System and method to monitor and control reciprocating rod lift system

Abstract

A computerized process here is used for managing a reciprocating rod lift system equipped with an electric motor and a downhole pump. The process obtains real-time acquisition of pump card information (reflecting position and load of the system) and energy usage data of the electric motor. The energy data is mapped onto the scale of the pump card information, incorporating two energy draw thresholds: one for the motor's downstroke and another for its upstroke. The process then initiates specific operational events based on certain determinations: if the energy usage during the downstroke exceeds the first threshold, if the energy usage surpasses the second threshold during the upstroke, or if the difference in energy usage between the downstroke and upstroke crosses a third predefined threshold.

Description

Atty. Dkt. No.: 230-0836WO (6756-PCT)- 1 -System and Method to Monitor and Control Reciprocating Rod Lift System -by-Ramakrishna Prabhu RanganathanCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Appl. No. 63 / 690,427 filed September 4, 2024, which is incorporated herein by reference in its entirety.BACKGROUND OF THE DISCLOSURE

[0002] In some wellbores, an artificial lift system may be necessary to carry production fluid (e.g., hydrocarbons) from a productive formation to a wellhead located at surface. A sucker rod lifting system is a common type of artificial lift system.

[0003] The sucker rod lift system generally includes a surface drive mechanism, a sucker rod string, and a downhole pump. Fluid is brought to the surface of the wellbore by a reciprocating pumping action of the surface drive mechanism attached to the rod string. The reciprocating pumping action moves a traveling valve on the pump, loading the pump with fluid on the downstroke of the rod string and lifting fluid to the surface on the upstroke of the rod string. A standing valve is typically located at the bottom of a barrel of the pump that prevents fluid from flowing back into the well formation after the pump barrel is filled and during the downstroke of the rod string. The rod string provides the mechanical link of the drive mechanism at the surface to the pump downhole.

[0004] Operators of sucker rod lifting systems are continually striving to improve the operation and control of the lift systems. To that end, additional techniques are needed to improve the operation and control of sucker rod lift systems, such as those using pump jack units and long-stroke pumping units. The subject matter of the present disclosure is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.SUMMARY OF THE DISCLOSURE

[0005] In one configuration, a method disclosed herein is implemented by a computerized device for a reciprocating rod lift system, which has a surface pumping unit (with an electric motor) and has a downhole pump. In the method, pump card information is obtained in real time during operation of the reciprocating rod lift system. The pump card information relates position and load of the reciprocating rod lift system.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 2 -Energy draw measurements of the electric motor are obtained in real time during the operation of the reciprocating rod lift system. The energy draw measurements are associated into a scale of the pump card information, and a first energy draw threshold and a second energy draw threshold are associated into the scale of the pump card information. The first energy draw threshold is associated with the electric motor being operated in a downstroke of the reciprocating rod lift system. The second energy draw threshold is associated with the electric motor being operated in an upstroke of the reciprocating rod lift system. At least one first operational event is associated in response to at least one of: determining that the energy draw measurements in the downstroke exceeds the first energy draw threshold; determining that the energy draw measurements in the upstroke exceeds the second energy draw threshold; and determining that a difference between the energy draw measurements in the downstroke and the energy draw measurements in the upstroke exceeds a third threshold.

[0006] To initiate the at least one first operational event in response to determining that the energy draw measurements in the downstroke exceeds the first energy draw threshold, a heavy crank condition can be indicated as the at least one first operational event for a beam pumping unit as the surface pumping unit having a crank.

[0007] To initiate the at least one first operational event in response to determining that the energy draw measurements in the downstroke exceeds the first energy draw threshold, a heavy weight box condition can be indicated as the at least one first operational event for a stroke unit as the surface pumping unit having a weight box.

[0008] To initiate the at least one first operational event in response to determining that the energy draw measurements in the upstroke exceeds the second energy draw threshold, a rod heavy condition can be indicated as the at least one first operational event. When the rod heavy condition is indicated, a second operational event can be indicated in response to: determining that a first peak value for the load in the upstroke has exceeded a first limit; and determining that a second peak value for torque of a reducer for the electric motor of the reciprocating rod lift system exceeds a second limit. For example, initiating the second operational event can include indicating a loading condition indicative of excess load on the reducer.

[0009] When the rod heavy condition is indicated, a second operational event can also be indicated in response to determining, based on pump parameters, a fluid poundAtty. Dkt. No.: 230-0836WO (6756-PCT)- 3 - condition or a pump-off condition associated with the downhole pump. The pump parameters can include one or more of: pump fillage, downhole fillage, pump intake pressure, fluid level, and downhole load span. Initiating the second operational event can include indicating a consumption condition indicative of excessive consumption of energy by the electric motor.

[0010] When the fluid pound condition or the pump-off condition is initiated for the reciprocating rod lift system being fixed speed or being a standard operation well, a third operational event can be indicated that stops the reciprocating rod lift system on idle for at least a time period.

[0011] When the fluid pound condition or the pump-off condition is initiated for the reciprocating rod lift system being variable speed, a third operational event can be indicated that reduces a strokes per minute of the reciprocating rod lift system. To do this, an input can be received setting a minimum strokes per minute of the reciprocating rod lift system. In this way, initiating the third operational event that reduces the strokes per minute of the reciprocating rod lift system can include setting the reciprocating rod lift system to the minimum strokes per minute.

[0012] When the fluid pound condition or the pump-off condition is initiated for the reciprocating rod lift system being variable speed, a third operational event can be indicated that reduces a frequency of the electric motor of a variable speed device for the reciprocating rod lift system.

[0013] To associate the first and second energy draw thresholds into the scale of the pump card information in the method, inputs can be received setting the first and second energy draw thresholds into the scale of the pump card information. In the method, an input can be received setting the third threshold.

[0014] The steps of obtaining the pump card information, obtaining the energy draw measurements, and initiating in response to the at least one determination can be performed and repeated at a set number of strokes of the reciprocating rod lift system.

[0015] In the method, surface measurements can be obtained that include the position and the load associated with one or more strokes of the surface pumping unit. Based on the surface measurements, a surface pump card can be calculated for the pump card information. Based on the surface measurements, a downhole pump card can be calculated for the downhole pump of the reciprocating rod lift system.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 4 -

[0016] In another configuration, a non-transitory computer readable medium has computer executable code stored thereon for causing a computerized device to perform a method according to the details discussed above.

[0017] In yet another configuration, a computerized device disclosed herein is used with a reciprocating rod lift system, which has a surface pumping unit (including an electric motor) and has a downhole pump. The computerized device comprises memory and one or more processors. The memory stores pump card information, energy draw measurements, and first and second energy draw thresholds. The pump card information is obtained in real time during operation of the reciprocating rod lift system, and the pump card information relates position and load of the reciprocating rod lift system. The energy draw measurements of the electric motor are obtained in real time during the operation of the reciprocating rod lift system.

[0018] The one or more processors of the computerized system are in communication with the memory. The one or more processors are configured to associate the energy draw measurements into a scale of the pump card information and are configured to associate a first energy draw threshold and a second energy draw threshold into the scale of the pump card information. The first energy draw threshold is associated with the electric motor being operated in a downstroke of the reciprocating rod lift system, while the second energy draw threshold is associated with the electric motor being operated in an upstroke of the reciprocating rod lift system. The one or more processors are configured to initiate at least one first operational event in response to at least one of: a first determination that the energy draw measurements in the downstroke exceeds the first energy draw threshold; a second determination that the energy draw measurements in the upstroke exceeds the second energy draw threshold; and a third determination that a difference between the energy draw measurements in the downstroke and the energy draw measurements in the upstroke exceeds a third threshold.

[0019] The foregoing summary is not intended to summarize each potential embodiment or every aspect of the present disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Fig. 1A illustrates one example of a reciprocating rod lift system according to the present disclosure.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 5 -

[0021] Fig. 1B illustrates another example of a reciprocating rod lift system according to the present disclosure.

[0022] Fig. 2 schematically illustrates a correlation between surface data obtained at the surface of the well to downhole data for a downhole pump.

[0023] Fig. 3A illustrates a surface pump card, showing polished rod load with respect to polish rod position and showing motor energy draw.

[0024] Fig. 3B illustrates a downhole pump card, showing the fluid / downhole pump load with respect to pump plunger position and showing motor energy draw.

[0025] Fig. 4A illustrates another example of a surface pump card, showing polish rod load with respect to polish rod position and showing motor energy draw plotted as points for different speed segments.

[0026] Fig. 4B illustrates another example of a downhole pump card, showing pump / fluid load with respect to pump plunger position and showing motor energy draw plotted as points for different speed segments.

[0027] Fig. 5A illustrates an example of a surface pump card, showing pump load or load with respect to polished rod stroke length or polished rod position and showing motor energy draw.

[0028] Fig. 5B illustrates an example of a downhole pump card, showing pump load or load with respect to polished rod stroke length or polished rod position and showing motor energy draw.

[0029] Fig. 5C illustrates an example of a “generic” pump card, showing pump load or load with respect to polished rod stroke length or polished rod position and showing motor energy draw.

[0030] Fig. 6 schematically illustrates a computerized device according to the present disclosure.

[0031] Fig. 7 illustrates a process of monitoring and controlling operation of a reciprocating rod lift system according to the present disclosure.DETAILED DESCRIPTION OF THE DISCLOSURE

[0032] One type of reciprocating rod lift system 10 includes a beam pumping unit (e.g., pump jack) 20, such as shown in Fig. 1A. The surface drive mechanism of the beam pumping unit 20 uses a motor 28, a gear reducer 26 driven by the motor 28, counterweighted crank arms 24 turned by the gear reducer 26, and a walking beam 22, which is reciprocated by the crank arms 24 and connects at its head to a rod string 16.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 6 -Another type of system 10 includes a long-stroke pumping unit 20’, such as shown in Fig. 1 B. The surface drive mechanism of this type of long-stroke pumping unit 20' generally includes a motor 28, a gear reducer 26 driven by the motor 28, a chain and a carriage linking the reducer 26 to a counterweight 25w, and a belt 23 connecting the counterweight 25w to the rod string 16.

