Hydraulic fracturing pump health monitor

A failure detection system for a hydraulic pump including a lubrication system, the failure detection system comprising:

• a particle sensor operatively disposed in the lubrication system, the particle sensor configured to monitor and transmit particle data including a quantity of particles in a lubricant flowing through the lubrication system;
• an inlet temperature sensor operatively disposed in an inlet valve of the lubrication system and an outlet temperature sensor operatively disposed in an outlet valve of the lubrication system, each of the inlet temperature sensor and the outlet temperature sensor configured to monitor and transmit temperature data including a temperature of the lubricant;
• a plurality of vibration sensors coupled to a power end of the hydraulic pump, the plurality of vibration sensors configured to monitor and transmit vibration data including an acceleration of each of a plurality of roller bearings;
• and
• an electronic control module in operative communication with the particle sensor, the temperature sensor, and the plurality of vibration sensors, the electronic control module coupled to the power end of the hydraulic pump and configured to:
• receive the particle data transmitted by the particle sensor;
• determine a quantity of particles in the lubricant based on the received particle data;
• trigger a quality warning if the quantity of particles exceeds a predetermined threshold particle value;
• receive the temperature data transmitted by the inlet temperature sensor and the outlet temperature sensor;
• calculate a difference value between the temperature data received from the inlet temperature sensor and the temperature data received from the outlet temperature sensor;
• trigger a temperature warning if the difference value exceeds a predetermined threshold temperature value;
• receive vibration data transmitted by the plurality of vibration sensors;
• trigger a vibration warning if, after performing vibration based detection calculations on the vibration data, a threshold vibration value is exceeded;
• calculate a failure warning level of the hydraulic pump based on the quality warning, the temperature warning and the vibration warning;
• and
• transmit the failure warning level to an operator of the hydraulic pump.