Tower-style pumping unit

Abstract

A tower-style pumping system includes a motor configured to convert electrical power into a first rotational speed and a first torque, an amp meter associated with the motor and configured to measure an operating amperage of the motor, and a transmission coupled to the motor, where the transmission includes a carriage assembly having a counterweight, a polished rod, and a rod string coupled to the polished rod and configured to extend into a wellbore to a subterranean location. The system also includes a pump coupled to the rod string of the transmission, where the pump is configured to direct a fluid from the subterranean location in response to movement of the rod string and a controller coupled to the amp meter, where the controller includes a processor, a memory, and instructions stored on the memory and executable by the processor, where the instructions are configured to determine an operating load of the system based on the operating amperage of the motor during operation.

Description

IS25.0205 (SCFT:0488)TOWER-STYLE PUMPING UNITCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application is a U.S. Non-Provisional Patent Application claiming benefit of U.S. Provisional Patent Application No. 63 / 761,525, entitled “TOWER-STYLE PUMPING UNIT”, filed February 21, 2025, which is herein incorporated by reference in its entirety for all purposes.BACKGROUND

[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

[0003] Of the various ways to lift subterranean fluid (e g., gas) from an underground reservoir, tower-style pumping (e.g., long-stroke tower-style pumping, reciprocating pumping) enables a relatively large amount of fluid to be lifted with relatively low mechanical stress. Long-stroke tower-style pumping systems employ a vertical tower having a drive system (e.g., a motor) configured to vertically move a carrier in a reciprocating vertical movement (e.g., upstrokes and downstrokes). The carrier may be coupled to a polished rod, which connects the surface equipment to the downhole rod string. The reciprocating movement of the rod string, caused by the vertical movement of the carrier and polished rod, may cause pumping action of a downhole pump (e.g., a plunger pump), lifting fluid to the surface. To measure a load (e.g., tensile load) on the system during operation, typical units may employ a load cell between the carrier and the polished rod. The load cell may be wireless or wired, depending on the application. However, for both variations, problems associated with load cells may result in inaccurate readings, damage, frequent replacement, workovers, and so forth. To this end, an improved system and method for determining or calculating load of the system is desired.1SLB-PrivateIS25.0205 (SCFT:0488)SUMMARY

[0004] A summary of certain embodiments disclosed herein is set forth below. It should be noted that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

[0005] In an embodiment, a tower-style pumping system includes a motor configured to convert electrical power into a first rotational speed and a first torque, an amp meter associated with the motor and configured to measure an operating amperage of the motor, and a transmission coupled to the motor, where the transmission includes a carriage assembly having a counterweight, a polished rod, and a rod string coupled to the polished rod and configured to extend into a wellbore to a subterranean location. The system also includes a pump coupled to the rod string of the transmission, where the pump is configured to direct a fluid from the subterranean location in response to movement of the rod string and a controller coupled to the amp meter, where the controller includes a processor, a memory, and instructions stored on the memory and executable by the processor, where the instructions are configured to determine an operating load of the system based on the operating amperage of the motor during operation.

[0006] In another embodiment, a method for operating a tower-style pumping system includes attaching a weight to a carrier of the tower-style pumping system, attaching a counterweight to the tower-style pumping system, where the counterweight is based on the weight, and operating a motor of the tower-style pumping system at one or more motor speeds. The method also includes determining one or more accelerations of the tower-style pumping system based on the one or more motor speeds, where the one or more accelerations of the tower-style pumping system are based on one or more velocities of a stroke motion of the tower-style pumping system, measuring, via an amp meter associated with the motor, one or more amperages of the motor during operation, where the one or more amperages are based on the one or more motor speeds, and determining a correlation between the one or more amperages and the one or more accelerations. The method also includes determining a conversion factor based on the correlation, determining an2SLB-PrivateIS25.0205 (SCFT:0488)operating amperage, via the amp meter, during operation of the tower-style pumping system, and determining an operating load of the tower-style pumping system based on the conversion factor and the operating amperage.

[0007] In a further embodiment, a method for operating a tower-style pumping system includes, during an experimental operational mode of the tower-style pumping system, determining one or more initial loads of the tower-style pumping system, where the one or more initial loads are based on a known weight attached to a carrier of the tower-style pumping system, a known counterweight attached to a carriage assembly of the tower-style pumping system, one or more parameters of a motor of the tower-style pumping system operating during the experimental operational mode, a stroke position of the tower-style pumping system, or any combination thereof. The method includes, during an experimental operational mode of the tower-style pumping system, measuring, via an amp meter associated with the motor, one or more amperages of the motor during the experimental operational mode, where the one or more amperages are based on one or more motor speeds, and determining a conversion factor based on the one or more amperages and the one or more initial loads. The method also includes, during an operational mode of the tower-style pumping system, determining an operating amperage, via the amp meter; and determining an operating load of the tower-style pumping system based on the conversion factor and the operating amperage.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

[0009] FIG. 1 is a schematic illustration of an embodiment of a tower-style pumping system (e.g., a system), which may not include a load cell, in accordance with an aspect of the present disclosure;

[0010] FIG. 2 is a method of operating the system of FIG. 1, in accordance with an aspect of the present disclosure; and3SLB-PrivateIS25.0205 (SCFT:0488)

[0011] FIG. 3 is a method of operating the system of FIG. 1, in accordance with an aspect of the present disclosure.DETAILED DESCRIPTION

[0012] One or more specific embodiments of the present disclosure will be described below. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0013] When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0014] As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms "up" and "down"; "upper" and "lower"; "top" and "bottom"; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. Commonly,4SLB-PrivateIS25.0205 (SCFT:0488)these terms relate to a reference point at the surface from which drilling operations are initiated as being the top point and the total depth being the lowest point, wherein the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.

[0015] Tower-style pumping, and more specifically, long-stroke tower-style pumping systems (e.g., system), offers a reliable method for lifting subterranean fluids (e.g., gas) from underground locations (e.g., reservoirs). In particular, the long or extended stroke movement (e.g., several meters) of a long-stroke tower-style pump system (e.g., one or more components of the system) creates high displacement of fluid, increasing efficiency, and reducing rod fatigue. In general, long-stroke tower-style pump systems, or the systems for short, employ an above ground section (e.g., the tower) and a below ground (e.g., downhole) section (e.g., rod string, pump, etc.) The tower, which extends vertically from the surface, includes a tower frame which may facilitate vertical movement of the components of the tower, such as a carrier or traveling carriage (e.g., and a counterweight). The carrier may include a relatively high weight or mass, effective for creating clean or smooth movement, dampening vibration, maintaining alignment, and so forth. To move the carrier, a motor, gearbox reducer, and motion conversion system may be used, converting electric energy into rotational movement and further into vertical movement. The carrier may be coupled to a polished rod, which may connect, couple, or otherwise attach the above ground or surface section to the below ground or downhole components, such as the rod string. In operation, vertical movement of the carrier results in reciprocating vertical movement of the downhole rod string. That is, as the carrier moves up and down, the rod string may move up and down. The reciprocating movement of the rod string may cause the pump to intake the subterranean fluid into the rod string, and further lift the fluid to the surface. Various types and configurations of the pump system may be used, such as a plunger system, a pump barrel system, a traveling valve, a standing valve, and so forth.

