Hydraulic fracturing pump health and performance monitoring using iot sensor networks

A method for monitoring a hydraulic fracturing pump, comprising:

• receiving measurement data from a plurality of sensors coupled to various components of the hydraulic fracturing pump forming a fog network and configured to measure certain operating parameters of the hydraulic fracturing pump, the plurality of sensors selected from the group consisting of a discharge pressure sensor, a suction pressure sensor, a fluid end vibration sensor, a power end vibration sensor, an rpm sensor, a cycle count sensor, a lubrication input oil quality sensor, a lubrication input temperature sensor, a lubrication input pressure sensor, a crankshaft position sensor, a crankshaft rotation sensor, a power end triaxial accelerometer, a lubrication supply pressure sensors, a lubrication supply temperature sensors, a cylinder drain pan temperature sensors, a fluid end triaxial accelerometer, a suction slurry pressure sensor, a suction slurry temperature sensor, and a discharge slurry pressure sensor;
• analyzing, at a processor co-located with and in communication with the plurality of sensors, the measurement data received from the plurality of sensors;
• determining whether the measurement data are indicative of faults and failures in the hydraulic fracturing pump, and generating prediction data;
• and
• transmitting the prediction data to at least one user device.

A system for monitoring a piece of hydraulic fracturing equipment, comprising:

• a plurality of sensors coupled to various components of the equipment forming a fog network and configured to measure certain operating parameters of the equipment, the plurality of sensors selected from the group consisting of a discharge pressure sensor, a suction pressure sensor, a fluid end vibration sensor, a power end vibration sensor, an rpm sensor, a cycle count sensor, a lubrication input oil quality sensor, a lubrication input temperature sensor, a lubrication input pressure sensor, a crankshaft position sensor, a crankshaft rotation sensor, a power end triaxial accelerometer, a lubrication supply pressure sensors, a lubrication supply temperature sensors, a cylinder drain pan temperature sensors, a fluid end triaxial accelerometer, a suction slurry pressure sensor, a suction slurry temperature sensor, and a discharge slurry pressure sensor;
• a processor communicatively coupled to and co-located with the fog network formed by the plurality of sensors and configured to receive and analyze measurement data received from the plurality of sensors to predict faults and failures in the equipment, and generate prediction data;
• and
• a communication interface configured for transmitting prediction fault data to at least one user device.