RODSTAR-D/V

Modern Design and Simulation

of Rod Pumping Systems
for Deviated or Ver tical Wells

Theta Oilfield Services, Inc.

1901 E. Lambert Rd. Suite 108
La Habra, CA 90631 USA
Telephone #: (562) 694-3297
Fax #: (562) 694-8641
www.gotheta.com or www.xspoc.com

Email Addresses:
John G. Svinos - President: jsvinos@gotheta.com
Terry Treiberg - XSPOC Dev. Manager: terry@xspoc.com
Software Support: Rudy Nesmith: rudy@gotheta.com
Orders: Sandy B. Rodriquez - Off. Manager: sandyb@gotheta.com
© Theta Oilfield Services, Inc., 2006.
All Rights Reserved. This manual may not be reproduced in whole or in part without the written per-
mission of Theta Oilfield Services, Inc.

RODSTAR, RODSTAR-D, RODSTAR-V, RODDIAG, XDIAG, CBALANCE, and XTOOLS are

trademarks of Theta Oilfield Services, Inc..

Printed in the United States of America

First Edition, October 2006
 RODSTAR  | iii

Contents
Technical Support . . . . . . . . . . . . . . . . v
System Requirements . . . . . . . . . . . . . . v

1 Introduction 1
1.1 Program Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Advanced Capabilities and Program Limitations. . . . . . . . . . . . . . . 2
1.3 Help System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 RODSTAR CD and Software Sentinel. . . . . . . . . . . . . . . . . . . . . 3

2 Software Installation 5
2.1 RODSTAR Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Questions About Installation . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Installing the Software Sentinel. . . . . . . . . . . . . . . . . . . . . . . 5

3 Starting and Setting Up RODSTAR 7

3.1 Starting RODSTAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Exiting RODSTAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Setting up RODSTAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.2 General setup options . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.3 Defaults, Limits, and Rod Guide Setup. . . . . . . . . . . . . . . . . 11
3.3.4 Output Options. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.5 Pumping Unit Options. . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.6 Rod Grade Options. . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.7 Batch Mode Options. . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Running RODSTAR 21
4.1 RODSTAR’s User Interface. . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.1 RODSTAR’s Help System. . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Entering Rod Pumping System Data . . . . . . . . . . . . . . . . . . . . 22
4.2.1 Entering Well Information Data. . . . . . . . . . . . . . . . . . . . 23
4.2.2 Entering Production Information. . . . . . . . . . . . . . . . . . . 25
4.2.3 Entering Pump and Tubing Information Data. . . . . . . . . . . . . . 26
4.2.4 Entering Rod String Data. . . . . . . . . . . . . . . . . . . . . . . 29
4.2.5 Entering Wellbore Deviation Data (RODSTAR-D). . . . . . . . . . . . 33
4.2.6 Entering Pumping Unit Data. . . . . . . . . . . . . . . . . . . . . 38
iv |  Table of Contents

4.2.7 Entering Motor Information and Energy Cost. . . . . . . . . . . . . . 47

5 Changing, Loading and Saving Data 51

5.1 Visual Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2 Storing Data Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3 Running and Viewing the Output. . . . . . . . . . . . . . . . . . . . . 52
5.3.1 Saving the output. . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.3.2 Running in Batch Mode. . . . . . . . . . . . . . . . . . . . . . . 54
5.4 Loading Data from Disk. . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.4.1 Viewing Previously Saved Output . . . . . . . . . . . . . . . . . . . 57
5.5 Manipulating Input Windows. . . . . . . . . . . . . . . . . . . . . . . 58

6 Rod Pump System Design 59

6.1 Understanding RODSTAR’s Output. . . . . . . . . . . . . . . . . . . . . 60
6.1.1 Dynamometer and Permissible Load Plots . . . . . . . . . . . . . . . 60
6.1.2 Torque Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1.3 IPR Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1.4 Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.2 RODSTAR-D Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.2.1 Deviation Plots. . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.3 Rod Pump System Design Guidelines . . . . . . . . . . . . . . . . . . . . 71
6.3.1 Shallow, High Rate Well Simulation . . . . . . . . . . . . . . . . . . 72
6.3.2 Selecting the Target Production . . . . . . . . . . . . . . . . . . . 72
6.3.3 Avoiding Rod Compression. . . . . . . . . . . . . . . . . . . . . . 72
6.3.4 Minimizing Power Consumption. . . . . . . . . . . . . . . . . . . 73
6.3.5 Reducing Gearbox Torque . . . . . . . . . . . . . . . . . . . . . . 73
6.3.6 Using RODSTAR for Correct Equipment Sizing . . . . . . . . . . . . . 73
6.3.7 Using RODSTAR for Diagnostic Analysis. . . . . . . . . . . . . . . . 74
6.3.8 Using RODSTAR-D for better Wellbore Designs . . . . . . . . . . . . . 74
 RODSTAR  | 

Technical Support CD-ROM or DVD-ROM drive for installation

CD.
Technical Support for RODSTAR is provided by
phone and e-mail to customers with a current An-
nual Technical Support Agreement. Display:
The first year of technical support is provided free 1024 x 768 or higher-resolution display with 256
with the initial purchase of a license. colors recommended.
Support for customers with an expired agreement 800 x 600 resolution can be displayed.
is billed at $100/hour with a one-hour minimum
per incident.
Please include the Serial Number from your Senti-
nel bitlock when contacting support.

Phone Support:
Monday-Friday 8:00 AM - 4:00 PM PST.
(562) 694-3297

E-Mail Support:
support@gotheta.com

System Requirements
Processor:
1-GHz Pentium III-class processor recommended.

Operating System:
Windows XP
Windows 2000 (Service Pack 2 recommended)

Memory:
512 megabytes (MB) of RAM recommended.

Hard Disk Space:

20 megabytes (MB) free disk space.

1 Introduction
RODSTAR™ for Windows is a powerful, easy-to-
use rod pumping system simulator and design tool.
With RODSTAR you can design new rod pump-
ing installations or make changes to existing rod
pumping systems. It is a tool that you can use to
compare pumping units, pumping speeds, plunger
sizes, rods, motor types, etc. You can evaluate the
effect of pump fillage, fluid level, or an out-of-bal-
ance unit. Also, you can study the effect of prime
mover speed variation, stuffing box friction, etc.
RODSTAR also allows you to combine sophisti-
cated rod pumping system modeling with inflow
performance data for even more powerful capabili-
ties.
There are two versions of RODSTAR: ROD-
STAR-D and RODSTAR-V. This manual applies
to both for most items since the program’s user
interface is practically identical except for an addi-
tional input window in RODSTAR-D for entering
the wellbore deviation survey. RODSTAR-D is
primarily for rod pumping systems with deviated
wellbores, while RODSTAR-V is for vertical well-
bores (little to no deviation).
When the program discusses “RODSTAR” it
applies to both versions of the program. If there
are differences between RODSTAR-D and V, the
description in the manual will specify the program
version (RODSTAR-D, or RODSTAR-V).
RODSTAR is very easy to use, flexible, customiz-
able, and fast. With a single click of the mouse you
can access any input screen at any time. You can
change an input by simply clicking on it, and when
you have a question, simply press ! for context
sensitive help for any input item. You can also take
advantage of standard Windows features such as
being able to copy the dynamometer, torque plots,
or IPR plots to the clipboard and then paste them
RODSTAR  | 
in any other Windows document.
By taking advantage of the program’s powerful
“expert” knowledge you can save time and come
up with better answers. This makes it possible to
optimize rod string designs, find out the pumping
speed and plunger size you need for a target pro-
duction, etc. in minutes instead of hours. ROD-
STAR makes it possible to get these answers even
with little rod pumping expertise.
1.1 Program Features
RODSTAR remembers the information you type
when you start a case from scratch. You can exit
RODSTAR while in the middle of entering data
for a new case, and RODSTAR will save the data
you have entered so far. This works the same way
if the program crashes. The next time you start
RODSTAR, the program will ask you if you want
to resume entering data. If so, you will be returned
to the data entry window you were using when you
left RODSTAR, with all the data you had entered
already in place. RODSTAR contains data for
all common pumps, rod sizes, rod grades, pump-
ing units, tubing sizes, etc. Also, it “knows” when
you need slim hole couplings or a thin wall pump,
what rods fit in the tubing size you selected, the
maximum recommended pumping speed for any
system design, etc.
RODSTAR can read well files created with ROD-
DIAG™, XDIAG™ (Theta Oilfield Services,
Inc.’s diagnostic computer programs) and CBAL-
ANCE™ (Theta Oilfield Services, Inc.’s pumping
unit balancing program). RODSTAR can read all
the data contained in a RODDIAG or XDIAG
file, including the measured dynamometer card.
 |  Introduction
This allows you to redesign pumping systems with-
out having to reenter system data. RODSTAR can
display and print the measured dynamometer card
overlaid on the same plot as the predicted surface
dynamometer card. This feature has many uses
that include finding the correct rod-tubing friction,
or determining whether the load cell used to record
the dynamometer card may be out of calibration.
By being able to read CBALANCE files, ROD-
STAR can get the existing maximum counterbal-
ance moment based on the existing position of
the counterweights. This eliminates the need for a
field measurement of counterbalance effect. Also,
you can enter the calculated balanced maximum
counterbalance moment back into CBALANCE
to find out how to balance the pumping unit in one
step.
RODSTAR can simulate any pumping system and
can accurately predict its performance. For a sys-
tem you specify, the program predicts the surface
and downhole dynamometer cards. Also, it calcu-
lates the peak gearbox torque and gearbox loading,
structure loading, rod loading, pump stroke, mini-
mum required pump length, plunger length, pump
spacing, expected production rate, the counterbal-
ance needed to balance the unit, the prime mover
size, overall system efficiency, daily energy con-
sumption, monthly electricity bill, and other useful
information. Also, RODSTAR allows you to enter
inflow performance data so that you can easily de-
sign a pumping system for any pump intake pump
intake pressure, calculate the expected production
rate, pump intake pressure and pump condition for
any rod pumping system, find out the maximum
production rate you can get, and more.
Also, in contrast to the conventional trial and error
system design, with RODSTAR you can enter a
target production and ask the program to simulta-
neously calculate the strokes per minute, plunger
size, and rod string design. It even recommends
the pumping unit size you need. Or, you can enter
IPR data and have RODSTAR calculate the target
production and design the system for that target
production based on any pump intake pressure or
fluid level you want.
RODSTAR comes with a large pumping unit
data base so that you can easily select and com-
pare pumping units without having to get the unit
dimensions yourself. RODSTAR can model any
pumping unit geometry including long stroke units
such as the Rotaflex. Also, you can enter your own
pumping unit data in case your unit is not in the
program’s database. Advanced error trapping and
warning messages help prevent errors and make
you aware of special requirements necessary for
proper system operation.
RODSTAR-D also allows you to enter a deviation
survey and calculates side load, dogleg severity, rod
guide spacing recommendations, etc.
1.2 Advanced Capabilities and
Program Limitations
RODSTAR has many advanced features that
enable you to accurately predict system perfor-
mance for any rod pumping system. It can simulate
wells of any depth including very deep or shal-
low wells. It is the only program of its kind that
models fluid inertia effects that are present in wells
that pump incompressible fluids with larger than
2.00” plungers from depths of less than 4000 feet.
RODSTAR-D can simulate deviated wells, while
RODSTAR-V can only be used for wells that are
vertical or have little deviation.
By calculating the minimum stress at the bottom
of each rod section, RODSTAR shows whether
the rods are in compression or not. This is vital for
fiberglass rods which must never be in compression
to avoid premature failures. This is also important
for steel rods since excessive compression can cause
buckling failures.
RODSTAR-V can model the effect of prime
mover speed variation and pumping unit inertia
and can accurately calculate electricity consump-
tion and the monthly energy bill. Because ROD-
STAR uses actual motor efficiency curves, the
results are very accurate. You can use this capabil-
ity to compare the energy consumption of systems
 RODSTAR  | 

with different rod designs, plunger sizes, or pump- RSWIND.Exe The program file for
ing unit types. RODSTAR-D. It is
the file that your Desk-
RODSTAR’s Inflow Performance Relationship top Icon runs when you
(IPR) capabilities allow you to select the IPR double-click it.
relationship you want RODSTAR to use (Vogel or RODSTAR.CDB Contains the costs for
Fetkovich), your can enter one to ten test points, both rods and pumping
and can integrate IPR and rod pumping system units. Once you create
models to predict the maximum production rate this file by entering rod
possible, the fluid level and pump condition for a and pumping unit cost
data, you can provide
given pumping speed, or the target production for copies to other users in
any fluid level or pump intake pressure you want. your company.
Because of all these features, RODSTAR has vir- CUSTOM32.PUD This file contains the
tually no limitations and is the most advanced and measured pumping
easiest to use program of its kind. unit information you
entered in Setup. Once
you create this file, you
can distribute copies
to other users in your
1.3 Help System company.
RODSTAR takes full advantage of Microsoft Files ending in .PUD The program’s pumping
unit database. When
Windows to bring you state-of-the-art context- updates are announced
sensitive help for any input field by simply press- on our Website for new
ing the ! key. Also, you can search help for any pumping units that
have been added, you
other item. can download a zipped
file that contains addi-
tional PUD files to add
to your folder.
1.4 RODSTAR CD and Software Files beginning with Several files are in-
demo_ cluded that are example
Sentinel cases to demonstrate
the program functions.
The RODSTAR program installation CD con- During installation,
tains many compressed files that the installation there are copies of these
program copies to the hard disk of your computer. files placed in the folder
Some of these are useful to know about. These are used when opening
case files.
located in the same folder where you elected to
install RODSTAR. The default is “C:\Program Files ending in .RST Case files saved by
RODSTAR release
Files\Theta Enterprises\RODSTAR-V” or “C:\ prior to 3.0.
Program Files\Theta Enterprises\RODSTAR-D”.
Files ending in .RSVX Case files saved by
RODSTAR-V.
Files ending in .RSDX Case files saved by
RSWINV.Exe The program file for RODSTAR-D.
RODSTAR-V. It is the
file that your Desktop Files ending in .RDG Case files saved by
Icon runs when you RODDIAG.
double-click it. Files ending in .XDG Case files saved by
XDIAG.
 |  Introduction

Files ending in .CBL Case files saved by

CBALANCE
SENTINEL.INI For installations using
a Network license, this
file is located in the
program folder on the
client PC and has the
name or IP address of
the license server being
used.

