Hydraulic Fracturing Pumps to Enhance Flow of Fracturing Fluid into Wellheads and Related Methods

This application is a continuation of U.S. Non-Provisional application Ser. No. 18/453,257, filed Aug. 21, 2023, titled HYDRAULIC FRACTURING PUMPS TO ENHANCE FLOW OF FRACTURING FLUID INTO WELLHEADS AND RELATED METHODS,” which is a continuation of U.S. Non-Provisional application Ser. No. 17/989,607, filed Nov. 17, 2022, titled “HYDRAULIC FRACTURING PUMPS TO ENHANCE FLOW OF FRACTURING FLUID INTO WELLHEADS AND RELATED METHODS,” which is a continuation of U.S. Non-Provisional application Ser. No. 17/664,578, filed May 23, 2022, titled “HYDRAULIC FRACTURING PUMPS TO ENHANCE FLOW OF FRACTURING FLUID INTO WELLHEADS AND RELATED METHODS,” which claims the benefit of and priority to U.S. Provisional Application No. 63/202,031, filed May 24, 2021, titled “HYDRAULIC FRACTURING PUMPS TO ENHANCE FLOW OF FRACTURING FLUID INTO WELLHEADS AND RELATED METHODS,” the entire disclosures of which are incorporated herein by reference.

The present disclosure relates to hydraulic fracturing pumps to enhance the flow of fracturing fluid into wellheads and related methods and, more particularly, to hydraulic fracturing pumps to provide increased flow of fracturing fluid into wellheads and related methods.

Hydraulic fracturing is an oilfield operation that stimulates the production of hydrocarbons, such that the hydrocarbons may more easily or readily flow from a subsurface formation to a well. For example, a hydraulic fracturing system may be configured to fracture a formation by pumping a fracturing fluid into a well at high pressure and high flow rates. Some fracturing fluids may take the form of a slurry including water, proppants, and/or other additives, such as thickening agents and gels. The slurry may be forced via operation of one or more pumps into the formation at rates faster than can be accepted by the existing pores, fractures, faults, or other spaces within the formation. As a result, pressure may build rapidly to the point where the formation may fail and may begin to fracture. By continuing to pump the fracturing fluid into the formation, existing fractures in the formation may be caused to expand and extend in directions away from a well bore, thereby creating additional flow paths for hydrocarbons to flow to the well bore. The proppants may serve to prevent the expanded fractures from closing or may reduce the extent to which the expanded fractures contract when pumping of the fracturing fluid is ceased. Once the formation is fractured, large quantities of the injected fracturing fluid are allowed to flow out of the well, and the production stream of hydrocarbons may be obtained from the formation.

To pump the fracturing fluid into the well bore, a hydraulic fracturing system may include a number of hydraulic fracturing units, each including a prime mover to supply mechanical power and a hydraulic fracturing pump driven by the prime mover. The hydraulic fracturing pump may be supplied with fracturing fluid, and the hydraulic fracturing pump, driven by the prime mover, may pump the fracturing fluid at high-pressure and high flow rates into the wellhead during a fracturing operation. In order to facilitate use of the hydraulic fracturing units and other equipment related to a fracturing operation at different locations, the hydraulic fracturing units may often include a mobile platform, such as a trailer, onto which the prime mover, hydraulic fracturing pump, and other components of the hydraulic fracturing unit may be mounted. The hydraulic fracturing unit may be transported to one wellhead location, set-up for operation, used during the fracturing operation, and once the fracturing operation is completed, it may be partially disassembled for transportation and transported to another wellhead location for use in another fracturing operation. Because the hydraulic fracturing units are often transported on public highways, the maximum dimensions of the hydraulic fracturing units may often be constrained by government regulations.

