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.

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.

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, a computer program product, and a system for pump control that incorporates software algorithms, artificial intelligence, subject matter expertise and hardware for the autonomous optimization of a rod pump in a producing oil well, including various systems. The subject of the invention that is named here The Rod Pump Surveillancer System, is a built in a Pump Controller and integrates themodels for generation and diagnostic classification of dynamometer cards, the Neural Fuzzy Logic Algorithm for a programmable logic controller functioning stand alone, or connected to an edge computer, a server at the office or in the cloud, and the program software for the Human Machine Interphase. The method includes a developed model to generate downhole dynamometer cards based on data from two sensors. A programmable logic controller and a Human Machine Interphase device is used to further enhance control capabilities.

A controller for operating a prime mover of a rod pumping unit includes a processor configured to operate the prime mover over a first stroke and a second stroke. The controller is further configured to compute a first motor torque imbalance value for the first stroke and engage adjustment of a counter-balance. The controller is further configured to estimate a second motor torque imbalance value for the second stroke. The controller is further configured to disengage adjustment of the counter-balance during the second stroke upon the second motor torque imbalance value reaching a first imbalance range.

An artificial lifting system is disclosed. The artificial lifting system comprises an elongated cylinder fixed to a base or ground. The elongated cylinder receives a piston rod axially movable therein. The piston rod engages a downhole rod pump for driving the rod pump reciprocating uphole and downhole to pump downhole fluid to the surface. A control unit controls the axial movement of the piston rod, and automatically adjust the system operation to adapt to drift of the top and bottom stop positions of the piston rod. In an alternative embodiment, the system further comprises a dump valve controlled by the control unit to prevent over-stroke. In another embodiment, the system further comprises a chemical injection unit for injecting treatment fluid to a wellbore under the control of the control unit.

Systems are provided comprising at least one driving cylinder comprising a driving chamber and a driving piston within the driving chamber. The driving piston separates the driving chamber into a driving fluid zone for receiving a driving fluid and a buffer zone for receiving a buffer fluid. The driving piston is movable in the driving chamber by the driving fluid. The systems may also comprise a driven cylinder comprising a driven chamber and a driven piston moveable in the driven chamber. The driven piston is connected to and driven by the driving piston to move within the driven chamber. The driven chamber comprises an input port configured to receive a driven fluid at a first, lower pressure into the driven chamber and an output port configured to expel the driven fluid at a second, higher pressure from the driven chamber when the driven fluid is pressurized by the driven piston. The buffer fluid is different from the driving fluid and the driven fluid, and the buffer fluid in the buffer zone separates the driving fluid from the driven fluid.