A method, a computer program product, and a system for pump control that incorporates data from fit for purpose sensors, transducers, meters, artificial intelligence tools, optimization algorithms and subject matter expertise for autonomous optimization of a rod pump producing oil well, comprising:
- a) a model to generate a Dynamometer Card based on data from two sensors, being the first one an accelerometer attached to the polished rod and the second one a positioning sensor attached to the horse head and a machine learning tool that enables a data-driven determination of the shape of the downhole dynamometer card using a database of real downhole dynamometer cards and Artificial Neural Network;
- b) a model to classify Dynamometer Card based on the generated Dynamometer Card in 1a) and a Machine Learning tool that enables the diagnostic of the pump operating condition using a data base of real downhole dynamometer cards, labelled according to the prevailing operating condition as determined by a Subject or Domain Matter Expert, which may include one or a combination of two, three or of multiple operational conditions occurring at the same time during the operation of the pump and sucker rods, at a given point on time, e.g. fluid pounding only or fluid pounding and leaking standing valve or fluid pounding, leaking standing valve and pump plunger tagging up-stroke or down stroke, etc;
- c) a program software for the programmable logic controller - PLC on the basis of Neural Fuzzy Logic, wherein the input data incorporates the by means of neural network generated and classified dynamometer card - 1a and 1b, measured parameters from reliable surface sensors and other calculated parameters, enabling autonomous optimization of the rod pump operation, by interacting with the variable speed drive-VSD, valve actuators, the start and stop switch, among others;
- d) a Human Machine Interphase - HMI device that displays the menu comprising 5 sub-menus:
- Data Input, Monitor, Troubleshooting, Optimizer and Operation. It enables the users to enter the input data. Further it shows the actual and trend of the key variables that enable to monitor the operation and shows the performed diagnostic of any anomaly that may be occurring or may be about to occur. Further in the menu are the Troubleshooting module and the Optimization module, while the Operation menu is the default screen that provides an overview of the current status of the rod pump system;
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- e) a computer program that is called here The Rod Pump Surveillancer - RPS System and is built in a Pump Controller that integrates a) and b) the models for generation and classification of the dynamometer cards, c) the algorithm and software program for the programmable logic controller - PLC and d) the program software for the Human Machine Interphase - HMI.