Transformation of academic teaching and research: Development of a highly automated experimental sucker rod pumping unit

Sucker rod pumps are one of the most popular solutions for artificial lift since their inception in the 19th century with minimum changes in design. Presently, companies are deploying digital technology in the field and, there has been a big push for a networked oilfield in recent years. This means technology is now able to control machines in remote places, evaluate their performances and control safety operating parameters. But these digital solutions are still not available in universities, causing a technological and technical gap for students and researchers. This study presents a prototype of a new dedicated Interactive Digital Sucker Rod Pumping Unit (ID-SRP) system at the University of Oklahoma with representative operating conditions. The prototype mimics sucker rod pump working principles and also imitates different realistic rod string motions. The application and solutions are focused on providing authentic learning experiences for petroleum engineers. The system is also designed to address and optimize SRP well performance and safety through Model Predictive Controller (MPC) implementation and meeting industrial requirements. It connects the physical and virtual interaction with learning technologies. The objective is to bridge the tangible and the abstract for a better understanding of sucker rod concept and implement existing theories into the digital system. Additionally, it aids our future petroleum engineers on how to apply basic industry principles and upsurge their problem-solving skills. The developed unit is capable of simulating any situations in real time and using Internet of Things (IoT) for data acquisition to create tailored diagnostic tools that students and laboratory staff can utilize. The software selected for the system is LabVIEW, which controls all the necessary equipment. This system can build personalized dynocard graphs, intake live data and export them to other programs live Excel, MATLAB, Python or any other programming languages.