The RODSTAR program is protected and cannot

run without a software sentinel supplied by Theta
Oilfield Services, Inc.. See Chapter 2 for details on
how to install the software sentinel.

2 Software Installation
Before you install the program, make sure you
have the hardware and software you need to run
RODSTAR for Windows.
2.1 RODSTAR Installation
RODSTAR is installed from the Theta Software
Suite installation CD that you received. Load the
CD onto your PC and the installation program
should load automatically. After the “Welcome”
screen you will have three options for whether
you are using a Network or Standalone license
and whether you have a USB Sentinel bitlock or a
Parallel Port Sentinel. After selecting the proper
choice, the next screen will prompt you for the
programs to install. That screen also has a button
that lets you display and print the detailed Installa-
tion Guide for your specific installation.
After installing the program, put your original CD
away in a safe place. If the Software Installation
Suite CD becomes damaged or lost, please call
Theta Oilfield Services, Inc. at (714)526-8878 for a
replacement.
2.2 Questions About Installation
The following are some answers to questions you
may have about installing RODSTAR for Win-
dows.
Do I need to delete earlier versions of ROD-
STAR before I install?
No. When updating versions of RODSTAR for
Windows, the program defaults to install to the
“C:\Program Files\Theta Enterprises\Rodstar-V
or Rodstar-D” directory. If your previous copy of
RODSTAR  | 
Rodstar is in another directory, you can specify to
install over it. It will not replace any of your case
files, just the old version of the program.
The installation defaults to setting “C:\THETA”
as the common folder for your case files. Using a
common folder is a good idea since several of the
Theta Enterprise applications that you might have
can all share the same case files.
Although a new version of RODSTAR can read
files created with older versions, an older version of
RODSTAR cannot read files created with a new
version of the software.
What happens to files I have created with older
versions of RODSTAR?
Nothing. When you install or reinstall ROD-
STAR for Windows, only program files are re-
placed. The latest version of RODSTAR saves files
in the XML file format but can read files created
with older versions of RODSTAR as well.
What happens to the Setup Settings from previ-
ous versions?
If the previous version is not very old (before the
new setup options were developed) then your set-
tings will be preserved.
2.3 Installing the Software
Sentinel
Your RODSTAR license is validated and protected
by a security bitlock called a Sentinel. For Stand-
alone installations, this is either a USB key or a
Parallel Port key that is attached to your PC. For
Network Licenses, the key is attached only to the
Network License Server. See the Detailed Instal-
 |  Program Installation

lation Guide that is available for printing from the

Software Installation Suite CD.
RODSTAR communicates with the sentinel and
although the program can be copied, it will not
operate without a sentinel supplied by Theta Oil-
field Services, Inc..
If the sentinel is not installed correctly, the pro-
gram will warn you that the sentinel does not ap-
pear to be connected. If this occurs, make sure the
sentinel in properly installed and the connection is
not loose. If the sentinel is properly installed but is
not working, it may have been damaged. Frequent
plugging and unplugging, and static electricity can
damage the sentinel. If this occurs, contact Theta
Oilfield Services Inc. to determine if you need a
replacement. Do not discard the damaged sentinel.
Even if it is damaged, you must return it to Theta
Oilfield Services, Inc. before a replacement can be
sent out. When RODSTAR first starts, it reads
and displays the serial number of your sentinel on
the opening screen.
Theta Oilfield Services, Inc. uses Sentinel “Super-
Pro” for software protection. If you use software
sentinels from other vendors, you may be able to
cascade Sentinels as long as the LPT1 port has
only one Sentinel “C” on it. The rest of the Sen-
tinels must be a different type. If you have one or
more Sentinel “PRO” and one Sentinel “C”, then
plug the Sentinel “C” at the end of the Sentinel
PROs or SuperPros. USB type Sentinels can be
plugged into any available USB port or hub on the
PC.
 RODSTAR  | 

3 Starting and Setting Up RODSTAR

3.1 Starting RODSTAR from the File Manager, simply double click on it.

The RODSTAR installation program will put an RODSTAR has a “getting-started” window,
Icon on your Desktop and an entry in your Start shown in Figure 3.1, that appears whenever you
Programs for access to RODSTAR. To start the start the program. The window shows the most
program, simply double-click on its icon. common toolbar icons you need to know to begin
using RODSTAR.
You can also start RODSTAR from the File
Manager by double clicking on RSWIND.EXE
for RODSTAR-D, or RSWINV.EXE for ROD-
STAR-V. Also, the Windows File Manager allows 3.2 Exiting RODSTAR
you to associate files with applications. When you
To exit RODSTAR, double click on its Control-
associate a file with an application, you open the
menu box (upper left hand corner) or select File
file and start the application at the same time.
and then Exit. Another way to exit RODSTAR
For example, to associate RODSTAR-D files (with is to press A+ $. Before exiting RODSTAR
an “.RSDX” file name extension) with RSWIND. make sure you have stored your data to disk
EXE, do the following: (RODSTAR asks you if you want to save the data
1. From the File manager, go to a directory that when you exit, if you have changed your data since
contains RODSTAR files and double-click on the last time you saved it). Otherwise it will be
one of these files. lost.
2. If the file is not already associated with ROD-
STAR-D, windows will let you know and ask
you to select the program from a list. Make The RODSTAR Window
sure this option is selected and click on the OK Figure 3.2 shows the RODSTAR window that
button. appears when you start the program. RODSTAR
3. Click on Browse, go to the directory where behaves like any other standard Windows pro-
RSWIND.EXE resides (typically, it will be in gram. You can use the mouse to move and size
C:\Program Files\
Theta Enterprises\
RODSTAR-D, and
double click on it.
4. Choose the OK but-
ton.
After you do the above
steps then to load and
run a RODSTAR file Figure 3.1 - The “Getting Started” Window
 |  Starting and Setting Up RODSTAR
Figure 3.2 - RODSTAR’s main window
windows, move and restore icons, select text,
choose commands from menus, and dialog boxes,
and complete almost any other task in RODSTAR
aside from typing text.
Following is an explanation of the parts of the
RODSTAR window as shown in Figure 3.2.
The control-menu box is in the upper-left corner
of each window. The control menu is most useful
if you use the keyboard. You can use the control
menu commands to resize, move, maximize, mini-
mize, and close windows. Also, you can use it to
switch to other applications. (If you use a mouse,
you can perform these tasks by clicking and drag-
ging.) Double-clicking on the control menu box
closes RODSTAR.
The title bar shows the name of the application and
the name of the file currently in memory. If more
than one window is open, the title bar for each
active window (the one that you are working with)
is a different color or intensity than the other title
bars.
The menu bar lists the available menus. A menu
contains a list of commands, or actions, you can
carry out with RODSTAR. For example, click on
the Help menu to see a list of helpful choices.
The Minimize button reduces RODSTAR to an
icon. After you minimize RODSTAR, you can
reopen it by double clicking on the RODSTAR
icon at the bottom of your screen.
The Maximize button causes the RODSTAR win-
dow to fill the entire screen. After you maximize
the RODSTAR window, the maximize button

shows a double box and is called the restore but-
ton. Clicking on the restore button re-sizes the
RODSTAR window to the size it was before you
maximized it.
Using the mouse you can resize RODSTAR’s
main windows. When you resize RODSTAR’s
window to a size smaller than required to display
all information, it will display vertical or horizon-
tal scroll bars as necessary. You can use these scroll
bars with the mouse to view unseen portions of
entry windows that do not fit in the allotted space.
The Close button causes RODSTAR to exit. It’s
easier to click the Close button once than to select
Exit from the File menu.
The Status bar shows useful messages during data
entry, when you load a case from disk or when you
point to a toolbar icon.
The toolbar gives you quick access to menu com-
mands using your mouse. When you first load
RODSTAR, only some of the buttons on the
toolbar are active. When you enter data or read a
file from disk, then the print button and all the
buttons that correspond to input windows become
active. If you load a file that contains output then
the report icon also activates. Otherwise, if the
file contains only input then the report icon re-
mains inactive until you run the case. For a quick
reminder of what each toolbar button does, simply
place the mouse pointer on it. A small message box
called a “tool tip” appears that tells you what the
toolbar icon does (see Figure 3.2). Also, the status
bar shows more information about the same tool
bar item.
Following is a more detailed explanation of each
button on the toolbar from left to right:
New file - This is the first button on the toolbar
and shows a picture of a blank page. Click on this
button to start entering data for a new case.
Open file - This is the second button on the toolbar
Figure 3.3 - RODSTAR’s toolbar
RODSTAR  | 
and shows the standard open file icon used by most
Windows programs. Click on this button to read
a RODSTAR, RODDIAG, or XDIAG file that
was previously stored on disk.
Save file - This is the third item on the toolbar and
shows a picture of a diskette. Click here to save the
data in memory to disk. If this is the first time you
are saving this case, RODSTAR asks for a new
file name. After you save a file, or after you load
a file from disk and make changes to it, click on
this button to quick-save the data under the same
file name. To save it under a different file name
click on File on the menu bar and then select Save
As....
Setup - This is the fourth item on the toolbar.
Click here to see RODSTAR’s Setup window.
This allows you to specify inputs and preferences
that normally do not change often such as: your
company name, electricity cost, units of measure,
standard sucker rod length, custom sucker grades,
measured pumping unit data, pumping unit and
sucker rod cost, batch run options, printed report
options, and custom summary spreadsheet formats.
Well information - This is the fifth item on the
toolbar and shows a picture of a file cabinet. Click
here to open the well information window. When
you first load RODSTAR this icon (and the next
five icons) is inactive until you enter well informa-
tion data or until you load a file from disk. The file
information window contains data such as pump
depth, run time, pump condition, tubing and cas-
ing pressures, fluid gravity, etc.
Production information - This is the sixth item on
the toolbar and shows a picture of a barrel. Click
here to open the production information window
that has data for items such as fluid level, pump
intake pressure, target production, IPR data, etc.
Pump and tubing information - This is the seventh
item on the toolbar and shows a picture of a down-
10 |  Starting and Setting Up RODSTAR
hole pump . Click here to see data for tubing size,
pump type and size, tubing anchor depth, rod-tub-
ing friction, and fluid inertia effects.
Rod string information - This is item eight on the
toolbar and shows a picture of a sucker rod. Click
here to open the rod string information window.
This is where you specify what kind of rod string
you want RODSTAR to design for you. Also, you
can enter your own rod string design, specify the
service factor you want to use, etc.
Deviation Survey Input - This is the ninth item on
the toolbar and shows a picture of a deviated well-
bore. It is only available in RODSTAR-D, since
this is the input window for the deviation survey
of the well. Click here see the deviation survey and
also to see the 3-D plot of the wellbore.
Pumping unit information - Click here to open
the pumping unit information window that has
data for pumping unit type, crank rotation, stroke
length, structural unbalance and counterbalance
data.
Motor information - This icon shows a picture of
a motor. Click here to open the motor information
window that has data for electricity cost, power
meter type, motor type and size, moments of iner-
tia and whether to include motor speed variation.
Previous window - This icon shows an arrow
pointing to the left. Click it to go back to the pre-
vious input window.
Next window - This shows an arrow pointing to
the right. Click here to advance to the next win-
dow when entering data for the first time or when
you are changing data.
Run - This item follows the arrow icon on the
toolbar and shows a picture of surface and down-
hole dynamometer plots. Click here to run ROD-
STAR after entering all your data or after you
change an input.
Report - This item follows the run icon on the
toolbar and shows a picture of a printed page.
Click here to view the output in memory. This
allows you to view the output saved in a file you
just loaded from disk, or to return to the output
screen. If this button is inactive (dimmed) it means
that there is no output report in memory. To make
it active, run the case, or load a case with saved
output.
Email Icon - Click on this icon to email one or
more cases to Theta Oilfield Services, in case you
have questions.
Print - This button follows the Report button on
the toolbar and shows a picture of a printer. Click
it to send the output to the printer.
If you have entered data for a case, but haven’t run
the calculations yet, you can get a printout of your
input data by itself. You get the same one-page
output, except that only the input data appears on
the page.
The Print… command on the File menu allows
you to select exactly which parts of the output you
want printed. For more information, see section
3.3.4, Output Options under Setup.
Export CBM - This item is second from last on
the toolbar and shows a picture of a crank and
counterweight. This button becomes active after
RODSTAR runs or after you load a file with saved
output. Click it to place the maximum counter-
balance moment for balanced conditions on the
clipboard for use in CBALANCE for Windows.
Help - This is the last item on the toolbar and
shows a picture of a question mark. Click this but-
ton at any time to get help.
3.3 Setting up RODSTAR
Click on the Setup button on the toolbar to open
RODSTAR’s Setup window. Another way to
access Setup is to open the Tools menu and then
select RODSTAR Setup. This window as shown
in Figure 3.5 allows you to enter items that do
not normally change from run to run. Also,
Setup allows you to customize RODSTAR by
entering your company name, default electricity
cost, custom rod grades, measured pumping units,
rod and pumping unit cost data, and a lot more.
 RODSTAR  | 11

The measured pumping unit

data you enter is saved in the
CUSTOM32.PUD file in
the program directory; the
cost data you enter for rods
and pumping units is saved
the RODSTAR.CDB file
in the program directory.
RODSTAR stores all other
information you enter in Setup
in the registry.

3.3.2 General setup options

Measurement Units Figure 3.4 - RODSTAR’s Setup window
For measurement units you
you customize the default information used by the
can select English, Canadian, or Metric/SI. Eng-
program when you begin entering data for a new
lish units are mainly used in the USA and South
case. You can also change the rod stress loading
America. If you select this option RODSTAR
limits used by RODSTAR in a steel or fiberglass
will ask for pump depth in feet, production rate
rod design, so that RODSTAR will use larger rods
in BFPD, plunger and rod diameters in inches,
rather than exceed the loading limits you specify.
etc. The “Canadian” option provides you with the
common mix of English and Metric units used in Any of the following items can be customized:
Canada. The “Metric/SI” option will cause ROD- • Casing pressure
STAR to use Metric/SI units for most inputs. Re-
• Company name
gardless of the units you select, you can press @
while entering numeric data to convert from one • Electricity cost
system of units to the
other. When you press
@ to convert units, the
background of the input
field box changes color
from light blue to light
green.

