System and method of controlling single or dual pump operation

A method for calibrating a unit controller with a managing process determining a position of a decoupler mechanism on the pumping unit. The managing process can calibrate the unit controller with a dual pump mode in response to determining the decoupler mechanism is in a coupled position. The managing process can calibrate the unit controller with a single pump mode in response to determining the decoupler mechanism is in a decoupled position with the pumping unit operating with the first fluid end coupled to the power end and the second fluid end decoupled from the power end. The system controller can pump a wellbore treatment fluid in accordance with the pumping unit in i) the dual pump mode or ii) the single pump mode.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

BACKGROUND

Hydraulic fracturing operations may include a number of high pressure pumps directing proppant laden fluid into a hydrocarbon bearing formation. The proppant laden fluid must be pumped at pressure into downhole earth formations to produce fractures within the formation and provide a flow path to produce the desired hydrocarbons such as oil and gas. The pressures, flowrates, and concentration of the proppant laden fluids must be controlled to achieve the intended effect, and typically multiple pumps are used for purposes of volume and redundancy. When one pump fails, operators can compensate by manually adjusting the remaining pumps to maintain the desired concentration and flowrate of proppant into the downhole formation. An increase in pumping properties to one or more of the remaining pumps may be detrimental based on the health of the remaining pumps. A method of balancing the pumping properties among multiple pumps is desirable.

DETAILED DESCRIPTION

As used herein, a pumping unit can comprise two pumps coupled to a prime mover. The term pump can refer to a fluid end, a positive displacement pump, a plunger pump, a piston pump, a progressive cavity pump, a gear pump, a screw pump, a lobe pump, a double screw pump, an impeller and diffuser, a centrifugal pump, a multistage centrifugal pump, a turbine, or any other type of pump suitable for pressurizing fluids. In some embodiments, the prime mover can include an electric motor, an internal combustion engine, or a hybrid motor configured to alternate between the two types of motor.

As used herein, a wellbore treatment can be any fluid pumped into a wellbore during the multiple stages of oil well construction. Each stage can be carried out with specialized equipment and wellbore treatments. Examples of various wellbore treatments can include drilling mud that is pumped down the wellbore by mud pumps. Drilling mud as a wellbore treatment can bring cutting back to surface and stabilize the inner surface of the wellbore. In another example, the various wellbore treatments can include cementitious slurry and any variety of spacer fluids that are pumped down the wellbore by cement pumps. Cement slurry as a wellbore treatment can be used to stabilize the wellbore, isolate subterranean formations, and form a barrier between formation fluids and a string of casing. In another scenario, the various wellbore treatments can include a fracturing slurry that is pumped down the wellbore by fracturing pumps. Fracturing slurry as a wellbore treatment can be used to fracture the wellbore, create seams, and fill the fractures with a propping material, e.g., sand, to provide a pathway for the production of wellbore fluids. The various wellbore treatments can include a wide variety of fluids including fracturing slurry, acidizing fluid, cementing fluid, spacer fluids, resin compounds for formation consolidation or isolation, weighted fluids for well control and/or intervention, gravel packing fluids for sand placement, solvent for cleaning, water and/or completion fluids for tool placement, clean-out, circulating, jetting and other remediation treatments.

As used herein, a “clean” pump may refer to a pump that is used for pumping fluid that substantially comprises water. Similarly, “clean” fluid may refer to fluid that contains a minimal amount or no proppant or sand. In certain instances, “clean” fluid may comprise additives such as salts, friction reducers, corrosion inhibitor, gelling agents, acidifying agents, chemical additives, or any other types of additives. “Dirty” fluid may refer to fluid that comprises sand or proppant, or fluid that is sand-laden. A “dirty” pump may refer to a pump that is used for pumping fluid that comprises sand or proppant. In certain instances, the dirty pumping units may pump fluids with a proppant concentration of 5% to 60%. As used herein, “dirty” fluid may also be referred to as “slurry”. In certain instances, “dirty” fluid may also comprise one or more additives, for example, the additives listed above with respect to the “clean” fluid. In certain instances, “low pressure” can refer to pressures less than 1,000 psi and “high pressure” can refer to pressures between 1,000 and 30,000 psi.

Certain embodiments of the present disclosure are directed to systems and methods for balancing the pumping load across multiple pumping units simultaneously fracturing one or more wellbores. In certain instances, it may be desirable to have independent control of the one or more pumping units, for example, both clean pumping units and dirty pumping units, to maintain a constant rate of proppant-laden fluid delivered to the wellbore. Adjusting the pumping load of individual pumping units downstream of the blender based on a number of weighted factors, also referred to as operational factors, may provide more reliability and fewer maintenance events while maintaining the amount and pressure of fracturing fluid pumped into a given well bore. Balancing the pumping load on a plurality of pumping units may allow for the reduction in pumping load and eventual replacement of a pump with decreasing pumping performance.

A balancing process can remove a pump, e.g., fluid end, from a pumping operation while compensating for the loss of pumping flowrate with the pumps, e.g., fluid ends, of the remaining pumping units. In some embodiments, the balancing process can stop the pumping operation of a selected pumping unit, decouple a pump, e.g., fluid end, with decreased pumping performance from the prime mover and return the selected pumping unit to the pumping operation utilizing the other pump coupled to the prime mover. In some embodiments, the balancing process can remove and replace a selected pumping unit with a pumping unit held in reserve.

Turning now toFIG.1, a partial cross-sectional view of a wellbore servicing environment100is described. In some embodiments, a pumping unit110may be fluidically coupled to a wellbore112at a remote wellsite114. The remote wellsite114may be on land and the wellbore treatment and the pumping unit110can be optimized for the wellsite on land. In some embodiments, the remote wellsite114may be offshore and the wellbore treatment and pumping unit110can be optimized for a wellsite offshore. For example, the pumping unit110utilized offshore may be skid mounted whereas the pumping unit110utilized on land may be truck mounted or trailer mounted.

The wellbore112can be drilled with any suitable drilling system. A casing string116can be conveyed into the wellbore112by a drilling rig, a workover rig, an offshore rig, or similar structure (not shown). A wellhead120may be coupled to the casing string116at surface122. The pumping unit110, located offshore or on land, can be fluidically coupled to a wellhead120by a high pressure line124. The wellbore112can extend in a substantially vertical direction away from the earth's surface122and can be generally cylindrical in shape with an inner bore126. At some point in the wellbore path, the vertical portion128of the wellbore112can transition into a substantially horizontal portion130. The wellbore112can be drilled through the subterranean formation131to a hydrocarbon bearing formation132. Perforations133made during the completion process that penetrate the casing string116and hydrocarbon bearing formation132can enable the fluid in the hydrocarbon bearing formation132to enter the casing string116.

In some embodiments, the pumping unit110, also called a fracturing unit, comprises a pumping system138and a unit controller140. The pumping system138comprises a first pump144, a second pump146, and a prime mover148. The prime mover148can be an electrical motor rotationally coupled to the first pump144and the second pump146. The pumping system138can receive a fracturing fluid from a fluid source, e.g., a blender, and can deliver the fracturing fluid to the wellbore112via the high pressure line124. The unit controller140may be a computer system suitable for communication with the service personnel, communication with a central controller, and control of the pumping system138as will be described further herein.

In some embodiments, the wellbore112can be completed with a cementing process that places a cement slurry between the casing string116and the wellbore112to cure into a cement barrier152. The wellhead120can be any type of pressure containment equipment connected to the top of the casing string116, such as a surface tree, production tree, subsea tree, lubricator connector, blowout preventer, or combination thereof. The wellhead120can include one or more valves to direct the fluid flow from the wellbore112and one or more sensors that measure wellbore properties such as pressure, temperature, and/or flowrate data.

The pumping unit110can follow a pump procedure with multiple sequential steps to deliver a wellbore treatment, e.g., proppant slurry, into the wellbore112. The pumping unit110can be fluidically coupled to a wellbore treatment fluid source, e.g., a blender (not shown). The pumping unit110can deliver a wellbore treatment fluid to the hydrocarbon bearing formation132via the perforations134. The pumping unit110can place the wellbore treatment fluid with sufficient volume and pressure to split or “fracture” the formation132along veins or planes extending from the wellbore112. In some embodiments, the fracturing fluid comprises propping agents, also referred to as proppant, that are deposited into the fractures, e.g., veins, to support and/or prevent the fractures from closing. These proppants, e.g., sand and/or ceramic beads, can create a highly permeable fluid pathway to the inner bore of the casing string116via the perforations134.

In some embodiments, the wellbore servicing environment100can comprise additional completion equipment to direct the wellbore treatment fluids into a target location. For example, a fracturing plug, e.g., wellbore isolation plug, can be set or installed below a target location for a set of perforations, e.g., perforations134, to isolate the wellbore112below the target location from pumping pressures. In some embodiments, one or more perforating guns can be utilized to produce additional perforations, in coordination with, the one or more fracturing plugs. In another scenario, a fracturing valve, e.g., production sleeve, can be coupled to the casing string116and installed at a target depth. The fracturing valve can be opened for the placement of a wellbore treatment and can closed afterward. Although one set or location for the perforations134is illustrated in the wellbore servicing environment100, it is understood that the wellbore servicing environment can comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or any number of sets of perforations134.

