Methods and systems for operating a fleet of pumps

A controller to control operation of a plurality of pump units associated with a hydraulic fracturing assembly, the controller in communication with the plurality of pump units and including one or more processors and memory having computer-readable instructions stored therein and operable by the one or more processors to:

• receive a demand hydraulic horse power (HHP) signal for the hydraulic fracturing assembly,
• based at least in part on the demand HHP signal, operate all available pump units of the plurality of pump units at a first output power to achieve the demand HHP,
• receive a loss of power signal from one or more of the plurality of pump units,
• designate one or more pump unit of the plurality of pump units as a reduced power pump unit (RPPU),
• designate the remaining pump units of the plurality of pump units as operating pump units (OPUs), wherein the one or more pump units of the OPUs includes at least two pump units,
• operate one or more of the OPUs at a second output power to meet the demand HHP signal of the hydraulic fracturing assembly, the first output power being in a first range based on a maximum continuous power (MCP) level of the plurality of pump units, the second output power being greater than the first output power and being in a second range between the MCP level and a maximum intermittent power (MIP) level of the one or more OPUs,
• obtain the second output power by operating a turbine engine associated with the one or more OPUs to above 100% of an MCP level of the turbine engine, and
• operate one or more of the OPUs at a third output power, the third output power being in a third range based on the MIP level.

A system to control operation of a plurality of pump units associated with a hydraulic fracturing assembly, the system comprising:

• a plurality of direct drive turbine (DDT) pump units associated with a hydraulic fracturing assembly, each DDT pump unit comprising:
• a turbine engine,
• a driveshaft, and
• a gearbox connected to the turbine engine and driveshaft, for driving the driveshaft;
• and
• a controller in communication with the plurality of DDT pump units, the controller including one or more processors and memory having computer-readable instructions stored therein and operable by the processor to:
• receive a demand hydraulic horse power (HHP) signal for the hydraulic fracturing assembly,
• based at least in part on the demand HHP signal, operate all available DDT pump units of the plurality of pump units at a first output power to achieve the demand HHP,
• receive a loss of power signal from one or more of the plurality of pump units,
• designate one pump unit of the plurality of pump units as a reduced power pump unit (RPPU) and the computer readable instructions being operable to operate the RPPU at a reduced output power below the first output power,
• designate one or more DDT pump units of the plurality of DDT pump units as operating pump units (OPUs), wherein the one or more DDT pump units of the OPUs includes at least two DDT pump units,
• operate one or more of the OPUs at a second output power to meet the demand HHP signal of the hydraulic fracturing assembly, the first output power being in a selected range of a maximum continuous power (MCP) level of the plurality of DDT pump units, the second output power being greater than the first output power and being in a first range of MCP level based on a maximum intermittent power (MIP) level of the plurality of DDT pump units, and
• obtain the second output power by operating a turbine engine associated with the one or more OPUs to above 100% of an MCP level of the turbine engine.

A hydraulic fracturing assembly comprising:

• a plurality of pump units operatively connected to a manifold, the plurality of pump units comprising a plurality of direct drive turbine (DDT) pump units, each DDT pump unit comprising:
• a turbine engine,
• a driveshaft associated with each turbine engine, and
• a gearbox connected to the turbine engine and driveshaft, for driving the driveshaft, and
• a controller in communication with the plurality of pump units, the controller including one or more processors and memory having computer-readable instructions stored therein and operable by the processor to:
• receive a demand hydraulic horse power (HHP) signal for the hydraulic fracturing assembly,
• based at least in part on the demand HHP signal, operate all available DDT pump units of the plurality of pump units at a first output power to achieve the demand HHP,
• receive a loss of power signal from one or more of the plurality of pump units,
• designate any DDT pump units not generating a loss of power signal as operating pump units (OPUs), wherein the one or more DDT pump units of the OPUs includes at least two DDT pump units,
• operate one or more of the OPUs at a second output power to meet the demand HHP signal of the hydraulic fracturing assembly,
• the first output power being in a first range based on a maximum continuous power (MCP) level of the plurality of DDT pump units, the second output power being greater than the first output power and being in a second range of MCP level to a maximum intermittent power (MIP) level of the plurality of the DDT pump units, and
• obtain the second output power by operating the turbine engine associated with each of the one or more OPUs to above 100% of an MCP level of the turbine engine.