3.3.3 Defaults, Limits,

and Rod Guide Setup
The “Defaults” input
window in Setup for
RODSTAR-V is shown
in Figure 3.6. Here,
RODSTAR allows Figure 3.5 - Help for RODSTAR’s setup
12 |  Starting and Setting Up RODSTAR

• IPR correlation ing limits discussed above, you can also specify the
type of rod guides you want to use and how much
• Motor type
side load each rod guide can take, according to the
• Oil gravity manufacturer of the rod guide.
• Plunger size
• Pump condition 3.3.4 Output Options
• Pump efficiency RODSTAR gives you full control over what is
• Pump fillage shown on the printed output. Using the Output
Options tab in Setup, shown in Figure 3.7, you
• Pump load adjustment
can select the items you want included on the
• Run time output. The options you select here are the items
• Standard steel sucker rod length printed by default when you select Print… from
the File menu, or use the Print toolbar button.
• Steel rod service factor You can choose from among the following:
• Stuffing box friction ♦ Input data and calculated results.
• Tubing pressure This option prints one page showing all the input
• User name data and the results of the calculations, as well
as miniature predicted dynamometer and torque
• Water cut
plots.
• Water specific gravity
♦ Cost analysis.
The program uses the standard steel sucker rod
This option prints both the rod string and the
length (typically 25 or 30 ft.) to calculate steel
pumping unit costs. You must already have entered
rod string section lengths that are evenly divisible
the costs into RODSTAR’s cost database (see sec-
by it. This works whenever RODSTAR designs
tion 3.3.6, “Cost Database,” on page 23 for more
the rods string (when RODSTAR calculates a
steel rod string taper
design, whether for a
steel rod string, or a
tapered steel rod sec-
tion beneath a fiber-
glass.) For Corod rod
strings, RODSTAR
ignores this number.
For fiberglass rods,
the program uses the
standard length of
37.5 feet.
Figure 3.6d Shows the
Defaults input win-
dow for RODSTAR-
D. Here, in addition
to the default values
and rod stress load- Figure 3.6 - Setting up default quantities for RODSTAR-V
 RODSTAR  | 13

information). ing on type of rod guides selected in the “General”

section of setup).
♦ Inflow performance (IPR) chart.
Selecting this option gives you an additional page
with the IPR plots, the IPR data including the test 3.3.5 Pumping Unit Options
points, and a table of pressure versus production.
Under this item, there are two sub-items,
♦ Dynamometer cards and Torque Plots
Customize Pumping Unit List, and Measured
Selecting this option prints a separate single page Pumping Unit List. Let us take a look at each of
containing the predicted surface and downhole these items:
dynamometer cards with the predicted permissible
♦ Customize Pumping Unit List
load diagram. It also prints the net gearbox torque
plots for existing and balanced conditions on the This option allows you to customize the list of
bottom half of the page. The dynamometer card units displayed by the program at the pumping
plot may also show the actual (measured) surface unit selection window. Here you can select the
dynamometer card (if you loaded a RODDIAG or pumping unit manufacturer and the pumping unit
XDIAG case into RODSTAR). sizes you have for each manufacturer in the field.
After you customize the pumping unit list, you can
♦ Overlay actual (measured) dynamometer
select pumping units faster since the program will
card.
only show the units you have in the field instead of
If you load a RODDIAG or XDIAG case into displaying all the pumping units in the pumping
RODSTAR, the program can plot the surface unit database. This saves you time by minimizing
dynamometer card that was stored in the ROD- the time and effort required to select a pumping
DIAG or XDIAG file on the same plot as the unit. For example, if you only have 12 different
predicted dynamometer card. sizes of Lufkin Conventional, 10 sizes of Mark
Additional items on RODSTAR-D Output Op- II, and 14 American Conventional unit sizes, you
tions:. can setup RODSTAR to show only these units in
the pumping unit selection screen. To customize
♦ Deviation
Charts
If selected, it will add
a page with deviation
related charts such as
side load as a function
of measured depth,
axial loading, buck-
ling tendency, dog-
leg severity, and the
wellbore trajectory
views from North to
Looking down.
♦ Recommend-
ed Guide Report
This will print a
report of rod guide
Figure 3.6d - Setting up default quantities for RODSTAR-D
placement (depend-
14 |  Starting and Setting Up RODSTAR

RODSTAR’s pumping unit list, do the following: additional information about the pumping unit
as shown in Figure 3.10. This is especially use-
1. Click on the “+” symbol on the left of “Pump-
ful for manufacturers (for example, American
ing Unit Options.” Then, click on “Custom
conventional) who have more than one unit
pumping unit list”. This opens the window
with the same designation but different crank
shown in Figure 3.8.
types. In such a case, the Other: field shows
2. Drop down the manufacturer list by clicking the crank type of the unit or other information
on the down arrow next to “Manufacturer:” that helps identify the pumping unit type. This
3. Select a manufacturer you want to add to your is not the only way to customize the pump-
custom pumping unit list as shown in Fig- ing unit database. As discussed in the section
ure 3.9. If this is a new manufacturer for the dealing with the pumping unit information
custom list, all available pumping units will screen, you can also select a unit you want to
appear in the window on the right side of the add to the customized unit list by first selecting
screen. it from the full database and then selecting to
use the custom pumping unit list. At that point
4. You can select the units to include in the cus- RODSTAR will ask you if you want to add
tom pumping unit list using drag and drop. To this unit to the custom pumping unit database.
add a unit from the list of available units to the If you do, then select Yes.
custom database list, you simply drag (click on
it with the mouse and hold the left mouse but- 6. After you are done customizing the pumping
ton while moving it) the units you want from unit list, click on OK.
the list on the right to the custom list on the ♦ Measured Pumping Unit List
left. Or, you can click on a unit once to select
Here you can enter data for pumping units that are
it, and then click on the <<Add button (in the
not in RODSTAR’s main database. If you have the
middle of the screen). The program automati-
dimensions you need for these units you can enter
cally arranges the units in the proper order
them here to make them a permanent part of your
(largest stroke length and largest gearbox size
RODSTAR software. To enter dimensions for a
first).
pumping unit, do the following:
5. To remove a unit from
the customized list,
simply drag it from
the list on the left, and
drop it in the list to
the right. Or, you can
click on a unit once
and then click the Re-
move>> button (in the
middle of the screen).
To make sure you se-
lect the correct pump-
ing unit, highlight it
(click on it once with
the mouse) and the
Name: and Other:
fields on the bottom of
the screen will show Figure 3.7 - Selecting output options
 RODSTAR  | 15

1. Click on “Measured
Pumping Unit List”.
2. Click on the “+”
symbol (on the left of
the pencil symbol).
This will open the
window shown in
Figure 3.11.
3. Enter the data in
this window starting
with the pumping
unit manufacturer
name.
4. Enter the pumping Figure 3.8 - Customizing the pumping unit database
unit data for your
pumping unit. that is not in the program’s database, do the fol-
5. When you are done entering data click on lowing:
“OK”. 1. From the setup window, click on “Custom
If you need help with one of the items you have to Rod Grades.”
enter, press ! to get context sensitive help on that 2. To add a new rod grade, click on the “+” button
(to the left of the pencil icon). This opens up a
item. For example, if you press ! when you are
new window where you can enter the name of
in one of the pumping unit dimension input fields,
the rod you want to add, the tensile strength,
the program will show you an outline drawing of
and the stress analysis method you want ROD-
the pumping unit with a visual explanation of the
STAR to use for this rod as shown in Figure
pumping unit dimensions (see Figure 3.12). To get
3.13.
more information on any of the dimensions you
see, simply click on it with the mouse. For exam- 3. You can also specify that this is a sinker bar
ple, you can click on the
“P” box to see detailed
help on the P dimen-
sion. Also, you can click
on the “See Also” hot
button to get help for
any other pumping unit
related item.

3.3.6 Rod Grade Options

Entering Custom Rod
Grades
To enter a rod grade Figure 3.9 - Selecting a manufacturer
16 |  Starting and Setting Up RODSTAR

by clicking on the
“Sinker bar” option
at the lower left
hand corner of this
window.
4. Enter the rest of the
information for the
rod you want to add
and then click on
the “OK” button.
RODSTAR allows
you to select any of the
available stress analysis
methods. Once you
enter a special rod Figure 3.10 - Customizing the pumping unit database
grade to the program,
it becomes part of the unit manufacturer. As shown in Figure 3.15, after
program’s equipment database and it works exactly you select the manufacturer, RODSTAR dis-
the same way as RODSTAR’s built-in rod grades. plays a mini-spreadsheet that you can use to enter
pumping unit costs. To enter the cost for a pump-
For example, once you enter a special rod grade, ing unit, click on the cell to the right of the pump-
you can enter cost information for it, and you can ing unit and enter the cost.
select it from the same rod grade menu that ROD-
STAR uses for the built-in rod grades. When you are done entering pumping unit costs
for the pumping units you want, click on OK. Or,
The modify (Pencil Icon) and delete (“X” Icon) if you want to enter rod string cost data, Select
options allow you to change or erase custom rod “Rod string costs” and then select the rod type
grades you have already entered. and rod grade. RODSTAR will display a mini-

3.3.7 Cost Database

When you click on
this item in Setup,
RODSTAR displays
a window, shown in
Figure 3.14, that allows
you to enter or change
pumping unit or rod
string costs. To enter or
change pumping unit
costs select “Pumping
unit costs” This makes
the window change by
showing a drop-down
list box that you can use
to select the pumping Figure 3.11 - Entering custom pumping unit information
 RODSTAR  | 17

spreadsheet for you to

enter the cost per foot
(or per meter) for each
rod diameter as shown in
Figure 3.16. You do not
have to enter cost data
for all the rod diameters
you see. Simply enter
the cost only for the rod
grades and diameters
you use.

3.3.7 Batch Mode Options

When you click on this
tab, RODSTAR displays Figure 3.12 - Custom pumping unit help
a setup page that allows
you to choose different after you run several cases with the batch process,
options relating to the batch run capabilities of the program will automatically create an Excel
RODSTAR. The top portion of this input window spreadsheet and will load it into Excel automati-
allows you to select whether you want RODSTAR cally.
to print the results of each case it runs in batch, If you check the “Don’t re-run cases with saved
whether to create a summary spreadsheet file, or output” check box, RODSTAR will not rerun
whether to rerun cases that contain saved output. cases that have saved output. When you run
Also, it lets you choose what action to take when RODSTAR in batch mode, RODSTAR saves
you load a file that contains custom rod grades as the output in the same file as the input data. Also,
shown in Figure 3.17. For example, if you want to when you run one case at a time, you can save
update the setup informa-
tion with the data in the
file, then select the option
“Update Setup with file’s
information.”
If you check the Make
Printouts check box,
RODSTAR will print
out every case you run
in batch. If you check
the Create summary
spreadsheet check box,
RODSTAR will summa-
rize the results of all the
files you run in batch in
a Excel spreadsheet file.
If you select the option
“View spreadsheet file”, Figure 3.13 - Entering custom rod grade information
18 |  Starting and Setting Up RODSTAR

the output by saving the

file to disk when you are
looking at the output. The
option to avoid rerunning
cases that contain output
is useful when you want
to create more than one
spreadsheet file using dif-
ferent spreadsheet for-
mats. Once the files have
been run with batch, each
file will contain all the
output calculations.
For example, let us as-
sume that there are two
different users (John and
Paul) who are running Figure 3.14 - Cost Database Setup Window
RODSTAR and they
each have their favor- you can click on the “+” icon at the “Spreadsheet
ite spreadsheet formats. John can run 20 cases in Setup” section of the batch window to add a new
batch mode and create a spreadsheet that sum- batch spreadsheet format (design of the spread-
marizes the values he is interested in. Later Paul sheet). Also, this section lists the spreadsheet for-
can run the same cases in batch mode and create mats you have saved. To use one of these spread-
a spreadsheet with the items he is interested in sheet formats for your next batch run, highlight it
which are different that John’s. Since John ran by clicking on it and then click the OK button to
all 20 cases, the files now contain both input and exit Setup.
calculated results. When Paul runs the same cases If you have not created any spreadsheet formats,
in batch, he checks the Don’t re-run cases with
saved output option
to save time. Since the
output results are already
saved in the RODSTAR
files, Paul’s batch run
will proceed very quickly
since all RODSTAR has
to do is extract the cal-
culated values that Paul
specified in his spread-
sheet format from these
20 cases.

Creating and/or Changing

spreadsheet formats
As shown in Figure 3.17, Figure 3.15 - Pumping unit cost database
 RODSTAR  | 19

the only format that ap-

pears is the (Default) for-
mat that RODSTAR will
use when you run it in the
batch mode and choose to
create a summary spread-
sheet file. To create a new
spreadsheet format click on
the ”+” button. This opens
the spreadsheet setup win-
dow that you see in Figure
3.18.
The list on the left side
shows the columns that
are in the spreadsheet now
and their order. The list on
Figure 3.16 - Entering rod string cost in Setup
the right shows additional
variables you can add to the the <<Add Before or <<Add After buttons in the
spreadsheet. You can use drag and drop to move an middle of the screen. However, using the mouse is
item from one list to the other. For example, to add much easier. After you are done designing the for-
rod string cost as the last column in the spread- mat of the spreadsheet, you can save it by entering
sheet, locate it on the table on the right (variables a name for it in the Format name: field at the bot-
are listed in alphabetical order) and drag it (click tom of the screen. Then click OK to return to the
and hold while moving with the left mouse button) previous screen. From here, you can create another
to the other side. When you drag a value into the spreadsheet format, or modify or delete one of the
table on the left, the cursor shows an arrow that existing formats.
shows where this new value will be added. After
you drop the new item in the spreadsheet table, To modify an existing format, click on its name
it remains highlighted.
Then, to move it up or
down in the list click on
the Move Up or Move
Down buttons below the
list of spreadsheet vari-
ables. Or, you can click on
the Remove>> button to
send the highlighted vari-
able back to the “Available
values” list on the right.
Another way to add items
to your spreadsheet is by
highlighting a value on
the list on the right, high-
lighting a value on the list
on the left, and clicking Figure 3.17 - Batch mode options
20 |  Starting and Setting Up RODSTAR

and then click on the

edit icon (pencil). Or,
to delete an existing
format, highlight it,
and then click on the
delete icon (X).