[0016] In any case, for various lift systems, including tower-style lift systems, it may be desirable to measure or detect the load (e.g., tensile stress, axial force) on the system. The load may be indicative of the weight of the rod string, the weight of the fluid in the rod string being lifted, pump friction, inertial forces, along with other factors. Measuring or detecting load is important for various reasons as it may indicate how much fluid is being5SLB-PrivateIS25.0205 (SCFT:0488)lifted (to measure efficiency, to determine reservoir parameters, to optimize lift), to detect or predict equipment degradation (e.g., of the rod string, reducer, carrier, etc.), and so forth. In typical tower-style pumping systems, a load cell (e.g., force sensor, force transducer) may be disposed in the above ground section, such as between the carrier and the polished rod, and is configured to deform elastically to measure a force (e.g., the load). In some examples, the load cell is wired and may have a power or communication wire or cable running to the load cell. However, the cable may tend to degrade or even break completely during operation, resulting in operation blindness and / or downtime. In other examples, the load cell may be wireless and configured to operate without wires. However, a wireless load cell may lose signal for a variety or reason, such as environmental factors or interference from other components of the tower-style pumping system.

[0017] As such, the present disclosure is directed to an improved system and method for determining load for a tower-style pumping system. For instance, the tower-style pumping system (e.g., system) of the present disclosure may be configured to determine load without a load cell. To do so, the system may receive an amperage reading or measurement from an amp meter associated with the motor, where based on the amperage measurement, the system may determine an operating load. In particular, the system (e g., a system controller) may determine an operating load based on the amperage measurement and a Conversion Factor (Fc). The Conversion Factor (Fc) may be determined based on one or more methods discussed in detail below. For example, to determine the Conversion Factor (Fc), the system may be operated under experimental parameters (e.g., known weights, known frictions, etc.) to determine a correlation between a measured amperage (e.g., from the amp meter) and the load, which may be known. In an embodiment, the system may determine a correlation between one or more loads at various accelerations of the system and / or at various stroke positions of the system. To this end, during operation, the system of the present disclosure may determine an operating load of the system at any time, at any stroke position, and / or at any acceleration, based on the operating amperage (e.g., measured by the amp meter) and the Conversion Factor (Fc).

[0018] With the preceding in mind, FIG. 1 illustrates simplified schematic of an example of a tower-style pumping system 10 (e.g., long-stroke tower-style pumping6SLB-PrivateIS25.0205 (SCFT:0488)system, tower-style pumping unit; hereinafter “system”), in accordance with one or more embodiments of the present disclosure. FIG. 1 includes both a side view of the system 10 (e.g., drawing on the right), as well as a front view of the system 10 (e.g., drawing on the left). It will be appreciated that other configurations, types, sizes, and / or designs of the system 10 may utilize the embodiments of the present disclosure, and the embodiment shown in the drawing of FIG. 1 is not intending to be limiting. In general, the system 10 may be operable to lift fluid 14 (e.g., subterranean fluid, gas, hydrocarbons, oil, natural gases) from a subterranean location, such as a reservoir 18 (e.g., a geological formation), to an above ground location (e.g., a surface 22). While assembled or operating, the system 10 may include an above ground portion or section (e.g., a tower 26) and one or more downhole or below ground components (e.g., a rod string 30, a pump 34).

[0019] Referring to the above ground section, the tower 26 may include a tower frame or base 38, which may be configured to support or house various components, such as a motor 42, a transmission 44 (e.g., transmission components) including a reducer 46 (e.g., gear box), a drive sprocket 50, a drive chain 54, a top sprocket 58, a carriage assembly 62, a counterweight 66, a top drum 70, a load belt 74, a carrier 76, a polished rod 78, and a hanger assembly 82. Referring to the below ground components, the rod string 30 may extend underground, such as within a wellbore, and toward the reservoir 18, where the pump 34 may be configured to intake the fluid 14 and further force or direct the fluid 14 to the surface 22. For clarity of illustration and discussion, not all reference numerals and elements are included in this figure; however, the illustrated embodiment may include more elements typically used for tower-style pumping systems.

[0020] In general, the above ground section, including the components thereof, may operate to provide mechanical motion to the below ground components, such as the rod string 30 and the pump 34, to facilitate intake and movement (e.g., vertical movement) of the fluid 14. In particular, the motor 42 (e.g., electric motor) may convert energy (e.g., electric energy, chemical energy), into mechanical energy (e.g., rotation). To this end, the motor 42 may be an electric motor, a chemical motor, or any suitable motor. The gearbox or reducer 46 may receive the rotational energy and convert the rotational energy to reduce the speed of rotation (which may be relatively high) and increase the torque (e.g., rotational7SLB-PrivateIS25.0205 (SCFT:0488)force). To this end, the reducer 46 may receive an input shaft 48 coupled to the motor 42 and configured to provide the rotational energy from the motor 42 to the reducer 46. One or more gears (e.g., spurs, helical gears, bevel gears, worm gears) of the reducer 46 may then interact or engage with the input shaft 48 to reduce the rotational speed, while increasing the torque. An output shaft 59 of the reducer 46 may then deliver or provide the adjusted rotational speed and increased torque to the drive sprocket 50. The reducer 46 ensures the system 10 operates in a controlled manner, reducing degradation and risk while increasing efficiency. The drive sprocket 50 may engage the drive chain 54 to convert rotational motion into linear chain movement (e.g., revolutions or cycles). For instance, the drive sprocket 50 may include sprocket teeth configured to engage the drive chain 54, pulling the drive chain 54 during operation. The drive chain 54 may include a closed loop chain, with one side traveling upward (e.g., up the tower 26) and another side returning back down (e.g., to the drive sprocket 50), creating continuous vertical movement. At the top of the drive chain 54, the top sprocket 58 may also be coupled to the drive chain 54, such that the drive chain 52 is driven in an orbital loop around the drive sprocket 50 and the top sprocket 58.

[0021] The carriage assembly 62 and the components thereof (e.g., the counterweight 66) may be disposed within the tower base 38 and configured to vertically translate or move within the tower base 38, such as within a track or guiderails of the tower base 38. To drive the vertical motion, the carriage assembly 62 may be mechanically coupled to the drive chain 54 to produce both a downward motion (e.g., upstroke) and an upward motion (e.g., upstroke). The carriage assembly 62 may be coupled to the load belt 74 via a cable 86, which may extend over (e.g., draped over) the top drum 70 (e.g., a rotating drum, wheel, pulley system). The load belt 74 may couple to the carrier 76, which may couple to the polished rod 78 and / or the hanger assembly 82. The load belt 74 may be a heavy-duty belt or strap that may reciprocate the vertical movement of other components of the above ground components (e.g., the carriage assembly 62), thereby transmitting the vertical movement to the carrier 76 and / or polished rod 78. The polished rod 78 may be the main point connecting the above ground components (e.g., the load belt 74) to the below ground components, such as the rod string 30 (e.g., sucker rod). To assist or facilitate the vertical movement of the polished rod 78 (and downhole components), the polished rod 78 may be8SLB-PrivateIS25.0205 (SCFT:0488)supported (e.g., coupled, secured) by the hanger assembly 82. To this end, the hanger assembly 82 may include one or more bearings to facilitate movement (e.g., vertical movement) of the polished rod 78.

