Professional Documents
Culture Documents
Sucker Rod Pumping Wells Design Operation Optimization PDF
Sucker Rod Pumping Wells Design Operation Optimization PDF
CP
Calculated Production:
TP
or
hFL
hD,FL
Dead FL
(gas free)
Due to its compressible nature, free gas in the pump requires the plunger to
travel much further into the down-stk before the gas becomes compressed
enough (>PDP) for the TV to open. Additionally, as the plunger rises at the start
of the up-stk the free gas expands to fill the new chamber volume created by
the vacating plunger. This prevents the pressure in the chamber from rapidly
dropping & necessitates the plunger travel further before PChamber < PIP (so the
SV will open to admit new fluid into the pump). [see Gas Int. card next page]
Fluid Load on Pump (FO) & Pump Intake/Displacement P. (PIP/PDP):
GFLAP
Gas Free Liquid
Above Pump
Chamber
FO A P Pgr =
SV
PIP
PBHP
Note:
Note: Nomenclature table with units for all figures
& equations given on the last page.
CP
0.132
0.182
0.262
0.357
0.466
0.590
PDP
TV
Pump
1-1/16"
1-1/4"
1-1/2"
1-3/4"
2"
2-1/4"
d P 2 ( PDP PIP)
1) Only use TVD depths with hydrostatic calculations (if well is not vertical).
2) In steady-state production, only oil (no water) resides above the pump in the annulus.
3) For a pumped off well, as the SN depth increases the PPgr increasesand the potential
for gas interference worsens due to the higher compression required to admit fluid into
the tbg. Good gas separation and longer SLs can mitigate this problem.
1. Design the DHGS (and its placement) so that gas naturally bypasses the Fluid Entry Ports on the Mud Anchor.
- Best achieved by sumping the pump. If pumping above perfs, it might be beneficial to decentralize the DHGS (set the TAC 2-4
jts above SN), & since no well is 100% vertical: the gas will ride the high side while the DHGS (& liquid) occupy the low side.
2. Design the DHGS so the downward fluid velocity is slower than the Gas Bubble Rise Velocity: allowing the gas to escape.
Decentralized DHGS: when a
3. If the gas cannot be adequately removed look to install a specialty pump that is better equipped to pass gas.
crooked hole has its benefits.
- Managing gas: close pump spacing & long SL; hold more TP (to prevent gas from heading the top of the tbg dry).
4. Sand-Screens or other frictional restrictions can strain the gas out of solution leading to gas interference.
OD
ID
5. In certain situations (depending on the producing zones, TAC placement, & more), the TACin conjunction w/ a col+
GA:
Gas
Anchor
(always
listed
by
ID
)
umn of fluid (providing back-P.)can bottle up high-pressure gas below the anchor leading to severe gas interference.
3/4" GA
1.05
0.82
1" GA
1.315
1.05
1-1/4" GA
1.66
1.38
1-1/2" GA
1.90
1.61
MA: Mud Anchors (Mother Hubbard)
2-3/8" 4.7#
2.375 1.995
2-7/8" 6.5#
2.875 2.441
3-1/2" 9.3#
3.5
2.922
Casing as ID of Mud Anchor
4-1/2" 11.6#
4.5
4.000
5-1/2" 17#
5.5
4.892
7" 26#
7
6.276
+
GA: API Line Pipe (standard weight).
V fluid
Quiet Zone
Gas Anchor
d p 2 SLDH SPM
60 IDMA 2 ODGA 2
1 GA
3/4 GA
Comparison of
X-Sectional Area
Mud Anchor
(drawn to proportion)
2-3/8 MA
2
2.3
2014 by Downhole Diagnostic | Midland, TX. Free for unaltered distribution. 1.0
1.8
2-7/8 MA
3.5 MA
3.3
5.4
Up-Stk
23
12
Bot. of Stk
Down-Stk
@3
Top of Stk
41
SLTop
Surface Card
1
Load,
lbs.
4
2
(SV Open)
Wave
Equation
SLBot
3
FO
Tbg Breathing
Pump Card
SLEPT
Rod Stretch
(TV Open)
1
Stroke Length, in
SLDH
SL
Comp Ratio
Expansion
SLEPT
SLEPT
Unswept Volume
Vol @ Bot of Stk
Note: except for DH friction assumptions, this is true for a horseshoe or donut
load-cell (installed between the Bridle & PR Clamp). For many reasons, most
Dynos commonly used by Well Techs are the quick-install PRT Dyno (Polished
Rod Transducer) that measures the radial strain (change in diameter) of the PR
each stroke & uses this data to back-calculate the FO& these Pump Cards can
sometimes be slightly tilted due to surface misalignment & bending of the PR.
