A novel method of output metering with dynamometer card for SRPS under fault conditions

Remote monitoring of sucker rod pumping system (SRPS) based on polished rod dynamometer cards (DC) is an effective means to reduce the operating costs and realize the real-time control. Nevertheless, how to obtain the working process and the production rate of SRPS from polished rod DC is always a puzzle because of complex down-hole motions. The typical solution for this problem is deriving the pump DC via the wave equation to achieve the effective stroke of plunger. But some key parameters involved in this approach such as valve leakage and the fill factor are difficult to determine accurately, especially under fault conditions, which may influence the accuracy of output metering. In order to address this tough issue, in this paper, a novel method of output metering with DC is proposed based on quantitative analysis of fault. The method consists of two parts, the first part is an approach to simulate the working process of SRPS under fault conditions, specifically it's an improved simulation model characterized by a set of fault parameters, which is presented through analyzing the mechanisms of sucker rod pumps at normal and several faulty scenarios. And the second part is a method implemented by genetic optimization algorithm to determine the fault parameters set of the actual SRPS. Using parameters of typical well, the analysis of effects of faults on SRPS is carried out. The simulation results show that valves leakage reduces the flow rate of liquid significantly in the period of effective stroke, which leads to the distortion of output metering results of effective stroke method. Compared with single faults, coupling faults aggravate the production reduction of SRPS. Furthermore, when the well fluid contains gas, the impact of traveling valve leakage on the reduction of production is greater than that of standing valve leakage, but the consequence is opposite when formation energy is insufficient. Besides, the carbon fiber rod and fiberglass rod SRPS are more sensitive to valve leakage, while the steel rod and wire rope SRPS are more sensitive to the condition of insufficient liquid supply. Eventually, the proposed method is verified experimentally through the productive parameters and measured DC of actual wells collected from an oilfield. The obtained results demonstrate the effectiveness of the proposed method for output metering and fault diagnosis as well.