The pumping unit110can be part of a fracturing fleet, also referred to as a fracturing spread, comprising a plurality of pumping units fluidically coupled to a wellbore via a high pressure manifold and working in concert to place a proppant slurry into a subterranean formation. Turning now toFIG.2, an exemplary fracturing spread200is described. As illustrated inFIG.2, the exemplary fracturing spread200can comprise one or more groups of pumping units fluidically coupled to a wellbore210. A first group of pumping units212can be coupled to a blender unit214providing a proppant slurry and can be referred to as dirty pumping units212. The dirty pumping units212can be fluidically coupled to the dirty blender214by a low pressure manifold216and the wellbore210by a high pressure manifold218and a high pressure line248. The first group of pumping units212can include pumping units220,222,224, and226. Each of the pumping units, e.g., pumping unit220, can be an embodiment of pumping unit110fromFIG.1and comprise a prime mover230, e.g., prime mover148, rotationally coupled to a first pump232, e.g., first pump144, and a second pump234, e.g., second pump146. The prime mover230can be an electric motor. For reference, the pumps232,234are labeled A, B and the prime mover230is labeled M. Hereinafter, the term pump220A will refer to the first pump232powered by the prime mover230of the pumping unit220. The term pump220B will refer to the second pump234of the pumping unit220. The term motor220M will refer to the prime mover230of the pumping unit220. Likewise, the pumps and prime movers of the other pumping units are labeled with A, B, and M. For example, the term pump222A, pump224A, and pump226A will refer to the first pump of each corresponding pumping units222,224, and226respectively.

The fracturing units of the fracturing spread200can be communicatively coupled to a control center236. The control center236comprises one or more controllers, e.g., computer systems, configured to direct the pumping operation of each of the fracturing units of the fracturing spread200while receiving periodic datasets indicative of the pumping operation. For example, the control center236can direct the dirty pumping units212to pump the proppant slurry into the wellbore210at a desired flowrate and pressure with the dirty blender214to suppling the desired concentration of proppant slurry to the dirty pumping units212via the low pressure manifold216. The controller within the control center can be communicatively connected to a unit controller, e.g., unit controller140ofFIG.1, of each of the fracturing units. The controller can be communicatively connected to the unit controller of each of the fracturing units by wired communication, wireless communication, or combinations thereof.

The blender unit214can mix liquid, e.g., water, with various chemicals and a proppant, e.g., sand, to produce the proppant slurry. In some embodiments, the blender unit214, also referred to as the dirty blender, can produce a gelled water by mixing water from a water supply unit240and various chemicals from a chemical unit242. The proppant slurry can be produced by mixing proppant from a proppant supply unit244to produce a desired concentration of proppant within the proppant slurry. The dirty blender214can be fluidically coupled to the low pressure manifold216by a supply line246.

The fracturing units of the fracturing spread200can include a plurality of sensors to provide periodic datasets to the unit controller within each fracturing unit and to the controller within the control center236. For example, each pumping unit, e.g., pumping unit220can have a flowrate sensor coupled to the pump220A inlet, a pressure sensor coupled to the pump220A outlet, and a position sensor coupled to the motor220M. The plurality of sensors can provide periodic datasets of the pumping operation and of a status of each of the pumping units, e.g., pumping unit220, to the controller within the control center236. The sensors can be communicatively connected to the unit controller and/or the controller within the control center236by wired communication, wireless communication, or combinations thereof.

In some embodiments, one or more sensors can be fluidically coupled with the wellbore210, for example, a sensor can be coupled to a wellhead, a production tree, a fracturing tree, a wellhead isolation device, or combinations thereof. The sensors can be configured to measure one or more wellbore environment properties such as wellbore pressure and wellbore temperature. The sensors can be configured to measure wellbore treatment fluid properties, such as, density, flowrate, pressure, and temperature. In some embodiments, the one or more sensors can be located within the wellbore210, for example, proximate to the formation, e.g., formation132ofFIG.1. In some embodiments, one or more sensors can be located in or coupled to adjacent wellbores, for example, in offset wells and/or observation wells. The one or more sensors coupled to the wellhead, located within the wellbore210, or installed within adjacent wellbores can be communicatively coupled, by wired or wireless communication, to the one or more controllers within the control center236.

In some embodiments, the first pumping unit group212can be an example of a typical fracturing spread with a dirty blender214supplying a proppant slurry with a desired proppant concentration to a plurality of pumping units, e.g., dirty pumping units212, configured to pump the proppant slurry at a desired pressure and flowrate to a wellbore210. In some embodiments, the first pumping unit group212can be coupled to two or more wellbores, e.g., wellbore210, to perform a sequential or simultaneous fracture of the two or more wellbores.

The exemplary fracturing spread200can comprise a second pumping unit group250configured to pump a clean fluid to the wellbore210. The second group of pumping units, also referred to as clean pumping units250, can be coupled to a blender unit254providing a clean fluid by a low pressure manifold256via a supply line258. A water supply unit280and a chemical unit282can be fluidically coupled to the blender unit254, also referred to as a clean blender. The clean pumping units250can be fluidically coupled to the wellbore210by a high pressure manifold260and a high pressure line262. The second pumping unit group250, e.g., the clean pumps, can include pumping units270,272,274, and276. Each of the pumping units, e.g., pumping unit270, can be an embodiment of pumping unit110fromFIG.1and comprise a prime mover “M”, e.g., prime mover148, rotationally coupled to a first pump “A”, e.g., first pump144, and a second pump “B”, e.g., second pump146. As previously described, the pumps of each pumping unit are labeled A, B and the prime mover is labeled M. For example, the term pump270A will refer to the first pump “A” powered by the prime mover “M” of the pumping unit270.

The fracturing spread200can combine the clean fluid from the clean pumping units250with the dirty fluid, e.g., proppant slurry, from the dirty pumping units212at the wellbore210. In some embodiments, the high pressure line262from the high pressure manifold260of the clean pumping units250and the high pressure line248from the high pressure manifold218of the dirty pumping units212can be coupled a fluid junction278. The fluid junction278can be a fluid control component or could be a part of a fracturing manifold or wellhead coupled to the wellbore210. In some embodiments a pressure and flowrate sensor can be located between the high pressure manifold260of the clean pumping units250and the fluid junction278, for example, along the high pressure line262. In some embodiments a pressure and flowrate sensor can be located between the high pressure manifold218of the clean pumping units212and the fluid junction278, for example, along the high pressure line248. The controller within the control center236can establish a flowrate of proppant slurry with a desired proppant concentration at the fluid junction278and/or the wellbore210by controlling the supply of clean fluid from the clean pumping units250and the supply of proppant slurry from the dirty pumping units212. The fracturing spread200can maximize the concentration of proppant within the proppant slurry by shutting down the clean pumping units250and supplying proppant from the proppant supply unit244at an operational limit or operational maximum value. The fracturing spread200can minimize the concentration of proppant by pumping the clean fluid from the clean pumping units250and shutting down the dirty pumping units212. Alternatively, the fracturing spread200can pump clean fluid from the clean pumping units250and clean fluid from the dirty pumping units212by shutting off the proppant supply unit244feeding the dirty blender214.

In some embodiments, the fracturing spread200can simultaneously fracture two wellbores. Each pumping unit group, clean pumping units250and dirty pumping units212, can be divided or split into two or more groups. For example, pumping unit270,272of the clean pumping units250and pumping units220,222of the dirty pumping units212can be coupled to a first wellbore and pumping unit274,276of the clean pumping units250and pumping units224,226of the dirty pumping units212can be coupled to a second wellbore. Although the fracturing spread200is described as fracturing two wellbores, it is understood that the fracturing spread200could fracture 2, 3, 4, 5, 6, or any number of wellbores simultaneously by adding more fracturing units.

Turning now toFIG.3A, an exemplary fluid network300for a pumping unit is described. In some embodiments, a fluid network300can comprise a pumping unit, a fluid manifold310, a supply line246, and a high pressure line248. Although the exemplary fluid network300is described with pumping unit220from the first pumping unit group212ofFIG.2, it is understood that pumping unit220is an example and thus, any pumping unit similarly coupled to a blender and a wellbore could be utilized. The fluid manifold310, commonly referred to as a missile, comprises the low pressure manifold216and the high pressure manifold218and may be movably mounted on a skid or trailer. A first inlet arm312can fluidically couple the pump A, e.g., first pump232, to the low pressure manifold216. The second inlet arm316can couple pump B, e.g., second pump234, to the low pressure manifold216. The first discharge arm314can fluidically couple the pump A to the high pressure manifold218and the second discharge arm318can couple the pump B to the high pressure manifold218. The first inlet arm312, the second inlet arm316, the first discharge arm314and the second discharge arm318can include a swivel, an isolation valve, a fluid choke, a manual disconnect, an automatic disconnect, or combinations thereof. A supply line246can fluidically couple the low pressure manifold216to the dirty blender214or the clean blender254. A high pressure line248can fluidically couple the high pressure manifold218to the wellbore210. Although one pumping unit, e.g., pumping unit220, is illustrated coupled to the fluid manifold310, it is understood that there may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or any number of pumping units coupled to the fluid manifold310via corresponding inlet arms and discharge arms.

During pumping operations, exemplary fluid network300can feed the pumping unit220either a clean fluid or a dirty fluid from the blender unit214,254and deliver high pressure fluid from the pumping unit220to the wellbore210. The pumping unit220can receive clean fluid from the clean blender254via the low pressure manifold216. The pumping unit220can receive either clean fluid or dirty fluid when the low pressure manifold216is coupled to the dirty blender214. The fluid network300can deliver high pressure fluid from the pumping unit220to the wellbore210via the high pressure manifold218. The pumping unit220can be configured in a dual pump mode or a single pump mode. In the dual pump mode, both of the pumps can be coupled to the motor and actively pumping. In the single pump mode, one of the two pumps can be coupled and the other pump can be decoupled so that only one pump is actively pumping. The unit controller, e.g., unit controller140, can be calibrated to measure, calculate, and communicate the pumping operation of both pumps operating in the dual pump mode or the pumping operation of a single pump in the single pump mode. For example, the unit controller can report the flowrate of the pumping unit in dual mode is double the flowrate of the pumping unit in single mode. Similarly, the unit controller can calculate an increase or decrease rate of flowrate change in dual mode that is double the rate of flowrate change in single mode. If one of the pumps of the pumping unit220needs to be shut down due to decrease in pumping performance, the controller within control center236can direct the pumping unit220to ramp down and stop the pumping operation. The effected pump, for example pump220B, can be isolated from the fluid manifold310and disconnected from the motor220M. For example, an isolation valve on the inlet arm316can be closed to isolate the pump220B from the low pressure manifold216. An isolation valve on the discharge arm318can be closed to isolate the pump220B from the high pressure manifold218. The controller with in the control center236can recalibrate the unit controller of pumping unit220in single mode and restart the pumping unit220with the motor220M powering the pump220A while the pump220B remains idle. The unit controller can direct the pumping operation of pumping unit220per the single mode calibration.