[0022] During upward vertical movement (e.g., the upstroke) of the system 10, one or more components of the system 10, such as the polished rod 78 and the rod string 30 coupled thereto, may move vertically upwards. During downward vertical movement (e.g., the downstroke) of the system 10, one or more components of the system 10, such as the polished rod 78, and the rod string 30 coupled thereto, may move vertically downwards. Repetitive upstrokes and downstrokes of the system 10 may enable vertical translation of the fluid 14 from a downhole location (e.g., the reservoir 18) towards the surface 22. In particular, during the upstroke movement, the pump 34 (e.g., plunger pump) may be configured to receive and direct the fluid 14 (e.g., fluid already within the pump 34) in an upward direction within the rod string 30. In some embodiments, the upstroke may be considered the “heavier stroke,” due to the higher torque and / or amps needed to lift the fluid 14. During the downstroke movement, the pump 34 may be configured to intake (e g., suck, plunge) or receive the fluid 14 from outside of the pump 34 (e.g., the reservoir 18). In some embodiments, one or more fluid stops (e.g., valves (e.g., stop or check valves)) may block the fluid 14 from moving or flowing downhole while within the rod string 30. In some embodiments, the downstroke may be considered the “lighter stroke,” due to the lower torque and / or amps needed (e.g., due to assistance from gravity). As such, the fluid 14 may flow up the rod string 30 towards the surface 22 incrementally (e.g., during upstroke motions), while remaining stagnant or unmoving during downstroke motions (e.g., due to the one or more fluid stops).

[0023] As discussed above, it may be desirable to determine a load (e.g., the weight of downhole components, force, tension, strain, stress) of the system 10 during operation of the system 10. As used herein, the load of the system 10 may refer to, may be based on, and / or may be determined with the weight of the above ground components (e.g., the carriage assembly 62, the counterweight 66, the drive chain 54, the load belt 74, the carrier 76, the polished rod 78, and so forth), a weight of downhole components (e.g., the rod string 30, the pump 34), the weight of fluid 14 within the downhole components (e.g., an9SLB-PrivateIS25.0205 (SCFT:0488)amount of the fluid 14 within the rod string 30 and / or the pump 34), a resistance (downhole fluid viscosity, mechanical frictions (e.g., friction factors)) acting on one or more components of the system 10, various dimensions of one or more components of the system 10 (e.g., radii, diameters, drive chain 54 length, and so forth), relative angles of one or more components of the system 10, relative distances or lengths between one or more components of the system 10, stroke length (e.g., length of the upstroke or the downstroke), velocities (e.g., rotations for minute (RPM), strokes per minute, angular velocities, and so forth), accelerations, mass moment of inertia (MMI), and so forth.

[0024] For example, it may be desirable to determine the load of the system 10 to ensure the motor 42 is operating under safe and / or predetermined limits (e.g., to protect against degradation (e.g., overheating), increase motor life, operate the system 10 in a safe manner, and so forth); mitigate and / or block mechanical failure (e.g., to the rod string 30, the polished rod 78, one or more bearings); to increase pumping efficiency; to determine one or more operating conditions (e.g., downhole or well conditions (e.g., jamming, debris, gas interference, cavitation, etc.); to calculate fluid production; to control fluid production; and so forth. For instance, a relatively high load may cause or result in component degradation and / or mechanical failure while a relatively low load may be indicative of undesirably high counterbalance rod string problems, resulting in low system efficiency.

[0025] As discussed above, to determine the load in a typical or traditional tower-style pump systems, a load cell (e.g., force sensor, force transducer) may be disposed in the above ground section, such as between the carrier and the rod string, and may be configured to compress (e.g., deform), resulting in a measurable force, which may be directly indicative of the load. In some examples, the load cell is wired and may have a power or communication wire or cable running to the load cell. However, the cable may have a tendency to degrade over time or even break completely during operation, resulting in operation blindness and / or operational downtime. In other examples, the load cell may be wireless and configured to operate without wires. However, a wireless load cell may lose signal for a variety of reasons, such as environmental factors and / or interference from other components of the traditional tower-style pumping system. Additionally, wireless load10SLB-PrivateIS25.0205 (SCFT:0488)cells may include batteries and / or other on-board energy sources, which may demand frequent replacement and / or recharging.

[0026] As such, embodiments of the present disclosure are directed to determining the load using an amp meter 90 (e.g., Ammeter, current meter, current gauge, Alternating Current (AC) meter). In embodiments, the load may be determined without a load cell. As such, in some embodiments, the system 10 of the present disclosure may not include or not use a load cell to determine load, but may instead determine or calculate load based on or in response feedback or data (e.g., a current reading) from the amp meter 90. However, the present embodiments for determining the load without a load cell may be implemented in systems also having a load cell for redundancy and / or improved accuracy in the load used for various controls. In either case, the present embodiments are directed toward determining the load without load measurements from a load cell in the system 10. The amp meter 90 may be associated with the motor 42 and configured to measure, detect, and / or read an electrical current flowing to the motor 42. In some embodiments, the amp meter 90 may be configured to receive an electrical reading (e.g., an amperage reading) associated with a drive (e.g., a variable speed drive (VSD)) of the motor 42.

[0027] Additionally, the system 10 may include one or more sensors 91 (e.g., in addition to the amp meter 90) configured to measure or detect one or more parameters of the system 10. For instance, a first subset 92 of the one or more sensors 91 may be configured to measure or detect a stroke position of the system 10. In an embodiment, the first subset 92 of sensors 91 may include a proximity sensor (e.g., an inductive proximity sensor, a cylindrical, inductive proximity sensor), which may be configured to detect a location of the drive chain 54 relative to the carriage assembly 62 (e.g., components thereof), which may also be called the location of the chain to counterweight box connecting shaft (C2CW connecting shaft). In particular, the top sprocket 58 may include or may be coupled to the first subset 92 of sensors 91 to determine position of the drive chain 54, based on a relative position of a reference point (e.g., a knuckle) of the drive chain 54. Additionally or alternatively, the first subset 92 of sensors 91 may determine a speed (e.g., rotations per minutes, revolutions per minute) of the system 10 (e.g., the drive chain 54). In an embodiment, a second subset 93 of the sensors 91 may be configured to11SLB-PrivateIS25.0205 (SCFT:0488)measure or detect a speed (e.g., rotations per minute, revolutions per minute) of the system 10 (e.g., the reducer 46), in addition to or alternative to the speed measured or detected by the first subset 92 of sensors 91. For instance, the second subset 93 of the sensors 91 may include a proximity sensor (e.g., an inductive proximity sensor, a cylindrical, inductive proximity sensor), which may be configured determine the speed based on a relative position of a component (e.g., a brake rotor, an input shaft) of the reducer 46. The stroke position and / or speed of the system 10 may be used to determine one or more initial loads of the system 10, for example, to determine the Conversion Factor (Fc) as will be discussed below.