Although the maximum dimensions of the hydraulic fracturing units may be constrained, it may be desirable for the hydraulic fracturing units to be capable of increased pumping capacity. For example, by increasing the pumping capacity of the hydraulic fracturing units, it may be possible to successfully complete a fracturing operation using fewer hydraulic fracturing units, which may lead to reduced set-up and tear-down time, the need for fewer operators, more efficient operation, and more cost-effective completion of the fracturing operation. However, due at least in part to the constrained maximum dimensions of the hydraulic fracturing units, it may be difficult to increase the pumping capacity of a hydraulic fracturing unit.

In addition, larger hydraulic fracturing pumps driven by more powerful prime movers may develop relatively larger shock and vibration during operation, for example, due to torque loads generated by more powerful prime movers driving higher capacity hydraulic fracturing pumps. Such shock and vibration, if unmitigated, may result in premature wear or failure of components of the hydraulic fracturing unit and manifolds carrying the fracturing fluid to the wellhead. Thus, although hydraulic fracturing units having larger pumping capacities may be desirable, such larger capacities may result other possible drawbacks.

Accordingly, Applicant has recognized a need for hydraulic fracturing units and related methods for providing greater pumping capacity, while mitigating or eliminating possible drawbacks. The present disclosure may address one or more of the above-referenced drawbacks, as well as other possible drawbacks.

As referenced above, it may be desirable to provide hydraulic fracturing units having higher pumping capacities, but achieving higher pumping capacities may be constrained by limited physical dimensions enabling transportation of hydraulic fracturing units between well sites. In addition, higher pumping capacities may require more powerful prime movers and higher capacity hydraulic fracturing pumps, and operation of such prime movers and hydraulic fracturing pumps may lead to premature wear or failure of components of the hydraulic fracturing units and the manifolds that carry the fracturing fluid to the wellhead due, for example, to increased shock and vibration during operation and proppant settling due to increased stroke lengths.

The present disclosure generally is directed to hydraulic fracturing pumps to enhance the flow of fracturing fluid into wellheads and related methods and, more particularly, to hydraulic fracturing pumps to provide increased flow of fracturing fluid into wellheads and related methods. For example, in some embodiments, a hydraulic fracturing pump may be configured to provided increased pumping capacity while retaining dimensions able to fit within physical dimension limitations for transportation between well sites. In addition, in some embodiments, the hydraulic fracturing pumps and related methods may provide higher pumping capacities while keeping shock and vibrations to relatively low levels, or in some instances, reducing shock and vibration levels. As a result, at least some embodiments may reduce the likelihood of, or prevent, premature component wear or failure in hydraulic fracturing systems.

According to some embodiments, a hydraulic fracturing pump to enhance flow of fracturing fluid into a wellhead during a high-pressure fracturing operation may include a pump frame at least partially defining a shaft aperture, and a crankshaft extending through the shaft aperture. The hydraulic fracturing pump further may include a plurality of first plungers connected to the crankshaft and positioned to reciprocate relative to the crankshaft as the crankshaft rotates. Each of the plurality of first plungers may reciprocate in a first plane and draw-in fracturing fluid at a first pressure and discharge the fracturing fluid at a second pressure greater than the first pressure. The hydraulic fracturing pump also may include a plurality of second plungers connected to the crankshaft and positioned to reciprocate relative to the crankshaft as the crankshaft rotates. Each of the plurality of second plungers may reciprocate in a second plane and draw-in fracturing fluid at a third pressure and discharge the fracturing fluid at a fourth pressure greater than the third pressure. The first plane and the second plane may define a non-zero offset angle between the first plane and the second plane.

In some embodiments, a hydraulic fracturing pump to enhance flow of fracturing fluid into a wellhead during a high-pressure fracturing operation may include a pump frame at least partially defining a shaft aperture, and a crankshaft extending through the shaft aperture. The crankshaft may include a plurality of crankpins, and each of the crankpins may be offset from a longitudinal rotation axis of the crankshaft. The hydraulic fracturing pump further may include a plurality of first plungers, and each of the plurality of first plungers may be connected to the crankshaft via a respective crankpin of the plurality of crankpins and be positioned to reciprocate relative to the crankshaft as the crankshaft rotates. The hydraulic fracturing pump also may include a plurality of second plungers. Each of the plurality of second plungers may be connected to the crankshaft via a respective crankpin of the plurality of crankpins and may be positioned to reciprocate relative to the crankshaft as the crankshaft rotates. Each of plurality of crankpins may be connected to one of the plurality of first plungers and one of the plurality of second plungers.