The calibration of the unit controller for either single mode or dual mode comprises a variety of parameters including pump count, power limit, torque limit, speed limit, temperatures, pressures, pressure/torque ratio, discharge rate per revolution, auxiliary system settings, prime mover drive settings/limits. For example, the flowrate of the pumping unit220in single mode is half the flowrate of the pumping unit220in single mode. In another example, the ramp rate (e.g., rate of change of flowrate) in single mode is twice as fast as the ramp rate in dual mode. In still another example, the torque limit in single mode is half the torque limit in dual mode. The unit controller can be calibrated or recalibrated based on the status of the pump, e.g., pump220A. For example, the unit controller can determine if the pump220A and pump220B is connected to the motor220M and calibrate the unit controller accordingly.

Turning now toFIG.3B, a fluid network320for a pumping unit is described. In some embodiments, the fluid network320can comprise a pumping unit, a fluid manifold322, a supply line246, and a high pressure line248. The fluid network320can share similar parts to previous embodiments that may likewise share the same reference numbers. The fluid manifold322, e.g., the missile, comprises the low pressure manifold216with a wye-block324and the high pressure manifold218with a wye-block326. A first inlet arm312and second inlet arm316can be coupled to the wye-block324and thus, to the low pressure manifold216. The first discharge arm314and second discharge arm318can be fluidically coupled to the wye-block326and thus, to the high pressure manifold218. A supply line246can fluidically couple the low pressure manifold216to the dirty blender214or the clean blender254. A high pressure line248can fluidically couple the high pressure manifold218to the wellbore210. Although one pumping unit, e.g., pumping unit220, is illustrated coupled to the manifold322, it is understood that there may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or any number of pumping units coupled to the manifold322via corresponding inlet arms and discharge arms.

During pumping operations, exemplary fluid network320can feed the pumping unit220either a clean fluid or a dirty fluid from the blender unit214,254and deliver high pressure fluid from the pumping unit220to the wellbore210. The pumping unit220can receive clean fluid from the clean blender254or can receive either clean fluid or dirty fluid when the low pressure manifold216is coupled to the dirty blender214. The fluid network320can deliver high pressure fluid from the pumping unit220to the wellbore210via the high pressure manifold218. As previously described, the unit controller can be calibrated for dual mode and the pumping unit220can be operating in dual mode, e.g., both pump A and pump B operating. If one of the pumps of the pumping unit220needs to be shut down due to decrease in pumping performance, the controller within control center236can direct the pumping unit220to ramp down and stop the pumping operation. The effected pump, for example pump220B, can be isolated from the fluid manifold322and disconnected from the motor220M. For example, an isolation valve on the inlet arm316and the discharge arm318can be closed to isolate the pump220B from the low pressure manifold216and high pressure manifold218respectively. The controller with in the control center236can recalibrate the unit controller of pumping unit220in single mode and can restart the pumping unit220with the motor220M powering the pump220A while the pump220B remains idle.

Turning now toFIG.3C, a fluid network330for a pumping unit is described. In some embodiments, the fluid network330can comprise a pumping unit, a fluid manifold332, a supply line246, a supply line258, and a high pressure line248. The fluid network330can share similar parts to previous embodiments that may likewise share the same reference numbers. The fluid manifold332, e.g., the missile, includes a dual low pressure manifold334and the high pressure manifold218. The dual low pressure manifold334comprising a clean manifold336coupled via a supply line258to the clean blender254and a dirty manifold338coupled via a supply line246to the dirty blender214. The clean manifold336and the dirty manifold338can be coupled to the pump220A by a first connector block340and a first inlet arm312. The clean manifold336and the dirty manifold338can be coupled to the pump220B by a second connector block342and a second inlet arm316. An isolation valve344A,346A can be located on a connector branch between the dirty manifold338and clean manifold336and the first connector block340. An isolation valve344B,346B can be located on a connector branch between the dirty manifold338, the clean manifold336, and the second connector block342. The first discharge arm314and second discharge arm318can be fluidically coupled to the high pressure manifold218. A high pressure line248can fluidically couple the high pressure manifold218to the wellbore210. Although one pumping unit, e.g., pumping unit220, is illustrated coupled to the manifold332, it is understood that there may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or any number of pumping units coupled to the manifold332via corresponding inlet arms and discharge arms.

During pumping operations, exemplary fluid network330can feed the pumping unit220either a clean fluid, a dirty fluid, or a blend of clean and dirty fluid via the dual manifold334. The pumping unit220can receive clean fluid from the clean blender254via the low pressure manifold336. The pumping unit220can receive either clean fluid or dirty fluid from the low pressure manifold338coupled to the dirty blender214. The controller within the control center236can blend the clean fluid from the clean manifold336with dirty fluid from the dirty manifold338by operating the isolation valves344A,346A,344B, and346B. For example, the controller can decrease the concentration of the proppant entering the inlet arm316via the connector block342by partially closing the isolation valve344B connected to the dirty manifold338to decrease the flowrate of dirty fluid, e.g., proppant slurry. In some embodiments, the controller can increase the opening valve of the isolation valve346B coupled to the clean manifold336to increase the flowrate of clean fluid to compensate for the decrease in the flowrate of dirty fluid. The fluid network330can deliver high pressure fluid from the pumping unit220to the wellbore210via the high pressure manifold218. As previously described, the unit controller can be calibrated for dual mode and the pumping unit220can be operating in dual mode, e.g., both pump A and pump B operating. If one of the pumps of the pumping unit220needs to be shut down due to decrease in pumping performance, the controller within control center236can direct the pumping unit220to ramp down and stop the pumping operation. The effected pump, for example pump220B, can be isolated from the fluid manifold310and disconnected from the motor220M. For example, an isolation valve on the inlet arm316can be closed to isolate the pump220B from the low pressure manifold216. An isolation valve on the discharge arm318can be closed to isolate the pump220B from the high pressure manifold218. The controller with in the control center236can recalibrate the unit controller of pumping unit220in single mode and can restart the pumping unit220with the motor220M powering the pump220A while the pump220B remains idle.

In some embodiments, the controller can direct the fluid network330to flush a pump before isolating the pump from the fluid network330. Using the prior example of pump220B, the controller can close the isolation valve344B coupled to the dirty manifold338and fully open isolation valve346B coupled to the clean manifold336to flush all of the proppant slurry from the pump220B. This flushing operation can occur during the pumping operation, as the pumping unit220is ramping down, e.g., decreasing the flowrate, or operating at a decreased value of flowrate. After the flushing operation, the controller can isolate the pump220B, shut down the pumping unit220, disconnect the motor220M from the pump220B, and resume the pumping operation with pump220A.

Turning now toFIG.3D, a fluid network350for a pumping unit is described. In some embodiments, the fluid network350can comprise a pumping unit, a fluid manifold352, a supply line246of dirty fluid, a supply line258of clean fluid, and a high pressure line248. The fluid network350can share similar parts to previous embodiments that may likewise share the same reference numbers. The fluid manifold352, e.g., the missile, includes a dual low pressure manifold334and the high pressure manifold218. The dual low pressure manifold334comprises a clean manifold336coupled via a supply line258to the clean blender254and a dirty manifold338coupled via a supply line246to the dirty blender214. The clean manifold336and the dirty manifold338can be coupled to the pumping unit220by a first connector block340and a wye-block324. The wye-block324can be coupled to the pump220A by a first inlet arm312and to the pump220B by the second inlet arm316. An isolation valve344A,344B can be located on a connector branch between the dirty manifold338and clean manifold336and the first connector block340. The first discharge arm314and second discharge arm318can be fluidically coupled to the high pressure manifold218. A high pressure line248can fluidically couple the high pressure manifold218to the wellbore210. Although one pumping unit, e.g., pumping unit220, is illustrated coupled to the fluid manifold352, it is understood that there may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or any number of pumping units coupled to the fluid manifold352via corresponding inlet arms and discharge arms.

During pumping operations, exemplary fluid network350can feed the pumping unit220either a clean fluid, a dirty fluid, or a blend of clean and dirty fluid via the dual manifold334and wye-block324. The pumping unit220can receive clean fluid from the clean blender254via the low pressure manifold336. The pumping unit220can receive either clean fluid or dirty fluid from the low pressure manifold338coupled to the dirty blender214. The controller within the control center236can blend the clean fluid from the clean manifold336with dirty fluid from the dirty manifold338by operating the isolation valves344A,346A,344B, and346B. For example, the controller can decrease the concentration of the proppant to pump220A and pump220B via the wye-block324by partially closing the isolation valve344A connected to the dirty manifold338to decrease the flowrate of dirty fluid, e.g., proppant slurry. In some embodiments, the isolation valve346A coupled to the clean manifold336can be operated to a greater open value by the controller to compensate for the decrease in flowrate of the dirty fluid. The fluid network350can deliver high pressure fluid from the pumping unit220to the wellbore210via the high pressure manifold218. As previously described, the unit controller can be calibrated for dual mode and the pumping unit220can be operating in dual mode, e.g., both pump A and pump B operating. If one of the pumps of the pumping unit220needs to be shut down due to decrease in pumping performance, the controller within control center236can direct the pumping unit220to ramp down and stop the pumping operation. In some embodiments, the controller can initiate a flushing operation previously described to flush the proppant slurry from the pump220A and pump220B before disconnecting one of the pumps. The effected pump, for example pump220B, can be isolated from the fluid manifold352and disconnected from the motor220M. For example, an isolation valve on the inlet arm316can be closed to isolate the pump220B from the dual manifold334. An isolation valve on the discharge arm318can be closed to isolate the pump220B from the high pressure manifold218. The controller within the control center236can recalibrate the unit controller of pumping unit220in single mode and can restart the pumping unit220with the motor220M powering the pump220A while the pump220B remains idle.