[0028] To this end, the system 10 may include a controller 94 (e g., control system control panel, control circuitry, automation controller, programmable controller) that is communicatively coupled to one or more components of the system 10 (e.g., above ground components, downhole components (e.g., the pump 34), the motor 42, the amp meter 90, one or more sensors 91 (e.g., digital and / or analog sensors) and is configured to monitor, adjust, and / or otherwise control operation of one or more components of the system 10. For example, one or more control transfer devices, such as wires, cables, wireless communication devices, and the like, may communicatively couple the components of the system 10 to the controller 94. That is, the components of the system 10 may each have one or more communication components that facilitate wired or wireless (e.g., via a network) communication with the controller 94. In some embodiments, the communication components may include a network interface that enables the components of the system 10 to communicate via various protocols such as EtherNet / IP, ControlNet, DeviceNet, or any other communication network protocol. Alternatively, the communication components may enable the components of the system 10 to communicate via mobile telecommunications technology, Bluetooth®, near-field communications technology, and the like. As such, the components of the system 10 may wirelessly communicate data between each other. In other embodiments, operational control of certain components of the system 10 may be regulated by one or more relays or switches (e.g., a 24 volt alternating current [VAC] relay).12SLB-PrivateIS25.0205 (SCFT:0488)

[0029] The controller 94 may include processing circuitry 98 (e.g., processor), such as a microprocessor, which may execute software or instructions for controlling the components of system 10. The processing circuitry 98 may include multiple microprocessors, one or more “general-purpose” microprocessors, one or more specialpurpose microprocessors, and / or one or more application specific integrated circuits (ASICS), or some combination thereof. For example, the processing circuitry 98 may include one or more reduced instruction set (RISC) processors.

[0030] The controller 94 may also include a memory device 102 (e.g., a memory) that may store information, such as instructions, executable code, control software, look up tables, configuration data, other data, or any combination thereof. The memory device 102 may include a volatile memory, such as random access memory (RAM), and / or a nonvolatile memory, such as read-only memory (ROM). The memory device 102 may store a variety of information and may be used for various purposes. For example, the memory device 102 may store processor-executable instructions including firmware or software for the processing circuitry 98 to execute, such as instructions for determining the load of the system 10 during operation and performing one or more actions based on the load (or feedback or data indicative of the load). The memory device 102 may also store data relating to operating parameters of the system 10 (e.g., measured parameters, set points, assumptions, etc.). In an embodiment, one or more operating parameters may be stored (e.g., manually stored) into the memory device 102 by an operator (e.g., a human operator), such as certain parameters or factors to determine load. In some embodiments, the memory device 102 is a tangible, non-transitory, machine-readable-medium that may store machine-readable instructions for the processing circuitry 98 to execute. The memory device 102 may include ROM, flash memory, a hard drive, or any other suitable optical, magnetic, or solid-state storage medium, or a combination thereof.

[0031] With the foregoing in mind, FIG. 2 is a method 106 of operating the system 10, in accordance with aspects of the present disclosure. As will be appreciated, one or more steps (e.g., control sequences) of the method 106 may be performed by the controller 94. For example, computer executable instructions or code for performing the one or more control sequences and / or other portions of the method 106 may be stored on the memory13SLB-PrivateIS25.0205 (SCFT:0488)device 102, and the processing circuitry 98 may execute the instructions to perform the one or more control sequences of the method 106. In some embodiments, one or more steps of the method 106 may be performed by another controller of the system 10. In additional or alternative embodiments, multiple components or systems may perform one or more steps of the method 106. It should also be noted that additional steps may be performed with respect to the illustrated method 106 and control sequences thereof. Moreover, certain steps of the method 106 may be removed, modified, and / or performed in a different order. In some embodiments, certain steps of the method 106 may not be performed. Further still, one or more of the steps of the method 106 described herein may be performed in any suitable relation with one another, such as in response to one another and / or in parallel with one another. The method 106 is discussed with respect to element numbering illustrated in FIG. 1 and discussed above. As will be appreciated, one or more values or parameters that are known or determined below may be stored within the memory device 102.

[0032] The method 106 may be performed to determine a Conversion Factor (Fc), which may be used during operation of the system 10 to determine one or more Operating Loads (Loi, LQ2, . .. , Lon) based on one or more Operating Amperages (Li, Io2, ... , Ln) (e.g., measured from the amp meter 90 during operation). As such, the method 106 may be performed prior to actual operation of the system 10, or before the system 10 is operating to pump or lift the fluid 14. In other words, method 106 may be performed during experimental or testing operation (e.g., experimental operational mode) of the system 10. Referring to block 110, a Known Weight (Wk) may be attached to the system 10. For example, the Known Weight (Wk) may be attached or added to the carrier 76 of the system 10. At block 114, a Known Counterweight (Wkc) may be attached to the system 10. For example, the Known Counterweight (Wkc) may be a known or predetermined weight attached to the carriage assembly 62 (e.g., the counterweight 66). In an embodiment, the Known Counterweight (Wkc) may be based on the Known Weight (Wk). For example, the total weight of the Known Counterweight (Wkc) may be a fraction (e.g., 30%, 40%, 50%, 60%, and so forth) of the Known Weight (Wk). In preferred embodiments, the Known Counterweight (Wkc) is around or approximately 50% of the Known Weight (Wk).14SLB-PrivateIS25.0205 (SCFT:0488)

[0033] At block 118, the system 10 may be operated at a First Motor Speed (Sr) (e.g., a reference speed, a steady state speed, a first motor speed value). For example, the motor 42 may be initially operated at the First Motor Speed (Sr), such as at a first or reference RPM. The First Motor Speed (Sr) may be determined indirectly (e.g., based on a supplied frequency) and / or may be determined directly (e g., based on one or more sensors). For example, the First Motor Speed (Sr) may be based on or determined from a frequency that is received, converted, and / or directed from the drive of the motor 42.

[0034] At block 122, one or more Initial Amperages (In, Ii2, ..., lin) (e.g., initial amperage values) may be determined and recorded at various stroke positions at the First Motor Speed (Sr). In an embodiment, the one or more Initial Amperages (In, Ii2, ..., lin) may be measured via the amp meter 90 at various positions of the stroke of the system 10, such as positions during the upstroke and the downstroke. In an embodiment, the various positions of the stroke of the system 10 may be determined via sensors (e.g., the one or more sensors 91, a string potentiometer, a rod position sensor, and so forth). In an embodiment, the various positions of the stroke of the system 10 may be calculated based on certain operating parameters and relative positions of one or more components of the system 10, such as the reducer 46.

[0035] At block 126, one or more loads (Ln, Li2, ..., Lin) (e.g., reference loads, experimental loads, initial loads, load values) of the system 10 may be determined at the various stroke positions and at the First Motor Speed (Sr). In an embodiment, the one or more loads (Ln, Li2, ... , Ljn) of the system 10 may be based on, and / or may be determined with the weight of the above ground components (e.g., the carrier assembly 62, the drive chain 54, the load belt 74, the polished rod 78, the Known Counter Weight (Wkc), the Known Weight (Wk), and so forth), the weight of downhole components (e.g., the rod string 30, the pump 34), the weight of fluid 14 within the downhole components (e g., an amount of the fluid 14 within the rod string 30 and / or the pump 34), the resistance (downhole fluid viscosity, mechanical frictions (e.g., friction factors)) acting on one or more components of the system 10, various dimensions of one or more components of the system 10 (e.g., radii, diameters, drive chain 54 length, and so forth), relative angles of one or more components of the system 10, relative distances or lengths between one or more15SLB-PrivateIS25.0205 (SCFT:0488)components of the system 10, stroke length (e.g., length of the upstroke or the downstroke), velocities (e.g., rotations for minute (RPM), strokes per minute, angular velocities, and so forth), accelerations, mass moment of inertia (MMI), other assumptions, other parameters, and so forth. As will be appreciated, the one or more loads (Lii, Li2, ..., Lin) may vary at the various positions of the stroke.

[0036] At block 130, a Steady State Conversion Factor (Fss) may be determined based on the one or more loads (Ln, Li2, ..., Lin) and the one or more Initial Amperages (Li, Ii2, ... , lin). For example, values for the one or more loads (Ln, Li2, ... , Lin) and values for the one or more Initial Amperages (lii, Ii2, ..., Ln) may be plotted against one another (e.g., against corresponding values), where then a correlation (e.g., a trendline, equation, factor) may be determined from the plot.