Note: Stretch (inches); Ltbg (in 1000s of ft); FPull (1000s of #s).
ktbg = Stretch Constant: is not affected by the grade of steel,
only the x-sec area (given on p.5 or use above equation).
Grd C
Grd K
Non-Corrosive
1.00
0.65
0.45
1.00
0.90
0.70
Salt Water
H2S
Grd D HS Rods
1.00
0.90
0.65
1.00
0.70
0.50
Rod Force to
Diam. Buckle
3/4
23#
7/8
162#
1 3/8
641#
Pump:
Tbg Pumps: largest bore pumps (dPgr just a 1/4 < ID of tbg).
Equation for FG Rod Spacing: Inches Off Bottom
Rod (Insert) Pumps, 3-types: based on where the hold-down is located (top
9 hFG _ Rod 2 hSN
FG Spacing
Failure Prevention
SRP Optimization
Design Considerations:
On 1.5 K-bars, run 3/4 SH-boxes (1.5 OD) instead of FH-boxes. This
creates a uniform diameter over the bar section & spreads out any side
loading on the tbg over a larger area, minimizing stress (Stress = F/Area).
Install boronized (EndurAlloy) tbg or Poly-Lined tbg in bottommost jts
where most tbg leaks occur.
Spray Metal Boxes: corrosion resistant and made for highly erosive/
corrosive environments. The SM coating is more abrasive on the tbg
because the tbg will wear down before the box does (as opposed to Tboxes where the protruding edge will wear out & conform to the tbg ID).
SPM New
1-3/8"
1-5/8"
284T, 286T
1-7/8"
324T, 326T
TAC
143T, 215T
254T, 256T
2-1/8"
sheave size (d1) & the motor shaft
364T, 365T
2-3/8"
diameter (measured or correlated with
404T,
405T
2-7/8"
Frame Size on motor) must be known.
3-3/8"
Drive belts sit ~4/10 within the sheave 444T, 445T
OD, thus a measured 7.4 sheave OD is really a 7 sheave.
For an expanded list of frame sizes: www.downholediagnostic.com
The smallest sheave size is 5. If the desired SPM would require a
sheave size smaller than 5 look into: upsizing the Bull sheave (on
GBox), install a jack-shaft or a VFD (Variable Frequency Drive), or
consider shortening the SL. FYI: sheave is pronounced shiv.
Fluid Level & Dyno Surveys are noninvasive diagnostic tools that quantify
the wells Producing Performancein terms of the wells Production
Potential (reservoir drawdown) & the Operational Lifting Efficiency of the
rod pumping system (how efficiently the fluid is being lifted to surface).
By interpreting the diagnostic data in context of the well, producing inefficiencies can be detected & corrected. The diagnostic data lays the foundation from which prudent operational decisions can be made & justified.
Dynos: measure rod/pump performance (see Pump & Dyno page).
Fluid Level Gun: generates an acoustic wave (pressure pulse) that travels
down the well, reflects off cross-sectional changes in area (collars, perfs,
TAC) until the wave encounters the fluid level & completely reflects back.
The guns internal microphone records the amplitude and polarity of the
reflections on an Acoustic Trace and allows the depth to the top of the
Gaseous Fluid Level to be determined.
The subsequent Casing Pressure Build-Up Test allows for the quantification
of the MCFPD of gas producing up the casing and, consequentially, allows
for the determination of the GFLAP (Gas Free Liquid Above Pump) and
BHPs (Bottom Hole Pressures), like: PIP, PBHP, & SBHP.
Polarity of Acoustic Reflections:
kick: Opening in Cross-Sec Area (negative reflectionRarefaction)
kick: Restriction in Cross-Sectional Area (positive reflection).
d
SPM 1 New
d1
Perfs
kick: Opening
Fluid Level
kick: Restriction
kick: Restriction
Steel
Rods
Sinker Bars
FG Rods
Diam of Coupling
Slim Hole
Full Hole
OD, in
OD, in
1 1/4
1 1/2
1 1/2
1 5/8
(Stuck Pump)
Grd D Rods
Max Short
Term Pull, lbs
24,500
35,500
Diam
in
5/8
3/4
Wt in Air
lb/ft
1.11
1.63
X-Sec
Area, in2
0.307
0.442
7/8
2.22
0.601
1 5/8
1 13/16
48,000
1
1 1/8
2.90
3.68
0.785
0.994
2 3/16
2 3/8
63,000
80,500
1 1/4
4.17
1.227
2
2 1/4
Pin Size
5/8 or 3/4
1 3/8
1 1/2
5.00
6.00
1.485
1.767
5/8 or 3/4
3/4 or 7/8
/
/
1 5/8
7.00
2.074
7/8
1 3/4
8.20
2.405
3/4
7/8
1
1 1/4
0.53MS
0.65MS
0.88MS
1.38MS
0.424MS
0.578MS
0.760MS
1.200MS
7/8
Pin Size
3/4
3/4
7/8
1
20 - 21,000
25 - 29,000
35 - 41,000
50 - 60,000
Rod
Grade
Grd C
Grd K
Not usually a
concern.