In some embodiments, a hydraulic fracturing pump to enhance flow of fracturing fluid into a wellhead during a high-pressure fracturing operation may include a pump frame at least partially defining a shaft aperture, and a crankshaft extending through the shaft aperture. The hydraulic fracturing pump further may include a plurality of first plungers, and each of the plurality of first plungers may be connected to the crankshaft and may be positioned to reciprocate relative to the crankshaft as the crankshaft rotates. The hydraulic fracturing pump also may include a plurality of second plungers, and each of the plurality of second plungers may be connected to the crankshaft and may be positioned to reciprocate relative to the crankshaft as the crankshaft rotates. The plurality of first plungers may be positioned to pump a first fracturing fluid including a first fracturing fluid composition while the plurality of second plungers pump a second fracturing fluid including a second fracturing fluid composition different from the first fracturing fluid composition.

In some embodiments, a hydraulic fracturing pump to enhance flow of fracturing fluid into a wellhead during a high-pressure fracturing operation may include a pump frame at least partially defining a shaft aperture, and a crankshaft extending through the shaft aperture. The hydraulic fracturing pump further may include a plurality of first plungers, and each of the plurality of first plungers may be connected to the crankshaft and may be positioned to reciprocate relative to the crankshaft as the crankshaft rotates. The hydraulic fracturing pump also may include a plurality of second plungers, and each of the plurality of second plungers may be connected to the crankshaft and many be positioned to reciprocate relative to the crankshaft as the crankshaft rotates. The hydraulic fracturing pump still further may include a first fluid end connected to the pump frame such that the plurality of first plungers draw fracturing fluid into the first fluid end at a first pressure and discharge the fracturing fluid from the first fluid end at a second pressure greater than the first pressure. The hydraulic fracturing pump also may include a second fluid end connected to the pump frame such that the plurality of second plungers draw fracturing fluid into the second fluid end at a third pressure and discharge the fracturing fluid from the second fluid end at a fourth pressure greater than the third pressure.

In some embodiments, a hydraulic fracturing pump to enhance flow of fracturing fluid into a wellhead during a high-pressure fracturing operation may include a pump frame at least partially defining a shaft aperture, and a crankshaft extending through the shaft aperture. The hydraulic fracturing pump further may include a plunger connected to the crankshaft and may be positioned to reciprocate relative to the crankshaft as the crankshaft rotates. The hydraulic fracturing pump also may include a fluid end connected to the pump frame. One or more of the fluid end or the plunger may be positioned such that as the plunger travels in a first direction, fracturing fluid is drawn into the fluid end and fracturing fluid is discharged from the fluid end, and as the plunger travels in a second direction opposite the first direction, fracturing fluid is drawn into the fluid end and fracturing fluid is discharged from the fluid end.

In some embodiments, a hydraulic fracturing pump to enhance flow of fracturing fluid into a wellhead during a high-pressure fracturing operation may include a pump frame at least partially defining a shaft aperture, and a crankshaft extending through the shaft aperture. The hydraulic fracturing pump further may include at least one plunger connected to the crankshaft and may be positioned to reciprocate relative to the crankshaft as the crankshaft rotates. The hydraulic fracturing pump also may include a drive assembly configured for transferring power from the prime mover to the hydraulic fracturing pump. In one embodiment, the drive assembly may include a first pinion gear engaged with the crankshaft at a first end of the pump frame, and a connector shaft connected to the first pinion gear. The hydraulic fracturing pump still further may include a second pinion gear connected to the hydraulic fracturing pump at a second end of the pump frame and connected to the first pinion gear via the connector shaft, such that the first pinion gear drives the connector shaft and the crankshaft at the first end of the pump frame, the connector shaft drives the second pinion gear at the second end of the pump frame, and the second pinion gear drives the crankshaft at the second end of the pump frame.

