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.

A control system for operating a beam pumping unit includes a strain gauge and a beam pumping unit controller. The strain gauge is coupled to a Samson post of the beam pumping unit, and is configured to measure a Samson post strain. The beam pumping unit controller is coupled to the strain gauge and is configured to operate the beam pumping unit to induce a variable load on a rod of the beam pumping unit. The beam pumping unit controller is further configured to receive the Samson post strain from the strain gauge and compute the variable load based on the Samson post strain.

A computer-implemented method may comprise attaching a plurality of wireless sensors to a pump jack; receiving time-stamped data from at least some of the plurality of wireless sensors attached to the pump jack, at least one of the plurality of wireless sensors comprising an accelerometer and a gyroscope and being attached to a crank arm of the pump jack; synchronizing the received time-stamped data; from the synchronized time-stamped data, calculating and generating information related to: a downhole load versus polished rod position of the pump jack; a relative balance of a counterweight of the pump jack relative to a horse head of the pump jack; deviations from a nominal acceleration profile of a bridle of the pump jack; and an angle of inclination of the bridle of the pump jack; and selectively generating, on a computing device, visualizations of the generated information.

Systems and methods are disclosed for extracting underground objects using a beam pumping unit including a rotating motor and one or more cranks coupled to a walking beam enabling the extraction. According to certain embodiments, the method includes receiving, at a control system, one or more input signals; and providing, based on the input signals, one or more control signals to the rotating motor to enable the rotating motor to directly drive the one or more cranks for extracting the underground objects. The method also includes varying, based on the one or more control signals, a rotating speed of the rotating motor based on one or more conditions of the underground objects; and enabling the extraction in a reciprocated manner based on the varying rotating speed of the rotating motor.

A sensor assembly can include a gyroscope, an accelerometer, and a housing assembly containing the gyroscope and the accelerometer. An axis of the gyroscope can be collinear with an axis of the accelerometer. A method of inspecting a well pumping unit can include attaching a sensor assembly to the pumping unit, recording acceleration versus time data, and in response to an amplitude of the acceleration versus time data exceeding a predetermined threshold, transforming the data to acceleration versus frequency data. A method of balancing a well pumping unit can include comparing peaks of acceleration versus rotational orientation data to peaks of acceleration due to circular motion, and adjusting a position of a counterweight, thereby reducing a difference between the peaks of acceleration due to circular motion and the peaks of the acceleration versus rotational orientation data for subsequent operation of the pumping unit.

A wireless load cell monitoring system and method may comprise a remote load cell assembly and a base station. Embodiments of the remote load cell assembly comprise a remote processor, a remote memory, a battery, a remote transceiver, an analog-to-digital converter, and a load cell. Embodiments of the base station comprise a base processor, a base memory, a base transceiver, and a digital-to-analog converter. Embodiments of the remote load cell assembly pair with the base station using a wireless communication protocol, read analog voltage data from the load cell, convert the load cell analog voltage data into digital load data, and transmit the digital load data to the base station. Embodiments of the base station convert the digital load data into analog voltage data and output the analog voltage data.

A wireless load cell monitoring system and method may comprise a remote load cell assembly and a base station. Embodiments of the remote load cell assembly comprise a remote processor, a remote memory, a battery, a remote transceiver, an analog-to-digital converter, and a load cell. Embodiments of the base station comprise a base processor, a base memory, a base transceiver, and a digital-to-analog converter. Embodiments of the remote load cell assembly pair with the base station using a wireless communication protocol, read analog voltage data from the load cell, convert the load cell analog voltage data into digital load data, and transmit the digital load data to the base station. Embodiments of the base station convert the digital load data into analog voltage data and output the analog voltage data.

A method for aligning a pump with a wellhead begins with the steps of attaching a target assembly to the pump and attaching an emitter assembly to the wellhead. The method continues with the step of emitting a beam of light from the emitter assembly to the target assembly. The method concludes with the step of determining the position of the pump with respect to the wellhead by evaluating the projection of the light beam on the target assembly. Based on this determination, the pump can be accurately aligned with the wellhead.

A pump apparatus has a downhole pump disposed in a wellbore and has a motor at the surface, and a rod string operatively moved by the motor reciprocates the downhole pump in the wellbore. Downhole data indicative of load and position of the downhole pump is generated using surface measurements and a wave equation model having an upstroke damping factor and a downstroke damping factor. Actual fluid load lines are determined from the downhole data for upstrokes and downstrokes of the downhole pump, and calculated fluid load lines for from the strokes are determined from the distribution of the load values in the downhole data. The actual fluid load lines are compared to the calculated fluid load lines to determine if the downhole card is over or under-damped. Then, at least one of the upstroke or downstroke damping factors of the wave equation model is adjusted so that new downhole data can be generated with appropriate damping.

A controller for operating a rod pumping unit at a pump speed. The controller includes a processor configured to operate a pump piston of the rod pumping unit at a first speed. The processor is further configured to determine a pump fillage level for a pump stroke based on a position signal and a load signal. The processor is further configured to reduce the pump speed to a second speed based on the pump fillage level for the pump stroke.