Turning now toFIG.3E, an exemplary fluid network360for a pumping unit is described. In some embodiments, a fluid network360can comprise a pumping unit, a fluid manifold (e.g., fluid manifold310), a supply line372, and a high pressure line248. The fluid manifold of fluid network360can be either fluid manifold310ofFIG.3Aor fluid manifold322ofFIG.3B. As previously described, fluid manifold, e.g., fluid manifold310,322, comprises the low pressure manifold216and the high pressure manifold218. The low pressure manifold216can be coupled to the supply line372and can receive a blended proppant slurry that comprises a portion of the clean fluid from the clean blender254and a portion of the dirty fluid from the dirty blender214. The blended proppant slurry can be the clean fluid from the clean blender254via connector extension362and dirty fluid from the dirty blender214via connector line370. The clean fluid and dirty fluid can be combined at the block368. The controller within control center236can control the flowrate and proppant concentration of the blended proppant slurry with a control valve366and by controlling the flowrate of the clean blender254and the flowrate of the dirty blender214. For example, the controller can increase the proppant concentration of the proppant slurry by decreasing the flowrate of the clean fluid from the connector extension362by closing the control valve366and/or decreasing the flowrate of clean fluid from the clean blender254. Although one pumping unit, e.g., pumping unit220, is illustrated coupled to the fluid manifold310, it is understood that there may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or any number of pumping units coupled to the fluid manifold310via corresponding inlet arms and discharge arms.

During pumping operations, exemplary fluid network360can feed the pumping unit220a clean fluid from the clean blender254, a dirty fluid from the dirty blender214, or a blended proppant slurry from both the clean blender254and the dirty blender214via a low pressure manifold216. As previously described, the unit controller can be calibrated for dual mode and the pumping unit220can be operating in dual mode, e.g., both pump A and pump B operating. The fluid network360can deliver high pressure fluid from the pumping unit220to the wellbore210via the high pressure manifold218. If one of the pumps of the pumping unit220needs to be shut down due to a decrease in pumping performance, the controller within control center236can direct the pumping unit220to ramp down and stop the pumping operation. The effected pump, for example pump220B, can be isolated from the fluid manifold310and disconnected from the motor220M. For example, an isolation valve on the inlet arm316can be closed to isolate the pump220B from the low pressure manifold216. An isolation valve on the discharge arm318can be closed to isolate the pump220B from the high pressure manifold218. The controller with in the control center236can recalibrate the unit controller of pumping unit220in single mode and can restart the pumping unit220with the motor220M powering the pump220A while the pump220B remains idle.

A pump with a decrease in pumping performance can be disconnected from the prime mover of the pumping unit. Turning now toFIG.4, a front view of an exemplary pumping system400of a pumping unit is described. The pumping system400can be an embodiment of the pumping system138ofFIG.1and the pumping unit220ofFIG.2. In some embodiments, the pumping system400comprises a prime mover400M can be releasably coupled to a first pump400A and releasably coupled to a second pump400B. The prime mover400M can be an embodiment of a prime mover230ofFIG.2and referred to as motor400M. The pump400A can be a first pump, e.g., first pump232ofFIG.2. The pump400B can be a second pump, e.g., second pump234ofFIG.2. Hereinafter, the pump400A will refer to the first pump powered by the motor400M and pump400B will refer to the second pump powered by the motor400M of the pumping system400.

The pump400A and the pump400B can be a positive displacement pump with a valve system402. In some embodiments, the pump400A and the pump400B can comprise multiple chambers404with plungers driven by a drive shaft and/or crankshaft406with the valve system402comprising intake valves and discharge valves. For example, each of the pumps, e.g., pump400A, can include three chambers404with a plunger (not shown) reciprocating within each chamber and mechanically coupled to a crankshaft406. Each chamber may include a suction valve and a discharge valve that operate with each stroke of the plunger. The suction valve fluidically couples the chamber to a low pressure manifold, e.g., manifold216ofFIG.2. The reciprocating plunger can draw in fluid through the suction valve, pressurize the fluid within the chamber, and discharge the fluid through a discharge valve that is fluidically coupled to a high pressure manifold, e.g., manifold218ofFIG.2. The drive shaft and/or crankshaft406can be rotationally and releasably coupled to the motor400M, e.g., an electric motor that drives the crankshaft206for powering the pump400A and/or pump400B. Although the motor400M is described as an electric motor, it is understood that the motor400M could be an internal combustion motor or turbine engine. Although the pump400A,400B is described as a positive displacement pump, it is understood that the pump can be a centrifugal pump, a multistage centrifugal pump, a turbine pump, a rod pump, a progressive cavity pump, or any combination thereof. Although the pump400A and pump400B are described as the same type of pump, it is understood that the pump400A can be a different type and/or model than pump400B.

The prime mover, e.g., motor400M, can be releasably coupled to the drive shaft and/or crankshaft406by a decoupler mechanism418. The decoupler mechanism can include an coupling actuator and a positioning sensor communicatively connected to the controller. The decoupler mechanism can be configured to engage or disengage the motor400M to the drive shaft and/or crankshaft406as will be described hereinafter.

The motor400M, e.g., prime mover, can be communicatively coupled to a unit controller410, e.g., unit controller ofFIG.1. The unit controller410can control the torque and speed of the motor400M. As previously disclosed, the unit controller410can be calibrated to measure, calculate, and communicate the pumping operation of both pumps, e.g., pump400A and pump400B operating in the dual pump mode or the pumping operation of a single pump, e.g., pump400A, in the single pump mode. For example, the unit controller410can report the flowrate of the pumping unit400in dual mode is double the flowrate of the pumping unit in single mode. Said another way, the unit controller can determine a motor speed (rpm) and acceleration (rpm/sec) in single mode that is double the a motor speed (rpm) and acceleration (rpm/sec) of dual mode to match or obtain a target (e.g., setpoint) total desired rate (bpm) and change in rate (bpm/sec). Similarly, the unit controller can calculate an increase or decrease rate of flowrate in dual mode that is double the rate of flowrate change in single mode. The unit controller410can be coupled to a set of sensors412to measure periodic datasets indicative of the pumping operation. In some embodiments, the set of sensors412can include pressure sensors, flowrate sensors, positional sensors, voltage sensors, or combinations thereof. The set of sensors412can include a positional sensor, e.g., a hall-effect sensor, configured to detect whether the pump400A,400B are operating and/or the speed at which each of the pumps400A,400B are operating. The sensors412can include a voltage sensor configured to detect the speed and/or torque of the motor400M. The sensors412can include one or more positional sensors configured to detect if the decoupler mechanism is coupled or decoupled.

In some embodiments, the unit controller410can be communicatively coupled to the system controller414within the control center, e.g., control center236ofFIG.2. The system controller414can direct a pumping operation utilizing the pumping system400via the unit controller410. The system controller414can receive periodic datasets (from the set of sensors412) of the pumping operation via the unit controller410.

Turning now toFIG.5A-5C, an illustration of a pump system500with a decoupler mechanism is described. In some embodiments, the decoupler mechanism418comprises a static element512, a dynamic element514, an actuator516, and a set of positional sensors518. The static element512can be a generally cylinder shape with an outer surface520, a front face522, and a set of protrusions, e.g., teeth. The static element512can be mechanically coupled to the drive shaft406of the motor400M and configured to transmit torque and rotational motion to the mating dynamic element514. The dynamic element514can be a generally cylinder shape with an outer surface528, a front face530, and a back face. The dynamic element514can be slidingly mounted on a drive shaft538of the pump400B. The front face530of the dynamic element514can engage a set of splines540on the drive shaft538. The front face530of the dynamic element514can include a set of protrusions532configured to transmit torque and rotational motion from the mating protrusions524of the static element512. The front face530of the dynamic element514can be configured to transmit torque and rotational motion to the drive shaft538via the splines540. The actuator516can comprise an extender mandrel, a housing, and an extend-retract mechanism and can couple the dynamic element514to the pump housing of the pump400B. The extender mandrel can be coupled to the dynamic element514and the extension retraction mechanism. The housing can be coupled to the pump housing of the pump400B and the extend-retract mechanism. The actuator516can have an extended position, a retracted position, and a locked position. The actuator516can be configured to position the dynamic element514into engagement with the static element512in the extended position as shown inFIG.5A. In some embodiments, the extender mandrel may not be coupled to the dynamic element514. For example, the extender mandrel may be configured to urge or move the dynamic element514into a position, for example, the coupled position, then return to a home position.