Figure 3.18 - Spreadsheet setup

 RODSTAR  | 21

4 Running RODSTAR

To start RODSTAR, double click on its icon.
After a few seconds you will see RODSTAR’s
introductory window and then the RODSTAR
main window. When RODSTAR first loads, only
the new file, open file, setup, and help buttons are
active on the toolbar. If you have not set up ROD-
STAR then do so before entering a new case (see
Chapter 1 for information on setting up ROD-
STAR).
programs have a menu bar with drop-down menus
and a control menu box at the top left corner. You
can access all menu items using either the mouse or
the keyboard. Using the mouse is by far the easiest
way.
When selecting an item from a menu, visual clues
tell you what will happen next.
♦ An item followed by no markings starts an
action. (For example, click on File and then click
on New.

4.1 RODSTAR’s User Interface ♦ An item followed by an ellipsis (...) needs

more information before taking action; normally,
RODSTAR has a user-friendly interface that the additional information is entered into a dia-
simplifies and speeds up data entry. The program log box. (For example, click on File and click on
uses standard Windows features along with other Open…)
unique features we designed to make entering and
changing data as easy as possible. Figure 4.1 shows
how to access the most recently saved files and
select the file you want to load into RODSTAR. An easy way to load files you recently saved:
If you are not familiar with Microsoft Windows, RODSTAR has a most-recently-used file list on
please take some time to study your Windows the File menu, as shown in Figure 4.1. Selecting
manual. Teaching you how
to use Windows is beyond
the scope of this manual
(although many Windows
procedures are explained).
By taking the time to un-
derstand and learn how to
use Windows, you will be
able to effectively use not
only RODSTAR, but any
other Windows program.
RODSTAR’s interface
has most of the elements
that are common to all
Windows programs. For
Figure 4.1 - The most recently saved d file list
example, all Windows
22 |  Running RODSTAR

the Recent Files sub-menu will show you up to
nine of the most recently accessed files. A file is
placed at the top of the list whenever it is loaded,
or saved with a new name. This list can also be ac-
cessed by clicking on the drop-down button on the
toolbar to the right of the open file icon.
diagram, press “P” and then click on Permissible
load diagram.
RODSTAR has context sensitive help for each
input item. To access the help, simply press !
while in the input field in question.

4.1.1 RODSTAR’s Help System 4.2 Entering Rod Pumping System

RODSTAR has a powerful help system that
provides context sensitive help for every input item. Data
Also, it allows you to easily locate help on any When entering data in RODSTAR’s input win-
subject relating to system design and simulation. It dows, it helps to know the following:
even includes a complete artificial lift glossary that
provides instant access to definitions for hundreds ♦ To replace the contents of an input box,
of artificial lift terms. Also, the help system helps
you learn how to use it by including extensive help
on itself.
Click on the Help drop-down menu to see the
Help menu choices which are:
♦ Contents..
♦ Index..
♦ Search..
♦ About RODSTAR..
To see RODSTAR’s version number, and your
sentinel’s serial number, click on About ROD-
STAR..
Click on Contents to see a list of items ROD-
STAR can provide help for. As you can see, ROD-
STAR shows text and pictures in its help screen.
For example, RODSTAR displays a picture of the
toolbar and instructs you to click on the button you
want help for. Using the mouse, you can resize or
move the Help window.
Next, click on Help and then click on Glossary to
see an alphabetical listing of artificial lift terms. To
see the definition of any of the terms in the glos-
sary, click on it. For example, click on API grav-
ity to see a definition. Also, you can click in the
list of items in the Glossary and then type a letter
to go to the terms that start with that letter. For, Figure 4.2 - RODSTAR’s Artificial
example, to find the definition for Permissible load Lift Glossary

Figure 4.3 - The Well Information input window
double click it before typing in it.
♦ If an input window contains a name that is
made up of more than one word, double click any
word to select it. Then, to replace it, simply type a
new word.
To enter rod system data in RODSTAR for the
first time, click on the first icon on the toolbar or
open the File menu and select New. This opens
the Well Information input window, shown in
Figure 4.3. You can move this window with the
mouse by dragging it to the desired location. Also,
you can use the mouse to resize this input window.
RODSTAR’s input windows use the following
unique color scheme:
♦ Required data input fields appear with a
yellow background. You must enter data in these
fields before closing the window, continuing to the
next window, or running the calculations.
♦ The active input field or list box appears in
cyan.
This color scheme helps you to easily see what data
you need and where you are in the input window.
There are two ways of moving around in an input
window. You can click the input field you want,
or you can enter data in order by pressing T to
move forward from field to field. Also, you can
press S+ T to move backwards. After enter-
ing data in fields with yellow background color,
RODSTAR  | 23
their color changes to
white when you move to
the next field.
You can get context sensi-
tive help for any input
field by pressing !.
Please use the context
sensitive help as often as
possible because it con-
tains important informa-
tion that will allow you to
make better use of ROD-
STAR. Also, the context
sensitive help makes you
aware of program as-
sumptions or limitations.
4.2.1 Entering Well Information Data
If you entered a company name in Setup, it appears
in the Company name field. This saves you from
having to enter the same company name every
time you enter data. The date defaults to the date
in your computer’s memory. If the date in your
computer is not correct, you can type over it. The
well name is required because RODSTAR uses it
to create the default file name when you save data
to disk.
The pump condition panel allows you to select
pump condition and pump efficiency or pump
fillage. To select one of these input fields click on
the input field or its label. Press ! while in one of
these fields for some useful information.
The option to have the pump condition and fillage
calculated works along with the Production Infor-
mation window. When you select this option you
must enter a pumping speed and IPR data in the
second input window. Based on the SPM you en-
ter, RODSTAR calculates the pump displacement
versus maximum available production from the
IPR data as well as the final pump intake pressure.
RODSTAR uses an iteration scheme to converge
to the correct pump condition and pump fillage
that will result from the SPM you enter, along
24 |  Running RODSTAR
with the calculated pump intake pressure.
The Production Information window also gives
you the option of having RODSTAR calculate the
required pumping speed based on a target produc-
tion you enter. However, the option of calculat-
ing the SPM from your target production is
only available if you select a full pump. For fluid
pound or gas interference, you must enter a pump-
ing speed in the Production Information window.
Other input data in the Well Information window:
Comment
You can enter a comment about the case. You can
type up to 100 characters in the comment field.
The comment string you enter is included on the
screen and printed outputs.
Pump Load Adjustment (RODSTAR-V Only)
The pump load adjustment allows you to increase
the fluid load picked up by the plunger. Usually
this is unnecessary. However, this input allows you
to account for extra downhole loads due to exces-
sive downhole friction (for example due to wellbore
deviation), or due to the “plunger effect” of large
sinker bars. It is recommended that you use zero
for this number unless you have more than 1000
feet of large sinker bars such as 15/8’’ or 1¾’’ bars
in 2’’ tubing. The value of this number in pounds
is typically 5% to 10% of the pump depth in feet.
For example, for a pump depth of 6000 feet, enter
a value of 300 to 600 pounds (but only if you use
more than 1000’ of large sinker bars). RODSTAR
will not allow you to enter a value that is larger
than 15% of pump depth. Also, you can use this
input to add pump load for more conservative
predictions.
Please note that RODSTAR assumes that the
tubing-casing annulus is full of oil. It calcu-
lates the specific gravity of the oil from the API
gravity you enter. If you do not agree with this
assumption then change the oil API gravity
to correspond to the specific gravity you want
RODSTAR to simulate. For example, if you
want to simulate water in the casing-tub-
ing annulus instead of oil, then enter an API
gravity of 10 (which corresponds to a fluid
specific gravity of 1.0).
Percent water cut
The percent water cut input along with oil API
gravity allows RODSTAR to calculate a default
specific gravity for the produced fluid. Also, it uses
this data to calculate $/bbl (or $/m3) electricity
costs.
Oil API gravity
RODSTAR uses the oil API gravity to calculate
fluid load on the plunger and the default specific
gravity of the produced fluid. Also, as discussed
above, RODSTAR uses this number to calculate
the specific gravity of the fluid in the casing-tubing
annulus which it assumes to be 100% oil.
Fluid specific gravity
RODSTAR uses the oil API gravity and per-
cent water cut you entered to calculate the default
specific gravity of the produced fluid. The program
will display this value when it prompts you to enter
the fluid specific gravity. RODSTAR calculates
the default specific gravity without considering free
gas. This is okay for designing new wells since we
prefer to be more conservative. However, if you
want to simulate an existing system that produces
gas, you must enter a lower number than the one
calculated by RODSTAR. With some experience
and with “history-matching” between predicted
and actual dynamometer cards you can come up
with effective specific gravities that will accurately
model your rod pumping systems. If you use a
specific gravity that only considers liquids, it will
result in higher predicted loads, power consump-
tion, etc.
If you are designing a new system and you are not
sure what the specific gravity is, use the higher
 RODSTAR  | 25

value you expect to have to make sure that your and bubble point pressure. Also, you can enter
system will not be overloaded when in operation. from one to 10 test points. If you select to use the
However, when matching measured dynamometer Vogel method for the oil IPR calculations then
cards, use a specific gravity that is as close as pos- you only need one point. If you use Vogel and enter
sible to the actual value. more than one point, then only the first point is
used. You can enter more than one test point if you
After you finish entering data for the Well Infor-
use the Fetkovich method. The pressure that cor-
mation window click on the next screen button
responds to each production test point can either
(right arrow) on the toolbar to open the Production
be pump intake pressure or flowing bottomhole
Information input window. To move back to the
pressure (in the middle of the perfs). To add a new
previous window, simply press the left arrow icon
pair of Pi and Fluid production data, click on the
on the toolbar.
add button (top right) icon. To delete a set of data
Remember that pressing @ converts to the op- points, click on the remove icon (bottom right).
posite system of units. For example, if you selected
You can get help for any input item by pressing !
English units but want to enter the pump depth
when in the input field or by clicking on the ques-
in feet, press @ before entering the value. If the tion mark icon on the toolbar.
value for any field with units has already been
If you do not know what the bubble point pres-
entered, pressing @ will show it in the opposite sure is, but you know the well is producing below
units. the bubble point pressure, then leave the bubble
point pressure field blank and click on “Producing
below bubble point” or in the check box next to
4.2.2 Entering Production Information it. After you enter the last piece of IPR data, click
The Production Information input window allows to a different input field, press T or click on the
you to enter a fluid level or pump intake pres- “Update prod.” button to allow RODSTAR to
sure as shown in Figure 4.4. Also, you can select calculate the maximum oil, water, and fluid pro-
to enter a pumping speed,
enter a target production
(the program will calculate
the pumping speed to get
the target production), or
you can select to calculate
the target production from
inflow performance data.
If you choose to enter IPR
data, the Production In-
formation window expands
to reveal the data you must
enter. This includes the cor-
relation you want to use for
the inflow performance re-
lationship (IPR), the depth
from surface to the middle
of the perforations, the
static bottom hole pressure, Figure 4.4 - The Production Information input window
26 |  Running RODSTAR

whether you want to enter

the value or have ROD-
STAR calculate it from
your data. If you enter
only one test point, ROD-
STAR uses a value of 1.0
for n unless you select
to input your own value.
However, if you enter
two or more test points,
RODSTAR calculates n
from a log-log plot.
If you enter inflow per-
formance (IPR) data,
RODSTAR can calculate
the pump intake pressure
using the target produc-
tion you have entered
(see Figure 4.7). You can
select to have RODSTAR
calculate the pump intake
Figure 4.5 - The inflow performance relationship (IPR) plot pressure from the IPR
data, or if there is no IPR
duction rates and target production. data available, you can
You can see the IPR plot by clicking on the IPR enter a pump intake pressure or fluid level yourself.
Plot... button (under the target production field). Usually, for new systems, it is recommended that
When the IPR plot is displayed as shown in Fig- the system be designed for the highest possible
ure 4.5, you can move the cyan line that you see
on the plot with the mouse to see the calculated
production rate for any bottomhole pressure. To
move this line, point to it with the mouse until
the mouse cursor changes shape and then drag the Figure 4.6 - Fetkovich ‘n’ value
line to any pressure point on this plot. As you are
moving this line, the producing bottom hole pres-
sure, pump intake pressure, oil production, water fluid load on the plunger. This is accomplished by
production and total fluid production are dynami- entering a fluid level that is equal to pump depth.
cally recalculated. You can print the IPR plot you
see on the screen by clicking on the Print button
at the bottom right hand corner of the screen, or 4.2.3 Entering Pump and Tubing Information Data
you return to the production information screen by
On the third input screen, you can select the
clicking on Close.
tubing size, tubing anchor depth (if anchored),
RODSTAR offers you the option to enter the pump type, plunger size, and the upstroke and
value of n for the Fetkovich IPR correlation as downstroke rod-tubing friction coefficients. Also,
shown in Figure 4.6. The window includes a check for shallow, high rate wells, you can include fluid
box, labeled Calculate ‘n’, that tells RODSTAR