Min Yield
Min Tensile
Strength, psi Strength, psi
60,000
90,000
60,000
90,000
AISI
Designation
C-1536-M
A-4621-M
Grd D
HS Rods
85,000
115,000
115,000
140,000
A-4630-M
A-4330-MI
FG Rods
90,000
115,000
Min. Yield Strength: the max stress the rod can bear before
yielding (i.e. before the stress crosses over from elastic
stretch to plastic deformation). Beyond this stress the
material is permanently elongated! (use for max stress calcs.)
Min. Tensile Strength, TMin: the stress that will cause the
material to pull into 2-pieces. Depending on the Max &
Min stress fluctuation experienced by a rod during the
pumping cycle the 100% MGD Loading resides between
25-56% of TMin. As the min. stress on the down-stk
approaches buckling (zero load), 100% MGD = 25% of TMin.
Weight of couplings not included. The lb./box (Full Hole) goes from: 1.3# (5/8) 3.1# (1-1/8).
Max Pull for new rods based on a smooth pull (not herky-jerky). The load pulled at the top of each
taper must be computed and the pull should not exceed the lowest limit. De-rate w/ a S.F.
MS
Manufacturer Specific: average values given (except the FG max pull shows the range between
the 3-primary manufacturers). Max Pull on FG Rods is limited by the end-fitting connection.
Stress
Force
Area
Strain
L
% Elongation
L
Diam
in
ID
in.
Drift
in.
OD of EUE
Collar, in.
Capacity
Displacement ktbg, Stretch
bbls/ft +ft/bbl
*bbls/ft
Constant
2 1/16
3.25#
0.933
1.751
1.657
na
0.00298
336
0.00116
0.42781
2 3/8
4.7#
1.304
1.995
1.901
3.063
0.00387
258
0.00167
0.30675
2 7/8
6.5#
1.812
2.441
2.347
3.668
0.00579
173
0.00232
0.22075
3 1/2
9.3#
2.590
2.992
2.867
4.500
0.00870
115
0.00334
0.15444
4 1/2
11.6#
3.338
4.000
3.875
5.00
0.0155
64
0.11983
5 1/2
15.5#
4.514
4.950
4.825
6.05
0.0238
42
0.08861
"
17#
4.962
4.892
4.767
"
0.0232
43
0.08061
"
20#
5.828
4.778
4.653
"
0.0222
45
0.06863
26#
7.549
6.276
6.151
7.656
0.0383
26
0.05299
"
29#
8.449
6.184
6.059
"
0.0371
27
0.04734
Tbg
(EUE)
Csg
Note: ft/bbl has been rounded. *Displacement (bbls/ft) for EUE open-ended tbg (includes the disp. volume of upsets & couplings).
Weight
#/ft
Grade
Collapse
Burst
Max Pull
MakeUp Torq.
Pressure, psi Pressure, psi to Yield, Lbs. (optim.), ft-lb
J-55
4.7#
8,100
7,700
71,730
1290
L/N-80
"
11,780
11,200
104,340
1800
P-110
"
13,800
15,400
143,470
2380
J-55
6.5#
7,680
7,260
99,660
1650
2 7/8
L/N-80
"
11,160
10,570
144,960
2300
P-110
"
13,080
14,530
199,320
3040
Tubing API Grade: Letter GradeMin. Yield Strength (in 1000s of psi)
2 3/8
WBuoyant
WAir
Capacity
Tbg/Csg Annulus
Tbg/Csg Annulus
+ Tbg Capacity
4-1/2" 10.5#
4-1/2" 11.6#
5-1/2" 15.5#
White
Yellow
Blue
Green
Red
Brand New
62.4 SGO / W
1
Material
5-1/2" 17#
5-1/2" 20#
7" 26#
CF
7" 29#
bbls/ft ft/bbl
bbls/ft
ft/bbl
bbls/ft
ft/bbl
bbls/ft
ft/bbl
bbls/ft
ft/bbl
bbls/ft ft/bbl
bbls/ft
ft/bbl
0.0105
96
0.0101
99
0.0183
55
0.0178
56
0.0167
60
0.0328
31
0.0317
32
2-7/8"
0.0079
126
0.0075
133
0.0158
63
0.0152
66
0.0141
71
0.0302
33
0.0291
34
2-3/8" 4.7#
2-7/8" 5.6#
0.0144
0.0137
70
0.0140
0.0133
72
0.0222
0.0216
45
0.0217
0.0210
46
0.0206
0.0199
49
0.0367
0.0360
27
0.0355
0.0349
28
75
46
(weight ratio)
2-3/8"
73
*Note: ft/bbl has been rounded to aid memory.
