Automated data collection from sucker rod pumps

Sucker rod pump data collection architecture: OrionMeter LA-IP-RSP modules poll the PLC and the VFD over RS-485 Modbus and send the data over LoRaWAN to the network server and OPCSync, which passes it to an industrial SCADA system over OPC.

Purpose of the solution

This reference solution automates monitoring and control of sucker rod pump (SRP) units over LoRaWAN. Its key feature is OPCSync, a proprietary technology that converts raw equipment data (VFD, PLC, sensors) into a structured format compatible with SCADA and OPC UA. With the built-in graphical data extraction designer, users configure the processing logic without programming and get clean, ready-to-use parameters from complex LoRaWAN payloads. This makes smart monitoring possible even at remote sites, with no changes at the SCADA level.

Oil well pumpjack with the number 3332 on the walking beam; next to it, a control cabinet and a ladder to the inspection platform.

Solution components

Variable frequency drive (VFD): controls the operating modes of the pump motor
PLC / relay control: signal processing, control of the pump and auxiliary equipment
Sensors: measure pressure, temperature, current, vibration, fluid level and other process parameters
Communication module: OrionMeter LA-IP-RSP connects to the equipment over Modbus RTU, collects data and transmits it over LoRaWAN
Data transmission medium: LoRaWAN provides reliable wireless communication with minimal power consumption and wide coverage
Service: OPCSync receives data over MQTT, converts the payload into flat JSON, extracts values with the graphical designer and produces ready-to-use parameters for SCADA
Upper-level interface: OPC UA, integration with SCADA, BMS and other industrial systems
Visualization platform: SCADA with real-time data display, alarms, logs and analytics

Open well control cabinet: controller, CyberPower UPS, Schneider Electric Altivar variable frequency drive and switchgear.

Data exchange architecture

Field devices such as variable frequency drives (VFD) and programmable logic controllers (PLC) connect directly to OrionMeter LA-IP-RSP over RS-485 using Modbus RTU. The device can poll both the PLC and the VFD directly, with no intermediate links. The collected data is converted and transmitted over the LoRaWAN network to the cloud or to a SCADA system for further analysis, visualization and control. This approach makes it quick and flexible to connect equipment from different manufacturers and to implement smart monitoring without laying cables or installing complex automation on site.

Benefits

Remote real-time monitoring and control
Configurable alerts on failures and deviations
Analysis and forecasting of pumping equipment efficiency
Lower maintenance costs
Support for open and reliable industrial protocols

What makes the solution unique: OPCSync

OPCSync is a proprietary software service developed to integrate LoRaWAN devices with SCADA.

Download Sucker rod pump data collection: solution overview (in Russian) Files marked (in Russian) are available in Russian only. PDF ← All solutions