In other embodiments, the drive assembly can include a planetary gear train including at least one planetary gearbox positioned at the first end of the pump frame. In some embodiments, an additional planetary gearbox also can be provided at the second end of the pump frame. The at least one planetary gearbox may include a first drive gear, which can be configured as a ring gear having a first series of gear teeth formed about an inner circumference thereof, and a second series of gear teeth formed about an outer circumference thereof. A sun gear can be positioned within the first drive gear, generally being arranged approximately in the center thereof and aligned with the longitudinal axis of the crankshaft. The sun gear can engage with the crankshaft, and further can be connected to a prime mover of the hydraulic fracturing unit; for example, such as by being coupled to a transmission arranged between the prime mover and the hydraulic fracturing pump. A series of planet gears may be positioned about the sun gear, each of the planet gears including a series of gear teeth configured to engage gear teeth of the sun gear, and engage with the first series of teeth formed about the inner circumference of the first drive gear. A first pinon gear can be arranged below the first drive gear and can be engaged with a first end of a connector shaft that extends through the pump frame. The first pinion gear further may have a series of gear teeth formed about its circumference, which gear teeth are configured to engage with the second series of gear teeth formed about the outer circumference of the first drive gear.

As the sun gear is driven by operation of the prime mover, the crankshaft is rotated, and at substantially the same time, the engagement of the gear teeth of the planet gears with the gear teeth of the sun gear and with the first series of gear teeth formed about the inner circumference of the first drive gear will correspondingly drive rotation of the first drive gear. As the first drive gear is rotated, the engagement of its second series of teeth arranged about its outer circumference with the teeth of the first pinion gear turn drives rotation of the first pinion gear, which in turn drives rotation of the connector shaft coupled at its first end to the first pinion gear. The connector shaft further can be coupled at a second, opposite end to a second pinion gear located at the second end of the pump frame. The second pinion gear may have a series of gear teeth configured to engage with the gear teeth of a second drive gear located at the second end of the pump frame such that as the connector shaft is rotated, this rotation is translated to the second drive gear by the second pinion gear for additionally driving rotation of the crankshaft by the second drive gear. The second drive gear thus can engage with the crankshaft so as to support and drive rotation of the crankshaft from the second end of the crankshaft, to help reduce torque therealong.

In embodiments, a second planetary gearbox such as utilized at the first end of the pump frame can be used at the second end of the pump frame. In such embodiments, the second drive gear can be configured as a ring gear having gear teeth along an inner and an outer circumference thereof, with a sun gear and a series of planet gears arranged approximately in the center of the second drive gear. The sun gear can be connected to or engaged with the second end of the crankshaft so as to support and drive rotation of the crankshaft so that the crankshaft is driven from both sides of the pump frame. Alternatively, the second drive gear can comprise a single gear engaged with the second end of the crankshaft and driven by the rotation of the second pinion gear by the connector shaft.

In some embodiments, a hydraulic fracturing pump to enhance flow of fracturing fluid into a wellhead during a high-pressure fracturing operation may include a pump frame including a plurality of pump frame sections, and one or more of the plurality of pump frame sections may at least partially define a shaft aperture. The hydraulic fracturing pump further may include a crankshaft extending through the shaft aperture, and one or more of the plurality of pump frame sections may have an inverted V-shaped cross-section as viewed in a direction substantially parallel to a longitudinal axis of the crankshaft. The hydraulic fracturing pump also may include a plunger connected to the crankshaft and positioned to reciprocate relative to the crankshaft as the crankshaft rotates.