[0033] On these reciprocating rod lift systems 10, the dynamics of the rod string 16 and the operation of the surface drive mechanism 20, 20’ are preferably matched to prolong the service life of the reciprocating rod lift system 10. Conventionally, the output data from a load cell and a position sensor connected to the polished rod 18 on the rod string 16 is processed using software to determine certain operational characteristics of the rod dynamics and the downhole pump 30. The operation of the surface drive mechanism 20, 20’ is then controlled to achieve optimum efficiency. Another parameter of interest in the operation of the reciprocating rod lift systems 10 includes the electric power used to power the electric motor 28 (i.e., motor energy draw) of the surface drive mechanism 20, 20’. The systems and methods of the present disclosure are used to monitor and control the reciprocating rod lift systems 10 based on load, position, and motor energy draw during operation.

[0034] Fig. 1A shows one type of reciprocating rod lift system 10 having a computerized device 100, which can be a control unit, controller, or the like, according to the present disclosure. In this example, the reciprocating rod lift system 10 includes a pump jack unit, a walking beam unit, or other like beam pumping unit 20 for the surface drive mechanism used to produce fluid from a well. Additional details of such a beam pumping unit 20 can be found in U.S. Pat. No. 9,810,212, which is incorporated herein by reference.

[0035] A downhole pump 30 has a barrel 32 with a standing valve 38 located at the bottom. The standing valve 38 allows fluid to enter from the wellbore but does not allow the fluid to leave. Inside the pump barrel 32, a plunger 34 has a traveling valve 36 located at the top. The traveling valve 36 allows fluid to move from below the plunger 34 to the production tubing 14 above but does not allow fluid to return from the tubing 14 to the pump barrel 32 below the plunger 34. A driving source (e.g., the beam pumping unit 20) at the surface connects by a rod string 16 to the plunger 34 and moves the plunger 34 up and down cyclically in upstrokes and downstrokes.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 7 -

[0036] During the upstroke, the traveling valve 36 is closed, and any fluid above the plunger 34 in the production tubing 14 is lifted towards the surface. Meanwhile, the standing valve 38 opens and allows fluid to enter the pump barrel 32 from the wellbore. The highest point of the plunger's motion is typically referred to as the “top of stroke” (TOS), while the lowest point of the pump plunger's motion is typically referred to as the “bottom of stroke” (BOS).

[0037] At the TOS, the standing valve 38 closes and holds in the fluid that has entered the pump barrel 32. Additionally, at the TOS, the weight of the fluid in the production tubing 14 is supported by the traveling valve 36 in the plunger 34 and, therefore, also by the rod string 16, which causes the rod string 16 to stretch.

[0038] During the downstroke, the traveling valve 36 initially remains closed until the plunger 34 reaches the surface of the fluid in the barrel 32. Sufficient pressure builds up in the fluid below the traveling valve 36 to balance the pressure. The build-up of pressure in the pump barrel 32 reduces the load on the rod string 16 so that the rod string 16 relaxes.

[0039] This process takes place during a finite amount of time when the plunger 34 rests on the fluid, and the beam pumping unit 20 at the surface allows the top of the rod string 16 to move downward. The position of the pump plunger 34 at this time is known as the “transfer point” because the load of the fluid column in the production tubing 14 is transferred from the traveling valve 36 to the standing valve 38. This results in a rapid decrease in load on the rod string 16 during the transfer.

[0040] After the pressure balances, the traveling valve 36 opens and the plunger 34 continues to move downward to its lowest position (i.e. , the BOS). The movement of the plunger 34 from the transfer point to the BOS is known as the “fluid stroke” and is a measure of the amount of fluid lifted by the pump 30 on each stroke. In other words, the portion of the pump stroke below the transfer point may be interpreted as the percentage of the pump stroke containing fluid, and this percentage corresponds to the pump's fillage. Thus, the transfer point can be computed using a pump fillage calculation.

[0041] If there is sufficient fluid in the wellbore, the pump barrel 32 may be completely filled during an upstroke. Yet, under some conditions, the pump 30 may not be completely filled with fluid on the upstroke so there may be a void left between the fluid and the plunger 34 as it continues to rise. Operating the reciprocating rod lift systemAtty. Dkt. No.: 230-0836WO (6756-PCT)- 8 -10 with only a partially filled pump barrel 32 is inefficient and, therefore, undesirable. In this instance, the well is said to be “pumped off,” and the condition is known as “pounding,” which can damage various components of the pump system. For a pumped off well, the transfer point most likely occurs after the TOS of the plunger 34.

[0042] A number of surface sensors 40 are used to make measurements and monitor operation of the beam pumping unit 20. The sensors 40 can include a load sensor 42, a position sensor 44, and a motor sensor 48, and the sensors 40 can be connected to or communicate with the computerized device 100. The load sensor 42 is used to measure the load or force exerted on the rod string 16. For example, the load sensor 42 can be a load cell positioned on the polished rod 18, which is the portion of the rod string 16 passing through a stuffing box 12 at the wellhead. The position sensor 44 is used to measure the position or stroke length at surface. The position sensor 44 can be located near the walking beam 22 or the horsehead of the beam pumping unit 20 to monitor the position of the walking beam 22 or the horsehead, as the walking beam 22 moves up and down during the pumping process. The motor sensor 48 can include a voltmeter, ammeter, or the like to measure usage of electric power by the electric motor 28.

[0043] Usually, direct measurements cannot be made of the conditions at the downhole pump 30, which may be located thousands of feet underground. Instead, numerical methods are used to calculate the position of the plunger 34 and to calculate the load acting on the plunger 34 based on the measurements of the position and load for the rod string 16 measured at the beam pumping unit 20 located at the surface.

[0044] The computerized device 100 is used for monitoring and controlling the reciprocating rod lift system 10. The computerized device 100 can include local circuitry and / or remote control circuitry with a communication link between them. For example, local elements of the computerized device 100 can be part of a local pump controller located at the beam pumping unit 20. These local elements of the computerized device 100 can be embodied in a programmable logic controller (PLC), an application-specific integrated circuit (ASIC), or field-programmable gate array (FPGA) Remote elements of the computerized device 100 can be a remote controller, a computer system, an EDGE computing system, a remote terminal unit, a Variable Frequency Drive, etc. located remotely and connected to the local elements (e.g., pump controller) by a communication link, such as a cellular network, satellite link, etc.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 9 -

[0045] To efficiently control the reciprocating rod lift system 10 and avoid costly maintenance, the computerized device 100 can gather system data and adjust operating parameters of the system 10 accordingly. Typically, the computerized device 100 gathers system data such as the load and rod string displacement by measuring these properties at the surface. While the surface-measured data provides useful diagnostic information, they may not provide an accurate representation of the same properties observed downhole at the pump. Because these downhole properties cannot be easily measured directly, they are calculated from the surface-measured properties.

[0046] In techniques to determine operational characteristics of the reciprocating rod lift system 10 as noted above, software analysis of the computerized device 100 computes surface data and downhole data (i.e., pump card information) using position and load data measured at the surface. The most accurate and popular of these methods is to compute the downhole data from the surface data by solving a onedimensional damped wave equation, which uses surface position and load as recorded at the surface. Various algorithms exist in the art for solving the wave equation and are not detailed here.

[0047] Although the disclosed system 10 can have a beam pumping unit 20 as shown in Fig. 1 A, other surface pumping units can be used, such as a belt-driven unit, a strap jack, or any other surface drive mechanism that reciprocates a rod string using cables, belts, chains, and hydraulic and pneumatic power systems.

[0048] For example, Fig. 1B shows another type of reciprocating rod lift system 10 having a computerized device 100 according to the present disclosure. In this example, the reciprocating rod lift system 10 includes a long-stroke pumping unit 20’, which can be a belt-driven unit, a strap jack, or the like, used for the surface drive mechanism to produce fluid from a well. Additional details of such a long-stroke pumping unit 20’ can be found in U.S. Pat. No. 10,113,544, which is incorporated herein by reference.

[0049] As noted previously, the long-stroke pumping unit 20’ generally includes an electric motor 28, a gear reducer 26 driven by the motor 28, a chain and carriage mechanism 27 linking the gear reducer 26 to a counterweight 25w, and a belt 23 connecting the counterweight 25w to the polished rod 18 and rod string 16. The long- stroke pumping unit 20’ can provide a longer stroke length compared to a beam pumping unit.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 10 -

[0050] Again, a number of surface sensors 40 are used to make measurements and monitor operation of the long-stroke pumping unit 20’. The sensors 40 can include a load sensor 42, a position sensor 44, and a motor sensor 48, and the sensors 40 can be connected to or communicate with the computerized device 100. For example, the load sensor 42 and the position sensor 44 can communicate wirelessly.

[0051] The motor sensor 48 is shown here monitoring a motor drive 29 for the motor 28 and can include a voltmeter, an ammeter, or the like. As an ammeter, the motor sensor 48 can be used to measure electric current in the circuitry of the motor drive 29 by being connected in series in the circuitry to measure the current to flow through the ammeter. As before, the load sensor 42 can be a load cell connected to the polished rod 18. The position sensor 44 can be a counterweight position sensor disposed on the counterweight 25w to determine the position of the counterweight 25w and to determine by correlation the position of the polished rod 18. Additional sensors 40 can be used, such as a tachometer 46 mounted on the gear reducer 26 to monitor an angular speed of its output shaft.