0-15%
16-30%
31-50%
51-100%
Capacity Factor (CF): for any size hole or annulus (in bbls/ft)
(Different heat treating processes & alloys combine to create the higher strength grades)
Tbg Size
Body Wall
Loss
Color
Band
48
50
28
ID 2 OD 2
1029
29
2014 by Downhole Diagnostic | Midland, TX. Free for unaltered distribution. 1.0
20125 R H B C 20540
C 320D 3 0 5 100
a #1 b
a: PPU Type:
#1
Max SL, in.
C: Crank Balanced
B: Beam Balanced
#1: GBox Torque, 1000s of in-lbs.
RM: Reverse Mark
b: D - Double Reduction GBox
A: Air Balanced
M: Mark II (grasshoppa)
Note: PPUs that have the Equalizer Bearing residing directly over
the GBox Crankshaft will use equal degrees of crank rotation for both
the up & down-stroke. The equalizer bearing is shifted forward
towards the horse head on the Reverse Mark & Mark II making
their up-stk 12% (RM) & 18% (MII) slower than their down-stk.
Nomenclature:
< or >
A
API
d
BFPD
BHP
CP
DH
DHGS
F
FO
GA
GFLAP
h
ID
k
L
MGD
OD
P
PBHP
Pgr
PIP
PDP
ppg
PPU
PPM
PR
SBHP
SG
SL
SPM
SV
tbg
TAC
TV
TVD
TP
W
#1:
#2:
a:
b:
c:
d:
#3:
#4:
#5:
#6:
a b c d #3 #4 #5 #6
#2
SGO
141.5
API 131.5
API
S.G.
30
35
0.88
0.85
40
0.83
45
50
0.80
0.78
The SG of produced water is a function of the TDS (Total Dissolved Solids), not just
Chlorides. So a Wolfberry well producing 100K Cl probably has a S.G. closer to ~1.09.
SGO /W
Assuming gas-free.
Bottom Hole Pressure: BHP PSurface 0.433 SG hTVD PSurface 0.052 ppg hTVD
Avg Polished Rod Velocity:
For comparing pumping speeds
(velocity) of wells w/ different SLs.
V PR
2 SL SPM ft / min
12
Fluid Slippage:
Failure Frequency:
Failure Frequency
Lpgr
(BFPD)
# of Failures / Year
Producing Wells
APBs & SRBs are the oilfields STDs! Both set-up shop on downhole metallurgy and wreak
havoc. Acid Producing Bacteria excrete acids while Sulfate Reducing Bacteria generate H2S
which both rapidly corrode the steel. Worse yet, the byproducts of the corroded steel further
inhibit the ability of chemicals to penetrate & kill the underlying colonies. MIC (Microbial
Influenced Corrosion) is highly penetrating and can quickly initiate rod parts & tbg leaks.
Protect your producers by biocide-treating any fluids introduced into a well (including frac
jobs). If introduced into the deepest part of each and every frac stage, there is no possible
recourse for their removal from the formationonly Hope & Faith remain. And if APBs &
SRBs are the oilfield STDsthat would make Pump Trucks the licentious couriers
propagating this most pernicious seed from lease-to-lease, operator-to-operator.
An ounce of prevention is worth a pound of cure. -Benjamin Franklin
Subscripts:
D,FL
DH
DT
EPT
FG_Rods
FL
MA
p
O or W
rf
RT
SN
tbg,x-sec
Downhole Diagnostic: Your Downhole Doctor & Lease Nanny! We combine Fluid Level & Dyno Surveys w/ Rod-Pumping Know-How to Optimize your Rod Pumping Wells.
2014 by Downhole Diagnostic | Midland, TX. Free for unaltered distribution. 1.0. Neither Downhole Diagnostic nor its members may be held liable for any
application or misapplication of the information contained herein. This brochure [& future updates] are posted @ www.DownholeDiagnostic.com.