Systems and methods for real-time monitoring and control of well operations at a well site use machine learning (ML) based analytics at the well site. The systems and methods perform ML-based analytics on data from the well site via an edge device directly at the well site to detect operations that fall outside expected norms and automatically respond to such abnormal operations. The edge device can issue alerts regarding the abnormal operations and take predefined steps to reduce potential damage resulting from such abnormal operations. The edge device can also anticipate failures and a time to failure by performing ML-based analytics on operations data from the well site using normal operations data. This can help decrease downtime and minimize lost productivity and cost as well as reduce health and safety risks for field personnel.

Systems and methods for real-time monitoring and control of well operations at a well site use machine learning (ML) based analytics at the well site. The systems and methods perform ML-based analytics on data from the well site via an edge device directly at the well site to detect operations that fall outside expected norms and automatically respond to such abnormal operations. The edge device can issue alerts regarding the abnormal operations and take predefined steps to reduce potential damage resulting from such abnormal operations. The edge device can also anticipate failures and a time to failure by performing ML-based analytics on operations data from the well site using normal operations data. This can help decrease downtime and minimize lost productivity and cost as well as reduce health and safety risks for field personnel.

An exemplary pump jack system (10) is operable to cause well liquid to be pumped to the surface by a subsurface well pump (29). The exemplary system includes a driver (42) that is in rotatable connection with a pump/motor (48). The pump/motor is a rotary type variable output positive displacement pump/motor that delivers working liquid at a selectively variable flow rate in closed liquid connection to a motor/pump (38). The exemplary motor/pump includes a rotatable output coupler (40) that is in operative connection with a gearbox (34) which causes the pump jack to undergo reciprocating motion. The motor/pump is a rotary type positive displacement motor/pump that is in closed liquid connection with the pump/motor liquid inlet of the pump motor. The pump/motor is operable to deliver working liquid flow therefrom to drive the motor/pump at a selectively variable speed while the driver operates at a generally constant rotational speed. Return force which acts on the motor/pump during at least a portion of the pump jack cycle is operative to cause the motor/pump to urge working liquid toward the pump/motor which assists the driver in pump/motor operation.

An exemplary pump jack system (10) is operable to cause well liquid to be pumped to the surface by a subsurface well pump (29). The exemplary system includes a driver (42) that is in rotatable connection with a pump/motor (48). The pump/motor is a rotary type variable output positive displacement pump/motor that delivers working liquid at a selectively variable flow rate in closed liquid connection to a motor/pump (38). The exemplary motor/pump includes a rotatable output coupler (40) that is in operative connection with a gearbox (34) which causes the pump jack to undergo reciprocating motion. The motor/pump is a rotary type positive displacement motor/pump that is in closed liquid connection with the pump/motor liquid inlet of the pump motor. The pump/motor is operable to deliver working liquid flow therefrom to drive the motor/pump at a selectively variable speed while the driver operates at a generally constant rotational speed. Return force which acts on the motor/pump during at least a portion of the pump jack cycle is operative to cause the motor/pump to urge working liquid toward the pump/motor which assists the driver in pump/motor operation.

Providing diagnostics or monitoring operation of a rod pressure includes using waves in production fluid produced by the rod pump may be used to determine one or more operating states of the rod pump. The one or more operating states of the rod pump may be used by a user to diagnose or monitor the operation of the rod pump.

Providing diagnostics or monitoring operation of a rod pressure includes using waves in production fluid produced by the rod pump may be used to determine one or more operating states of the rod pump. The one or more operating states of the rod pump may be used by a user to diagnose or monitor the operation of the rod pump.

An integrated wireless data system and method for controlling and measuring operational data of a pumpjack system, for safety, health monitoring, and pump control is provided. The integrated wireless data system and method may be configured to allow for bi-directional communication with a central station to enable human intervention with pumpjack and to store pump parameters in a database for use in development of predictive maintenance techniques.

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.

Sensor systems and methods for downhole pumping systems include a sensor subsystem for detecting movement of at least one component of the downhole pumping system. The sensor subsystem includes an axial motion sensor to be coupled to the at least one component of the downhole pumping system and to detect axial movement of the at least one component of the downhole pumping system and a rotational sensor to be coupled to the at least one component of the downhole pumping system and to detect rotational movement of the at least one component of the downhole pumping system by sampling rotational velocity values with the rotational sensor generated by rotation of the at least one component of the downhole pumping system.