[0037] At block 134, the system 10 may be operated at one or more Additional Motor Speeds (Si. S2, ..., Sn) (e.g., additional motor speed values). For example, the motor 42 may be operated at various RPMs. The one or more Additional Motor Speeds (Si. S2, ... , Sn) may be determined indirectly (e.g., based on a supplied frequency) and / or may be determined directly (e.g., based on one or more sensors). For example, the one or more Additional Motor Speeds (Si, S2, ... , Sn) may be based on or determined from one or more corresponding frequencies that are received, converted, and / or directed from the drive of the motor 42.

[0038] At block 138, one or more velocities (vi, V2, ..., V3) (e.g., one or more stroke velocities, one or more velocity values) and / or one or more accelerations (ai, a2, ..., an) (e.g., one or more stroke accelerations, one or more acceleration values) of the system 10 may be determined and / or recorded at each additional motor speed of the one or more Additional Motor Speeds (Si. S2, ..., Sn). For instance, the one or more velocities (vi, V2, ..., V3) may be based on the movement (e.g., vertical movement, revolutions, distance over time) of one or more components of the system 10, such as the drive chain 54, carriage assembly 62, the carrier 76, the polished rod 78, and so forth. For example, the one or more velocities (vi, V2, ..., V3) may be based on feedback or data received (e.g., received from the controller 94) from the first subset 92 of sensors 91, the second subset 93 of sensors 91, or both. In an embodiment, the one or more velocities (vi, V2, ... , V3) may be16SLB-PrivateIS25.0205 (SCFT:0488)based on relative distances moved by the polished rod 78 over time. The one or more one or more accelerations (ai, a2, .. an) may be based on or determined from the one or more velocities (vi, V2, ... , V3). In some embodiments, the one or more velocities (vi, V2, ... , V3) and / or the one or more accelerations (ai, a2, an) may be determined without sensors, such as by using crank geometry (e.g., stroke length) and strokes per time (e.g., strokes per minute (SPM)).

[0039] At block 142, one or more Additional Amperages (Iai, Ia2, ..., Ian) (e.g., additional amperage values) may be determined and / or recorded for each Additional Motor Speed of the one or more Additional Motor Speeds (Si, S2, ... , Sn). In an embodiment, the one or more Additional Amperages (lai, Ia2, ..., Ian) may be measured via the amp meter 90. In an embodiment, the one or more Additional Amperages (Iai, Ia2, ..., Ian) may be measured at various stroke positions of the system 10.

[0040] At block 146, the system 10 may correlate the one or more Additional Amperages (Ii, I2, ..., In) and the one or more accelerations (ai, a2, ..., an) (e g., corresponding acceleration) at each Additional Motor Speed of the one or more Additional Motor Speeds (Si. S2, ..., Sn). For instance, the each Additional Amperage of the one or more Additional Amperages (Ii, I2, ..., In) may be plotted against a corresponding acceleration of the one or more accelerations (ai, a2, ... , an), such as, using Microsoft Excel or another suitable software. At block 150, a correlation (e.g., a correlation factor, a correction factor, a trendline, an equation) may be determined based on the one or more Additional Amperages (Ii, I2, ... , In) and the one or more accelerations (ai, a2, ... , an). For example, the plot correlating values for the one or more Additional Amperages (Ii, I2, ... , In) and values for the one or more accelerations (ai, a2, ... , an) may be used to determine a correlation (e.g., a trendline, an equation, a factor).

[0041] At block 154, the Conversion Factor (Fc) may be determined based on the correlation between the one or more Additional Amperages (Ii, I2, ..., In) and load (e.g., the known load), based on the comparison of the one or more Additional Amperages (Ii, I2, ..., In) and the one or more accelerations (ai, a2, ..., an). As discussed above, during operation of the system 10 (e.g., during a pumping operation, not experimental operation), the Conversion Factor (Fc) may be used to determine the one or more Operating Loads17SLB-PrivateIS25.0205 (SCFT:0488)(Loi, O2, ..., Lon) based on the one or more Operating Amperages (Li, IO2, Ln) (e.g., measured from the amp meter 90). In some embodiments, the system 10 may determine additional Conversion Factors (Fci, FC2, ..., Fcn). In an embodiment, the system 10 may determine a conversion equation that may be used to determine the one or more Operating Loads (Loi, L02, ..., Lon) based on the Conversion Factor (Fc) and / or the additional Conversion Factors (Fci. FC2, ..., Fcn). An example conversion equation may be (Lo= FcnIMn+ Fcn-1IMn~1+ ■■■ + Fc2IM2+ FC1IM+ Fo). where Lois the Operating Load, F is the Conversion Factor(s), I is the Measured Amperage, and Fo is a constant. In an embodiment, the operating load (e.g., Lo) may be a factor of or based on acceleration of the system 10, such as acceleration of the stroke.

[0042] FIG. 3 is a method 158 of operating the system 10, in accordance with aspects of the present disclosure. As will be appreciated, one or more steps (e.g., control sequences) of the method 158 may be performed by the controller 94. For example, computer executable instructions or code for performing the one or more control sequences and / or other portions of the method 158 may be stored on the memory device 102, and the processing circuitry 98 may execute the instructions to perform the one or more control sequences of the method 158. In some embodiments, one or more steps of the method 158 may be performed by another controller of the system 10. In additional or alternative embodiments, multiple components or systems may perform one or more steps of the method 158. It should also be noted that additional steps may be performed with respect to the illustrated method 106 and control sequences thereof. Moreover, certain steps of the method 158 may be removed, modified, and / or performed in a different order. In some embodiments, certain steps of the method 158 may not be performed. Further still, one or more of the steps of the method 158 described herein may be performed in any suitable relation with one another, such as in response to one another and / or in parallel with one another. The method 158 is discussed with respect to element numbering illustrated in FIG. 1 and discussed above. As will be appreciated, one or more values or parameters that are known or determined below may be stored within the memory device 102. In an embodiment, the method 158 may be performed after the steps of method 106 of FIG. 2. For example, upon determination of the Conversion Factor (Fc), the method 158 may proceed.18SLB-PrivateIS25.0205 (SCFT:0488)

[0043] At block 162, the system 10 may be operated to pump or lift the fluid 14 from a below ground location to an above ground location, as discussed above with reference to FIG. 1. To operate the system 10, the motor 40 may receive a flow of electrical power, having one or more Operating Amperages (Li, L2, Ion). For example, operating the system 10 at an operating speed of the motor 40 may include various Operating Amperages of the one or more Operating Amperages (lot, Io2, ■ • , Ion) based on the stroke position and / or system acceleration. At block 166, the one or more Operating Amperages (Li, L2, ..., Ion) may be measured and / or recorded via the amp meter 90.

[0044] At block 170, the one or more Operating Loads (Loi, LO2, ..., Lon) may be determined based on the one or more Operating Amperages (Li, Io2, Ln) and the Conversion Factor (Fc). For instance, the Operating Loads (Loi, L02, Lon) may be calculated using a Conversion Equation (e.g., such as the Conversion Equation discussed above), where a respective Operating Load (Lo) is calculated by multiplying a corresponding Operating Amperage (L) by the Conversion Factor (Fc). As will be appreciated, during operation of the system 10, the one or more Operating Loads (Loi, L02, ..., Lon) may be determined based on (e.g., based solely on) the one or more Operating Amperages (Li, Io2, Ln). To this end, the system 10 may not use load cells or other systems and / or techniques for determining load based on electrical resistance caused by strain or deformation.