inertia effects. If you
select to include fluid
inertia effects then you
must also enter the fluid
compressibility index. Figure 4.7 - Options for calculating pump intake pressure
For more information
on this option read the
discussion that follows later in this section, or use
the context sensitive help system.
You can select the pump plunger size from a list
of standard sizes, or you can enter a non-standard
size by selecting “Other” from the list of plunger
sizes. If you are simulating a full pump and you
entered a target production, you can select to have
RODSTAR recommend the pump plunger size for
you. This option is only available when you enter
a target production and select full pump for pump
condition.
Please note that the pump type you select affects
the plunger size that the program will recommend.
It may be interesting to make one run with an
insert pump type and one with a tubing pump to
see what RODSTAR recommends.
Other input data in the Pump and Tubing Information
window:
Rod-tubing friction coefficients
For rod-tubing friction , RODSTAR-V allows you
to enter upstroke and downstroke friction coef-
ficients yourself, or you can have the program cal-
culate them for you. If you do not know what to
enter, then choose to have RODSTAR-V calculate
the rod-tubing friction for you. The friction fac-
tors calculated by RODSTAR-V are estimates for
average friction for a vertical wellbore. If you are
simulating a system with excessive downhole fric-
tion, you must enter your own rod-tubing friction
coefficients for more accurate results. There are
several downhole conditions that increase rod-tub-
 Fluid inertia effects are dynamic effects
that increase fluid load on the plunger in wells less
than 4000 feet with pump plungers larger than 2.0
inches
RODSTAR  | 27
ing friction such as: wellbore deviation, a well with
heavy oil production, paraffin or scale problems,
etc.
The most accurate way to figure out the rod
tubing friction in RODSTAR-V is to im-
port a measured dynamometer card from a
RODDIAG or XDIAG file. Then, “ history-
match” this actual card by manually adjust-
ing the friction. You do this by varying the
upstroke and downstroke rod-tubing friction
coefficients until the surface dynamometer
card predicted by the program matches the
measured dynamometer card. This technique
allows you to find the rod-tubing friction
that gives the best results when simulating
this system. From then on you can use these
friction factors every time you simulate this
pumping system.
Please note that this “history-matching” technique
works only if the dynamometer card that you mea-
sure corresponds to a pump condition that ROD-
STAR can simulate (full pump, fluid pound, or gas
interference). For example, if the pump is worn out
or is hitting up or down, etc., then this technique
will not work as well. This is because you will be
unable to get a good match between predicted and
measured dynamometer cards.
If you do not have a measured dynamometer card,
use the following guidelines for entering rod-tub-
ing friction coefficients in RODSTAR-V:
1. First select to have RODSTAR-V calculate
the rod-tubing friction coefficients for you. You
can use these calculated values as guidelines to
decide what values to enter yourself to better
simulate your rod pumping system.
2. For heavy oil or for wells with paraffin or scale
buildup, use 2-3 times the value calculated by
RODSTAR-V. You can use the same guideline
28 |  Running RODSTAR
for deviated wells when the deviation is close to
the bottom of the wellbore.
3. For deviated wells with the deviation close
to the surface you may need to enter a larger
number such as 4-6 times as high as the values
calculated by the program. Also, it may be
appropriate to use different values for upstroke
and downstroke frictions to better match your
downhole conditions.
The above comments refer to RODSTAR-V.
RODSTAR-D can calculate the effect of deviation
(such as side load) from the deviation survey.
RODSTAR-D Friction Coefficients
In RODSTAR-D, the upstroke and downstroke
rod-fluid damping coefficients on the pump and
tubing information window are only for fluid
damping on rods. RODSTAR-D also allows you
to enter rod-tubing friction (drag) coefficients for
each rod string section in the rod string input win-
dow. The default bare rod rod-tubing drag friction
coefficient is 0.2. The range for this value is from
0.1 (for oil lubrication between smooth rods and
tubing) to 0.3 (for high water cut wells and rough
rod and tubing surfaces). Again, the best way to
determine what to use is by plotting a measured
dynamometer card on the same plot as the pre-
dicted dynamometer card and changing the values
of the rod-tubing friction coefficients for each sec-
tion of the rod string. You can do this by loading a
RODDIAG or XDIAG file into RODSTAR.
To simulate the effect of rod guides, you need to
adjust the friction coefficients for each section
of the rod string. You can use the ratio of guide
friction to bare rod friction to adjust the default
friction coefficient. For example, the friction ratio
default value for molded rod guides is 1.5. This
means that if you use molded rod guides, you need
to increase the rod-tubing friction coefficient by
50% to accurately simulate the additional rod-
tubing drag. So, if you use molded rod guides,
you need to enter a friction coefficient of 0.3
(0.2*1.5=0.3) for the section of the rod string with
the molded rod guides.
Rod guide manufacturers need to provide you with
friction ratio values for the different rod guides
they make.
Buoyancy effects
The option to include buoyancy effects should
be left unchecked in most cases. This is because
buoyancy does not cause buckling of the rod string.
However, for fiberglass-steel rod strings, after the
design is finalized, It is recommended that an ad-
ditional run be made including buoyancy effects to
ensure that the fiberglass portion of the rod string
is not in compression. If it is in compression, then
more sinker bars must be used, the pumping speed
need to be reduced, or both.
When buoyancy is not included, the bottom of
each rod section except the last section should have
a positive stress. Otherwise the rods may be going
into buckling. It is normal for the very bottom of
the rod string to be in compression if you enter a
pump friction that is not zero (a minimum pump
friction of 200 lbs is recommended).
For more information on the theory behind these
recommendations, please read SPE paper number
25416 “Interpretation of Calculated Forces on
Sucker Rods” by J. F. Lea and P. D. Pattillo. Pre-
sented at the Production Operations Symposium
in Oklahoma City, March 1993.
Fluid inertia effects
If the well depth is less than 4250 feet and the
pump plunger size is larger than 2.00 inches,
RODSTAR allows you to consider fluid inertia
effects. These dynamic effects become important
in wells with plungers larger than 2.0” and pump
depths of 4000 feet or less. However, there is no
exact “magic” depth for which fluid inertia be-
comes important. Therefore, RODSTAR allows
you to include these effects for wells up to 4250
feet deep and with a plunger size equal to or larger
than 2.0”. Another important factor is fluid com-
 RODSTAR  | 29

pressibility. The more compressible the fluid is, the 4.8.

less prominent the fluid inertia effects are.
If you include fluid inertia effects, RODSTAR will
prompt you for the fluid compressibility index. The
default is 3 but you can vary this number between
1 and 7 (x10-6 psi-1). The compressibility index
tells RODSTAR how compressible the fluid in the
tubing is. The value of the compressibility index af-
fects the shape of the predicted dynamometer cards
(surface and downhole). If you are not sure what
number to use, experiment with different values
until you can match measured dynamometer cards
for the well you are simulating. When you include
fluid inertia effects, pump efficiency becomes a vari- Figure 4.8 - Rod string entry options
able that affects the dynamic fluid load on the plunger.
Therefore, using 90% pump efficiency gives higher
peak polished rod load than using 80%.
The option to include fluid inertia effects is only RODSTAR Steel Design
available if you are modeling a full pump. Please
do not confuse fluid inertia effects with the mo- If you select this option, RODSTAR displays
ments of inertia of the pumping unit that have to a window such as the one shown in Figure 4.9.
do with gearbox torque due to prime mover speed Here, you can select the maximum and minimum
variation. Fluid inertia effects refer to additional rod diameters to consider, whether to include
dynamic forces on the plunger caused by the sinker bars, the service factor, and additional rod
pickup and rapid acceleration of the fluid load. costs.
RODSTAR simulates fluid inertia effects with If you want to include sinker bars then you must
a second wave equation that models the pressure enter the diameter and length of the bar (or sinker
waves in the fluid in the tubing. This increases rod). RODSTAR does not calculate the length of
simulation accuracy by accounting for pressure the sinker bar section because there is no industry
pulses traveling up and down in the tubing fluid. consensus on how to design sinker bars. However,
These pressure waves have a direct affect on the RODSTAR will design the rod string above the
pump plunger. Since the program has to do many sinker bar section you specify.
additional calculations when you include fluid RODSTAR attempts to design an optimum rod
inertia effects, RODSTAR may take 60%-80% string based on the rod grade and the maximum
longer to run. and minimum rod diameters you enter. First,
RODSTAR figures out how many rod tapers are
needed. Then, it automatically adjusts the length
4.2.4 Entering Rod String Data of each section until the stress loading is the same
at the top of each rod section. This equalizes and
The fourth input window deals with the rod string
minimizes stress loading on the rod string. This
design. As Figure 4.8 shows, you can select one of
“stress balancing” approach gives the lowest cost
the three available rod string entry options:
rod string with equally distributed stress loading,
RODSTAR Steel design, RODSTAR Fiberglass- for the rod grade you select.
Steel design, or Manual rod string entry. The
This approach works the same regardless of steel
symbols for these options are explained in Figure
30 |  Running RODSTAR
rod grade or type. For example, you can have
RODSTAR design a Corod rod string for semi
elliptical “Ultra” Corods using a maximum diam-
eter of 17/16”, a minimum diameter of 13/16”, and
a 375’ section of 1 5/8’’ sinker bars on the bot-
tom. RODSTAR uses only the rod sizes it needs.
For example, if the loads are not high enough to
require the use of the 17/16” rod diameter then
RODSTAR will go to the next size (16/16”). If
this is still too big, it will use the 15/16”.
The maximum rod loading used by RODSTAR
to decide when the next larger diameter rods
are needed is 95% by default. However, you can
change this number if you like by going to the
Setup “Defaults” window.
Fiberglass/steel RODSTAR design
If you select the option to have RODSTAR-V de-
sign a fiberglass-and-steel rod string, you will see
the data input screen in Figure 4.10. For example,
let us say you want to use a design with fiberglass
rods on top followed by a tapered steel section with
1” and 7/8” rods, and then 375 feet of 1” sinker
bars. RODSTAR is able to design this rod string
for you. Also, it balances the steel design under the
Figure 4.9 - Steel rod string design options
fiberglass section (for two or more rod sections) so
that there is equal stress loading at the top of each
section as shown in Figure 4.11.
This Figure shows a fiberglass-steel rod string
designed with RODSTAR-V. RODSTAR-V can
design tapered steel rod strings under the fiber-
glass section for any type of steel rod, including
non-API high strength rods, and Corods. If you
want to fine-tune a RODSTAR design, select to
enter your own rod string design by clicking on
the manual rod string entry icon. RODSTAR will
show you the current rod string design in memory
as if you entered it yourself. Then, you can make
any changes you want to the rod string without
having to reenter everything.
Also, you can have RODSTAR design the rod
string while calculating the pumping speed and
plunger size, to get the target production. How-
ever, because of the complexity of the calculations,
simultaneous use of all or most of RODSTAR’s
“smart” options will result in longer run times.
This is especially true if you also select to include
the effect of prime mover speed variation. Also,
depending on the case, RODSTAR’s run time may
be longer if you enter a target production that is
too large for the pumping system.
 RODSTAR  | 31

If you select only sinker bars on the bottom (with-
out regular steel rods between the fiberglass and
sinker bar) then RODSTAR will calculate the
length of the sinker bar section for you. If you
select both sinker bars and a tapered steel design
between the sinker bars and the fiberglass rods,
then you must enter the length of the sinker bar (or
sinker rod) section. RODSTAR will determine the
length and diameters of the tapered steel portion
tapered steel section under the fiberglass, and a
500 foot 1.5 inch sinker bar section on the bottom.
RODSTAR will determine the fiberglass diameter
and length you need, and the steel rod section and
tapers you need. If RODSTAR cannot balance the
steel rod string design because the 3/4’’ section is
not needed, it will not use any 3/4” rods.
Another interesting capability of RODSTAR is
that if you use continuous rods (Corod or Prorod)

Figure 4.10 - Fiberglass rod string design window

instead of regular rods under the fiberglass, it may

based on the maximum and minimum diameter
limits you enter.
RODSTAR may reject a steel rod diameter if it is
not needed. For example, if you asked RODSTAR
to design a rod string with fiberglass on top, a
skip a rod diameter, if it has to, in order to bal-
ance the rod string stress loading. This is not a bug.
Sometimes the program has to do this to success-
fully balance the steel portion of the rod string.

Figure 4.11 - RODSTAR Designed Fiberglass-Steel Rod String

32 |  Running RODSTAR

Figure 4.12 - Selecting rod grades in RODSTAR

Entering Your Own (Manual) Rod String can be up to 50 feet shorter than the pump depth.
However, it cannot be longer than the pump
This option is primarily used for entering rod
depth. For example, if the pump depth is 5000
string data for an existing system you want to
feet, you can enter a rod string that is between
simulate, or to modify a design that RODSTAR
4950 and 5000 feet. When entering rod string
itself came up with (when you select to have the
data for the first time, RODSTAR shows a default
program design the rod string for you). This is
length for the last rod section equal to the differ-
not a good option to use when you first design a
ence between the pump depth and the rod string
new system because it requires the most work and
length you entered so far.
experience.
Selecting the option to enter your own rod string
When you select this option, you can enter data for
gives you maximum flexibility. However, it re-
either steel or fiberglass rods as Figure 4.12 shows.
quires the most expertise to come up with a good
You can enter the number of rod sections, the ser-
rod string design. You can use this option to select
vice factor you want to use, and rod string data for
different rod grade or manufacturer for each rod
up to eight rod sections. For each section, you can
section. In general, this option allows you to enter
select the rod type or grade, diameter, and length.
any rod string design, no matter how unusual. The
For Fiberflex fiberglass rods you can also specify
minimum length you can enter for any rod section
the sucker rod length.
is 25’ (length of a single sucker rod).
If you select one of the fiberglass manufacturers
When entering the rod string data manually,
listed on the drop down list next to the rod grade
RODSTAR allows you to add and remove rod sec-
input field, the program knows the weight per
tions from anywhere in the rod string, instead of
foot and modulus of elasticity and will not prompt
only at the bottom. The window has icons on the
you for them. The program warns you about rods
left side for inserting a rod section, for removing
that do not fit in the tubing. Also, it warns you if
a rod section, or for moving a section up or down.
the rod string length is shorter or longer than the
For example, if you want to remove a rod section,
pump depth. The total length of the rod string
first click on it and then click on the Delete Rod
 RODSTAR  | 33

rod section icon.