The extend-retract mechanism within the actuator516can operate the decoupler mechanism418from a coupled configuration to a decoupled configuration. In some embodiments, the extend-retract mechanism can be communicatively coupled to the unit controller410. The extend-retract mechanism can comprise a first volume of fluid, a pump, and a second volume of fluid. For example, an extender mandrel within housing can be urged outward from the housing by transferring fluid from the first volume to the second volume by the pump. In some embodiments, the extender mandrel within the housing can be extended by an electric motor turning a gearing system mechanically coupled to the mandrel. In some embodiments, the extender mandrel can be a threaded rod that is extended/retracted from the housing by an electric motor. The extend-retract mechanism can be controlled to move in a first direction, e.g., to a coupled configuration, and move in a second direction, e.g., to a decoupled configuration, by the unit controller410ofFIG.4. In some embodiments, the unit controller410is electrically coupled to the actuator516to provide voltage and power to the extend-retract mechanism.

The set of positional sensors518can provide feedback of the position of the dynamic element514and thus the configuration of the decoupler mechanism418to the unit controller410. Each of the sensors within the set of positional sensors518can be a magnetic sensor, e.g., a hall-effect sensor, configured to sense the position of the dynamic element514. As illustrated inFIG.5A, the decoupler mechanism418can be in the coupled configuration with the dynamic element514coupled to the static element512with the protrusions524of the static element512mated with the protrusions532of the dynamic element514. The position of the dynamic element514in the coupled configuration can activate the sensor518A, e.g., the sensor518A can return a positive value. In some embodiments, the extension mandrel of the actuator516can lock or hold the dynamic element514in the coupled position. In some embodiments, the extension mandrel of the actuator516can position dynamic element514in the coupled configuration, the extension mandrel can return to a home position, and a latching mechanism can lock or hold the dynamic element514in the coupled position.

In some embodiments, the unit controller410of the pumping unit400can determine if the pump400B is coupled to the motor400M by receiving a signal, e.g., a positive value, from sensor518A. In some embodiments, the unit controller410can calibrate or recalibrate the pumping unit400in single mode or dual mode in response to the signal from sensor518A.

As illustrated inFIG.5B, the actuator516of the decoupler mechanism418can retract the dynamic element514away from the static element512. The dynamic element514can be decoupled from the static element512with the protrusions524of the static element512decoupled or unmated with the protrusions532of the dynamic element514. The actuator516can move the dynamic element514to the end of the stroke of the extend-retract mechanism that can activate the sensor518C, e.g., the sensor518C can return a positive value. The unit controller410can actuate the decoupler mechanism418to move the dynamic element514to an end of stroke position of the actuator516and receive feedback of the position of the dynamic element514from sensor518C. In some embodiments, the extension mandrel of the actuator516can extend and couple to the dynamic element514and retract the dynamic element514to the end of stroke position.

As illustrated inFIG.5C, the actuator516of the decoupler mechanism418can position the dynamic element514in a decoupled and locked position with respect to the static element512. The dynamic element514can be in a decoupled configuration with the protrusions524of the static element512decoupled or unmated with the protrusions532of the dynamic element514. The actuator516can move the dynamic element514to a decoupled and locked position that can activate the sensor518B, e.g., the sensor518B can return a positive value. In some embodiments, the actuator516can lock or hold the dynamic element514in the decoupled position. In some embodiments, the actuator516can move, e.g., extend, the dynamic element514from the end of stroke position to the decoupled position, the actuator516can release from the dynamic element514, the actuator516can return to a home position, and a latching mechanism can lock or hold the dynamic element514in the decoupled position.

Turning now toFIG.5D, an embodiment of the decoupler mechanism550is described. In some embodiments, the drive shaft556of the motor400M can remain rotationally coupled to a drive shaft558of the pump400B when coupled or decoupled. The decoupler mechanism550comprises a torque coupling562slidingly mounted on the drive shaft558of the pump400B. The torque coupling can be a generally cylinder shape with an outer surface572and an inner surface with a set of splines574. The drive shaft558of the pump440B can include a set of splines560configured to slidingly mate with the set of splines574on the torque coupling562. The drive shaft556of the motor400M can include a bearing assembly566and a set of splines554. The bearing assembly566can be rotationally mated with a bearing race568within the drive shaft558of the pump400B. The set of splines554on the drive shaft556of the motor400M can be configured to engage the set of splines574inside the torque coupling562. In a coupled position, the set of splines574within the torque coupling562can be engaged with the splines554on the drive shaft556of the motor400M and the splines560on the drive shaft558of the pump. In the coupled position, the torque coupling562can be configured to transmit torque and rotational motion from the drive shaft556of the motor400M to the drive shaft558of the pump400B. The sensor518A of the set of sensors518can return an active signal. In some embodiments, the unit controller410may configure the pumping unit in a dual mode in response to the sensor518A returning an active signal. The actuator516can be configured to position the torque coupling562in a coupled position or a decoupled position. In some embodiments, the extender mandrel may not be coupled to the torque coupling562. For example, the extender mandrel may be configured to urge or move the torque coupling562into a position, for example, the coupled position, then return to a home position.

As shown inFIG.5D, the actuator516can move the torque coupling562to a decoupled position and then return to a home position. In the decoupled position, the torque coupling562can be engaged with the set of splines560on the drive shaft, disengaged from the set of splines554on the drive shaft556of the motor400M, and parked on the drive shaft558of the pump400B. The motor400M can remain rotationally coupled to the drive shaft558of the pump400B with the bearing assembly566but torque and rotational motion may not be transferred to the drive shaft558of the pump400B. The sensor518B of the set of sensors518can return an active signal. In some embodiments, the unit controller410may configure the pumping unit in a single mode in response to the sensor518B returning an active signal.

In some embodiments, the unit controller410of the pumping unit400can determine the pump400B is decoupled to the motor400M by receiving a signal, e.g., a positive value, from sensor518B. In some embodiments, the unit controller410can calibrate or recalibrate the pumping unit400from dual mode to single mode in response to the signal from sensor518B.

A wellbore servicing operation can utilize a fracturing spread to fracture one or more formations. As described inFIG.2, the fracturing spread can comprise a plurality of pumping units, e.g., pumping unit220, configured to place a wellbore treatment fluid, e.g., a proppant slurry, into a wellbore, e.g., wellbore210. The fracturing spread, e.g., fracturing spread200, can pump the wellbore treatment fluid into a formation, e.g., formation132ofFIG.1, per a pumping schedule designed to fracture the formation and deposit a proppant agent, e.g., sand, into the resultant fractures. A controller can direct the plurality of fracturing units comprises one or more blenders, e.g., dirty blender214, and the plurality of pumping units, e.g., dirty pumping units212, per a pumping schedule to place the wellbore treatment, e.g., the proppant slurry, into the formation, e.g., formation132, within the wellbore, e.g., wellbore210. Each of the plurality of pumping units within the fracturing spread can be operating at any period of time in accordance with job requirements. For example, the dirty pumping units212shown inFIG.2can be operating in accordance with a pumping schedule that is associated with a stage, e.g., an interval, of an overall fracturing operation. For example, during the stage the dirty pumping units212may need to operate at a designated period of time or to place a designated volume of wellbore treatment fluid at a predetermined slurry concentration, pumping pressure, and flowrate.

In some scenarios, the pumping units of the fracturing spread can utilize fluid network300described inFIGS.3A and3Bto receive fluid directly from a blender. The controller can direct the fracturing spread to deliver a designated concentration of proppant per the pumping schedule to the wellbore with the dirty blender214or with a combination of the dirty blender214and the clean blender254. The controller can adjust the concentration of proppant based on periodic datasets from one or more sensors coupled to or located within the wellbore.

In some scenarios, the pumping units of the fracturing spread can utilize fluid network330or fluid network350described inFIGS.3C and3Dto deliver a blended wellbore treatment fluid. The controller can direct the fracturing spread to deliver a designated concentration of proppant per the pumping schedule to the wellbore with one or more isolation valves, e.g., isolation valve344A,346A, and/or by varying the flowrates of the dirty blender214and the clean blender254. The controller can adjust the concentration of proppant based on periodic datasets from one or more sensors coupled to or located within the wellbore.

In some scenarios, the pumping units of the fracturing spread can utilize fluid network360described inFIG.3Eto deliver a blended wellbore treatment fluid. The controller can direct the dirty blender214and the clean blender254to deliver a designated concentration of proppant per the pumping schedule to the pumping units with one or more isolation valves, e.g., control valve366, and/or by varying the flowrates of the dirty blender214and the clean blender254. The controller can adjust the concentration of proppant based on periodic datasets from one or more sensors coupled to or located within the wellbore.

During the performance of a wellbore servicing operations, one or more pumps, e.g., pump220B of pumping unit220, may need to cease operation and in some cases be replaced. Referring to exemplary pumping system400inFIG.4that is a simplified pumping unit for illustration purposes. The system controller414may receive an indication of reduced pumping performance, for example, may detect a pump400B experiencing overheating or a decrease in pumping performance per the set of sensors412via the unit controller410. The system controller may execute a process for balancing the pumping loads of the pumping operation with one or more pumping units within the fracturing spread. Turning now toFIGS.6A and6B, an exemplary graph600of a pumping operation is used to illustrate a balancing process650for replacing a pump during a pumping operation. The exemplary graph600includes four pumps operating at various pumping rates of 6-9 barrels per minute (BPM) for a total pumping rate of 30 BPM as indicated by line610. The graph600includes a primary axis602for individual pumping rate (BPM) and a secondary axis606for total pumping rate (BPM) with an independent axis604for time (SEC). In the exemplary graph600, a first pumping unit (labeled PUMP 1) is operating at 6 BPM, a second pumping unit (PUMP 2) is operating at 7 BPM, a third pumping unit (PUMP 3) is operating at 8 BPM, and a fourth pumping unit (PUMP 4) is operating at 9 BPM. The system controller, e.g., system controller414, can designate the pumping rates for each pumping unit based on operational factors, e.g., a number of weighted factors, such as, capacity, capability, efficiency, service life, cost, and other factors designated by the user. The capacity of a pumping unit can be the operational capacity, e.g., pumping rate and pressure, of the pump and/or prime mover. The capability of a pumping unit can be the ability to connect to a fluid network and pump a specific fluid type, for example, a liquified gas fracturing system. The efficiency of a pumping unit can be determined based on the instantaneous hydraulic power and instantaneous power provided by the prime mover. The service life of the pumping unit can be a number of hours of operation remaining before required maintenance. The cost of the pumping unit can be determined by a function of the cost of the fuel and maintenance of the pumping unit, for example, the cost of diesel. For example inFIG.6B, the system controller may set the pumping rate of PUMP 4 at 9 BPM because of a high efficiency/capability score in combination with a high service life score. Likewise, the system controller may set the pumping rate of PUMP 1 at 6 BPM because of a low service life score.