In some embodiments, a hydraulic fracturing unit to enhance flow of fracturing fluid into a wellhead during a high-pressure fracturing operation may include a platform having a longitudinal platform axis and a width perpendicular to the longitudinal platform axis. The hydraulic fracturing unit further may include a prime mover supported by the platform, and the prime mover may include an output shaft. The hydraulic fracturing unit also may include a transmission including an input shaft and a transmission output shaft, and the transmission may be supported by the platform and connected to the output shaft of the prime mover via the input shaft. The hydraulic fracturing unit still further may include a hydraulic fracturing pump supported by the platform at a longitudinal position opposite the prime mover relative to the transmission. The hydraulic fracturing pump may include a pump frame at least partially defining a shaft aperture, and a crankshaft extending through the shaft aperture. The crankshaft may have a longitudinal axis of rotation substantially parallel to the longitudinal platform axis. The hydraulic fracturing pump further may include a plurality of first plungers connected to the crankshaft and positioned to reciprocate relative to the crankshaft as the crankshaft rotates. Each of the plurality of first plungers may reciprocate in a first plane and may draw-in fracturing fluid at a first pressure and discharge the fracturing fluid at a second pressure greater than the first pressure. The hydraulic fracturing pump also may include a plurality of second plungers connected to the crankshaft and positioned to reciprocate relative to the crankshaft as the crankshaft rotates. Each of the plurality of second plungers may reciprocate in a second plane and may draw-in fracturing fluid at a third pressure and discharge the fracturing fluid at a fourth pressure greater than the third pressure. The first plane and the second plane may define a non-zero offset angle between the first plane and the second plane.

In some embodiments, a method to enhance output of a hydraulic fracturing unit associated with a high-pressure fracturing operation may include connecting a plurality of first plungers to a crankshaft of a hydraulic fracturing pump. Each of the plurality of first plungers may be positioned to reciprocate relative to the crankshaft as the crankshaft rotates, and each of the plurality of first plungers may reciprocate in a first plane and may draw-in fracturing fluid at a first pressure and discharge the fracturing fluid at a second pressure greater than the first pressure. The method further may include connecting a plurality of second plungers to the crankshaft of the hydraulic fracturing pump. Each of the plurality of second plungers may be positioned to reciprocate relative to the crankshaft as the crankshaft rotates, and each of the plurality of second plungers may reciprocate in a second plane and may draw-in fracturing fluid at a third pressure and discharge the fracturing fluid at a fourth pressure greater than the third pressure. The first plane and the second plane may define a non-zero offset angle between the first plane and the second plane.

In some embodiments, a method to increase a service interval of a hydraulic fracturing pump associated with a high-pressure fracturing operation may include pumping a first fracturing fluid including a first fracturing fluid composition via a plurality of first plungers of a hydraulic fracturing pump. The method further may include, while pumping the first fracturing fluid, pumping a second fracturing fluid including a second fracturing fluid composition via a plurality of second plungers of the hydraulic fracturing pump. The first fracturing fluid composition may be different than the second fracturing fluid composition.

In some embodiments, a method to reduce torque shock magnitude generated during operation of a hydraulic fracturing pump associated with a high-pressure fracturing operation may include connecting a plurality of first plungers to a crankshaft of the hydraulic fracturing pump. Each of the plurality of first plungers may be positioned to reciprocate relative to the crankshaft as the crankshaft rotates. Each of the plurality of first plungers may reciprocate in a first plane and draw-in fracturing fluid at a first pressure and discharge the fracturing fluid at a second pressure greater than the first pressure. The method also may include connecting a plurality of second plungers to the crankshaft of the hydraulic fracturing pump. Each of the plurality of second plungers may be positioned to reciprocate relative to the crankshaft as the crankshaft rotates. Each of the plurality of second plungers may reciprocate in a second plane and draw-in fracturing fluid at a third pressure and discharge the fracturing fluid at a fourth pressure greater than the third pressure. The first plane and the second plane may define a non-zero offset angle between the first plane and the second plane.