[0052] The electric motor 28 may be a multi-phase motor, such as a three-phase motor. In other examples, the electric motor 28 may be an induction motor, a switched reluctance motor, or a permanent magnet motor, such as a brushless direct current motor. The motor drive 29 drives the electric motor 28. Depending on the type of motor used, the voltmeter, ammeter, or other motor sensor 48 may be connected to the motor drive 29 or between the motor drive 29 and the power source for measuring electrical power consumed by the motor drive 29 to drive the electric motor 28.

[0053] A chain of the chain and carriage mechanism 27 is meshed with a drive sprocket on the gear reducer 26 and extends to an idler. A carriage of the mechanism 27 longitudinally connects the counterweight 25w to the chain while allowing the chain to move relative to the counterweight 25w.

[0054] The counterweight 25w is longitudinally movable on the tower 21. The counterweight 25w is loaded with counterweights until a total balancing weight of the counterweight 25w corresponds to the weight of the rod string 16 and / or the weight of the column of production fluid. A drum 25d mounted to the tower’s crown 21c can support passage of the load belt 23 over the tower’s crown 21 c. One end of the load belt 23 is connected to the counterweight 25w, and another end is linked to the polished rod 18, using a hanger and wire ropes or the like.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 11 -

[0055] A long-stroke pumping unit 20’ is generally not very responsive to speed changes of the rod string 16. Moreover, any gear-driven pumping unit possesses inertia from previous motion so that it is difficult to stop the unit or change the direction of rotation of the unit quickly. Therefore, jarring (and resultant breaking / stretching) of the rod string 16 can result unless the speed of the rod string 16 during the upstroke and downstroke is decreased at the end of the upstroke and downstroke, respectively. Decreasing the speed of the rod string 16 for such a great distance of the upstroke and downstroke decreases the speed of fluid pumping, thus increasing the cost of the well.

[0056] Except for the different driving characteristics noted, the long-stroke pumping unit 20’ can reciprocate the sucker rod string 16 and operate a downhole pump (30) in a manner similar to that discussed previously. For example, the long-stroke pumping unit 20’ operates by converting the rotational motion of the electric motor 28 into a linear motion, which reciprocates the rod string 16 and activates the downhole pump (30).This movement allows the downhole pump (30) to lift production fluids from the reservoir to the surface in a manner similar to that discussed above.

[0057] In both of these systems 10 of Figs. 1A-1B, the computerized device 100 can obtain surface measurements of load, position, motor energy draw, and the like from the sensors 40 during operation and can calculate the pump card information (i.e., surface pump card and downhole pump card) associated with the operation of the surface pumping unit 20, 20’ and the downhole pump 30. The computerized device 100 can then compare the draw or usage of electric power by the electric motor 28 (i.e., motor energy draw) to the pump card information so the electric motor draw and pump operation can be monitored and controlled using the computerized device 100. The pump card information can include surface data (load and position) of the surface pumping unit 20, 20’ and / or can include downhole data (load and position) of the downhole pump 30.

[0058] Fig. 2 shows exemplary surface pump card 50 and downhole pump card 60. On the reciprocating rod lift system 10, the surface pump card 50 is used for analyzing the complete system (surface and downhole components), and the downhole pump card 60 is used specifically for analyzing the downhole pump (30).

[0059] The surface pump card plots the relationship between surface (polished) rod load and surface rod load position. Load (Y-axis) is plotted against position (X-axis). Measurements can be obtained at the surface of the well using the sensors (40) toAtty. Dkt. No.: 230-0836WO (6756-PCT)- 12 - measure load and position of the surface pumping unit, such as the beam pumping unit (20) of Fig. 1 A. For example, a dynamometer can measure the load on the rod string at various positions during the pumping cycle. The surface pump card 50 provides insights into the load dynamics and behavior of the surface pumping unit (20).

[0060] By analyzing the load (y-axis) in relation to position (x-axis) on the surface pump card 50, the computerized device (100) (and operators) can adjust the pump speed, stroke length, and other parameters to ensure optimal recovery of production while minimizing wear and tear on the equipment of the system (10).

[0061] Using the techniques discussed previously, the measured surface data for the surface pump card 50 can be mathematically translated using algorithms and equations known in the art to a downhole pump card 60’, which is first shown ideally in Fig 2. The ideal downhole pump card 60’ plots a representation of the downhole pump’s load versus the downhole pump’s position and provides information about the downhole pumping conditions. Again, load (Y-axis) is plotted against position (X-axis).

[0062] As shown, the downhole pump card 60’ has an upstroke fluid load line 62 (F0_up) and a downstroke fluid load line (F0_down). The height 63 of the downhole pump card 60’ is referred to as the fluid stroke F0, where F0=the upstroke fluid load line 62 (F0_up) minus the downstroke fluid load line 64 (F0_down).

[0063] The pump or downhole stroke (PS) refers to the measure of extreme travel of the sucker rod derived at the location of the pump (30). Thus, the “pump stroke” refers to the maximum displacement minus the minimum displacement and corresponds to the horizontal span or width of the downhole pump card 60’.

[0064] However, operation of the pump (30) experiences a net stroke 68 (NS), which refers to the measure of the portion of the pump stroke (PS) during which the fluid load is supported by the pump's standing valve. For a pumped-off downhole pump card 60 as shown in Fig. 2, the net stroke 68 (NS) is measured relative to the transfer point 66, which is the displacement in the pump stroke where load is transferred from the pump's traveling valve to the standing valve. (The transfer point can be computed using a pump fillage calculation.) The transfer point 66 occurs because the pressure in the pump barrel has exceeded the pressure in the plunger. The portion of the stroke below (with lower displacement than) the transfer point 66 is the net stroke NS and is interpreted as the portion of the pump stroke (PS) that actually contains liquid.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 13 -

[0065] The displacement and load data in the surface pump card 50 and the downhole pump card 60 can be used to determine one or more characteristics of the downhole pump's operation, such as the minimum pump stroke, the maximum pump stroke, and the transfer point in the downhole stroke. In turn, the area A of the downhole pump card 60 gives the pump horsepower of the downhole pump (30).

[0066] During operation, the electric motor (28) at the surface pumping unit (20, 20’) draws energy to reciprocate the surface pumping unit (20, 20’) and sucker rod string (16). As noted previously, the computerized device 100 disclosed herein captures the motor energy draw, which can be measured at surface using a voltmeter, ammeter, or other motor sensor (48). The disclosed computerized device 100 then analyzes the motor energy draw for the upstrokes and downstrokes of the surface pumping unit (20, 20’) relative to pump card information. The pump card information used for the comparison can be a surface pump card, a downhole pump card, a Dynacard, a Dynagraph card, a Dynamometer card, or another type of card. Reference may be made herein simply to a “pump card” or “pump card information.”

[0067] For example, the computerized device 100 reads the motor energy for the surface pumping unit (20, 20’) and correlates the motor energy draw with the position sensor signals to show the maximum and minimum motor energy draw on the upstroke and downstroke of the surface pumping unit (20, 20’). The comparison of the motor energy draw to the pump card information is then used to determine whether the surface pumping unit (20, 20’) has an out-of-balance condition. For example, the comparison can determine whether the surface pumping unit (20, 20’) is crank heavy or rod heavy, whether the gearbox (26) is overloaded, whether the motor (28) is consuming excess energy, etc. To do this, the maximum and the minimum motor energy draw of the surface pumping unit (20, 20’) can be compared to the load versus position on the surface pump card and / or the downhole pump card. A visual comparison can be displayed by the computerized device 100 so operators can make necessary determinations and implement changes in the computerized device 100 to control the surface pumping unit (20, 20’). Additionally, the computerized device 100 can make an automated comparison so the computerized device 100 can initiate different adjustments, alarms, actions, and other controls to mitigate the out-of-balance condition.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 14 -

[0068] In reciprocating rod lift applications, for example, readings of the motor’s energy (e.g., current (Amps), power, etc.) can be used to determine how much the surface pumping unit (20, 20’) is out-of-balance. For a fixed speed reciprocating rod lift system 10, the motor’s current can be read using an ammeter located in the power circuitry to capture amp peaks of the motor (28) for the upstrokes and the downstroke. For a reciprocating rod lift system 10 having a variable frequency drive (VFD) or having a variable speed drive (VSD), the output current of the electric motor (28) can be accessed in real time from existing power circuitry using the computerized device 100, a separate local controller, a user interface, etc. so the motor amps can be captured in real time for the upstrokes and the downstrokes.

[0069] In the reciprocating rod lift systems 10, for example, the surface pumping unit 20, 20’ operates in cyclic motion to transfer the energy to the downhole pump 30 and bring the fluid to surface. The surface pumping unit 20, 20’ can be operated by a three- phase Induction Motor (IM) or a Permanent Magnet Motor (PMM), which can be operated or controlled by a Rod Pump Controller (RPC) or Variable Speed Drive (VSD). Changes in the downhole conditions can cause the surface pumping unit 20, 20’ to run out-of-balance, which can stress the gear reducer 26 of the surface pumping unit 20, 20’. The unit’s imbalance can cause stress on the surface pumping unit 20, 20’ and the electric motor 28. As noted, running a unit out of balance using a 3-phase motor can cause higher power consumption.

[0070] As discussed in more detail below with reference to Figs. 3A-3B, 4A-4B, and 5A-5C, monitoring values for motor energy draw (80) in real time relative to a pump card (50, 60, 70) can provide an indication that the surface pumping unit 20, 20’ is operated optimally or is stressed. Also, overlaying the motor energy draw (80) on the pump card (50, 60, 70) can indicate where in the stroke the motor energy peaks are occurring.