To add a rod section,
click on an existing rod
section and then click
on the Insert/Add Rod
Section icon. The new
section will be added be-
low the selected section.
RODSTAR asks for
confirmation when-
ever you remove sections
from the rod string,
whether by using the
Remove rod section
button or by reducing
the number of rod sec-
tions.
Figure 4.13 - Wellbore deviation entry window

The meaning of the term Manual Entry of Deviation Survey

“Sinker Bar” in RODSTAR
In RODSTAR, the term “sinker bar” means a
steel rod that is made specifically to be used at the
bottom of the rod string for weight such as 1 3/8”,
1½”, 1 5/8”, etc. The term “sinker rod” means a
regular rod such as a 1” or 7/8” rod that is placed
on the bottom of the rod string for weight. For a 1”
or 7/8” rod to be considered a “sinker rod” it must
be larger than the diameter of the rod above it.
When entering the rod string manually, make sure
you select “Sinker bars” in the list of rod grades for
sinker bars as shown in Figure 4.11. Do not select
“Steel” rod type and then “Other” for the rod size.
To enter the deviation survey manually, you need
to know how many deviation points you have and
the measured depth, inclination and azimuth of
each deviation survey point.
Start by entering the number of survey points as
shown in Figure 4.15. As soon as you enter this
number, the program will created the correct num-
ber of rows for you to enter the data as shown in
Figure 4.16. The easiest way to enter the data is by

4.2.5 Entering Wellbore Deviation Data (RODSTAR-D)

RODSTAR-D has an additional input window
for entering wellbore deviation shown in Figure
4.13. Figure 4.14 explains the meaning of the icons
shown on the left side of this input window. You
can activate these icons by clicking on them with
the mouse.
Figure 4.14 - Deviation entry icons
34 |  Running RODSTAR

the numbers in the other columns of the

Figure 4.15 - Enter the number of entries
deviation input window. These numbers
are Dogleg severity, True Vertical Depth
(TVD), North-South distance (N-S),
and East-West (E-W) distance in feet or
meters.
Double-check your data to make sure
you are entering the numbers correctly

Figure 4.16 - Entering deviation data manually

using the tab key to move from field to field.

The “Add Entry” and “Remove Entry” buttons can
be used as needed. At any time during the data
entry, you can click on the “Plot Survey” tab to see
a 3-D plot of the wellbore deviation entered so far.
When inputting the Azimuth, RODSTAR recog-
nizes both degrees (i.e. 340) and degrees/minutes
formats (i.e. N20W or N20 0W). As you continue
to enter the deviation data, the program calculates
Figure 4.17 - Import Wizard Options
 RODSTAR  | 35

and will not display

any directional indica-
tors (i.e. N20E or N20
0E will be displayed as
20).

Using the Deviation

Survey Import
Wizard
You can use the de-
viation import wizard
option to import a
spreadsheet with devia-
tion data, or to import
a deviation survey
from a RODSTAR file
previously created with
Figure 4.18 - Step 1 of the Deviation Import Wizard RODSTAR-D and
which contains devia-
(especially if you see dogleg severity numbers in
tion data.
red).
To Import a Deviation Survey, click the “Import
If RODSTAR is being used to analyze an exist-
Wizard” button. Using the Import Wizard Dia-
ing well, the Deviation Survey Direction Toolbar
log window, select the source of your Deviation
should be disabled. To disable this toolbar, click
Survey. In this example we are using a Microsoft
the Setup icon, click the Defaults option, and un- Excel spreadsheet.
check the box labeled
“Show Deviation
Direction Toolbar”.
The Deviation Survey
Direction Toolbar
is used to design a
deviated well. While
the toolbar is active,
the Azimuth is input
in degrees and the
toolbar is utilized to
designate a direction.
Select a direction first,
then input the degree
value. The field will be
automatically updated
with the direction once
the field is left.
NOTE: The NE
Figure 4.19 - Step 2 of the Deviation Import Wizard
direction is the default
36 |  Running RODSTAR

Figure 4.20 - Step 3 of the Deviation Import Wizard

Figure 4.21 - The last screen of the Deviation Import Wizard

 RODSTAR  | 37

Figure 4.22 - The deviation survey after it was imported

Figure 4.23 - The 3-D Plot of the deviation Survey

38 |  Running RODSTAR
Step 1 prompts you to select the file to be imported
as shown in Figure 4.18.
Step 2 allows you to select the Workbook and
Spreadsheet to use in cases where there are more
than one in the Excel file as shown in Figure 4.19.
Step 3 automatically locates the columns in the
spreadsheet where the values are stored for the
Measured Depth, Inclination, and Azimuth as
shown in Figure 4.20.
The next step loads the data and then finishes as
shown in Figure 4.21.
Click “Done” and view the imported deviation
survey data as shown in Figure 4.22.
Please keep in mind that for program to be able to
load the deviation data from an Excel spreadsheet,
it must see three columns with the deviation data.
These columns need to be labeled as follows:
“Measured Depth (ft)” or “MD (ft)”, or “MD (m)”
“Inclination”
“Azimuth”
Clicking the “Plot Survey” tab on the right side
of the window will display the Deviation Plot as
shown in Figure 4.23. From this screen, you can
rotate the plot to better understand and visualize
the wellbore deviation, you can zoom in, etc.
4.2.6 Entering Pumping Unit Data
The pumping unit input screen allows you to select
a pumping unit from the database that comes with
RODSTAR, or from your measured pumping unit
database (if you entered your own pumping unit
dimensions in Setup).
Another option is to enter a pumping unit ID.
The pumping unit ID is a unique string of letters
and numbers. RODSTAR displays the pumping
unit ID along with other unit information after
you select a unit. If you make a note of this unit
ID (in the well file for example), you can use it
to specify the pumping unit instead of having to
select it from the list. This is a unique ID for each
pumping unit in the program’s database.
Selecting a pumping unit manufacturer
RODSTAR allows you to easily select a pumping
unit manufacturer and unit size with drop-down
list boxes. To display the menu with all pumping
unit types available, click on the drop arrow next
to the “Manufacturer” field (see Figure 4.24).
This is a scrollable list of all units in the program’s
database in alphabetical order. You can go to the
top of the list by pressing}. You can jump to
the bottom of the list by pressing ~. You can
also move up or down by pressing O (Page up)
or N (Page Down). A convenient way to move
through the list is to press the first letter of the
unit name you want to use. For example, to locate
the National “E” Series pumping unit entry, you
can press n and the highlight bar will jump to
the first name in the list that starts with N. Then
simply click on the National “E” Series entry. At
the top of the list of pumping unit manufactur-
ers is the item (Measured pumping units). This
option allows you to select a unit for which you
entered geometric data in Setup.
When you select the (Measured pumping units)
option, RODSTAR will display a list that only
shows the measured pumping units, as Figure 4.25
shows.
As Figures 4.24 and 4.25 show, there is a check
box that allows you to use the custom pumping
unit list instead of the main pumping unit list. If
you check this option, before you select a unit,
the Manufacturer list will show a shorter list that
contains only the manufacturers you selected in
Setup in your custom unit list as shown in Figure
4.26. When the “Use custom pumping unit list”
option is checked, when you select a pumping unit,
you will see a short list containing only the unit
sizes you selected for your customized list for this
manufacturer.
After you select a manufacturer you can use the
same procedure to select the unit size you want
from the pumping unit drop-down list box . You
 RODSTAR  | 39

Figure 4.24 - Pumping unit manufacturer list

can move through this list the same way as with How to add units to the custom pumping unit list
the pumping unit manufacturer selection menu.
You can use the “Use custom pumping unit list”
The pumping units on this menu are ordered from
check box to add units from the main list to your
largest to smallest stroke length, gearbox size, and
custom list. For example, if you run across a pump-
structure size. However, if the window shows the
ing unit that is not in your custom list yet, clear
pumping unit name (for old units) the units are
the “Use custom pumping unit list” check box so
listed alphabetically.
that you can use the general pumping unit list.
When you enter a unit, the Unit ID, the program
After you select the pumping unit then click on
automatically displays the unit that the ID cor-
the “Use custom pumping unit list” check box.
responds to. RODSTAR displays the information
RODSTAR asks if you want to add this pumping
necessary for you to correctly identify your unit.
unit to the custom pumping unit database. Select
For example, for American conventional units you
Yes to add this unit to your custom list. The pro-
will see that certain unit sizes appear more than
gram will add this unit to the custom list and also
once on the selection list. However, they have dif-
switches to the custom list.
ferent cranks.
This option only allows you to add units to your
custom list without having to do it from Setup. To
remove units from your custom list or to add more
40 |  Running RODSTAR
Figure 4.25 - Measured pumping unit list
than one unit, go to the setup window and cus-
tomize the list of units as described earlier in this
manual.
Selecting to enter a pumping unit ID
The unit ID option is the fastest way to enter
pumping unit information if you already know
the pumping unit ID for your unit. You can see
the pumping unit ID on the pumping unit entry
window after you select a unit. Once you locate
your unit, you can make a note of its ID in the well
file. Then, the next time you want to use this unit,
you can select to enter its ID. For example, for a
Lufkin Mark II M-456-305-144, the unit ID is
ML32.
To identify some units correctly, it is necessary
to know the crank number since they may have
the same API designation but different geometric
dimensions depending on crank number (primarily
units made by American International Manufac-
turing Company).
TIP: If your unit is not listed in RODSTAR
and you do not have the unit dimensions, then
use a unit that is closest to it. As long as you use
the same unit geometry and a unit with the same
stroke length and gearbox rating, the results should
be close to actual as long as the pumping unit is
the same unit type as the one you selected.
If after you enter a pumping unit ID RODSTAR
displays “The pumping ID you entered is not valid”
this means that ID you entered is not recognized
by RODSTAR. This can happen for two reasons:
1) You entered the wrong ID such as R0 (which
does not exist), or CL901 instead of CL91.
2) You have erased the pumping unit file by acci-
dent, or the pumping unit files are not in the same
directory as the program.
RODSTAR Recommended unit size
If you enter a target production instead of pump-
ing speed, RODSTAR will display a recommended
pumping unit size to help you select a pumping unit.
This recommendation can be very helpful if you are

Figure 4.26 - The custom pumping unit list
designing a new pumping system and must decide
what size unit you need. RODSTAR recom-
mends sizes that are closest to conventional units
as Figure 4.27 shows. Therefore, if you plan to use
uncommon unit geometries such as the Rotaflex,
then this recommendation may not be as useful.
RODSTAR makes this recommendation with-
out running through the predictive calculations.
Therefore, it may not necessarily recommend the
best pumping unit size for your application. How-
ever, in most cases it should be pretty close to the
size you need.
There are other important factors that you must
consider when deciding what unit size you need.
These include: available used pumping units, ex-
pected changes in well conditions, desired pump-
ing speed, etc. When you enter data for a case
for the first time and you are at the pumping unit
selection screen, RODSTAR will not only display
the recommended unit size, but will automatically
select the unit closest to the recommended size
from the available list. If you do not want to use
the unit recommended by RODSTAR then select
RODSTAR  | 41
another one. The recommended unit size is a push
button, as shown in Figure 4.27. So, whenever you
want to return to the pumping unit size recom-
mended by RODSTAR, just click the button and
RODSTAR will automatically select the unit size
that is closest to the recommended size.
In general, the size recommended by RODSTAR
will be close to the minimum required conventional
unit. RODSTAR recommends only the API unit
size. You must decide what manufacturer and
unit type to use. If you select a conventional unit
and RODSTAR predicts that the gearbox will
be overloaded, then try using the same size Mark
II or enhanced geometry unit. In some cases you
may be able to use a smaller unit by selecting a
geometry that is better suited for your application.
There are several factors that determine what unit
is best. They include, cost, gearbox loading, system
efficiency, rod compression, minimum polished rod
load (indicates separation of the polished rod from
the carrier bar if close to zero), etc.
42 |  Running RODSTAR
Figure 4.27 - RODSTAR recommends a unit size based on target production
Selecting crank hole number and crank rotation
After you select a pumping unit you must select
the crank hole number, and the direction of rota-
tion with the well to the right (if you are using a
unit that can rotate either way). For units with a
required direction of rotation, like the Mark II ,
Torqmaster, Lufkin Reverse Mark, or American
Producer II, the program will not allow you to
change crank rotation. For units that can rotate
either clockwise or counterclockwise, RODSTAR
defaults to the direction of rotation that will usu-
ally give the lowest torque. However, this default
direction of rotation may not always be ideal for
your system design. To find out for sure which
rotation is best for your system you must make
two runs: one with clockwise crank rotation and
one counterclockwise. Then look at the effect of
rotation on gearbox torque, system efficiency, rod
loading, etc.
Entering your own pumping unit data
If the pumping unit you want to simulate is not
in RODSTAR’s database, you can enter your own
pumping unit dimensions. To enter the data in the
program you have to first access the setup screen
of RODSTAR (click on fourth button on toolbar).
Then, double-click on “Pumping Unit Options”
tab and select “Measured Pumping Unit List” as
explained in section 3.3.5 in this manual. Then,
select to add a new unit to enter data for a new
pumping unit.
The data you must enter consists of geometric
dimensions as defined in the API 11E publication.
You can get these dimensions from the pumping
unit manufacturer or measure them yourself. Or,
you may be able to find most of the dimensions
you need from catalogs or blue prints. For old units
without an API designation on their nameplate,
you may be able to put together an equivalent API
designation. Look at the gearbox nameplate for the
gearbox rating in thousands of in-lbs. Measure the