With reference toFIG.2, the system controller within the control center236may receive an indication of reduced pumping performance, for example, an indication of an operational caution, e.g., overheating, or an indication that service is required, e.g., a reduction in pressure, from PUMP 1 (pumping unit220). The system controller can determine a new pumping rate for PUMP 2 (pumping unit222), PUMP 3 (pumping unit224), and PUMP 4 (pumping unit226) based on the weighted factors of capacity, capability, efficiency, service life, cost, or combinations thereof. The system controller may determine a first transition period614to reduce the pumping rate of PUMP 1 to zero while simultaneously compensating with the remaining pumping units so that the overall pumping rate does not change. Turning now toFIG.6A, the system controller may execute a balancing process650for flowrate balancing with the following steps. At step652, the balancing process can determine the total flowrate of the system. The total flowrate of the system can be referred to as the first balanced pump load. From the example ofFIG.6B, the first balance pump load can be from zero to 10 seconds, the first transitional balanced pump load can be from 10 to 16 seconds, the second balanced pump load can be from 16 to 36 seconds, a second transitional balanced pump load can be from 36 to 42 seconds, and a supplemented balanced pump load can be from 42 to 52 seconds. The total flowrate during each of the balanced pump loads, e.g., the first balanced pump load, is represented by line610and is 30 BPM. At step654, the balancing process can determine a total flowrate loss of the pumping system to be removed. From the example ofFIG.6B, Total Loss Flowrate=6 BPM for the removal of PUMP 1. At step656, the balancing process can determine the remaining flowrate of the system. FromFIG.6B, the Remaining Flowrate=24 BPM. At step658, the process can determine how to distribute the Total Loss Flowrate of 6 BPM to the remaining pumping units for the second balanced pump load from 16 to 36 seconds. For example, inFIG.6B, the remaining pumps comprise PUMP 2, PUMP 3, and PUMP 4. The system controller can determine the new pumping rate for each pump based on the weighted factors of capacity, capability, efficiency, service life, and cost. Based on the weighted factors, the first determination step658A may be capacity. The balancing process can determine the capacity available for each of the remaining pumping units from capacity values assigned to each pumping unit. As the pumping units have a maximum operational capacity, the process can exclude the pumping units within a threshold value of the maximum operational capacity. The second determination step658B may be based on value of efficiency or a range of efficiency that a pumping unit that is optional for a pumping unit to perform within. In some embodiments, the range of efficiency can be between 50% and 99%, from 60% and 90%, from 70% and 80%, or any range between 40% and 100%. For example, the balancing process may exclude less efficient pumps and transfer flowrate to more efficient pumps. In other scenarios, the process may transfer a greater portion of the flowrate to more efficient pumps and a lessor portion to less efficient pumps. The third determination step658C may be based on service life. For example, the balancing process may transfer flowrate to pumping units with a greater value of service life remaining. The value of service life can refer to a number of hours of operation remaining before required maintenance. The fourth determination step658D may be based on cost. For example, the cost of operation may be a fuel cost, for example, a diesel pumping unit may be more expensive to operate than an electric pumping unit. In other scenarios, a first model of pumping unit may be more expensive to operate than a second model of pumping unit. The steps of the balancing process may be determined by the weighting factors selected by the user or the customer and as such the order of the balancing process may change accordingly.

Returning to the example ofFIG.6B, the balancing process may divide the increase in flowrate equally among the remaining pumping units for the second balanced pump load. For example, the remaining pumping units of PUMP 2, PUMP 3, and PUMP 4 may increase a total amount equal to the Total Loss Flowrate of 6 BPM from step658. The balancing process may divide the 6 BPM equally so that each pump increases an amount of 2 BPM. As a result, PUMP 2 target flowrate increases from 7 BPM to 9 BPM, PUMP 3 target flowrate increases from 8 BPM to 10 BPM, and PUMP 4 target flowrate increases from 9 BPM to 11 BPM.

As used herein, ramp rate can refer to the acceleration/deceleration rate for the pumping unit. Ramps rates can be same or different for each pumping unit. In other words, ramp rate is defined as the rate-of-change of pumping rate (e.g., flowrate of the pump). By controlling an individual ramp rate of each pumping unit simultaneously receiving a pumping rate change, the overall combined flowrate can be a controlled constant. Overall pumping flowrate can be held constant while multiple pumps are simultaneously changing rates as long as the sum of the ramp rates (e.g., positive and negative slopes; increasing and decreasing) is zero.

Returning to the balancing process650, the balancing process650may determine a transition period at step660defined as a value of time between a first pump load, e.g., Total flowrate of step652, and a second pump load, e.g., distribution of flowrate at step658. The transition period, e.g., transition period614, may be determined based on the greatest rate change, e.g., PUMP 1. At step662, the balancing process may determine a ramp rate for each of the pumps during a transition period, e.g., transition period614, that results in a constant flowrate. Returning toFIG.6B, at step660, the balancing process may determine a transition period614for the pumping unit to be removed to ramp down, e.g., decrease pumping rate, and the remaining pumping units to ramp up, e.g., increase pumping rate. For example, the transition period614is 6 seconds in length, thus the balancing process can set the PUMP 1 rate change at 6 BPM per 6 seconds for a decrease in rate of 1 BPM per second. The balancing process can set the rate change for the remaining three pumps to 2 BPM per 6 seconds for an increase in rate of 1/3 BPM per sec. Thus, the balancing process can set the rate change of flowrate decreasing equal to the total combined ramp rate change of flowrate increasing. The balancing process can determine a ramp rate for each of the pumps so that the total flowrate of the plurality of pumps remains constant, e.g., the transitional balanced pump load.

The balancing process650may divide the transition period, e.g., transition period614and/or616, into multiple sequential time steps. For example, transition period614can be divided into six transition sub-periods of 1 second duration, e.g.,614A is 1 second,614B is 1 second, etc. The balancing process650can determine a balanced ramp rate within each sub-period, e.g.,614B, so that the total flowrate, e.g., the transitional balanced pump load, remains constant within each sub-period and thus, the flowrate of the plurality of pumps remains constant with the flowrate before the transition period, during the transition period, during each sub-period of the transition period, and after the transition period ends. Although the examples illustrate pumps with constant ramp rate throughout the transition period, it is understood that the transition period may include step changes and/or one or more pumps may return to a constant flowrate before the end of the transition period as long as the flowrate of the plurality of pumps remains constant during each sub-period of the transition period.

In some embodiments, the system controller can direct the unit controller of PUMP 1 to decouple a pump with the decrease in pumping performance. For example, the system controller414within the control center236can direct the unit controller410to activate the decouple mechanism418within PUMP 1, e.g., pumping system400, to decouple the pump400B, e.g., pump220B of pumping unit220, from the motor400M, e.g., motor220M. In this example, the pump400B with the decrease in pumping performance can be decoupled from the motor400M while the other pump400A with normal operation remains coupled to the motor400M. PUMP 1 can be returned to the pumping operation with pump400A operational and pump400B decoupled or non-operational. In some embodiments, the system controller can direct the isolation valves within a fluid manifold, e.g., fluid manifold310, to close. For example, the system controller within the control center236can direct the isolation valves within the inlet arm316and discharge arm318of fluid network300coupled to the non-operational pump to close.

In some embodiments, the system controller can isolate PUMP 1 from the fracturing spread and replace PUMP 1 with another pumping unit, for example, PUMP 5. A pumping unit, e.g., PUMP 5, can be held in reserve, e.g., in a non-operational state, in case of a pumping unit failure. In the example ofFIG.6B, PUMP 5, e.g., a pumping unit, is held in reserve, e.g., a non-operational state, until the system controller removes PUMP 1 from the pumping operation. The system controller can utilize the balancing process to replace the flowrate loss of PUMP 1 with PUMP 5 for the supplemental balanced pump load beginning at 42 seconds.

In some embodiments, the balancing process can utilize a second transition period616to add a pumping unit to the pumping operation. The balancing process may determine a ramp rate for each of the pumps during the second transition period616. Returning toFIG.6B, the balancing process may determine a second transitional balanced pump load for a second transition period616for the new pumping unit, PUMP 5, to be added with a ramp up, e.g., increase in pumping rate, and the remaining pumping units to ramp down, e.g., decrease in pumping rate. For example, the transition period616is 6 seconds in length, thus the balancing process can set the PUMP 5 rate change at 6 BPM per 6 seconds for an increase ramp rate of 1 BPM per second. The balancing process can set the rate change for the remaining three pumps to 2 BPM per 6 seconds for an decrease ramp rate of 1/3 BPM per sec. Thus, the balancing process can set the total combined ramp rate change of flowrate decreasing equal to the ramp rate change of flowrate increasing.