[0071] The maximum and minimum motor energy (e.g., electric draw or motor amps) for the upstrokes and downstrokes indicates whether the system’s balance is “crank heavy” or “rod heavy.” Then, the balance of the reciprocating rod lift system 10 can be adjusted based on the difference in the motor electric draw for the upstrokes and the downstrokes.

[0072] In the context of the reciprocating rod lift system 10, being "crank heavy" means that the balance of the system 10 is skewed towards the crank side of the system 10. This can occur when the weight on the crank side is greater than theAtty. Dkt. No.: 230-0836WO (6756-PCT)- 15 - counterbalancing force needed for optimal operation. In a properly balanced beam pumping unit (20), for example, the weight on both sides of the walking beam (22) is adjusted so that the electric motor (28) does not have to work disproportionately harder in either direction (upstroke or downstroke).

[0073] Being "crank heavy" can lead to inefficient operation because the condition may cause the electric motor (28) to exert more force than necessary during certain strokes, leading to increased wear and tear on the equipment, higher energy consumption, and potentially decreased effectiveness in lifting the fluids from the well. An opposite condition to "crank heavy" is being "counterweight heavy", meaning that the balance of the system 10 is skewed towards the counterweight end of the walking beam (22).

[0074] As will be expected, being "rod heavy" in the reciprocating rod lift system 10 refers to a condition where there is excessive weight on the rod string (16). Preferably, the weight and forces on the rod string (16) are balanced against the counterweight assembly (24, 25w) on the surface pumping unit (20, 20’). When the system 10 is "rod heavy," however, the weight of the rod string (16), along with the downhole pump (30) and the fluid load, is greater than what is ideal for the counterbalancing mechanism. This condition leads to increased load on the upstroke. During the upstroke, for example, as the pump (30) lifts the fluid from the well, the electric motor (28) and surface equipment in the rod heavy situation must work harder to lift the additional weight, leading to increased energy consumption and wear. Additionally, even though the downstroke might require less effort from the electric motor (28) in a rod heavy situation, the increased weight can lead to faster descent, potentially causing mechanical stress and impacting the longevity of the system’s components.

[0075] For a long-stroke pumping unit (20’), the VSD can be set up to run at different speeds during the stroke segments to achieve an overall higher strokes-per-m inute (SPM) or motor frequency. When running the long-stroke pumping unit (20’) at different stroke speeds, the complete stroke is broken into segments, such as upstroke, top of stroke, downstroke, and bottom of stroke, which allows different speeds to be programmed in each segment to achieve higher overall SPM. The disclosed computerized device 100 can determine what motor energy draw is needed to operate in those segments of the long-stroke pumping unit (20’) in a way that optimizes the segments to achieve an overall higher strokes-per-m inute (SPM) or motor frequency.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 16 -

[0076] Having an understanding so far about the conditions to be addressed, discussion now turns to some example plots in Figs. 3A-3B, 4A-4B, and 5 depicting comparisons of motor energy draw relative to pump card information.

[0077] Fig. 3A illustrates an example of a surface pump card 50 that shows polish rod load (lb. or kg.) on the left Y-axis with respect to surface polish rod position (in.) on the X-axis. This surface pump card 50 can be taken from a long stroke pumping unit (20’). As noted above, the surface pump card 50 taken from surface data reflects all forces (static and dynamic) that occur from the downhole pump (30) up to the wellhead. To analyze pump operations, the surface pump card 50 and the motor energy draw (80) are obtained and scaled together for comparison. As depicted in this comparison, the surface pump card 50 shows the motor energy draw 80 (amps) on the right Y-axis with respect to the surface polish rod position (in.) on X-axis. In this example, amps are given as representative of the motor energy draw 80. As can be seen, the maximum motor energy draw 80 can be associated on the surface pump card 50 for different segments, such as the upstroke, top of stroke, downstroke, and bottom of stroke segments for the beam pumping unit (20).

[0078] Fig. 3B illustrates a downhole pump card 60 that shows the fluid / downhole pump load (lb. or kg.) on the left Y-axis with respect to pump plunger position (in.) on the X-axis. This downhole pump card 50 can be calculated for a beam pumping unit (20). To analyze pump operations, the downhole pump card 50 and the motor energy draw (80) are obtained and scaled together for comparison. As noted above, computer analysis uses known algorithms to process surface data and to generate the downhole pump card 60, which represents the downhole pumping conditions. As depicted in this comparison, the downhole pump card 60 shows the motor energy draw 80 (amps) on the right Y-axis with respect to the pump plunger position (in.) on the X-axis. Again, amps are given in this example as representative of the motor energy draw 80. As can be seen, the maximum motor energy draw 80 can be associated on the downhole pump card 60 for different segments, such as the upstroke, top of stroke, downstroke, and bottom of stroke segments for the beam pumping unit (20).

[0079] Fig. 4A illustrates another example of a surface pump card 50 that shows polish rod load on the left Y-axis with respect to polish rod position on the X-axis. This surface pump card 50 can be taken from a long-stroke pumping unit (20’). MotorAtty. Dkt. No.: 230-0836WO (6756-PCT)- 17 - energy draw (amps) is plotted as points 85 for different speed segments on the right Y- axis with respect to the polish position on the X-axis.

[0080] Fig. 4B illustrates another example of a downhole pump card 60 that shows pump / fluid load on the left Y-axis with respect to pump plunger position on X-axis. This downhole pump card 50 can be calculated from the surface data for a long-stroke pumping unit (20’). Motor energy draw (amps) is plotted as points 85 for different speed segments on the right Y-axis with respect to the polish position on the X-axis.

[0081] For the long-stroke pumping unit (20’), the computerized device 100 as shown in the examples of Figs. 4A-4B can display an enhanced view of the surface and downhole pump cards 50, 60 by showing points 85 on the surface and downhole pump cards 50, 60 for the speed segments. In this way, the computerized device 100 can utilize the information to determine if the long-stroke pumping unit (20’) is rod heavy or if the weight box is heavy. The computerized device 100 can then modify operation of the speed segments so they are optimized based on the motor energy draw 80 at those angles.

[0082] Moreover, for a long-stroke pumping unit 20’, the computerized device 100 can show the motor energy draw 80 on the pump card 50, 60 along with Speed Trim Adjustment (STA), racetrack angles, or different stoke segments, which can be used to optimize the unit’s performance. Speed Trim Adjustment (STA) techniques can finetune the speed of the pumping unit's motor to optimize its performance. To do this, the strokes per minute (SPM) of the pump are adjusted to balance production against the constraints of the reservoir, the rod string, and the pump. In the tradeoff, for instance, a slower speed can reduce the stress on the rod string 16 and the pump 30, thereby extending their life, but a faster speed can increase production rates.

[0083] "Racetrack angles" refer to the angles at which the direction of motion changes (turning points) for the polished rod 18 or walking beam 22 during operation. The angles at which the direction changes can impact the stress on the rod string 60 and the efficiency of the pumping action. Monitoring and adjusting these angles can seek to smooth the transitions at these turning points to reduce the risk of equipment failure and to optimize the stroke length of the pump 30 for maximum fluid recovery.

[0084] On the long-stroke pumping unit 20’, STA setup allows the computerized device 100 to slow down the speed of the unit at the Top Of Stroke (TOS) and / or the Bottom Of Stroke (BOS) and allows the computerized device 100 to run the electricAtty. Dkt. No.: 230-0836WO (6756-PCT)- 18 - motor 28 faster on straight Up and Down segments. Correlating the motor energy peaks on the pump card 50, 60 with respect to upstroke and downstroke allows the computerized device 100 (and / or the user, operator, etc.) to adjust the Speed Trim Adjustment angles so the motor energy consumption is not high.

[0085] As some final comparative examples, Fig. 5A illustrates an example of a surface pump card 50, and Fig. 5B illustrates an example of a downhole pump card 60. Both cards 50, 60 show pump load or load with respect to polished rod stroke length or polished rod position and also show motor energy draw. The example pump cards 50, 60 shown here are for a beam pumping unit (20). The pump cards 50, 60 are graphed at a scale that encompasses the strokes (X-axis), including downhole stroke, bottom of stroke, upward stroke, and top of stroke, relative to the pump load or load (Y-axis) of those strokes.

[0086] In a further comparative example, Fig. 5C illustrates a pump card 70, showing pump load or load with respect to polished rod stroke length or polished rod position and including motor energy draw 80. In a general sense, for the purposes of discussion, this pump card 70 is referenced herein as a “generic” pump card and can be a surface pump card (e.g., 50) or a downhole pump card (e.g., 60). The pump card 70 is graphed at a scale that encompasses the strokes (X-axis), including downhole stroke, bottom of stroke, upward stroke, and top of stroke, relative to the pump load or load (Y- axis) of those strokes.

[0087] In each of Figs. 5A-5C, a first line is associated in the scale of the pump card 50, 60, 70 and defines a first energy draw limit or threshold 91 for the electric motor (28) being operated in a downstroke of the reciprocating rod lift system (10). A second line is associated in the scale of the pump card 50, 60, 70 and defines a second energy draw limit or threshold 92 for the electric motor (28) being operated in an upstroke of the reciprocating rod lift system (10). Motor energy draw 80 is associated in the scale of the pump card 50, 60, 70, and the motor energy draw 80 is graphed for at least one cycle or for every stroke of the reciprocating rod lift system (10). As shown, values for motor energy draw 80 are governed by the motor energy (amps) at the right-hand side of the graph.

[0088] In software analysis of the disclosed computerized device (100), these lines for the thresholds 91 , 92 can be automatically generated relative to information of the pump card 50, 60, 70 based on inputs, either received from a user or generated automaticallyAtty. Dkt. No.: 230-0836WO (6756-PCT)- 19 - through logic of the disclosed computerized device (100). Likewise, these lines for the thresholds 91 , 92 can be added automatically in a graphical user interface of the disclosed computerized device (100) to the pump card 50, 60, 70 based on inputs, either received from a user or generated automatically through logic of the disclosed computerized device (100).