[0045] Referring to block 174, the one or more Operating Loads (Loi, L02, ... , Lon) may be determined and / or recorded over time. For instance, the one or more Operating Loads (Loi, Lo2, ..., Lon) may be plotted against time for a single stroke of the system 10, which may be referred to as a load card. The graphical representation of the comparison may indicate maximum load, minimum load, work done by a stroke (e.g., fluid lifted), symmetry, and so forth. At block 178, the system 10 may determine one or more operating condition based on the comparison of the one or more Operating Loads (Loi, L02, ..., Lon) and time. For instance, the controller 94 may include instructions (e.g., one or more algorithms) configured to determine basic descriptive metrics (e.g., mean, median, min / max, slopes, area under curve, etc.), features (e.g., patterns, symmetry, etc.), and so forth based on the comparison (e.g., the data, the graphical representation or plot of the19SLB-PrivateIS25.0205 (SCFT:0488)data). The operating conditions may be indicative of certain downhole conditions (e.g., jamming, debris, gas interference, cavitation, etc.), fluid production, and so forth.

[0046] At block 182, the system 10 may perform one or more actions based on the comparison and / or the one or more operating conditions. For example, the system 10 may before the one or more actions based on the comparison of the one or more Operating Loads (Loi, LO2, ..., Lon) over time. In particular, based on specific parameters (e.g., basic descriptive metrics, features) of the comparison, the system 10 may perform the one or more actions. Additionally or alternatively, the system 10 may perform the one or more actions based on the one or more operating conditions, which may be determined based on the specific parameters (e.g., basic descriptive metrics, features) of the comparison. The one or more actions may include, but are not limited to, notifying or warning an operator of system 10 of parameters and / or downhole conditions, scheduling maintenance, adjusting or controlling an operating parameter of the system (e.g., adjust a motor 42 speed, adjust counterweight amount), system 10 shutdown, performing additional tests or analysis, and so forth.

[0047] In some embodiments, the system 10 may compare a single Operating Load (L) (e.g., an operating load at a given time, at a given location of the stroke, at a given system acceleration), to a Threshold Load (Lt), denoted in block 186. At block 190, the system 10 may determine one or more operating conditions based on the comparison of the Operating Load (L) to the Threshold Load (Lt). For instance, upon determining that the Load (L) is greater than the Threshold Load (Lt), the system 10 may determine a first condition; upon determining that the Load (L) is less than the Threshold Load (Lt), the system 10 may determine a second condition; upon determining that the Load (L) is equal to the Threshold Load (Lt), the system 10 may determine a third condition; and so forth.

[0048] At block 194, the system 10 may perform one or more actions based on the comparison and / or the one or more operating conditions. For example, the system 10 may before the one or more actions based on the comparison of the Operating Load (L) to the Threshold Load (Lt). For example, based on a determination that the Operating Load (L) is greater than the Threshold Load (Lt), the system 10 may perform a first action or a first subset of actions. Based on a determination that the Operating Load (L) is less than the20SLB-PrivateIS25.0205 (SCFT:0488)Threshold Load (Lt), the system 10 may perform a second action or a second subset of actions. Additionally or alternatively, the system 10 may perform the one or more actions based on the one or more operating conditions, which may be determined based on the comparison. The one or more actions may include, but are not limited to, notifying or warning an operator of system 10 of parameters and / or downhole conditions, scheduling maintenance, adjusting or controlling an operating parameter of the system (e.g., adjust a motor 42 speed, adjust counterweight amount), system 10 shutdown, performing additional tests or analysis, and so forth.

[0049] A technical effect of the embodiments described in detail above is the determination of a load using an input other than a load measurement from a load cell. The load is indirectly determined, estimated, or inferred from one or more inputs, such as amperage from an amp meter of a motor of a tower-style pumping system. For example, the disclosed embodiments may determine the load of the tower-style pumping system based on the measured amperage and a correction factor. The correction factor may be determined based on known values (e.g., weights, coefficients of friction, etc.) and measured values during experimental testing, computer models and simulations of the tower- style pumping system, machine learning and artificial intelligence (A), mathematical equations, or any combination thereof. Thus, in subsequent operation of the tower-style pumping system, a controller may perform various methods as described above to determine the load based on the measured amperage and correction factor, and make various adjustments to the tower-style pumping system. Advantageously, the disclosed embodiments do not require measurements of load during operation of the tower-style pumping system.

[0050] The subject matter described in detail above may be defined by one or more clauses, as set forth below.

[0051] A tower-style pumping system includes a motor configured to convert electrical power into a first rotational speed and a first torque, an amp meter associated with the motor and configured to measure an operating amperage of the motor, and a transmission coupled to the motor, where the transmission includes a carriage assembly having a counterweight, a polished rod, and a rod string coupled to the polished rod and configured21SLB-PrivateIS25.0205 (SCFT:0488)to extend into a wellbore to a subterranean location. The system also includes a pump coupled to the rod string of the transmission, where the pump is configured to direct a fluid from the subterranean location in response to movement of the rod string and a controller coupled to the amp meter, where the controller includes a processor, a memory, and instructions stored on the memory and executable by the processor, where the instructions are configured to determine an operating load of the system based on the operating amperage of the motor during operation.

[0052] The system of any preceding clause, where the transmission includes a reducer coupled to the motor, where the reducer is configured to reduce the first rotational speed to a second rotational speed and increase the first torque to a second torque, a drive sprocket coupled to the reducer and configured to receive the second rotational speed and the second torque, a top sprocket, a drive chain coupled to the drive sprocket and the top sprocket, where the drive chain is configured to move around the drive sprocket and top sprocket, the carriage assembly including the counterweight, where the carriage assembly is configured to move based on movement of the drive chain, a load belt coupled to the carriage assembly, where the load belt is configured to reciprocate a movement of the carriage assembly, a carrier coupled to the load belt, where the carrier is configured to reciprocate a movement of the load belt, the polished rod coupled to the carrier, where the polished rod is configured to reciprocate a movement of the load belt, and the rod string coupled to the polished rod, where the rod string is configured to reciprocate a movement of the polished rod.

[0053] The system of any preceding clause, where the instructions are configured to, in an experimental operational mode of the tower-style pumping system, determine one or more initial loads of the tower-style pumping system, operate the motor at one or more initial motor speeds, measure, via the amp meter, one or more additional amperages of the motor during the experimental operational mode, where the one or more additional amperages are based on the one or more initial motor speeds, and determine a conversion factor based on the one or more additional amperages and the one or more initial loads.

[0054] The system of any preceding clause, where the instructions are configured to, in an operating mode of the tower-style pumping system, measure, via the amp meter, an22SLB-PrivateIS25.0205 (SCFT:0488)operating amperage of the motor during the operating mode of the tower-style pumping system, and determine the operating load based on the conversion factor and the operating amperage.

[0055] The system of any preceding clause, where the instructions are configured to, in the experimental operational mode of the tower-style pumping system, determine one or more accelerations of the tower-style pumping system based on the one or more initial motor speeds, where the one or more accelerations of the tower-style pumping system are based on one or more velocities of a stroke motion of the tower-style pumping system, and determine a correlation between the one or more initial amperages and the one or more accelerations, and in an operating mode of the tower-style pumping system, determine the operating load of the tower-style pumping system at an acceleration of the one or more accelerations based on the operating amperage of the motor and the correlation.