Turning now to a second example ofFIG.6C, the system controller within the control center236may receive an indication of reduced pumping performance, for example, an indication of an operational caution, e.g., overheating, or an indication that service is required, e.g., a reduction in pressure or rate, from PUMP 1 (pumping unit220). The system controller can determine a new pumping rate for PUMP 2 (pumping unit222), PUMP 3 (pumping unit224), and PUMP 4 (pumping unit226) based on the weighted factors of capacity, efficiency, service life, cost, or combinations thereof. The system controller may determine a first transition period614to reduce the pumping rate of PUMP 1 to zero while simultaneously compensating with the remaining pumping units so that the overall pumping rate does not change. The system controller may determine a second transition period616to increase the pumping rate of a new or replacement PUMP 5 while compensating with the remaining pumping units so that the overall pumping rate does not change.

The system controller may execute a balancing process650for flowrate balancing with the following steps. At step652, the balancing process can determine the total flowrate of the system for the first balanced pump load. From the example ofFIG.6C, the total flowrate from line610is 30 BPM. At step654, the balancing process can determine a total flowrate loss of the pumping system to be removed. From the example ofFIG.6C, Total Loss Flowrate can be 6 BPM for the removal of PUMP 1. At step656, the balancing process can determine the remaining flowrate of the system. FromFIG.6C, the Remaining Flowrate can be 24 BPM. At step658, the process can determine how to distribute the Total Loss Flowrate of 6 BPM to the remaining pumping units for the second balanced pump load.

The balancing process executing on the system controller can determine the new pumping rate target for each pump based on the weighted factors of capacity, efficiency, service life, and cost for the second balanced pump load. In the example ofFIG.6C, the balancing process may set PUMP 4 to a pumping rate target with an increase of 2 BPM due to the weighted factors. For example, PUMP 4 may have capacity and service life, but may be limited on efficiency and cost. The balancing process may set PUMP 3 to an increase of 3 BPM based on positive scores of capacity, service life, and efficiency but limited score for cost. The balancing process may set PUMP 2 to an increase of 1 BPM due to limited capacity.

The balancing process may determine a ramp rate for each of the pumps for a first transitional pump load during the transition period614. For example, the transition period614is 6 seconds in length, thus the balancing process can set the PUMP 1 rate of change at 6 BPM per 6 seconds for a decrease in ramp rate of 1 BPM per second. The balancing process can set the rate change for the remaining three pumps based on the new pumping rate target. For example, the balancing process can set PUMP 4 to 2 BPM per 6 seconds for an increase ramp rate of 1/3 BPM per sec. The balancing process can set PUMP 3 to 3 BPM per 6 seconds for an increase ramp rate of 1/2 BPM per sec. The balancing process can set PUMP 2 to 1 BPM per 6 seconds for an increase ramp rate of 1/6 BPM per sec. Thus, the balancing process can set the ramp rate change of flowrate decreasing equal to the total combined ramp rate change of flowrate increasing.

The balancing process can simultaneously execute the new target flowrates for each of the pumps during the transition period614and prepare for the second transition period616. In the example ofFIG.6C, PUMP 5 is idle, e.g., non-operating, during the initial pumping operation. The balancing process can determine a target flowrate for PUMP 5 based on the weighted factors. In the example provided, the balancing process can determine that PUMP 5 can replace the flowrate of PUMP 1 with a target rate of 6 BPM after the transition period616. The balancing process can determine a balanced supplemental pump load based on the weighted factors that a new target rate for PUMP 4 is 9 BPM, a new target rate for PUMP 3 is 8 BPM, and a new target rate for PUMP 2 is 7 BPM.

In some embodiments, the balancing process can simultaneously execute the new target rates during the second transition period616with ramp up and ramp down rates. For example, the balancing process may determine a second transitional pump load with an increase ramp rate for the new pumping unit, PUMP 5, to be 6 BPM per 6 seconds for an increase in rate of 1 BPM per second. The balancing process can set the rate change for PUMP 4 to 2 BPM per 6 seconds for a decrease in rate of 1/3 BPM per sec. The balancing process can set PUMP 3 to 3 BPM per 6 seconds for an decrease of 1/2 BPM per sec. The balancing process can set PUMP 2 to 1 BPM per 6 sec for a decrease ramp rate of 1/6 BPM per sec. Thus, the balancing process can determine a second transitional pump load with the total combined ramp rate change for the flowrate decreasing equal to the ramp rate change of flowrate increasing.

Turning now to a second example ofFIG.6D, the system controller within the control center236may receive an indication of reduced pumping performance, for example, an indication of an operational caution, e.g., overheating, or an indication that service is required, e.g., a reduction in pressure, from PUMP 1 (pumping unit220). The system controller can determine a new pumping rate for PUMP 2 (pumping unit222), PUMP 3 (pumping unit224), and PUMP 4 (pumping unit226) based on the weighted factors of capacity, efficiency, service life, cost, or combinations thereof. The system controller may determine a first transition period614to reduce the pumping rate of PUMP 1 to zero while simultaneously compensating with the remaining pumping units so that the overall pumping rate does not change. The system controller may determine a second transition period616to increase the pumping rate of a new or replacement PUMP 5 while compensating with the remaining pumping units so that the overall pumping rate does not change.

The system controller may simultaneously execute a balancing process for flowrate balancing with the following steps. At step652, the balancing process can determine the total flowrate of the system. From the example ofFIG.6D, the total flowrate from line610is 30 BPM. At step654, the balancing process can determine a total flowrate loss of the pumping system to be removed. From the example ofFIG.6D, the Total Loss Flowrate is 6 BPM for the removal of PUMP 1. At step656, the balancing process can determine the remaining flowrate of the system. FromFIG.6D, the Remaining Flowrate is equal to 24 BPM. At step658, the process can determine how to distribute the Total Loss Flowrate of 6 BPM to the remaining pumping units.

The balancing process executing on the system controller can determine the new pumping rate target for each pump based on the weighted factors of capacity, efficiency, service life, and cost. In the example ofFIG.6D, the balancing process may set PUMP 3 to a pumping rate target of 11 BPM with an increase of 3 BPM due to the weighted factors. For example, PUMP 3 may have a positive value for capacity, service life, efficiency and cost. The balancing process may set PUMP 2 to a pumping rate target of 10 BPM with an increase of 3 BPM due to the weighted factors. For example, PUMP 2 may have a positive value for capacity, service life, efficiency and cost. The balancing process may determine that PUMP 4 to stay at the current pumping rate target of 9 BPM based on neutral or limited scores for capacity, service life, and efficiency.

The balancing process may determine a ramp rate for each of the pumps during the transition period614. For example, the transition period614is 6 seconds in length, thus the balancing process can set the PUMP 1 rate of change at a decrease ramp rate of 1 BPM per second. The balancing process can set the increase ramp rate change for PUMP 2 and PUMP 3 at 1/2 BPM per sec. The balancing process can set PUMP 4 to remain unchanged. Thus, the balancing process can set the ramp rate change of flowrate decreasing equal to the total combined rate change of flowrate increasing.

The balancing process can execute the new target flowrates for each of the pumps during the transition period614and prepare for the second transition period616. In the example ofFIG.6D, PUMP 5 is idle, e.g., non-operating, during the initial pumping operation. The balancing process can determine a target flowrate for PUMP 5 based on the weighted factors. In the example provided, the balancing process can determine that PUMP 5 can replace the flowrate of PUMP 1 with a target rate of 6 BPM after the transition period616. The balancing process can determine, based on the weighted factors, that a new target rate for PUMP 4 is 9 BPM, a new target rate for PUMP 3 is 8 BPM, and a new target rate for PUMP 2 is 7 BPM.

In some embodiments, the balancing process can simultaneously execute the new target rates during the second transition period616with ramp up and ramp down rates. For example, the balancing process may determine a ramp up rate for the new pumping unit, PUMP 5, to be an increase ramp rate of 1 BPM per second. The balancing process can set PUMP 2 and PUMP 3 to 3 BPM per 6 seconds for a decrease ramp rate of 1/2 BPM per sec. The balancing process can set PUMP 4 remain unchanged at 9 BPM. Thus, the balancing process can set the ramp rate change of total combined flowrate decreasing equal to the ramp rate change of flowrate increasing.

The computer system at the wellsite may be a computer system suitable for communication and control of the pumping equipment, e.g., a fracturing spread200. The pumping operation described inFIG.2can be directed by a controller within the control center236that establishes control over each of the unit controllers, e.g., unit controller140ofFIG.1, and thus, establishes control of the pumping operations. A balancing process can be executing on the controller within the control center236, a networked computer system, a remote computer system, or combinations thereof. In some embodiments, the controller within the control center236, the unit controller140ofFIG.1, and unit controller410ofFIG.4may be an exemplary computer system700described inFIG.7. Turning now toFIG.7, a computer system700suitable for implementing one or more embodiments of the unit controller, for example, unit controller140, including without limitation any aspect of the computing system associated with the pumping operation ofFIG.2. The computer system700may be suitable for implementing one or more embodiments of a remote computer system, for example, a cloud computing system, a virtual network function (VNF) on a network slice of a cloud computing platform, and a plurality of user devices. The computer system700includes one or more processors702(which may be referred to as a central processor unit or CPU) that is in communication with memory704, secondary storage706, input output devices708, and network devices710. The computer system700may continuously monitor the state of the input devices and change the state of the output devices based on a plurality of programmed instructions. The programming instructions may comprise one or more applications retrieved from memory704for executing by the processor702in non-transitory memory within memory704. The input output devices may comprise a Human Machine Interface with a display screen and the ability to receive conventional inputs from the service personnel such as push button, touch screen, keyboard, mouse, or any other such device or element that a service personnel may utilize to input a command to the computer system700. The secondary storage706may comprise a solid state memory, a hard drive, or any other type of memory suitable for data storage. The secondary storage706may comprise removable memory storage devices such as solid state memory or removable memory media such as magnetic media and optical media, i.e., CD disks. The computer system700can communicate with various networks with the network devices710comprising wired networks, e.g., Ethernet or fiber optic communication, and short range wireless networks such as Wi-Fi (i.e., IEEE 802.11), Bluetooth, or other low power wireless signals such as ZigBee, Z-Wave, 6LoWPan, Thread, and WiFi-ah. The computer system700may include a long range radio transceiver712for communicating with mobile network providers.