[0089] As can be seen, the downstroke’s energy draw threshold 91 may lie below the upstroke’s energy draw threshold 92. Although not necessary for all implementations, the motor energy draw threshold 91 for the downstroke can be less than the upstroke threshold 92 because the downstroke can take advantage of gravity as the reciprocating rod lift system (10) cycles.

[0090] As analysis would show, the motor energy draw 80 for both upstroke and downstroke remain below the thresholds 91 , 92 for the majority of the stroke but both exceed the thresholds 91 , 92 as the transitions. Various alarms or other indications can be generated through analysis of the data to provide feedback to the user. Additionally, where appropriate, various actions or adjustments can be manually initiated or automatically initiated to mitigate (or reduce the chances of) the motor energy draw 80 exceeding the thresholds 91 , 92. In this way, the disclosed computerized device 100 analyzes the motor energy draw 80 and determines any trends for balancing and optimizing different speeds in each segment of the surface pumping unit’s strokes to achieve higher overall strokes per minute (SPM) for the reciprocating rod lift system (10). Details of one form of analysis are discussed below with reference to Fig. 7.

[0091] As can be seen from the examples above, the comparisons or plots comparing the pump card information (50, 60, 70) having load versus position relative to the motor energy draw 80 can be used to identify exactly where the motor energy draw 80 is high in the strokes of the surface pumping unit (20, 20’). Knowing this information can be used to optimize the speed in the various segments of the strokes. In one aspect, the computerized device 100 can display the motor energy draw 80 in the pump card information 50, 60, 70. The visual comparison of the motor energy draw 80 at scale in the pump card information 50, 60, 70 can then help an operator to visually determine the maximum and minimum motor energy for each stroke so adjustments can be initiated. In another aspect, the computerized device 100 can analyze the motor energy draw 80 in the pump card information 50, 60, 70. Comparative analysis by the computerized device 100 can then determine the maximum and minimum motor energyAtty. Dkt. No.: 230-0836WO (6756-PCT)- 20 - for each stroke so the computerized device 100 can automatically initiate (or at least recommend) suitable adjustments, alarms, or other operations.

[0092] Fig. 6 illustrates a schematic view of a computerized device 100 according to an example of the present disclosure for use with a reciprocating rod lift system (10). The computerized device 100 can be implemented in a remote processing system, a local pump controller, or a combination of these.

[0093] The computerized device 100 includes monitoring electronics 110 that interface with the surface pumping unit 20 (and other components of the reciprocating rod lift system). The monitoring electronics 110 include a bus 111 , a processor 112, a memory 116, a storage component 117, an input component 113, an output component 115, a communication interface 118, and a power module 119. The computerized device 100 includes or communicates with sensing components or sensors 120.

[0094] The bus 111 permits communication among the components of the computerized device 100. The processor 112 is implemented in hardware, firmware, or a combination of hardware and software. The processor 112 can include a central processing unit (CPU), a microprocessor, a microcontroller, a digital signal processor (DSP), a field-programmable gate array (FPGA), an application-specific integrated circuit (ASIC), or another type of processing component. In some examples, the processor 112 includes one or more processors capable of being programmed to perform a function. The memory 116 may include one or more storage devices, such as a random-access memory (RAM), a read only memory (ROM), and / or another type of dynamic or static storage device (e.g., a flash memory, a magnetic memory, and / or an optical memory) that stores information and / or instructions for use by processor 112. The storage component 117 stores information, data, pressure measurements, and / or software related to the operation and use of the computerized device 100.

[0095] The input component 113 includes an input that permits the computerized device 100 to receive information. Additionally, or alternatively, the input component 113 may include or may communicate with the sensors 120 for sensing information associated with operation of the reciprocating rod lift system (10). The output component 115 includes an output that provides output information from the computerized device 100 (e.g., outputting sensor measurements, pump card information, display, motor driver controls, etc.).Atty. Dkt. No.: 230-0836WO (6756-PCT)- 21 -

[0096] In general, the input component 113 includes one or more sensor interfaces receiving measurements from one or more sensors 120 (i.e., load sensor 122, wireless load sensor 122, position sensor 124, wireless position sensor 124, voltmeter 126, ammeter 128, tachometer, etc.) variable frequency drive, variable speed drive, and the like. Additional inputs of the computerized device 100 can connect to other devices, such as an infrared water-cut meter, an acoustic sounding device (ASD) provide realtime data which can be logged for pressure buildup analysis and real-time calibration for fluid-level control.

[0097] Additionally, the computerized device 100 can receive a number of other inputs for operations. These inputs can be obtained as user inputs, remotely communicated inputs, or the like and can be obtained using user interfaces, communication interfaces, etc. One input can include a delta threshold for the difference in motor energy between upstroke and downstroke. Threshold level inputs can be obtained that define maximum upstroke motor energy and maximum downstroke motor energy for the analysis. In one example, a graphical user interface, a human machine interface, a local display, a remote display, or the like of the computerized device 100 can allow a user to set the limit lines for the thresholds 91 , 92 directly in the pump card 50, 60, 70 displayed in the graphical user interface. Additional inputs can include a minimum SPM, a frequency, a VSD speed, a number of strokes to monitor to make a decision, and the like.

[0098] In general, the load and position sensors 122 and 124 measure load and position data of the reciprocating rod lift system 10 at the surface, and the measured data from the sensors 122 and 124 is relayed to the computerized device 100. After processing the information, the computerized device 100 sends signals to a motor control or driver 130 to operate the motor.

[0099] As shown, the load sensor 122 can detect the weight of the fluid in the production tubing during operation of the reciprocating rod lift system 10, and position sensor 124 can measure the position of the reciprocating rod lift system 10 over each cycle of stroke. The position sensor 124 can be any position measurement device used for measuring position relative to the top or bottom of the stroke. For example, the position sensor 124 can be arranged relative to the polished rod to measure position.

[0100] Alternatively, the degree of rotation of the pump system's crank arm can provide displacement data. For example, the position sensor 124 can determine when the system's crank arm passes a specific location, and a pattern of simulated polishedAtty. Dkt. No.: 230-0836WO (6756-PCT)- 22 - rod displacement versus time can be adjusted to provide an estimate of polished rod positions at times between these crank arm indications. In another alternative, a degree of inclination of a walking beam of the surface pumping unit 20 can provide displacement data. For example, the position sensor 124 can be attached to the walking beam to measure the degree of inclination of the surface pumping unit.

[0101] Load data of the system 10 can be directly measured using a load cell 122 inserted between a polished rod clamp and carrier bar. Alternatively, the strain on the walking beam 22 can provide the load data. Using a load sensor 122, for example, the computerized device 100 can measure the strain on the polished rod 18 and can then control the reciprocating rod lift system 10 based on the strain measured. The load sensor 122 may use any of a variety of strain-measuring devices known to a person of ordinary skill in the art. For example, the load sensor 122 can be a load measurement device used on the reciprocating rod lift system 10 that includes a load cell installed on the polished rod 18 or mounted on the walking beam 22. The load sensor 122 can measure strain in the polished rod 18 and can use a strain-gage transducer welded to the top flange of the walking beam 22. For example, the load sensor 122 can be a strain measuring device that clamps on to a load-bearing surface of the walking beam (22) or any convenient location.

[0102] Finally, the amplitude and frequency of the electrical power signal applied to the motor (28) via the motor driver 130 can be used to determine motor rotation (i.e., displacement data) and motor torque (i.e., load data). In this way, the motor speed and the displacement of the polished rod 18 can provide a series of motor speed and displacement data pairs at a plurality of displacements along the polished rod 18. That displacement data which represents a complete stroke of the reciprocating rod lift system 10 can then be converted to load on the rod string 16 and displacement of the rod string 16 at a plurality of displacements along the polished rod 185.

[0103] The communication interface 118 includes a transceiver-like component (e.g., a transceiver and / or a separate receiver and transmitter) that enables the computerized device 100 to communicate with other devices, such as via a wired connection, a wireless connection, an acoustic connection, or a combination of such connections.The communication interface 118 may permit the computerized device 100 to receive information from another device and / or provide information to another device. For example, the communication interface 118 may include any suitable interface, such asAtty. Dkt. No.: 230-0836WO (6756-PCT)- 23 - optical, electrical, or acoustic interface. The power module 119 is connected along the bus 111 to supply power to the processor 112, the memory 116, and the internal components of computerized device 100.

[0104] The computerized device 100 may perform one or more processes described herein. The computerized device 100 may perform these processes by the processor 112 executing software instructions stored by a non-transitory computer-readable medium, such as the memory 116 and / or the storage component 117. For example, software stored in the memory 116 can include motor control software and pump diagnostic software. A computer-readable medium is defined herein as a non-transitory memory device. A memory device includes memory space within a single physical storage device or memory space spread across multiple physical storage devices.

[0105] Software instructions may be read into the memory 116 and / or the storage component 117 from another computer-readable medium or from another device via the communication interface 118. When executed, software instructions stored in the memory 116 and / or the storage component 117 may instruct the processor 112 to perform one or more processes described herein. Additionally, or alternatively, hardwired circuitry may be used in place of or in combination with software instructions to perform one or more processes described herein. Thus, implementations described herein are not limited to any specific combination of hardware circuitry and software.

[0106] The number and arrangement of components shown in Fig. 6 are provided as an example. In practice, the computerized device 100 may include additional components, fewer components, different components, or differently arranged components than those shown in Fig. 6. Additionally, or alternatively, a set of components (e.g., one or more components) of the computerized device 100 may perform one or more functions described as being performed by another set of components of the computerized device 100.

