respectively;
• wherein the first and second diameters are different in that the first outer diameter is greater than the second outer diameter;
• and
• wherein the difference between the first and second outer diameters defines the first and second outer-diameter transition regions.

A monitoring apparatus adapted to monitor a hydraulic fracturing pump system comprising an engine, a transmission operably coupled to the engine, and a reciprocating pump assembly operably coupled to the transmission, the reciprocating pump assembly comprising a crankshaft via which the transmission is operably coupled to the reciprocating pump so that the engine is configured to rotate the crankshaft, via the transmission, to drive the reciprocating pump assembly, the monitoring apparatus comprising:

• an element configured to rotate along with the crankshaft;
• wherein the element defines first and second outer-diameter transition regions;
• and
• wherein the first and second outer-diameter transition regions are circumferentially spaced by about 180 degrees.