[0056] The system of any preceding clause, where the instructions are configured to, in the experimental operational mode of the tower-style pumping system, operate the motor at a first motor speed, determine an initial amperage, via the amp meter, associated with the first motor speed, determine an initial load of the one or more initial loads of the system associated with the first motor speed, and determine a steady state conversion factor based on the initial amperage and the initial load, where the conversion factor is based on the steady state conversion factor.

[0057] The system of any preceding clause, where the initial load is based on a known weight attached to a carrier during the experimental operational mode, a known counterweight attached to the carriage assembly during the experimental operational mode, one or more parameters of the motor operating during the experimental operational mode, a stroke position, a rotational speed of a reducer of the transmission, or any combination thereof.

[0058] The system of any preceding clause, including one or more sensors configured to determine the stroke position, where the one or more sensors are configured to determine a relative location of a drive chain of the transmission, and the stroke position is based on23SLB-PrivateIS25.0205 (SCFT:0488)the relative location of the drive chain, one or more sensors configured to determine the rotational speed of the reducer, or any combination thereof.

[0059] The system of any preceding clause, where the tower-style pumping system does not include a load cell.

[0060] A method for operating a tower-style pumping system includes attaching a weight to a carrier of the tower-style pumping system, attaching a counterweight to the tower-style pumping system, where the counterweight is based on the weight, and operating a motor of the tower-style pumping system at one or more motor speeds. The method also includes determining one or more accelerations of the tower-style pumping system based on the one or more motor speeds, where the one or more accelerations of the tower-style pumping system are based on one or more velocities of a stroke motion of the tower-style pumping system, measuring, via an amp meter associated with the motor, one or more amperages of the motor during operation, where the one or more amperages are based on the one or more motor speeds, and determining a correlation between the one or more amperages and the one or more accelerations. The method also includes determining a conversion factor based on the correlation, determining an operating amperage, via the amp meter, during operation of the tower-style pumping system, and determining an operating load of the tower-style pumping system based on the conversion factor and the operating amperage.

[0061] The method of any preceding clause, including operating the motor at a first motor speed, determining an initial amperage, via the amp meter, associated with the first motor speed, determining an initial load of the system associated with the first motor speed, and determining a steady state conversion factor based on the initial amperage and the initial load, where the conversion factor is based on the steady state conversion factor.

[0062] The method of any preceding clause, including determining the operating load of the tower-style pumping system at a stroke position based on the conversion factor and an operating amperage.24SLB-PrivateIS25.0205 (SCFT:0488)

[0063] The method of any preceding clause, including determining the operating load of the tower-style pumping system at an acceleration of the tower-style pumping system based on the conversion factor and an operating amperage.

[0064] The method of any preceding clause, where the operating load is one or more operating loads, and the method includes comparing the one or more operating loads over time to obtain a comparison, determining an operating condition of the tower-style pumping system based on the comparison, and performing one or more action based on the comparison, based on the operating condition, or both.

[0065] The method of any preceding clause, including comparing the operating load to a threshold load to obtain a comparison, determining an operating condition of the towerstyle pumping system based on the comparison, and performing one or more actions based on the comparison, based on the operating condition, or both.

[0066] The method of any preceding clause, where the one or more actions includes notifying an operator of the tower-style pumping system of the operating condition, adjusting a motor speed of the motor, suspending operation of the motor, performing additional tests, or any combination thereof.

[0067] A method for operating a tower-style pumping system includes, during an experimental operational mode of the tower-style pumping system, determining one or more initial loads of the tower-style pumping system, where the one or more initial loads are based on a known weight attached to a carrier of the tower-style pumping system, a known counterweight attached to a carriage assembly of the tower-style pumping system, one or more parameters of a motor of the tower-style pumping system operating during the experimental operational mode, a stroke position of the tower-style pumping system, or any combination thereof. The method includes, during an experimental operational mode of the tower-style pumping system, measuring, via an amp meter associated with the motor, one or more amperages of the motor during the experimental operational mode, where the one or more amperages are based on one or more motor speeds, and determining a conversion factor based on the one or more amperages and the one or more initial loads. The method also includes, during an operational mode of the tower-style pumping system,25SLB-PrivateIS25.0205 (SCFT:0488)determining an operating amperage, via the amp meter; and determining an operating load of the tower-style pumping system based on the conversion factor and the operating amperage.

[0068] The method of any preceding clause, including, during the operating mode of the tower-style pumping system, determining an operating condition of the tower-style pumping system based on the operating load, and performing one or more actions based on the operating condition, based on the operating load, or both.

[0069] The method of any preceding clause, including, during the operational mode of the tower-style pumping system, determining the operating load at an acceleration of the tower-style pumping system, and determining the operating load at a position of the stroke of the tower-style pumping system.

[0070] The method of any preceding clause, where determining the conversion factor includes plotting values associated with the one or more amperages and values associated with the one or more initial loads on a plot and determining the conversion factor based on the plot.

[0071] A tower style pumping unit includes an amperage (amp) meter, where the amperage meter is used to determine amp draw data during operations.

[0072] The unit of any preceding clause, where the determined amp draw data together with rotational, positional, and counterweight information are used to determine a rod string load during operation.

[0073] The unit of any preceding clause, where the rotational and positional information are determined using a cylindrical, inductive proximity sensor.

[0074] The unit of any preceding clause, where the counterweight information includes weight of a counterweight box together with weight of added counterbalance plates.

[0075] A method includes determining amperage (amp) draw data, determining rotational information, determining positional information, determining counterweight26SLB-PrivateIS25.0205 (SCFT:0488)information, and determining a rod string load based on the determined amp draw data, the rotational information, the positional information, and the counterweight information.

[0076] The method of any preceding clauses, where the determined amp draw data is determined using an amp meter.

[0077] The method of any preceding clauses, where the rotational and positional information are determined using a cylindrical, inductive proximity sensor.

[0078] The method of any preceding clauses, where the counterweight information includes weight of a counterweight box together with weight of added counterbalance plates.

[0079] While only certain features and embodiments have been illustrated and described, many modifications and changes may occur to those skilled in the art, such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, such as temperatures and pressures, mounting arrangements, use of materials, colors, orientations, and so forth, without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.

[0080] Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described, such as those unrelated to the presently contemplated best mode, or those unrelated to enablement. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.27SLB-PrivateIS25.0205 (SCFT:0488)

[0081] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function], .. ” or “step for [perform]ing [a function]...”, it is intended that such elements are to be interpreted under 35 U.S.C.112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).SLB-Private

Claims

IS25.0205 (SCFT:0488)CLAIMS:

1. A tower-style pumping system, comprising:a motor configured to convert electrical power into a first rotational speed and a first torque;an amp meter associated with the motor and configured to measure an operating amperage of the motor;a transmission coupled to the motor, wherein the transmission comprises a carriage assembly comprising a counterweight, a polished rod, and a rod string coupled to the polished rod and configured to extend into a wellbore to a subterranean location;a pump coupled to the rod string of the transmission, wherein the pump is configured to direct a fluid from the subterranean location in response to movement of the rod string; anda controller coupled to the amp meter, wherein the controller comprises a processor, a memory, and instructions stored on the memory and executable by the processor, wherein the instructions are configured to determine an operating load of the system based on the operating amperage of the motor during operation.