[0107] Fig. 7 illustrates a process 200 of monitoring and controlling operation of a reciprocating rod lift system 10 according to the present disclosure. Reference to numeral elements in other Figures are provided here for descriptive purposes. During operation of the surface pumping unit 20, the computerized device 100, which can include part of a rod pump controller (RPC) and other system components, obtains surface data, measuring the load and position at surface using sensors and techniques discussed above (Block 202). Using the measured surface data and known algorithms,Atty. Dkt. No.: 230-0836WO (6756-PCT)- 24 - equations, and techniques, the computerized device 100 can generate a pump card 70, such as a surface pump card 50 and can calculate a downhole pump card 60 (Block 204). (Either one or both of the surface pump card 50 and the downhole pump card 60 is referred to below generically as a “pump card 70” for the purposes of discussion.) As will be appreciated, the surface pump card 50 and the downhole pump card 60 can be used for monitoring and controlling the surface pumping unit (e.g., a beam pumping unit 20 or a long stroke pumping 20’).

[0108] In addition to the types of monitoring and control that can be gleaned directly from analysis of the pump card 70, the computerized device 100 obtains measurements of the motor energy draw 80 in real time for every stroke (Block 210). The motor energy draw 80 can be obtained from an analog input, communications of the MODBUS protocol from the Variable Speed Drive (VSD), readings from the Variable Frequency Drive (VFD), or a motor energy reading transmitter.

[0109] In the process 200, first and second energy draw thresholds 91 , 92 are associated into the scale of the pump card 70. As noted, the first energy draw threshold 91 is associated with the electric motor 28 being operated in a downstroke of the reciprocating rod lift system 10. Meanwhile, the second energy draw threshold 92 is associated with the electric motor 28 being operated in an upstroke of the reciprocating rod lift system 10. In general, the downstroke threshold 91 is less than the upstroke threshold 92.

[0110] For the benefit of a user (e.g., field operator, remote engineer, etc.), the computerized device 100 can display the motor energy draw 80 overlayed on the pump card 70 (e.g., Dynagraph, Dynacard, etc.) (Block 212). The computerized device 100 can be set with configurable thresholds 91 , 92 for maximum motor energy draw 80 during the upstroke and downstrokes. The configurable thresholds 91 , 92 can be set by the user, may be predefined, or may be automatically adjusted by the computerized device 100. For example, the user can position the thresholds 91 , 92 as vertical lines in a graphical use interface depicting the pump card 70.

[0111] The computerized device 100 now performs two forms of analysis (Block 220, 280) using the motor energy draw 80. In the first analysis, the computerized device 100 obtains peak motor energy values for the upstroke and downstroke using position sensor values for every stroke (Block 220). The computerized device 100 then reviews both the downstroke and the upstroke in various steps (Blocks 230 to 274) discussedAtty. Dkt. No.: 230-0836WO (6756-PCT)- 25 - below. Meanwhile, in the second analysis, the computerized device 100 calculates the difference or delta in the motor energy draw 80 between the peaks captured for the upstroke and downstroke (Block 280). The computerized device 100 then reviews delta using steps (Blocks 282 to 284) discussed below.

[0112] Looking back at the first analysis, the computerized device 100 reviews both the downstroke and the upstroke using the obtained peak energy (Block 220). For the downstroke, the computerized device 100 determines if the motor energy draw 80 for the downstroke has exceeded a first threshold 91 (Block 230). As before, this first threshold 91 can be configured and set by the user, the computerized device 100, or the like. If the downstroke’s peak motor energy draw does not exceed the threshold 91 (No at Block 230), the computerized device 100 can return to obtaining surface data (Block 202), calculating (i.e., updating) the pump card 70 (Block 204), and obtaining measurements of the motor energy draw 80 (Block 230).

[0113] If the downstroke’s peak motor energy draw does exceed the first threshold 91 (Yes at Block 230), the computerized device 100 activates a first alarm and / or initiates a first adjustment (Block 232). For a beam pumping unit 20, the first alarm can be a crank heavy alarm, which is determined when the motor energy draw 80 monitored during the downstroke segment exceeds a downstroke threshold 91 on the pump card 70. As noted, the crank heavy alarm indicates that the balance of the system 10 is skewed towards the crank side of the system 10 (Block 232). Should the beam pumping unit 20 have any automated features to adjust the crank side of the beam pumping unit 20 (such as a movable crank arm weight, adjustable weight, motor feature, etc.), then a “crank heavy” adjustment can be initiated that adjusts the crank side of the surface pumping unit 20, 20’ in an automated fashion. For a long-stroke pumping unit 20’, such as a belt-driven unit, this first alarm can be a weight box heavy alarm indicating that the weight box of the belt-belt unit is “heavy” (i.e., out-of-balance relative to the rod side of the surface pumping unit 20’). Should the long-stroke pumping unit 20’ have automated features for its motor 28 or its mechanical components (e.g., the weight box, gear reducer 26, etc.), then the computerized device 100 can perform a suitable adjustment in a weight box heavy action to alter a condition of the surface pumping unit’s motor or equipment to counteract the weight box heavy condition.

[0114] As an example for either surface pumping unit 20, 20’, the computerized device 100 can adjust operation of the motor 28 so that the downstroke’s peak motor energyAtty. Dkt. No.: 230-0836WO (6756-PCT)- 26 - draw does exceed the threshold 91. Alternatively, in some circumstances, the computerized device 100 can adjust the threshold 91 automatically to account for heuristic changes during operation as long as operational rules are followed. Should any of the mechanical equipment of the surface pumping unit 20, 20’ allow for automatic adjustment, the computerized device 100 can implement those adjustments. For further reference, systems and methods for handling surface pumping units 20, 20’ in an out-of- balance condition in an automated fashion are described, for example, in U.S. Pat. No. 10,546,159, which is incorporated herein by reference.

[0115] Looking at upstroke in the first analysis, the computerized device 100 determines if the motor energy draw 80 for the upstroke has exceeded a second threshold 92 (Block 230). As before, this second threshold 92 can be configured and set by the user, the computerized device 100, or the like. If the upstroke’s peak motor energy draw does not exceed the second threshold 92 (No at Block 240), the computerized device 100 can return to obtaining surface data (Block 202), calculating (i.e., updating) the pump card 70 (Block 204), and obtaining measurements of motor energy draw 80 (Block 230).

[0116] If the upstroke’s peak motor energy draw does exceed the second threshold 92 (Yes at Block 240), the computerized device 100 activates a second alarm and / or initiates a second adjustment (Block 242). The second alarm is a rod heavy alarm, which is determined when the motor energy draw 80 monitored during the upstroke segments exceeds an upstroke threshold 92 on the pump card 70 of the computerized device 100. As noted above, the rod heavy alarm indicates that there is excessive weight on the rod string 16 (Block 232). Should the surface pumping unit 20, 20’ have automated features for its motor 28, its mechanical components, etc., then the computerized device 100can perform a suitable adjustment in a rod heavy action to alter a condition of the surface pumping unit’s motor 28 or equipment to counteract the rod heavy condition.

[0117] As an example for either surface pumping unit 20, 20’, the computerized device 100 can adjust operation of the motor 28 so that the upstroke’s peak motor energy draw does not exceed the threshold 92. Alternatively, in some circumstances, the computerized device 100 can adjust the threshold 92 automatically to account for heuristic changes during operation as long as operational rules are followed. ShouldAtty. Dkt. No.: 230-0836WO (6756-PCT)- 27 - any of the mechanical equipment of the surface pumping unit 20, 20’ allow for automatic adjustment, the computerized device 100 can implement those adjustments.

[0118] Given the rod heavy determination, the computerized device 100 determines if a peak or maximum load value for the upstroke and a gearbox torque value calculated by the computerized device 100 has exceeded a third threshold (Block 250). As before, this third threshold can be configured and set by the user, the computerized device 100, or the like.

[0119] If the third threshold is not exceeded (No at Block 250), the computerized device 100 can return to obtaining surface data (Block 202), calculating (i.e., updating) the pump card 70 (Block 204), and obtaining measurement of the motor energy draw 80 (Block 230). If the peak or maximum load value for the stroke and the gearbox torque value has exceeded the third threshold (Yes at Block 250), the computerized device 100 activates a third alarm and / or initiates a third adjustment. The third alarm is a loading alarm, which is determined when the motor energy draw 80 has exceeded the upstroke threshold 92 and is determined when a peak or maximum load on the gearbox 26 has crossed an operating limit (third threshold). The gearbox loading alarm indicates that the gearbox 26 may be subject to excessive or undesirable levels of torque (Block 252).

[0120] Should the surface pumping unit 20, 20’ have automated features for its motor 28 and / or its mechanical components, then the third adjustment can perform a suitable adjustment to alter a condition of the surface pumping unit’s motor 28 and / or equipment to counteract the loading condition. For instance, the computerized device 100 can adjust operation of the motor 28 so that the load or torque on the gearbox 26 does exceed the third threshold. Alternatively, in some circumstances, the computerized device 100 can adjust the third threshold automatically to account for heuristic changes during operation as long as operational rules are followed. Should any of the mechanical equipment of the surface pumping unit 20, 20’ allow for automatic adjustment, the computerized device 100 can implement those adjustments.

[0121] Given the that the upstroke peak motor energy draw exceeds the second threshold 92 (Yes at Block 240), the computerized device 100 can additionally verify if a fluid pound or a pump-off condition is detected (Block 260). The determination uses one or more parameters, including, for example, pump fillage or downhole fillage, pump intake pressure (PIP), fluid level, and downhole load span. These are calculated based on analysis of the downhole pump card as noted previously.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 28 -

[0122] If the fluid pound or pump-off condition is not detected (No at Block 260), the computerized device 100 returns to obtaining surface data (Block 202), calculating pump card information (Block 204), capturing motor energy draw 80 (Block 210), etc.

