Abstract
Accurately obtaining the working status of the sucker rod pumping wells is a challenging problem for oil production. Sensors at the polished rod collect working data to form surface dynamometer cards for fault diagnosis. A prevalent method for recognizing these cards is the convolutional neural network (CNN). However, this approach has two problems: an unbalanced dataset due to varying fault frequencies and similar dynamometer card shapes that complicate recognition. This leads to a low accuracy of fault diagnosis in practice, which is unsatisfactory. Therefore, this paper proposes a hybrid approach of the deep learning method and rule-based method for fault diagnosis of sucker rod pumping wells. Specifically, when the CNN model alone fails to achieve satisfactory accuracy in the working status, historical monitoring data of the relevant wells can be collected, and expert rules can assist CNN to improve diagnostic accuracy. By analyzing time series data of factors such as the maximum and minimum loads, the area of the dynamometer card, and the load difference, a knowledgebase of expert rules can be created. When performing fault diagnosis, both the dynamometer cards and related time series data are used as inputs. The dynamometer cards are used for the CNN model to diagnose, and the related time series data are used for expert rules to diagnose. The diagnostic results and the confidence levels of the two methods are obtained and compared. When the two diagnostic results conflict, the one with higher confidence is preserved. Out of the 2066 wells and 7 fault statuses analyzed in field applications, the hybrid approach demonstrated a 21.25% increase in fault diagnosis accuracy compared with using only the CNN model. Additionally, the overall accuracy rate of the hybrid approach exceeded 95%, indicating its high effectiveness in diagnosing faults in sucker rod pumping wells.