Systems and methods to autonomously operate hydraulic fracturing units

A method of operating one or more hydraulic fracturing pumps to pump fracturing fluid, the method comprising:

• receiving one or more operational signals indicative of operational parameters associated with pumping fracturing fluid;
• determining, based at least in part on the one or more operational signals, an amount of required fracturing power sufficient to perform the hydraulic fracturing operation;
• receiving one or more characteristic signals indicative of fracturing pump characteristics associated with at least one of the one or more hydraulic fracturing pumps, at least one of the one or more characteristic signals indicative of a detrimental condition of any of the one or more hydraulic fracturing pumps;
• determining, based at least in part on the one or more characteristic signals, an available power from one or more engines to perform the hydraulic fracturing operation;
• determining a power difference between the available power and the required power;
• and
• when the power difference occurs to perform the hydraulic fracturing operation, increasing power output of the one or more of the engines associated with the at least one of the one or more hydraulic fracturing pumps, thereby to supply power to a respective hydraulic fracturing pump of the one or more hydraulic fracturing pumps, the increasing power output of the one or more engines including increasing a first power output ranging from about 75% to about 95% of maximum rated power output to a second power output ranging from about 90% to about 110% of the maximum rated power output.

A hydraulic fracturing control assembly to operate a plurality of hydraulic fracturing pumps, each of the plurality of hydraulic fracturing pumps positioned to be driven by one or more engines, thereby to pump fracturing fluid, the hydraulic fracturing control assembly comprising:

• an input device configured to facilitate communication of one or more operational signals indicative of operational parameters associated with pumping fracturing fluid into a wellhead according to performance of a hydraulic fracturing operation;
• one or more sensors configured to generate one or more sensor signals indicative of one or more of a flow rate of fracturing fluid or a pressure associated with fracturing fluid;
• and
• a controller in communication with one or more of the plurality of hydraulic fracturing pumps, the input device, or the one or more sensors, the controller configured to:
• receive the one or more operational signals indicative of operational parameters associated with pumping fracturing fluid,
• determine, based at least in part on the one or more operational signals, an amount of required fracturing power sufficient to perform a hydraulic fracturing operation,
• receive one or more characteristic signals indicative of fracturing pump characteristics associated with at least one of the plurality of hydraulic fracturing pumps, at least one of the one or more characteristic signals indicating a detrimental condition of which any of the plurality of hydraulic fracturing pumps has experienced,
• determine, based at least in part on the one or more characteristic signals, an available power from the one or more engines to perform the hydraulic fracturing operation,
• determine a power difference between the available power and the required power, and
• control operation of the at least one of the plurality of hydraulic fracturing pumps based at least in part on the power difference, and when the power difference is indicative of a power deficit to perform the hydraulic fracturing operation, increase a power output of the one or more engines, thereby to supply power to a respective hydraulic fracturing pump of the plurality of hydraulic fracturing pumps, the increase of the power output of the one or more engines including increasing power output from a first power output ranging from about 75% to about 95% of maximum rated power output to a second power output ranging from about 90% to about 110% of the maximum rated power output.

A hydraulic fracturing system comprising:

• a plurality of hydraulic fracturing pumps, each of the plurality of hydraulic fracturing pumps being positioned to be driven by one or more engines, thereby to pump fracturing fluid into a wellhead;
• an input device configured to facilitate communication of one or more operational signals indicative of operational parameters associated with pumping fracturing fluid into a wellhead according to performance of a hydraulic fracturing operation;
• one or more sensors configured to generate one or more sensor signals indicative of one or more of a flow rate of fracturing fluid or a pressure associated with fracturing fluid;
• and
• a controller in communication with one or more of the plurality of hydraulic fracturing pumps, the input device, or the one or more sensors, the controller configured to:
• receive the one or more operational signals indicative of operational parameters associated with pumping fracturing fluid into a wellhead according to performance of a hydraulic fracturing operation,
• determine, based at least in part on the one or more operational signals, an amount of required fracturing power sufficient to perform the hydraulic fracturing operation,
• receive one or more characteristic signals indicative of fracturing pump characteristics associated with at least one of the plurality of hydraulic fracturing pumps, at least one of the one or more characteristic signals indicating a detrimental condition of which any of the plurality of hydraulic fracturing pumps has experienced,
• determine, based at least in part on the one or more characteristic signals, an available power from the engines to perform the hydraulic fracturing operation,
• determine a power difference between the available power and the required power, and
• control operation of at least some of the plurality of hydraulic fracturing pumps based at least in part on the power difference, and when the power difference is indicative of a power deficit to perform the hydraulic fracturing operation, increase a power output of at least one of the one or more engines, thereby to supply power to a respective hydraulic fracturing pump of the plurality of hydraulic fracturing pumps, the increase of the power output of the at least one of the one or more engines comprising increasing a power output from a first power output ranging from about 75% to about 95% of maximum rated power output to a second power output ranging from about 90% to about 110% of the maximum rated power output.