Predictive Maintenance · Rod Pump
Rod pump failures. Caught 24–72 hours early.
Per-well dynamometer ML detects pump fillage degradation, gas interference, parted rod, and fluid pound. Each signature flagged before the production rate moves enough to cross a fixed SCADA threshold. Workover avoidance ($15-30K) plus deferred production recovery ($5-15K/day) is the math that justifies the annual license.
Four rod-pump signatures.
Signature
Pump fillage degradation
ML detects
Card area shrinking >15% over 7 days
Root cause
Wear, gas interference, formation issue
Action
Schedule pump pull at 14-21 days, not after parted-rod event
Signature
Gas interference
ML detects
Card shape: filled → gas-interfered at top-of-stroke
Root cause
GOR increase, separator failure, formation gas breakthrough
Action
Investigate separator before scheduling pump work
Signature
Parted rod
ML detects
Sudden bottom-load drop with maintained top-load
Root cause
Rod failure, typically at coupling or transition joint
Action
Pull immediately; production at risk every hour
Signature
Fluid pound
ML detects
Characteristic late-stroke spike pattern
Root cause
Pump-off / over-pumping (rate exceeds inflow)
Action
Adjust SPM via controller before mechanical damage compounds
Continue the cluster
Rod pump is one equipment class. The platform covers them all.
Other equipment classes
Predictive maintenance
The work it triggers
When the signature flags
Frequently asked
What rod-pump foremen ask.
What rod pump failures does WorkSync detect?
Pump fillage degradation, gas interference, parted rod, fluid pound. Each flagged with dollar-impact + intervention cost + ranked into the work plan.
What is the lead time vs fixed SCADA?
24-72 hours advance warning. Card-shape signatures change before production rate does. ~$3,750/day avoided deferred production at 50 BO/d, $75/bbl.
Workover math?
Reactive workover $15-30K + 24-72hr deferred production at $5-15K/day. Scheduled catch 48hrs pre-failure: same workover cost, near-zero deferred, no emergency rig premium.
What data does it need?
Dyno cards from pump-off controller, production rate from SCADA/run tickets, well-test data. Trains on 90-180 days of historical card data per well.
Pump-off controller brands?
Lufkin SAM, Weatherford WellPilot, eProduction, Theta SmartCard. Any controller exporting standard dyno card formats.
See rod-pump ML on your wells.
4-week pilot at no license cost. Pick one field. Day 14 we show the at-risk pumps. Day 28 you decide.