Predicting frac pump component life interval

A system for predicting component life intervals, the system comprising:

• a frac fleet including a plurality of frac pump transports, each of the plurality of frac pump transports including a plurality of frac pumps, and each of the plurality of frac pumps including a plurality of components;
• a memory;
• and
• one or more processors operatively coupled to the memory, the memory comprising instructions that, when executed by the one or more processors, cause the one or more processors to:
• access pump maintenance data associated with each of the plurality of components of the frac fleet, wherein the pump maintenance data includes:
• (i) usage data of a plurality of historical well completion operations performed by the frac fleet, and (ii) actual component life intervals and associated metrics of replaced components corresponding to each of the plurality of components, wherein an actual component life interval of each replaced component defines a time period from installation to replacement of the replaced component, and wherein the associated metrics include, for a given replaced component (a) a maintenance event type indicator indicating whether the given replaced component was replaced due to a preventative maintenance event or a failure maintenance event, and (b) operating conditions during a life of the given replaced component, the operating conditions including one or more frac job design metrics specifying pumping parameters recorded during the actual component life interval of the given replaced component;
• analyze the pump maintenance data to generate a maintenance prediction model, the maintenance prediction model being configured to output for each of the plurality of components, a predicted component life interval as a function of an operating condition of a current well completion operation, wherein the predicted component life interval is measured in one of a number of pump strokes and a number of barrels pumped;
• apply the maintenance prediction model to the current well completion operation to generate the predicted component life interval for each of the plurality of components of the frac fleet;
• track, based on sensor data, a current component life indicating usage of each of the plurality of components during the current well completion operation;
• determine a remaining component life interval for each of the plurality of components based on the predicted component life interval and the tracked current component life;
• determine, for at least one component, whether the remaining component life interval, determined based on the predicted component life interval and the tracked current component life, is within a predetermined threshold range of the predicted component life interval corresponding to an end-of-life condition for the component;
• and
• automatically control operation of the frac fleet by transmitting, from a central server, a control signal to actuate a controllable coupling mechanism to disengage a frac pump from a prime mover and thereby cease pumping operation of the frac pump in response to determining that the remaining component life interval for the at least one component is within the predetermined threshold range.

A server operatively coupled to a frac fleet including a plurality of frac pump transports, each of the plurality of frac pump transports including a plurality of frac pumps, and each of the plurality of frac pumps including a plurality of components, the server comprising:

• memory;
• and
• one or more processors operatively coupled to the memory, the memory comprising instructions that, when executed by the one or more processors, cause the one or more processors to:
• access pump maintenance data associated with each of the plurality of components of the frac fleet, wherein the pump maintenance data includes:
• (i) usage data of a plurality of historical well completion operations performed by the frac fleet, and (ii) actual component life intervals and associated metrics of replaced components corresponding to each of the plurality of components, wherein an actual component life interval of each replaced component defines a time period from installation to replacement of the replaced component, and wherein the associated metrics include, for a given replaced component (a) a maintenance event type indicator indicating whether the given replaced component was replaced due to a preventative maintenance event or a failure maintenance event, and (b) operating conditions during a life of the given replaced component, the operating conditions including one or more frac job design metrics specifying pumping parameters recorded during the actual component life interval of the given replaced component;
• analyze the pump maintenance data to generate a maintenance prediction model, the maintenance prediction model being configured to output for each of the plurality of components, a predicted component life interval as a function of an operating condition of a current well completion operation, wherein the predicted component life interval is measured in one of a number of pump strokes and a number of barrels pumped;
• apply the maintenance prediction model to the current well completion operation to generate the predicted component life interval for each of the plurality of components of the frac fleet;
• track, based on sensor data, a current component life indicating usage of each of the plurality of components during the current well completion operation;
• determine a remaining component life interval for each of the plurality of components based on the predicted component life interval and the tracked current component life;
• determine, for at least one component, whether the remaining component life interval, determined based on the predicted component life interval and the tracked current component life, is within a predetermined threshold range of the predicted component life interval corresponding to an end-of-life condition for the component;
• and
• automatically control operation of the frac fleet by transmitting, from the server, a control signal to actuate a controllable coupling mechanism to disengage a frac pump from a prime mover and thereby cease pumping operation of the frac pump in response to determining that the remaining component life interval for the at least one component is within the predetermined threshold range.