According to one aspect, a pump comprises: a pump frame at least partially defining a shaft aperture; a crankshaft extending through the shaft aperture; a plurality of first plungers connected to the crankshaft and configured to reciprocate relative to the crankshaft as the crankshaft rotates, each of the plurality of first plungers configured to reciprocate in a first plane; and a plurality of second plungers connected to the crankshaft and configured to reciprocate relative to the crankshaft as the crankshaft rotates, each of the plurality of second plungers configured to reciprocate in a second plane; wherein a non-zero offset angle is defined between the first plane and the second plane.

In one embodiment of the pump, the non-zero offset angle ranges from about forty-five degrees to about one-hundred-eighty degrees.

In one embodiment, the pump further comprises a plurality of crankpins mounted along the crankshaft, wherein each of the plurality of crankpins being offset from a longitudinal rotation axis of the crankshaft, and each of the plurality of crankpins being connected to one of the plurality of first plungers and one of the plurality of second plungers; wherein the first and second plungers are configured to move in opposite directions to draw fluid and to discharge fluid; wherein each of the plurality of first plungers configured to draw in fluid at a first pressure and discharge fluid at a second pressure greater than the first pressure, and each of the plurality of second plungers configured to draw in fluid at a third pressure and discharge fluid at a fourth pressure greater than the third pressure.

In embodiments, the pump can include a first pair of plungers comprising a first one of the plurality of first plungers and a first one of the plurality of second plungers, and a second pair of plungers comprising a second one of the plurality of first plungers and a second one of the plurality of second plungers; and wherein the first pair of plungers is offset from the second pair of plungers such that the first pair of plungers and the second pair of plungers are engaged in a non-consecutive firing sequence sufficient to provide at least partial cancellation of forces generated by the first and second pairs of plungers.

In embodiments, the pump further comprises a plurality of connector rods, each of the connector rods configured to connect one of the plurality first plungers to one of a plurality of crankpins or one of the plurality of second plungers to one of the plurality of crankpins; each of the connector rods comprising a plunger end connected to one of the plurality first plungers or one of the plurality of second plungers; and a crank end connected to one of the plurality of crankpins, each of the crank ends comprising at least one crank end connector.

In embodiments, the pump further comprises a drive assembly configured to be driven by one or more prime movers. In some embodiments of the pump, the one or more prime movers comprise one or more gas turbine engines, electric motors, or combinations thereof.

In embodiments of the pump, the drive assembly comprises: a first pinion gear engaged with the crankshaft at a first end of the pump frame; a connector shaft having a first end connected to the first pinion gear; and a second pinion gear connected to a second end of the connector shaft at a second end of the pump frame, and engaged with the crankshaft at the second end of the pump frame; wherein the first pinion gear is configured to drive the crankshaft at the first end of the pump frame upon rotation of the crankshaft, such that the connector shaft drives the second pinion gear at the second end of the pump frame, and the second pinion gear drives the crankshaft at the second end of the pump frame.

In embodiments of the pump, the drive assembly comprises: at least one planetary gearbox connected to the pump at a first end of the pump frame, at a second end of the pump frame, or at both the first and the second end of the pump frame, the planetary gearbox comprising: a sun gear engaged with the crankshaft at the first end of the pump frame; a ring gear surrounding the sun gear; and a plurality of planetary gears disposed between the ring gear and the sun gear and configured to engage with the ring gear, and sun gear such that rotation of the sun gear is translated to the ring gear.

In embodiments of the pump, one or more of: the plurality of first plungers reciprocate in a first direction away from the crankshaft and a second direction opposite the first direction and toward the crankshaft, the first direction and the second direction lie in the first plane, the first direction having a downward component and an outward component, and the second direction having an upward component and an inward component; or the plurality of second plungers reciprocate in a third direction away from the crankshaft and a fourth direction opposite the third direction and toward the crankshaft, the third direction and the fourth direction lying in the second plane, the third direction having a downward component and an outward component, and the fourth direction having an upward component and an inward component.

In embodiments of the pump, the plurality of first plungers comprises at least three plungers, and the plurality of second plungers comprises at least three plungers.