[0123] If the fluid pound or pump-off condition exists (Yes at 260), however, the computerized device 100 activates a fourth alarm and / or initiates a fourth adjustment (Block 262). This fourth alarm is a high motor energy consumption alarm, which is determined when the motor energy draw 80 exceeds the threshold 92 on the upstroke along combined with a detection of a fluid level drop indicated by pump fillage or pump intake pressure (PIP) or downhole load span. The consumption alarm indicates that the electric motor 28 is drawing too much energy relative to how effectively the downhole pump 30 is operating.

[0124] Should the surface pumping unit 20, 20’ have automated features for its electric motor 28 and / or its mechanical components, then the fourth adjustment can perform a suitable adjustment to alter a condition of the surface pumping unit’s motor 28 and / or equipment to counteract the consumption condition. For instance, the computerized device 100 can adjust operation of the electric motor 28 so that the consumption is reduced. Alternatively, in some circumstances, the computerized device 100 can adjust the fourth threshold automatically to account for heuristic changes during operation as long as operational rules are followed. Should any of the mechanical equipment of the surface pumping unit 20, 20’ allow for automatic adjustment, the computerized device 100 can implement those adjustments.

[0125] In an additional determination when there is a fluid pound or pump-off condition (Yes at Decision 260), the computerized device 100 determines if the surface pumping unit 20, 20’ is a fixed speed unit or is part of a standard operation well (Block 270). If so (Yes at Block 270), the computerized device 100 stops the well on idle or down time (Block 272).

[0126] If the implementation is not a fixed speed unit or part of a standard operation well (No at Block 270), then the computerized device 100 can adjust the SPM or VSD frequency (Block 274). For example, the computerized device 100 can reduce the strokes per minute (SPM) to a minimum SPM, can adjust frequency of VSD speed set by the user or the computerized device 100, or can idle the well (Block 274). The computerized device 100 can then return to obtaining surface data (Block 202),Atty. Dkt. No.: 230-0836WO (6756-PCT)- 29 - calculating (i.e., updating) the pump card 70 (Block 204), and obtaining measurements of the motor energy draw 80 (Block 230)

[0127] In the second analysis (Block 280), the computerized device 100 determines if the difference (delta) in the motor energy draw 80 between upstroke and downstroke is greater than a fifth threshold, which is a delta averaged over a number of strokes (Decision 282). If the delta falls below the threshold, the computerized device 100 can return to obtaining surface data (Block 202), calculating (i.e., updating) the downhole pump card (Block 204), and obtaining measurements of the motor energy draw 80 (Block 230).

[0128] If the delta threshold is exceeded, however, the computerized device 100 activates a fifth alarm for the surface pumping unit 20, 20’ and / or initiates a fifth adjustment (Block 284). This fifth alarm is an out-of-balance alarm, which is determined when the motor energy difference or delta between the upstroke and downstroke exceeds a set value. As its name implies, the out-of-balance alarm indicates that the surface pumping unit 20, 20’ is out-of-balance.

[0129] Should the surface pumping unit 20, 20’ have automated features for its electric motor 28 and / or its mechanical components, then the fourth adjustment can perform a suitable adjustment to alter a condition of the surface pumping unit’s motor 28 and / or equipment to counteract the balance condition. For instance, the computerized device 100 can adjust operation of the electric motor 28 so that the out-of-balance condition is reduced. Alternatively, in some circumstances, the computerized device 100 can adjust the fourth threshold automatically to account for heuristic changes during operation as long as operational rules are followed. Should any of the mechanical equipment of the surface pumping unit 20, 20’ allow for automatic adjustment, the computerized device 100 can implement those adjustments.

[0130] As the depiction of the process 200 shows in Fig. 7, the process 200 can be repeated in real time during operation of the reciprocating rod lift system 10. The steps of obtaining surface data (Block 202), calculating the pump card information (Block 204), obtaining the energy draw measurements (Block 210) to the steps of initiating responses based on the determinations can be performed according to a set number of strokes of the reciprocating rod lift system 10. The number of strokes can be configurable and can be set by a user, remote source, or internal logic of the computerized device, for example.Atty. Dkt. No.: 230-0836WO (6756-PCT)- 30 -

[0131] The techniques disclosed herein allow the disclosed computerized device 100, either located in the field site and / or remotely at the back office, to analyze maximum and minimum motor energy captured throughout the pump card information 70 (e.g., Dynacard, Dynagraph, dynamometer, etc.) for the surface pumping unit 20, 20’ in real time without a manual process. From that analysis, the disclosed computerized device 100 can generate alarms, which can be useful in making decisions to balance the reciprocating rod lift system 10 or to correct aspects of its operation. Moreover, the disclosed computerized device 100 can initiate automated adjustments to balance the reciprocating rod lift system 10 or to correct aspects of its operation when automated functions are available on the system 10.

[0132] Additionally, the techniques implemented by the disclosed computerized device 100 at a minimum allow an operator, either locally in the field site and / or remotely at the back office, to visually review maximum and minimum motor energy draw captured in combination with the pump card 70 in real time without a manual process. For example, based on the alarms, the user (e.g., operator, production engineer, etc.) can identify if the reciprocating rod lift system 10 is crank heavy or rod heavy. From that review, the operator can make decisions to balance the reciprocating rod lift system 10. Furthermore, for a long-stroke pumping unit 20’, for example, the computerized device 100 can optimize the speed segments by looking at the motor energy draw 80 at the different angles of the speed segments in the unit’s strokes.

[0133] The teachings of the present disclosure can be characterized by the following clauses:Clause 1 : A method implemented by a computerized device (100) for a reciprocating rod lift system (10), the reciprocating rod lift system (10) having a surface pumping unit (20, 20’) with an electric motor (28) and having a downhole pump (30), the method comprising: obtaining pump card information (70) in real time during operation of the reciprocating rod lift system (10), the pump card information (70) relating position and load of the reciprocating rod lift system (10); obtaining energy draw measurements (80) of the electric motor (28) in real time during the operation of the reciprocating rod lift system (10); associating the energy draw measurements (80) into a scale of the pump card information (70) (Block 210);Atty. Dkt. No.: 230-0836WO (6756-PCT)- 31 - associating a first energy draw threshold (91) and a second energy draw threshold (92) into the scale of the pump card information (70), the first energy draw threshold (91 ) associated with the electric motor (28) being operated in a downstroke of the reciprocating rod lift system (10), the second energy draw threshold (92) associated with the electric motor (28) being operated in an upstroke of the reciprocating rod lift system (10); and initiating at least one first operational event (Block 232, 242, 262) in response to at least one of: determining that the energy draw measurements (80) in the downstroke exceeds the first energy draw threshold (91 ) (Block 230); determining that the energy draw measurements (80) in the upstroke exceeds the second energy draw threshold (92) (Block 240); and determining that a difference between the energy draw measurements (80) in the downstroke and the energy draw measurements (80) in the upstroke exceeds a third threshold (Block 260).Clause 2: The method of Clause 1 , wherein initiating the at least one first operational event in response to the at least one of determining that the energy draw measurements (80) in the downstroke exceeds the first energy draw threshold (91 ) (Block 230) comprises: indicating a heavy crank condition as the at least one first operational event (Block 232) in response to determining that the energy draw measurements (80) in the downstroke, of a beam pumping unit as the surface pumping unit (20, 20’) having a crank, exceeds the first energy draw threshold (91 ) (Block 230); or indicating a heavy weight box condition as the at least one first operational event (Block 242) in response to determining that the energy draw measurements (80) in the downstroke, of a long-stroke pumping unit (20’) as the surface pumping unit (20, 20’) having a weight box, exceeds the first energy draw threshold (91 ) (Block 240).Clause 3: The method of Clause 1 or 2, wherein initiating the at least one first operational event (Block 242) in response to the at least one of determining that the energy draw measurements (80) in the upstroke exceeds the second energy draw threshold (92) (Block 240) comprises indicating a rod heavy condition as the at least one first operational event in response to determining that the energy drawAtty. Dkt. No.: 230-0836WO (6756-PCT)- 32 - measurements (80) in the upstroke exceeds the second energy draw threshold (92) (Block 242).Clause 4: The method of Clause 3, further comprising initiating a second operational event (Block 252) in response to: determining that a first peak value for the load in the upstroke has exceeded a first limit; and determining that a second peak value for torque of a reducer (26) for the electric motor (28) of the reciprocating rod lift system (10) exceeds a second limit (Block 250).Clause 5: The method Clause 4, wherein initiating the second operational event comprises indicating a loading condition indicative of excess load on the reducer (26) (Block 252).Clause 6: The method of any one of Clauses 4 to 6, further comprising initiating a second operational event (Block 262) in response to determining, based on pump parameters, a fluid pound condition or a pump-off condition associated with the downhole pump (30) (Block 260), optionally wherein the pump parameters include one or more of pump fillage, downhole fillage, pump intake pressure, fluid level, and downhole load span.Clause 7: The method of Clause 6, wherein initiating the second operational event comprises indicating a consumption condition indicative of excessive consumption of energy by the electric motor (28) (Block 262).Clause 8: The method of any one of Clauses 6 or 7, further comprising initiating a third operational event, based on the reciprocating rod lift system (10) being fixed speed or being a standard operation well, that stops the reciprocating rod lift system (10) on idle for at least a time period (Block 270).Clause 9: The method of any one of Clauses 6, 7 or 8, further comprising initiating, based on the reciprocating rod lift system (10) being variable speed (VSD), a third operational event that reduces a strokes per minute (SPM) of the reciprocating rod lift system (10) (Block 272); and optionally wherein the method further comprises receiving an input setting a minimum strokes per minute (SPM) of the reciprocating rod lift system (10), whereby initiating the third operational event that reduces the strokes per minute of the reciprocating rod lift system (10) comprises setting the reciprocating rod lift system (10) to the minimum strokes per minute.Clause 10: The method of any one of Clauses 6 to 9, further comprising initiating, based on the reciprocating rod lift system (10) being variable speed, a third operationalAtty. Dkt. No.: 230-0836WO (6756-PCT)- 33 - event that reduces a frequency of the electric motor (28) of a variable speed device for the reciprocating rod lift system (10) (Block 272).Clause 11 : The method of any one of Clauses 1 to 10, wherein associating the first energy draw threshold (91 ) and the second energy draw threshold (92) into the scale of the pump card information (70) (Block 212) comprises receiving inputs setting the first energy draw threshold (91 ) and the second energy draw threshold (92) into the scale of the pump card information (70).Clause 12: The method of any one of Clauses 1 to 11 , comprising receiving an input setting the third threshold.Clause 13: The method of any one of Clauses 1 to 12, wherein the steps of obtaining the pump card information (70), obtaining the energy draw measurements (80), and initiating in response to the at least one determination comprises performing and repeating the steps at a set number of strokes of the reciprocating rod lift system (10).Clause 14: The method of any one of Clauses 1 to 13, further comprising: obtaining surface measurements including the position and the load associated with one or more strokes of the surface pumping unit (20, 20’) (Block 202); calculating, based on the surface measurements, a pump card for the pump card information (70) (Block 204), e.g., calculating, based on the surface measurements, a surface pump card (50) and / or a downhole pump card (60) for the reciprocating rod lift system (10) (Block 210).Clause 15: A non-transitory computer readable medium having computer executable code stored thereon for causing a computerized device (100) to perform a method according to any one of Clauses 1 to 14.Clause 16: A computerized device (100) for use with a reciprocating rod lift system (10), the reciprocating rod lift system (10) having a surface pumping unit (20, 20’) with an electric motor (28) and having a downhole pump (30), the computerized device (100) comprising: memory (116, 117) storing pump card information (70), energy draw measurements (80), and first energy draw threshold (91) and the second energy draw threshold (92), the pump card information (70) being obtained in real time during operation of the reciprocating rod lift system (10), the pump card information (70) relating position and load of the reciprocating rod lift system (10), the energy drawAtty. Dkt. No.: 230-0836WO (6756-PCT)- 34 - measurements (80) of the electric motor (28) being obtained in real time during the operation of the reciprocating rod lift system (10); and one or more processors (112) in communication with the memory and being configured to: associate the energy draw measurements (80) into a scale of the pump card information (70); associate a first energy draw threshold (91 ) and a second energy draw threshold (92) into the scale of the pump card information (70), the first energy draw threshold (91 ) associated with the electric motor (28) being operated in a downstroke of the reciprocating rod lift system (10), the second energy draw threshold (92) associated with the electric motor (28) being operated in an upstroke of the reciprocating rod lift system (10); and initiate at least one first operational event in response to at least one of: a first determination that the energy draw measurements (80) in the downstroke exceeds the first energy draw threshold (91 ); a second determination that the energy draw measurements (80) in the upstroke exceeds the second energy draw threshold (92); and a third determination that a difference between the energy draw measurements (80) in the downstroke and the energy draw measurements (80) in the upstroke exceeds a third threshold.Clause 17: The computerized device (100) of Clause 16, wherein the one or more processors (112) in communication with the memory (116, 117) and being configured to perform the method according to any one of Clauses 2 to 14.

