An apparatus includes a first clamping mechanism configured to grip a tubular member at a first location along the tubular member. The apparatus also includes a second clamping mechanism configured to grip the tubular member at a second location along the tubular member that is axially-offset from the first location. The apparatus also includes a base positioned between the first and second clamping mechanisms. The apparatus also includes a strain gauge coupled to the base.

A system and method for predicting failures of rod pumps using a scaled load ratio is configured to: optimize the size of a rolling window, the upper and lower bounds of the normal range of the scaled load ratio, an alert period, and an alert frequency ratio; receive data of a current maximum/minimum loads on a surface rod, and a current speed; remove outliers showing an abnormality; scale the current maximum/minimum loads on the surface rod using the maximum/minimum loads on the surface rod in normal operation; calculate a scaled load ratio; calculate the average of scaled load ratios in the rolling window; determine whether the average of scaled load ratios is in the normal range, and classify the values as normal and abnormal events; calculate the ratio of the abnormal events in the alert period, and generate an alert when the calculated ratio exceeds the alert frequency ratio; and monitor a pump state using the pump failure prediction system.

A system and method for optimizing performance of an artificial lift system are provided. The optimization process can be performed automatically by a controller configured to receive optimization parameters from the user and information regarding the performance of the system. The optimization process adjusts the pumping speed of the system in response to measured rod load and a position of the downhole pump or surface pumping unit. More particularly, the optimization process can increase or decrease the pump speed of the system in response to the measured rod load at a reference position relative to a reference rod load at the reference position. The reference load and position can be selected to indicate pump inefficiencies. For example, the target reference load and position can indicate fluid pounding if the measured rod load at the reference position is greater than the reference rod load at the reference position.

A method for evaluating data from a reciprocating downhole pump includes the steps of acquiring downhole position and load data, providing the position and load data to a processing unit, normalizing the position and load data, converting the position and load data to a calculated polar coordinate data set, evaluating the calculated polar coordinate data set to determine a condition or occurrence at the reciprocating pump, and outputting calculated key parameters for controlling and optimizing the reciprocating pump and beam pumping unit. The method further comprises a step of creating a library of reference data sets, comparing the calculated polar data set against the library of ideal and reference data sets, identifying one or more reference data sets that match one or more portions of the calculated polar data set, and outputting the probability of one or more of the known conditions within the calculated polar data set.

A method for evaluating data from a reciprocating downhole pump includes the steps of acquiring downhole position and load data, providing the position and load data to a processing unit, normalizing the position and load data, converting the position and load data to a calculated polar coordinate data set, evaluating the calculated polar coordinate data set to determine a condition or occurrence at the reciprocating pump, and outputting calculated key parameters for controlling and optimizing the reciprocating pump and beam pumping unit. The method further comprises a step of creating a library of reference data sets, comparing the calculated polar data set against the library of ideal and reference data sets, identifying one or more reference data sets that match one or more portions of the calculated polar data set, and outputting the probability of one or more of the known conditions within the calculated polar data set.

An apparatus includes a body. The body includes first and second clamping mechanisms that are configured to grip a tubular member of a beam pump unit at first and second axially-offset locations along the tubular member, respectively. The body also includes a base positioned at least partially between the first and second clamping mechanisms. The apparatus also includes a strain gauge coupled to the base and configured to measure a strain on the tubular member as the tubular member moves. The apparatus also includes a gyroscope configured to measure an orientation, an angular velocity, or both of the beam pump unit as the beam pump unit operates. The apparatus also includes an accelerometer configured to measure an acceleration of the beam pump unit as the beam pump unit operates.

A method for controlling a well pumping system is provided. The method includes the steps of entering a pump intake depth, a minimum fill preset, a maximum fill preset, and a gain value into a controller for the well pumping system, and determining a fluid over pump level. If the fluid over pump level is zero, the method calls for setting a target pump fill equal to the maximum fill preset. If the fluid over pump level is not zero, the method calls for calculating a fluid over pump ratio using the pump intake depth, and calculating the target pump fill using the fluid over pump ratio and the gain value. Further, the method includes calculating a pump fill error as the difference between the target pump fill and an actual pump fill. The method further includes controlling a pumping speed of the well pumping system based on the pump fill error.

A method for controlling a well pumping system is provided. The method includes the steps of entering a pump intake depth, a minimum fill preset, a maximum fill preset, and a gain value into a controller for the well pumping system, and determining a fluid over pump level. If the fluid over pump level is zero, the method calls for setting a target pump fill equal to the maximum fill preset. If the fluid over pump level is not zero, the method calls for calculating a fluid over pump ratio using the pump intake depth, and calculating the target pump fill using the fluid over pump ratio and the gain value. Further, the method includes calculating a pump fill error as the difference between the target pump fill and an actual pump fill. The method further includes controlling a pumping speed of the well pumping system based on the pump fill error.

A load cell system for measuring rod load in a pumpjack. The system includes a tension load cell operatively coupled to a bridle between first and second bridle cables at a location longitudinally spaced between a horsehead and a bridle plate of the pumpjack. The bridle plate is coupled to the first bridle cable at a first connection point and the tension load cell is coupled to the first bridle cable at a second connection point longitudinally spaced between the bridle plate and the horsehead. The load cell system defines a third connection point longitudinally spaced between the second connection point and the horsehead. The load cell system is configured to maintain substantially constant longitudinal distances between the second connection point and each of the first and third connection points during operation of the horsehead. The load cell system is further configured to maintain a substantially constant lateral distance between the first and second bridle cables at the third connection point during operation of the horsehead.

A load cell system for measuring rod load in a pumpjack. The system includes a tension load cell operatively coupled to a bridle between first and second bridle cables at a location longitudinally spaced between a horsehead and a bridle plate of the pumpjack. The bridle plate is coupled to the first bridle cable at a first connection point and the tension load cell is coupled to the first bridle cable at a second connection point longitudinally spaced between the bridle plate and the horsehead. The load cell system defines a third connection point longitudinally spaced between the second connection point and the horsehead. The load cell system is configured to maintain substantially constant longitudinal distances between the second connection point and each of the first and third connection points during operation of the horsehead. The load cell system is further configured to maintain a substantially constant lateral distance between the first and second bridle cables at the third connection point during operation of the horsehead.