2. The tower-style pumping system of claim 1, wherein the transmission comprises:a reducer coupled to the motor, wherein the reducer is configured to reduce the first rotational speed to a second rotational speed and increase the first torque to a second torque;a drive sprocket coupled to the reducer and configured to receive the second rotational speed and the second torque;a top sprocket;a drive chain coupled to the drive sprocket and the top sprocket, wherein the drive chain is configured to move around the drive sprocket and top sprocket;the carriage assembly comprising the counterweight, wherein the carriage assembly is configured to move based on movement of the drive chain;a load belt coupled to the carriage assembly, wherein the load belt is configured to reciprocate a movement of the carriage assembly;29SLB-PrivateIS25.0205 (SCFT:0488)a carrier coupled to the load belt, wherein the carrier is configured to reciprocate a movement of the load belt;the polished rod coupled to the carrier, wherein the polished rod is configured to reciprocate a movement of the load belt; andthe rod string coupled to the polished rod, wherein the rod string is configured to reciprocate a movement of the polished rod.

3. The tower-style pumping system of claim 1 , wherein the instructions are configured to:in an experimental operational mode of the tower-style pumping system:determine one or more initial loads of the tower-style pumping system; operate the motor at one or more initial motor speeds;measure, via the amp meter, one or more additional amperages of the motor during the experimental operational mode, wherein the one or more additional amperages are based on the one or more initial motor speeds; anddetermine a conversion factor based on the one or more additional amperages and the one or more initial loads.

4. The tower-style pumping system of claim 3, wherein the instructions are configured to:in an operating mode of the tower-style pumping system:measure, via the amp meter, an operating amperage of the motor during the operating mode of the tower-style pumping system; anddetermine the operating load based on the conversion factor and the operating amperage.

5. The tower-style pumping system of claim 3, wherein the instructions are configured to:in the experimental operational mode of the tower-style pumping system:determine one or more accelerations of the tower-style pumping system based on the one or more initial motor speeds, wherein the one or more30SLB-PrivateIS25.0205 (SCFT:0488)accelerations of the tower-style pumping system are based on one or more velocities of a stroke motion of the tower-style pumping system; and determine a correlation between the one or more additional amperages and the one or more accelerations; andin an operating mode of the tower-style pumping system:determine the operating load of the tower-style pumping system at an acceleration of the one or more accelerations based on the operating amperage of the motor and the correlation.

6. The tower-style pumping system of claim 3, wherein the instructions are configured to:in the experimental operational mode of the tower-style pumping system:operate the motor at a first motor speed;determine an initial amperage, via the amp meter, associated with the first motor speed;determine an initial load of the one or more initial loads of the system associated with the first motor speed; anddetermine a steady state conversion factor based on the initial amperage and the initial load, wherein the conversion factor is based on the steady state conversion factor.

7. The tower-style pumping system of claim 6, wherein the initial load is based on a known weight attached to a carrier during the experimental operational mode, a known counterweight attached to the carriage assembly during the experimental operational mode, one or more parameters of the motor operating during the experimental operational mode, a stroke position, a rotational speed of a reducer of the transmission, or any combination thereof.

8. The tower-style pumping system of claim 7, comprising:one or more sensors configured to determine the stroke position, wherein the one or more sensors are configured to determine a relative location of a drive chain of the transmission, and the stroke position is based on the relative location of the drive chain;31SLB-PrivateIS25.0205 (SCFT:0488)one or more sensors configured to determine the rotational speed of the reducer; or any combination thereof.

9. The tower-style pumping system of claim 1, wherein the tower-style pumping system does not include a load cell.

10. A method for operating a tower-style pumping system, the method comprising: attaching a weight to a carrier of the tower-style pumping system;attaching a counterweight to the tower-style pumping system, wherein the counterweight is based on the weight;operating a motor of the tower-style pumping system at one or more motor speeds; determining one or more accelerations of the tower-style pumping system based on the one or more motor speeds, wherein the one or more accelerations of the tower-style pumping system are based on one or more velocities of a stroke motion of the tower-style pumping system;measuring, via an amp meter associated with the motor, one or more amperages of the motor during operation, wherein the one or more amperages are based on the one or more motor speeds;determining a correlation between the one or more amperages and the one or more accelerations;determining a conversion factor based on the correlation;determining an operating amperage, via the amp meter, during operation of the tower-style pumping system; anddetermining an operating load of the tower-style pumping system based on the conversion factor and the operating amperage.

11. The method of claim 10, comprising:operating the motor at a first motor speed;determining an initial amperage, via the amp meter, associated with the first motor speed;determining an initial load of the system associated with the first motor speed; and32SLB-PrivateIS25.0205 (SCFT:0488)determining a steady state conversion factor based on the initial amperage and the initial load, wherein the conversion factor is based on the steady state conversion factor.

12. The method of claim 10, comprising:determining the operating load of the tower-style pumping system at a stroke position based on the conversion factor and an operating amperage.

13. The method of claim 10, comprising:determining the operating load of the tower-style pumping system at an acceleration of the tower-style pumping system based on the conversion factor and an operating amperage.

14. The method of claim 10, wherein the operating load is one or more operating loads, and the method comprises:comparing the one or more operating loads over time to obtain a comparison; determining an operating condition of the tower-style pumping system based on the comparison; andperforming one or more action based on the comparison, based on the operating condition, or both.

15. The method of claim 10, comprising:comparing the operating load to a threshold load to obtain a comparison; determining an operating condition of the tower-style pumping system based on the comparison; andperforming one or more actions based on the comparison, based on the operating condition, or both.

16. The method of claim 15, wherein the one or more actions comprises notifying an operator of the tower-style pumping system of the operating condition, adjusting a motor speed of the motor, suspending operation of the motor, performing additional tests, or any combination thereof.33SLB-PrivateIS25.0205 (SCFT:0488)17. A method for operating a tower-style pumping system, the method comprising: during an experimental operational mode of the tower-style pumping system: determining one or more initial loads of the tower-style pumping system, wherein the one or more initial loads are based on a known weight attached to a carrier of the tower-style pumping system, a known counterweight attached to a carriage assembly of the tower-style pumping system, one or more parameters of a motor of the tower-style pumping system operating during the experimental operational mode, a stroke position of the tower-style pumping system, or any combination thereof;measuring, via an amp meter associated with the motor, one or more amperages of the motor during the experimental operational mode, wherein the one or more amperages are based on one or more motor speeds; anddetermining a conversion factor based on the one or more amperages and the one or more initial loads; andduring an operational mode of the tower-style pumping system:determining an operating amperage, via the amp meter; and determining an operating load of the tower-style pumping system based on the conversion factor and the operating amperage.

18. The method of claim 17, comprising:during the operating mode of the tower-style pumping system:determining an operating condition of the tower-style pumping system based on the operating load; andperforming one or more actions based on the operating condition, based on the operating load, or both.

19. The method of claim 17, comprises:during the operational mode of the tower-style pumping system:determining the operating load at an acceleration of the tower-style pumping system; and34SLB-PrivateIS25.0205 (SCFT:0488)determining the operating load at a position of a stroke of the tower-style pumping system.

20. The method of claim 17, wherein determining the conversion factor comprises plotting values associated with the one or more amperages and values associated with the one or more initial loads on a plot and determining the conversion factor based on the plot.SLB-Private

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