[0134] The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. It will be appreciated with the benefit of the present disclosure that features described above in accordance with any embodiment or aspect of the disclosed subject matter can be utilized, either alone or in combination, with any other described feature, in any other embodiment or aspect of the disclosed subject matter.

[0135] In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof.

Claims

Atty. Dkt. No.: 230-0836WO (6756-PCT)- 35 -CLAIMS:

1. A method implemented by a computerized device for a reciprocating rod lift system, the reciprocating rod lift system having a surface pumping unit with an electric motor and having a downhole pump, the method comprising: obtaining pump card information in real time during operation of the reciprocating rod lift system, the pump card information relating position and load of the reciprocating rod lift system; obtaining energy draw measurements of the electric motor in real time during the operation of the reciprocating rod lift system; associating the energy draw measurements into a scale of the pump card information; associating a first energy draw threshold and a second energy draw threshold into the scale of the pump card information, the first energy draw threshold associated with the electric motor being operated in a downstroke of the reciprocating rod lift system, the second energy draw threshold associated with the electric motor being operated in an upstroke of the reciprocating rod lift system; and initiating at least one first operational event in response to at least one of: determining that the energy draw measurements in the downstroke exceeds the first energy draw threshold; determining that the energy draw measurements in the upstroke exceeds the second energy draw threshold; and determining that a difference between the energy draw measurements in the downstroke and the energy draw measurements in the upstroke exceeds a third threshold.

2. The method of claim 1 , wherein initiating the at least one first operational event in response to determining that the energy draw measurements in the downstroke exceeds the first energy draw threshold comprises indicating, for a beam pumping unit as the surface pumping unit having a crank, a heavy crank condition as the at least one first operational event.

3. The method of claim 1 , wherein initiating the at least one first operational event in response to determining that the energy draw measurements in the downstrokeAtty. Dkt. No.: 230-0836WO (6756-PCT)- 36 - exceeds the first energy draw threshold comprises indicating, for a stroke unit as the surface pumping unit having a weight box, a heavy weight box condition as the at least one first operational event.

4. The method of claim 1 , wherein initiating the at least one first operational event in response to determining that the energy draw measurements in the upstroke exceeds the second energy draw threshold comprises indicating a rod heavy condition as the at least one first operational event.

5. The method of claim 4, further comprising initiating a second operational event in response to: determining that a first peak value for the load in the upstroke has exceeded a first limit; and determining that a second peak value for torque of a reducer for the electric motor of the reciprocating rod lift system exceeds a second limit.

6. The method of claim 5, wherein initiating the second operational event comprises indicating a loading condition indicative of excess load on the reducer.

7. The method of claim 4, wherein further comprising initiating a second operational event in response to determining, based on pump parameters, a fluid pound condition or a pump-off condition associated with the downhole pump.

8. The method of claim 7, wherein the pump parameters include one or more of: pump fillage, downhole fillage, pump intake pressure, fluid level, and downhole load span.

9. The method of claim 7 or 8, wherein initiating the second operational event comprises indicating a consumption condition indicative of excessive consumption of energy by the electric motor.

10. The method of claim 7, 8 or 9, further comprising initiating a third operational event, based on the reciprocating rod lift system being fixed speed or being a standard operation well, that stops the reciprocating rod lift system on idle for at least a time period.11 . The method of claim 7, 8 or 9, further comprising initiating, based on the reciprocating rod lift system being variable speed, a third operational event that reduces a strokes per minute of the reciprocating rod lift system.

12. The method of claim 11 , comprising receiving an input setting a minimum strokes per minute of the reciprocating rod lift system, whereby initiating the third operationalAtty. Dkt. No.: 230-0836WO (6756-PCT)- 37 - event that reduces the strokes per minute of the reciprocating rod lift system comprises setting the reciprocating rod lift system to the minimum strokes per minute.

13. The method of claim 7, 8 or 9, further comprising initiating, based on the reciprocating rod lift system being variable speed, a third operational event that reduces a frequency of the electric motor of a variable speed device for the reciprocating rod lift system.

14. The method of any one of claims 1 to 13, wherein associating the first and second energy draw thresholds into the scale of the pump card information comprises receiving inputs setting the first and second energy draw thresholds into the scale of the pump card information.

15. The method of any one of claims 1 to 14, comprising receiving an input setting the third threshold.

16. The method of any one of claims 1 to 15, wherein the steps of obtaining the pump card information, obtaining the energy draw measurements, and initiating in response to the at least one determination comprises performing and repeating the steps at a set number of strokes of the reciprocating rod lift system.

17. The method of any one of claims 1 to 16, further comprising: obtaining surface measurements including the position and the load associated with one or more strokes of the surface pumping unit; and calculating, based on the surface measurements, a surface pump card for the pump card information.

18. The method of claim 17, further comprising calculating, based on the surface measurements, a downhole pump card for the downhole pump of the reciprocating rod lift system.

19. A non-transitory computer readable medium having computer executable code stored thereon for causing a computerized device to perform a method according to any one of claims 1 to 18.

20. A computerized device for use with a reciprocating rod lift system, the reciprocating rod lift system having a surface pumping unit with an electric motor and having a downhole pump, the computerized device comprising: memory storing pump card information, energy draw measurements, and first and second energy draw thresholds, the pump card information being obtained in real time during operation of the reciprocating rod lift system,Atty. Dkt. No.: 230-0836WO (6756-PCT)- 38 - the pump card information relating position and load of the reciprocating rod lift system, the energy draw measurements of the electric motor being obtained in real time during the operation of the reciprocating rod lift system; and one or more processors in communication with the memory and being configured to: associate the energy draw measurements into a scale of the pump card information; associate a first energy draw threshold and a second energy draw threshold into the scale of the pump card information, the first energy draw threshold associated with the electric motor being operated in a downstroke of the reciprocating rod lift system, the second energy draw threshold associated with the electric motor being operated in an upstroke of the reciprocating rod lift system; and initiate at least one first operational event in response to at least one of: a first determination that the energy draw measurements in the downstroke exceeds the first energy draw threshold; a second determination that the energy draw measurements in the upstroke exceeds the second energy draw threshold; and a third determination that a difference between the energy draw measurements in the downstroke and the energy draw measurements in the upstroke exceeds a third threshold.

21. The computerized device of claim 20, wherein the one or more processors are configured to perform steps of the method according to any one of claims 2 to 18.

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