In embodiments of the pump, the pump frame comprises a plurality of pump frame sections, each of the plurality of pump frame sections at least partially defining the shaft aperture; and wherein at least one of the plurality of pump frame sections has an inverted V-shaped cross-section as viewed in a direction substantially parallel to a longitudinal axis of the crankshaft.

In another aspect, a hydraulic fracturing pump is provided to enhance flow of fracturing fluid into a wellhead during a high-pressure fracturing operation, the hydraulic fracturing pump comprising: a pump frame at least partially defining a shaft aperture; a crankshaft extending through the shaft aperture, the crankshaft comprising a plurality of crankpins, each of the crankpins being offset from a longitudinal rotation axis of the crankshaft; a plurality of first plungers, each of the plurality of first plungers being connected to the crankshaft via a respective crankpin of the plurality of crankpins and configured to reciprocate relative to the crankshaft as the crankshaft rotates; and a plurality of second plungers, each of the plurality of second plungers being connected to the crankshaft via a respective crankpin of the plurality of crankpins and configured to reciprocate relative to the crankshaft as the crankshaft rotates, each of the plurality of crankpins being connected to one of the plurality of first plungers and one of the plurality of second plungers.

In embodiments, the hydraulic fracturing pump further comprises a plurality of connector rods, each of the connector rods connecting one of the plurality first plungers to one of the plurality of crankpins or one of the plurality of second plungers to one of the plurality of crankpins.

In embodiments of the hydraulic fracturing pump, each of the plurality of connector rods comprises: a plunger end connected to one of the plurality first plungers or one of the plurality of second plungers; and a crank end connected to one of the plurality of crankpins, each of the crank ends comprising two crank end connectors separated by a crank end space.

In embodiments of the hydraulic fracturing pump, the plurality of connector rods comprises: a plurality of first connector rods, each of the plurality of first connector rods being connected to one of the plurality of first plungers; and a plurality of second connector rods, each of the plurality of second connector rods being connected to one of the plurality of second plungers, wherein a crank end connector of each of the plurality of first connector rods is positioned at least partially in a crank end space of one of the plurality of second connector rods and a crank end connector of each of the plurality of second connector rods is positioned at least partially in a crank end space of one of the plurality of first connector rods.

In embodiments of the hydraulic fracturing pump each of the plurality of first plungers reciprocates in a first plane, and each of the plurality of second plungers reciprocates in a second plane, the first plane and the second plane defining a non-zero offset angle between the first plane and the second plane.

In embodiments of the hydraulic fracturing pump the plurality of first plungers is positioned to pump a first fracturing fluid comprising a first fracturing fluid composition while the plurality of second plungers to pumps a second fracturing fluid comprising a second fracturing fluid composition different than the first fracturing fluid composition, and wherein the first fracturing fluid composition comprises proppants, and the second fracturing fluid composition comprises water and is devoid of proppants.

In embodiments, the hydraulic fracturing pump further comprises: a first fluid end connected to the pump frame such that the plurality of first plungers draw fracturing fluid into the first fluid end at a first pressure and discharge the fracturing fluid from the first fluid end at a second pressure greater than the first pressure; and a second fluid end connected to the pump frame such that the plurality of second plungers draw fracturing fluid into the second fluid end at a third pressure and discharge the fracturing fluid from the second fluid end at a fourth pressure greater than the third pressure.

In embodiments of the hydraulic fracturing pump, one or more of: one or more of the plurality of first plungers or the first fluid end are configured such that as each of the plurality of first plungers travels in a first direction, fracturing fluid is drawn into the first fluid end and fracturing fluid is discharged from the first fluid end, and as each of the plurality of first plungers travels in a second direction opposite the first direction, fracturing fluid is drawn into the first fluid end and fracturing fluid is discharged from the first fluid end; or one or more of the plurality of second plungers or the second fluid end are configured such that as each of the plurality of second plungers travels in a third direction, fracturing fluid is drawn into the second fluid end and fracturing fluid is discharged from the second fluid end, and as each of the plurality of second plungers travels in a fourth direction opposite the third direction, fracturing fluid is drawn into the second fluid end and fracturing fluid is discharged from the second fluid end.