stroke length, and try to decipher additional infor-
mation from the unit’s nameplate for the structure
rating, stroke length, and structural unbalance.
If the nameplate is legible then write down the
unit’s serial number or order number. If the unit’s
manufacturer is still in business, you may be able
to get the data you need from the serial number
or order number. For help in locating dimensional
data for pumping units not in the manual call
Theta Oilfield Services, Inc..
RODSTAR allows you to enter data for Conven-
tional, Mark II, Air Balanced, Enhanced Geom-
etry, or Long Stroke units. When you enter your
own pumping unit dimensions, RODSTAR cal-
culates and displays the stroke length based on the
dimensions you enter. For all pumping unit types
you must first enter the name of the manufacturer,
the unit name or model number, the gearbox rating
in thousands of inch pounds, the structure rating
in hundreds of pounds, and the maximum stroke
length in inches. From these numbers RODSTAR
puts together the API pumping unit designation.
The API pumping unit designation is a standard
way of describing the size and capacity of pumping
units as the following example explains:
The first number is the gearbox rating in thousand
inch-pounds. In this example the gearbox rating is
320,000 inch-lbs. The second number is the struc-
ture rating in hundreds of pounds. In this case the
structural rating is 256. This means that to avoid
overloading the structure of the unit, polished rod
load must not exceed 25,600 lbs. The last number
shows the maximum stroke length of the unit in
inches (100 inches in this case). Following is an
explanation of the rest of the data needed for each
unit type:
Conventional and Enhanced Geometry
Pumping Unit Data
For these units you must enter pumping unit di-
mensions R, A, C, I, P, and K in inches, the struc-
tural unbalance in pounds, and the crank offset
angle in degrees. For enhanced geometry units the
crank offset angle must be negative. The API spec.
RODSTAR  | 43
11E defines the above dimensions as follows:
Dimension: Description:
R Radius of the crank (inches)
A Distance from the centerline of the
saddle bearing to the centerline of
the polished rod (inches)
C Distance from the centerline of the
saddle bearing to the centerline of
the polished rod (inches)
I Horizontal distance from the
centerline of the saddle bearing to
the centerline of the crankshaft
(inches)
P Effective length of the pitman
arm, in inches (from the center of
the equalizer bearing to the center
of the crank-pin bearing)
K Distance from the center of the
crankshaft to the center of the
saddle bearing (inches). Some-
times, instead of the K dimen-
sion, pumping unit manufacturers
supply data for dimensions H and
G instead (described below). From
these dimensions and dimension I
(defined above) you can calculate
) 2
K as follows: K= ( H-G + I
2
H Height from the center of the
saddle bearing to the bottom of
the base beams (inches)
G Height from the center of the
crank shaft to the bottom of the
base beams (inches)
Mark II Pumping Unit Data
For Mark II units you must also enter pumping
unit dimensions R, A, C, I, P, and K in inches, the
structural unbalance in pounds, and the crank off-
set angle in degrees. This angle is positive for Mark
II units. The API spec. 11E defines the above
dimensions as follows:
44 |  Running RODSTAR
Dimension: Description:
R Radius of the crank (inches)
A Distance from the center of the
Sampson Post bearing to the cen-
terline of the polished rod (inches)
C Distance from the centerline of the
Sampson Post bearing to the cen-
ter of the equalizer (or cross yoke)
bearing (inches)
I Horizontal distance between the
centerline of the Sampson Post
bearing and the centerline of the
crankshaft (inches)
P Effective length of the pitman
arm, in inches (from the center of
the equalizer (or cross yoke) bear-
ing to the center of the crank-pin
bearing)
K Distance from the center of the
crankshaft to the center of the
Sampson Post bearing (inches)
H Height from the center of the
saddle bearing to the bottom of
the base beams (inches)
G Height from the center of the
crank shaft to the bottom of the
base beams (inches)
Air Balanced Pumping Unit Data
For these units you must also enter pumping unit
dimensions R, A, C, I, P, and K in inches. In ad-
dition, you need data for M, S and V0.
The API spec. 11E defines the above dimensions
as follows:
Dimension: Description:
R Radius of the crank (inches)
A Distance from the center of the
Sampson Post bearing to the cen-
terline of the polished rod (inches)
C Distance from the centerline of
the Sampson Post bearing to the
center of the equalizer bearing
(inches)
I Horizontal distance between the
centerline of the Sampson Post
bearing and the centerline of the
crankshaft (inches)
P Effective length of the pitman
arm, in inches (from the center of
the equalizer bearing to the center
of the crank-pin bearing)
K Distance from the center of the
crankshaft to the center of the
Sampson Post bearing (inches).
M Geometry constant (in2). It is the
distance from the Sampson Post
bearing to air tank bearing (dis-
tance X in Figure 2.3) multiplied
by the area of the piston in the air
cylinder divided by dimension A
or: X*Ap/A, where Ap is the area
of the air cylinder piston in square
inches.
S Pressure in the air counterbal-
ance cylinder required to offset
the weight of the walking beam,
horsehead, equalizer, pitman arms,
etc. (psig).
V0 Minimum air volume between the
plunger and cylinder at the bottom
of the stroke (in3).
Long Stroke Pumping Unit Data
For these units you must enter the sprocket diam-
eter (D), the centerline distance between the top
and bottom sprockets (distance C), the pitman arm
length (P) if one exists (usually this is zero), and
the top drum diameter ratio (usually equal to 1).
You can see a diagram of the dimensional data you
need by pressing F1 in any input field, or you can
take a look at Figure 4.28.
You can also use this pumping unit model to sim-
ulate any non-beam pumping unit with a long,
slow stroke. You can do this by entering data that
will produce the same stroke length as the unit you
want to model. The stroke length of a long stroke
unit is given by:
Stroke = C + D
For example, to simulate a hydraulic pumping unit
 RODSTAR  | 45

with a stroke length of 200 inches, you can enter a

sprocket diameter (D) of 20 inches and a centerline
distance between sprockets equal to 180 inches.
If you use this approach to design a system with a
hydraulic unit then the torque calculations, energy
consumption, and other results that depend on
torque will be incorrect or meaningless. However,
the predicted polished rod dynamometer card,
polished rod horsepower, stress analysis, etc. will
be valid. This technique can be used as long as the
upstroke and downstroke polished rod velocities
of the hydraulic or long stroke unit you want to
simulate are approximately equal.
Tip: To predict energy consumption more ac-
curately for hydraulic units using the long stroke
pumping unit model, input a pitman arm length of
zero and a drum diameter ratio of 2.
Another thing to keep in mind is that even though
the combination of C and D dimensions deter-
mines the stroke length of long stroke units, the
Figure 4.28 - Dimensions for long stroke units
ratio of C/D determines the acceleration and de-
celeration of the polished rod. For the long stroke unbalance for the unit you want to simulate then
geometry shown in Figure 4.28, when the connec- enter zero. In most cases the structural unbalance
tion point between the belt and the chain touches will not affect the results significantly (especially
the sprocket, the polished rod speed changes for Conventional geometry units).
(accelerates or decelerates). When the connection
point leaves the sprocket (C section in Figure 4.28)
the speed is constant. Therefore, different com- Definition of Crank Offset Angle
binations of C and D dimensions may be needed
to correctly simulate the polished rod motion of a The crank offset angle (or crank phase angle) is
hydraulic pumping unit. the angle between a line through the crank holes

Definition of Structural Unbalance

Structural unbalance is a term used for pumping
units with walking beams. It is defined in API
11E as the force you need at the polished rod
to hold the walking beam horizontal with the
pitman arms disconnected from the crank pins.
This force is positive when acting down and neg-
ative when acting up. See Figure 4.29 for a visual
explanation of structural unbalance. Structural
unbalance for conventional units can be either
positive or negative. For Mark II units it is al-
ways negative. If you do not know the structural Figure 4.29 - Definition of structural unbalance
46 |  Running RODSTAR

and a line through the counterweight arm. Figure

4.30 shows how the crank offset angle is defined.
RODSTAR expects a positive crank offset angle
for Mark II units and a negative one for enhanced
geometry units such as the Torqmaster, Lufkin
Reverse Mark, or American Producer II. For
conventional pumping units the crank offset angle
is zero.

Entering Counterbalance Information

After you select a pumping unit or enter your own
pumping unit data, the crank hole number, and Figure 4.30 - Definition of crank offset angle
direction of rotation, you must enter counterbal-
ance information. recommended prime mover size and overall system
efficiency will be for the existing conditions. If
Entering an existing maximum counterbalance
you select “unknown” for maximum counterbal-
moment allows you to simulate an existing sys-
ance moment then RODSTAR calculates all these
tem to find out if the unit is overloaded or out of
numbers and the permissible load diagram for bal-
balance. If you only want to find the maximum
anced conditions only.
counterbalance moment required to balance the
unit (which is usually the case for new designs) The range of allowable counterweight is differ-
then click on the “Unknown” check box and ent for different Rotaflex units. RODSTAR takes
RODSTAR will calculate it for you. this into account when validating your entry for
counterbalance weight. For example, the mini-
For beam pumping units except for air balanced,
mum counterweight possible for the 1200 model
you can enter a maximum counterbalance moment
is 13,500 lbs. Therefore, if you try to enter a coun-
in thousand inch-lbs. RODSTAR also gives you
terweight that is less than 13.5 M lbs, (M =thou-
the option to import the maximum counterbalance
sands) RODSTAR will warn you that the counter-
moment from a CBALANCE file or from the
weight for this unit must be between 13.5 and 32.5
clipboard. If you ran CBALANCE before run-
M lbs.
ning RODSTAR, then the value of the existing
maximum counterbalance moment will be in the
clipboard. Then, as soon as you click on the Use Changing Structural Unbalance
CBALANCE information button, RODSTAR
will allow you to use the value exported by CBAL- In some cases, when the pumping unit is signifi-
ANCE or to read a CBALANCE file from disk. cantly oversized for the downhole equipment, you
may have to add counterweights on the walking
For air balanced units you must enter the air cyl- beam next to the horsehead to balance the unit.
inder pressure in psig at the bottom of the stroke. This changes the structural unbalance from the
For long stroke units you must enter the counter- catalog value. RODSTAR allows you to change
balance weight in thousands of pounds. For these the structural unbalance even when you select a
units, the option to read a CBALANCE file is pumping unit from the program’s database.
disabled since it does not apply.
The structural unbalance field can also be used to
If you enter existing counterbalance data, ROD- simulate beam balanced units. By changing the
STAR calculates and displays the permissible value of the structural unbalance, you can figure
load diagram for existing conditions. Also, the out how much weight you need to add or remove

from the walking beam to balance a beam bal-
anced unit.
4.2.7 Entering Motor Information and Energy Cost
RODSTAR can simulate NEMA D or ultra high
slip motors and calculates power consumption
from actual motor efficiency curves. The program
uses the electricity cost you enter to predict the
monthly electricity bill, $/bbl fluid, and $/bbl oil
(based on water cut). RODSTAR defaults to the
cost number you specify in Setup. The $ symbol
here is meant to represent currency (not just US
dollars). As Figure 4.31 shows, under the electric-
ity cost input box there are option buttons that you
can use to select the power meter type. You have
two options: Detent, or Non-detent. A Detent
KWH meter can rotate only in one direction. A
ratchet prevents it from turning the other way.
Therefore, if your unit is generating electricity, you
do not get credit for it. The non-detent meter can
rotate either way and so it credits you for electricity
the pumping unit generates.
Prime mover type selection
Using drop-down list boxes you can select the
motor type you want to simulate. RODSTAR has
Figure 4.31 - Entering motor information
RODSTAR  | 47
motor performance and efficiency data for NEMA
D, Sargent Ultra High Slip, Reliance Ultra High
Slip motors, and Rotaflex Multi-HP NEMA
C motors. If you select a NEMA D motor you
can enter a motor size, or you can choose to have
RODSTAR recommend a NEMA D motor for
you. If you select an ultra high slip motor then you
must select the motor size and torque mode. If you
select a motor size or mode that is too small for
the well conditions then RODSTAR will display
a warning message and will give you the option to
change your data.
RODSTAR warns you if you select an ultra-high-
slip motor when you have selected an air-balanced
or long stroke pumping unit. These units have little
or no rotating moment of inertia, so using an ultra-
high-slip motor does not result in any significant
differences in the calculations. Therefore, for these
units, do not select an ultra high slip motor or to
include speed variation effects.
If you select a NEMA D motor type for a new
case, or switch from an ultra-high-slip motor to
a NEMA D motor, RODSTAR automatically
selects the option to recommend the motor size.
Motor speed variation
The option to include the effect of motor speed
48 |  Running RODSTAR
variation is only available for conventional, en-
hanced geometry, and Mark II units. Inertia ef-
fects are negligible for long stroke and air balanced
units.
If you select not to include speed variation effects
then RODSTAR assumes constant prime mover
speed and will not model the effect of pumping
unit inertia. If you choose to include speed varia-
tion then RODSTAR gives you the option to enter
a percent speed variation or have the program
calculate the speed variation for your prime mover.
Pumping unit moments of inertia
If you select to include the effect of motor speed
variation then you can enter a rotating moment
of inertia in lbs-ft2, or have the program estimate
this number for you. For the articulating moment
of inertia RODSTAR defaults to a number that
is either the actual articulating moment of inertia
supplied by the pumping unit manufacturer, or
an estimate based on unit size. Therefore, unless
you have an even more accurate number for the
articulating moment of inertia, it is recommended
that you use the default number displayed by the
program.
For more accurate results, have RODSTAR cal-
culate the prime mover speed variation. However,
you can also enter a speed variation value if de-
sired. If you select to enter speed variation, ROD-
STAR shows a default value of 8% which corre-
sponds to a recommended average speed variation
for NEMA D motors. You can get more conser-
vative results by entering a speed variation that is
less than the maximum expected speed variation
for your prime mover. Selecting to include prime
mover speed variation will approximately double
RODSTAR’s run time.
What is moment of inertia?
Although this manual is not intended to teach
engineering or physics, it is important to briefly
explain moment of inertia and how it can affect
RODSTAR’s results. The mass moment of inertia
of a body is a measure of its resistance to accelera-
tion. In other words, the higher the moment of
inertia of a body, the more difficult it is to quickly
speed it up or slow it down.
The rotating and articulating moments of inertia
are important in accurately simulating the behavior
or the pumping unit and in calculating net gearbox
torque when you use a high speed variation prime
mover. The rotating moment of inertia that ROD-
STAR needs is the total rotating moment of iner-
tia. This includes the individual rotating moments
of inertia of the cranks and counterweights about
the slow speed shaft of the pumping unit, the total
gear reducer inertia, and the motor rotor inertia.
The articulating moment of inertia of the pumping
unit around the saddle bearing includes the inertia
of the walking beam, horsehead, and pitman arms.
As mentioned above, you can either enter a rotat-
ing moment of inertia, or you can have ROD-
STAR estimate it for you. To calculate accurately
the rotating moment of inertia you must have
moment of inertia data for the cranks and coun-
terweights, gearbox, motor rotor, etc. Also, the
rotating moment of inertia depends on the position
of the counterweights on the cranks. Since this
data may not be known, it is recommended that
you let RODSTAR estimate the rotating moment
of inertia for you.
Since the articulating moment of inertia depends
on the walking beam size, horsehead and pitman
arms, it is a fixed number for any given pumping
unit. Therefore, it is easier to calculate than the
rotating moment of inertia. RODSTAR’s pump-
ing unit data base contains accurate articulating
moment of inertia values that were either obtained
from unit manufacturers, or were estimated based
on unit size. The articulating moment of inertia
from the pumping unit database appears as the
default number when the program prompts you for
the articulating moment of inertia.
Including speed variation and moments of inertia
will usually result in lower predicted peak gearbox
torque, lower peak polished rod load, and higher
minimum polished rod load. This is because a
 RODSTAR  | 49

high speed variation prime mover slows down as

the torque on it increases. The rotational inertia of
cranks and counterweights causes a release of ener-
gy that lowers the torque the gearbox must supply.
The articulating inertia adds torque to the gearbox
since it opposes the acceleration of the walking
beam and horsehead. However, the effect of the
articulating moment of inertia is usually small
compared to the effect of the rotating moment
of inertia. When the prime mover slows down in
response to high torque, it causes the polished rod
to slow down as well. This results in lower dynamic
forces and therefore lower peak polished rod load.
 RODSTAR  | 51

5 Changing, Loading and Saving Data

5.1 Visual Input then choosing Save As... This brings up a stan-
dard Windows dialog box that allows you to save
Figure 5.1 shows RODSTAR’s “visual” input facil- your file with the file name you want. RODSTAR
ity that makes it easy to locate a system parameter shows the default file name it creates from the well
you want to change. As you are entering the data name and by adding an “.RSVX” file name exten-
for a new case, or after you have loaded a case from sion for RODSTAR-V or “.RSDX” for ROD-
disk, the visual input window can be displayed by STAR-D. If you enter data for a case in ROD-
clicking on the Visual Input button on the toolbar.
This shows an interactive picture of the pumping
system.
As you move your mouse over the picture of the
system, tool tips appear naming various parts of
the system. Whenever a tool tip is showing, you
can right-click with the mouse to get a pop-up
menu listing input variables associated with that
part of the system. This visual way of changing
data is more useful when you are changing data
in existing files or when you are making “what
if...” runs. If you are entering a case from scratch,
menu items that correspond to data you haven’t yet
entered will be disabled.
Left-clicking when a tool tip is displayed opens the
data entry window associated with the part of the
system you clicked on. Another way to change data
is to click on the “Alphabetical list…” button at
the bottom of the visual input window. This brings
ups an alphabetical listing of all variables you can
change. You can locate the variable you want to
change by scrolling down using the mouse.