In some embodiments, the computer system700may comprise a DAQ card714for communication with one or more sensors. The DAQ card714may be a standalone system with a microprocessor, memory, and one or more applications executing in memory. The DAQ card714, as illustrated, may be a card or a device within the computer system700. In some embodiments, the DAQ card714may be combined with the input output device708. The DAQ card714may receive one or more analog inputs716, one or more frequency inputs718, and one or more Modbus inputs920. For example, the analog input716may include a volume sensor, e.g., a tank level sensor. For example, the frequency input718may include a flow meter, i.e., a fluid system flowrate sensor. For example, the Modbus input720may include a pressure transducer. The DAQ card714may convert the signals received via the analog input716, the frequency input718, and the Modbus input720into the corresponding sensor data. For example, the DAQ card714may convert a frequency input718from the flowrate sensor into flowrate data measured in gallons per minute (GPM).

ADDITIONAL DISCLOSURE

A first embodiment, which is a computer-implemented method of managing a pumping unit during a pumping operation, comprising determining, by a managing process executing on a system controller, a position of a decoupler mechanism on the pumping unit; calibrating, by the managing process, a unit controller with a dual pump mode in response to determining the decoupler mechanism is in a coupled position, wherein the pumping unit is operating with a first pump and a second pump coupled to a prime mover in the dual pump mode; calibrating, by the managing process, the unit controller with a single pump mode in response to determining the decoupler mechanism is in a decoupled position, wherein the pumping unit is operating with the first pump coupled to the prime mover and the second pump decoupled from the prime mover in the single pump mode; and pumping, by the system controller, a wellbore treatment fluid in accordance with the pumping unit in i) the dual pump mode or ii) the single pump mode.

A second embodiment, which is the method of the first embodiment, wherein the pumping unit comprises the first pump, the second pump, and the prime mover.

A third embodiment, which is the method of the first or second embodiment, wherein the first pump is coupled to the prime mover, and wherein the decoupler mechanism couples the second pump to the prime mover.

A fourth embodiment, which is the method of any of the first through the third embodiments, wherein the decoupler mechanism comprises a static element, a dynamic element, an actuator, and a set of sensors; wherein the static element is coupled to a drive shaft of the prime mover; wherein the dynamic element is slidingly coupled to a drive shaft of the second pump; and wherein the actuator is coupled to the dynamic element and a housing of the second pump.

A fifth embodiment, which is the method of any of the first through the fourth embodiments, wherein the set of sensors comprises a first positional sensor in a location associated with the coupled position and a second positional sensor in location associated with the decoupled position.

A sixth embodiment, which is the method of any of the first through the fifth embodiments, wherein the set of sensors are positional sensors, and wherein the positional sensors are hall-effect sensors.

A seventh embodiment, which is the method of any of the first through the sixth embodiments, wherein the coupled position of the decoupler mechanism comprises an actuator positioning a dynamic element in engagement with a static element, wherein a first positional sensor is configured to return a signal based on the position of the dynamic element, and wherein the coupled position is configured to transfer torque and rotation from the static element to the dynamic element.

An eighth embodiment, which is the method of any of the first through the seventh embodiments, wherein the decoupled position of the decoupler mechanism comprises an actuator positioning a dynamic element away from and not engaged with a static element, wherein a second positional sensor is configured to return a signal based on the position of the dynamic element, and wherein the decoupled position is configured to rotationally isolate the second pump from the prime mover.

A ninth embodiment, which is the method of any of the first through the eighth embodiments, wherein the power end is an internal combustion engine or an electric motor.

A tenth embodiment, which is the method of any of the first through the ninth embodiments, further comprising transporting a pumping unit to a remote wellsite; fluidically coupling a pumping unit to a wellbore; beginning the pumping operation by a system controller communicatively coupled to the pumping unit; retrieving, by the system controller, one or more datasets of periodic pumping data indicative of the pumping operation; and mixing a wellbore treatment, by a blender unit, per a pumping schedule.

An eleventh embodiment, which is a method of replacing a pumping unit during a pumping operation delivering a wellbore treatment fluid into a wellbore penetrating a formation, comprising pumping a wellbore treatment with a pumping unit configured in a dual mode and a unit controller calibrated for the dual mode; receiving, by the unit controller comprising a processor and non-transitory memory, an indication of reduced pump operation; stopping, by the unit controller, the pumping operation of the pumping unit by reducing a rotational speed of a prime mover to zero during a transitional period; activating, by the unit controller, a coupling actuator of a decoupler mechanism to move a dynamic element from a coupled configuration to a decoupled configuration; receiving feedback from one of a set of sensors that the dynamic element is positioned in a decoupled position; recalibrating, by the unit controller, from the dual mode to a single mode in response to the decoupled position of the dynamic element; and pumping a wellbore treatment with the pumping unit configured in the single mode and the unit controller calibrated for the single mode.

A twelfth embodiment, which is the method of the eleventh embodiment, wherein the wellbore treatment fluid comprises i) a clean fluid, ii) a dirty fluid, or iii) a blended fluid, and wherein the blended fluid comprises a portion of clean fluid and a portion of dirty fluid.

A thirteenth embodiment, which is the method of any of the eleventh and the twelfth embodiments, wherein the dual mode comprises a first pump and a second pump coupled to a prime mover.

A fourteenth embodiment, which is the method of any of the eleventh through the thirteenth embodiments, wherein the indication of reduced pump operation is received via i) sensors, or ii) a system controller; wherein a plurality of sensors provide periodic datasets indicative of the pumping operation; and wherein the system controller is communicatively coupled to the unit controller via wired or wireless communication device.

A fifteenth embodiment, which is the method of any of the eleventh through the fourteenth embodiments, further comprising determining, by the unit controller, the transitional period to reduce the pumping operation of the pumping unit to zero.

A sixteenth embodiment, which is the method of any of the eleventh through the fifteenth embodiments, wherein the wellbore treatment fluid is selected from a group consisting of a drilling mud, a fracturing slurry, a cementitious slurry, a spacer fluid, a completion fluid, an acidizing fluid, a gravel packing fluid, a resin compound, and water.

A seventeenth embodiment, which is a system of a dual-pumping unit, comprising a prime mover; a first pump coupled to the prime mover via a decoupler mechanism; a set of sensors configured to identify a position of the decoupler mechanism; a unit controller comprising a processor and a non-transitory memory communicatively coupled to the prime mover, the decoupler mechanism, and the set of sensors, configured to: control a pump rate of a pumping operation with the dual-pumping unit in a dual mode via control of the prime mover; stop a pumping operation by slowing a rotational motion of a drive shaft via the prime mover to a stop during a transitional period; activate an coupling actuator of the decoupler mechanism to move a dynamic element from a coupled configuration to a decoupled configuration; receive feedback from the set of sensors of the dynamic element in a decoupled position; and recalibrate the unit controller from the dual mode to a single mode in response to the decoupled position of the dynamic element.

An eighteenth embodiment, which is the system of the seventeenth embodiment, further comprising a second pump coupled to the prime mover.

A nineteenth embodiment, which is the system of the seventeenth embodiment, further comprising deactivating the coupling actuator of the decoupler mechanism in response to receiving feedback from the set of sensors of the dynamic element being in the decoupled position.

A twentieth embodiment, which is the system of any of the seventeenth through the nineteenth embodiments, further comprising the decoupler mechanism is in a locked position in response to the deactivating the coupling actuator.

A twenty-first embodiment, which is the system of any of the seventeenth through the twentieth embodiments, a fluid network coupled to the first pump; wherein the first pump receives a treatment fluid from the fluid network; and wherein the treatment fluid is i) a clean fluid, ii) a dirty fluid, or iii) a blended fluid.

A twenty-second embodiment, which is a computer-implemented method of managing a pumping unit during a pumping operation, comprising determining, by a managing process executing on a system controller, a position of a decoupler mechanism on a pumping unit; calibrating, by the managing process, the unit controller with a dual pump mode in response to determining the decoupler mechanism in the coupled position, wherein the pumping unit is operating with first fluid end and the second fluid end coupled to the power end in the dual pump mode; calibrating, by the by the managing process, the unit controller with a single pump mode in response to determining the decoupler mechanism in the decoupled position, wherein the pumping unit is operating with first fluid end coupled to the power end and the second fluid end decoupled from the power end in the single pump mode; and pumping, by the system controller, a wellbore treatment fluid in accordance with the pumping unit in i) the dual pump mode or ii) the single pump mode.

A twenty-third embodiment, which is the method of the twenty-second embodiment, wherein the pumping unit comprises a first fluid end, a second fluid end, and a power end.

A twenty-fourth embodiment, which is the method of the twenty-second or twenty-third embodiment, wherein the first fluid end is coupled to the power end, and wherein the decoupler mechanism couples the second fluid end to the power end.

A twenty-fifth embodiment, which is the method of any of the twenty-second through the twenty-fourth embodiments, further comprising transporting a pumping unit to a remote wellsite; fluidically coupling a pumping unit to a wellbore; beginning the pumping operation by a system controller communicatively coupled to the pumping unit; retrieving, by the system controller, one or more datasets of periodic pumping data indicative of the pumping operation; and mixing a wellbore treatment, by a blender unit, per the pump schedule.