In embodiments of the hydraulic fracturing pump, the pump frame comprises a plurality of pump frame sections and at least one of the plurality of pump frame sections has an upright or inverted V-shaped cross-section as viewed in a direction substantially parallel to a longitudinal axis of the crankshaft.

According to another aspect, a method of assembling a hydraulic fracturing unit is provided, the method comprising: connecting a plurality of first plungers to a crankshaft of a hydraulic fracturing pump, each of the plurality of first plungers positioned to reciprocate relative to the crankshaft as the crankshaft rotates and each of the plurality of first plungers configured to reciprocate in a first plane and draw in fracturing fluid at a first pressure and discharge the fracturing fluid at a second pressure greater than the first pressure; and connecting a plurality of second plungers to the crankshaft of the hydraulic fracturing pump, each of the plurality of second plungers positioned to reciprocate relative to the crankshaft as the crankshaft rotates and each of the plurality of second plungers configured to reciprocate in a second plane and draw in fracturing fluid at a third pressure and discharge the fracturing fluid at a fourth pressure greater than the third pressure, the first plane and the second plane defining a non-zero offset angle between the first plane and the second plane.

In embodiments of the method, the crankshaft comprises a plurality of crankpins each offset from a longitudinal rotation axis of the crankshaft; and connecting the plurality of first plungers to the crankshaft and connecting the plurality of second plungers to the crankshaft comprises connecting one of the plurality of first plungers and one of the plurality of second plungers to each of the plurality of crankpins.

In embodiments of the method, each of the plurality of first plungers has a first diameter and each of the plurality of second plungers has a second diameter, and connecting one of the plurality of first plungers and one of the plurality of second plungers to each of the plurality of crankpins comprises connecting the one of the plurality of first plungers and the one of the plurality of second plungers to each of the plurality of crankpins such that a longitudinal distance occupied by the one of the plurality of first plungers and the one of the plurality of second plungers is less than a sum of the first diameter and the second diameter.

In embodiments of the method, the hydraulic fracturing unit comprises a platform having a longitudinal platform axis and a width perpendicular to the longitudinal platform axis, the method further comprising connecting the hydraulic fracturing pump to the platform, such that a longitudinal axis of the crankshaft is parallel to the longitudinal platform axis. In some embodiments, connecting the hydraulic fracturing pump to the platform comprises connecting the hydraulic fracturing pump to the platform, such that one or more of the plurality of first plungers or the plurality of second plungers are closer to the platform than the crankshaft.

In embodiments, connecting the plurality of first plungers to the crankshaft of the hydraulic fracturing pump and connecting the plurality of second plungers to the crankshaft of the hydraulic fracturing pump comprises arranging first and second plungers of each of the plurality of first plungers and the plurality of second plungers in plunger groups with adjacent groups of plungers offset by between about 45 degrees to about 90 degrees; wherein during pumping of the fracturing fluid, the plunger groups are engaged in a non-consecutive sequence to provide at least partial force cancellation of forces generated by the plunger groups.

In embodiments, the method comprises connecting a first fluid end to the hydraulic fracturing pump, such that the plurality of first plungers reciprocate in the first fluid end; and connecting a second fluid end to the hydraulic fracturing pump, such that the plurality of second plungers reciprocate in the second fluid end.

In another aspect, a method to increase a service interval of a hydraulic fracturing pump associated with a high-pressure fracturing operation is provided, the method comprising: pumping a first fracturing fluid comprising a first fracturing fluid composition via a plurality of first plungers of a hydraulic fracturing pump; and while pumping the first fracturing fluid, pumping a second fracturing fluid comprising a second fracturing fluid composition via a plurality of second plungers of the hydraulic fracturing pump, the first fracturing fluid composition being different than the second fracturing fluid composition.