5.2 Storing Data Files

After you finish entering data for a system, you can
save the data to disk by clicking on the Quick Save
button on the toolbar (third from left with diskette
icon), or by selecting File from the menu bar and Figure 5.1 - RODSTAR’s Visual Input window
52 |  Changing, Loading and Saving Data
STAR-D but do not enter deviation survey data,
the program will save the file with an extension of
“.RSVX” instead of “.RSDX”. You can change the
file name by typing over it, but you cannot change
the file name extension. When you type your own
file name, you do not have to type the file name
extension. RODSTAR automatically adds this
extension for you.
You do not have to store your data every time
you make a change. It is recommended that you
save the original data and then wait until you get
a good design before storing data to disk. After
saving data once, RODSTAR makes it very easy
to update the file with the data in memory with a
single mouse click on the Quick Save button on
the toolbar.
If you save your data after running RODSTAR
and the output is displayed on screen, then ROD-
STAR saves both the input and output in the file.
This is advantageous because once you save the
Figure 5.2 - Summary output report - upper half
output then you can view and print the output
without having to rerun the case.
5.3 Running and Viewing the
Output
After you enter all your data and you press the
Next Screen button from the motor information
window, the Run button on the toolbar becomes
active. To run the program simply click on the
Run button on the toolbar (the dynamometer card
icon to the right of the right arrow icon). Another
way to run the program is to click on Run on the
menu bar. After RODSTAR runs, it displays the
output report, as Figure 5.2 shows. At the bottom
of this screen there are buttons that allow you to
view the dynamometer, torque, or IPR plots and
the report. When you select to see the dynamom-

Figure 5.3 - Summary output report - lower half
eter plots, you can select to animate then surface
and downhole pump cards.
To look at different parts of the output you can
click the appropriate buttons at the bottom of the
screen (Dynamometer, Torque, IPR Plot, Dev.
Plots when using RODSTAR-D, or Report).
When you click on Report, you can scroll up or
down with the mouse, or you can click and drag on
the report itself. Figure 5.3 shows the bottom sec-
tion of the summary report. The summary report
looks exactly the same as the printed report.
If you have CBALANCE for Windows on your
computer, you can have RODSTAR export the
balanced maximum counterbalance moment it
calculates to CBALANCE. You can do this any
time the calculations have been run (whether or
not you are actually viewing them) by clicking on
RODSTAR  | 53
the Export CBM button on the toolbar ( ).
RODSTAR can calculate two possible ways to
balance a unit: for minimum torque, or for mini-
mum energy consumption.
The most common way to balance a unit is for
minimum torque. However, if the gearbox is not
overloaded, you may want to balance the unit for
minimum energy consumption instead.
After viewing the output you can decide which
value of balanced counterbalance moment you
want to export to CBALANCE (so that CBAL-
ANCE can calculate the counterweight positions
required to balance the unit). When you click on
the Export CBM... button RODSTAR displays
the window shown in Figure 5.4 (if there are two
possible ways to balance the unit). Click on the op-
tion you want and click on the OK button. ROD-
54 |  Changing, Loading and Saving Data

on the status bar (at the bottom of

the RODSTAR window).

5.3.2 Running in Batch Mode

You can run more than one case at a
time by selecting to run two or more
files in batch mode. The batch mode
Figure 5.4 - Exporting the maximum CB moment starts automatically when you select
to load more than one file. This capa-
STAR confirms that the value of the maximum bility allows you to make an unlim-
counterbalance moment has been exported by ited number of RODSTAR runs automatically,
displaying the message box shown in Figure 5.5. and without you having to be at the computer.
RODSTAR even allows you to schedule the batch

Figure 5.5 - Maximum CB moment exported

run to start at any time (from the Setup window).

5.3.1 Saving the output
If you save the file while
the output is being dis-
played on the screen,
RODSTAR saves the
output along with the input
in the same file. Then, you
can load a file with output
and you can display and
print the output without
having to rerun the pro-
gram. To save the output,
click on the quick save icon
on the tool bar, or select
File on the menu bar and
then select Save As..
When you load a file that
has output saved, the
program will tell you that
output results are available Figure 5.6 - Selecting files for a batch run
 RODSTAR  | 55

To start the batch, select to open a file (either by

clicking the Open File toolbar button, or by select-
ing Open… from the File menu). This brings up
the open file dialog box. To select a group of files
to run in batch, click on the first file and then,
while pressing S, click on the last file in the
list. Or, you can click on the first file and then
drag the mouse to highlight all the files you want
to run (it must be a continuous group). To select
individual files, click on the files you want to select
while pressing C. The selected files are high-
lighted as Figure 5.6 shows. When you are done
selecting files, click OK.
At this point, RODSTAR will display the option
box in Figure 5.7 asking you to choose the options
you want for the batch run. The first option causes
RODSTAR to create printouts for all the files
it runs. This option is unselected by default. The
second option causes RODSTAR to create a sum-
mary spreadsheet file for all the cases it runs. The
option to view the spreadsheet in Excel means that
once the cases are processed and the spreadsheet is
created, RODSTAR will automatically load Excel
and display the results for you.
Figure 5.7 - Batch run options
in a very concise way. After the results are in a
spreadsheet file, you can plot one variable versus
another, you can sort the spreadsheet columns by
rod string cost, system efficiency, energy cost per
barrel of oil, etc. There is no limit to what you can
do with the results.
The spreadsheets that RODSTAR create summa-
rize the results of all the runs and loads it directly
into Excel. Under the Setup window you can “de-
sign” and save an unlimited number of spreadsheet
formats. If you do not specify a spreadsheet format
before running many cases in batch mode, ROD-
STAR uses the default spreadsheet format that
comes with RODSTAR and contains the most

The last option allows

you to specify whether
you want RODSTAR to
rerun cases with saved
output or not.
If you do not select the
option “View spreadsheet
in Excel” when you click
on “Proceed”, ROD-
STAR asks you for Excel
file name as shown in
Figure 5.8. Otherwise, if
you select to view spread-
sheet in Excel, ROD-
STAR starts running in
batch immediately.
Creating a summary
spreadsheet is very use-
ful because it allows you
to summarize many runs Figure 5.8 - Selecting a spreadsheet file to create
56 |  Changing, Loading and Saving Data

common system design

comparison variables.
The option “Don’t re-run
cases with saved output”
allows you to create dif-
ferent summary spread-
sheet files with the same
set of RODSTAR files.
When you select this
option RODSTAR runs
very fast in batch because
all it has to do is extract
the calculated values that
have already been saved
in the RODSTAR files
and enter them in the
spreadsheet.
Figure 5.9 - A batch run log
When RODSTAR starts
to run the files you select- plexity of the calculations for deviated wellbores,
ed, it displays a batch run log window such as that RODSTAR-D runs may rake a minute or two
shown in Figure 5.9 that shows the number of files to run in most cases and sometimes even longer.
you selected, the number of runs that have been Therefore, using the batch process can save you
completed so far, and the overall percent comple- from having to wait for each case to run. You
tion. RODSTAR shows the name of each file that can have your case execute while at lunch or even
it runs. RODSTAR prints warnings or errors after overnight.
the name line while running each case. After each
new run is complete, the program prints “** Run
Complete **”.
This is a useful record of the cases that ROD- 5.4 Loading Data from Disk
STAR ran and any warning or errors generated After you enter data and store a file you can easily
while running them. You can cancel a batch run modify it by loading it back in memory. Also, you
at any time by clicking on “Cancel”. The program can load a file with saved output and view or print
will stop after it finishes running the current case the output results without having to rerun a case.
and it will display a message box that says: “The You can do this by:
batch run was canceled.”
- Clicking on the Open button on the toolbar
After the batch run is done, click OK to close this (second from left).
information box. Then, click on the print icon on
the tool bar. We recommend printing the batch - Clicking on File on the Menu bar and then on
run log, especially when running many ROD- Open, or by pressing C+ o.
STAR cases. The batch run log shows what files Also, RODSTAR keeps track of up to nine of the
you ran, and any errors or warnings for each case. most recent files you saved or loaded and allows
The batch run capability is especially useful for you to quickly load any of them. To see a list of
RODSTAR-D because it requires more calcula- these files click on the drop-down icon between
tions than RODSTAR-V. Because of the com- the file open and file save icons on the tool bar and
 RODSTAR  | 57

then click on the file you

want to load. Or, you
can click on File from
the menu bar and select
“Recent Files”
If there is data in mem-
ory, RODSTAR will
warn you that loading
new data will erase the
existing data in memory.
This alerts you and helps
prevent accidental loss
of your data before you
have a chance to save it.
RODSTAR has a
powerful and easy-to-
use file management
system. When you select
to load data from disk,
RODSTAR displays the
current path and a list
of files in the current
directory in alphabetical
Figure 5.10 - Selecting a file to open
order. Also, RODSTAR
allows you to read
5.4.1 Viewing Previously Saved Output
RODDIAG files, XDIAG files, and even older
RODSTAR files. RODSTAR displays a list of the When you load a file that contains output you
file type you selected in the current directory as the can display the output without having to rerun
Figure 5.10 shows. the case. When you load a case that contains
input data only (no output results were saved),
To load one of these files, double click on it, or
RODSTAR displays the first input window (well
click on it once and then click on OK. If the file
information). Also, the report and print icons on
you want is not in the current directory, you can
the toolbar are not available. However, when you
easily move to any directory on any drive in your
load a file that contains both input and output,
system since this window also lists sub directories,
RODSTAR does not open any input windows.
and system drives.
The status bar at the bottom of the screen shows a
If your current directory contains many ROD- message like the following:
STAR files, it may be faster to press the first char-
“Successfully loaded file: C:\Theta\RODSTAR-V
acter of the file you are looking for. For example,
cases\special cases\abc#1.rsvx (output results are
if you are looking for well name “PR101.RSVX”,
available).”
click in the list once, and then press p and the
Also, the report and print icons on the tool bar are
program will jump to the first file in the list that
active. To see the output without having to re-run
starts with “P.”
the case, click on the report icon on the tool bar.
To print the output, click on the printer icon (next
to the email icon).
58 |  Changing, Loading and Saving Data

Figure 5.11 - Minimized input windows

5.5 Manipulating Input Windows

RODSTAR is a standard Microsoft Windows ap-
plication and it allows you to manipulate the input
windows several different ways. After entering data
for all the input windows, or after you load a file
from disk, you can display one window at a time,
you can open all windows, or you can arrange
them any way you want as explained below:
♦ After entering data for a case or after load-
ing a file from disk, click on each window’s icon on
the toolbar. This loads all input windows.
♦ You can click on the minimize button of
each form to minimize them into icons at the
bottom of the main window as Figure 5.11 shows.
To open any of the minimized windows, double
click on its icon or click on it once and then select
Restore.
♦ You can use the mouse to resize windows,
or to drag a window or an icon anywhere in the
RODSTAR main window.
 RODSTAR  | 59

6 Rod Pump System Design

You can use RODSTAR to quickly design any rod
pumping system, compare pumping units, sucker
rod designs, insert versus tubing pumps, clockwise
versus counterclockwise crank rotation, include
IPR modeling in your predictions, etc. ROD-
STAR can calculate the pumping speed, pump
plunger size, and rod string design for you. Also,
it can recommend motor size and pumping unit
size based on your target production. These power-
ful features help you design rod pumping systems
faster than ever before. Also, because RODSTAR
uses state-of-the-art design algorithms, it is very
accurate and reliable.
Because RODSTAR can predict energy consump-
tion very accurately, you can use it to select the
most economic system designs. The following
sections explain how to apply RODSTAR to solve
common design problems. As you become more

Figure 6.1 - RODSTAR Summary Report

60 |  Rod Pump System Design

familiar with RODSTAR you will discover many

different applications for this powerful rod pump
system design tool. RODSTAR’s capability to read
RODDIAG and XDIAG files and overlay the
measured dynamometer card on the same plot as
the predicted one is very useful. With this capabil-
ity you can:
1. “History match” existing rod pumping systems
before you make a design change. This allows
you to figure out unknown quantities such as
rod-tubing friction.
2. Detect an out-of-calibration load cell (used
to record the actual dynamometer card) by
checking for a consistent shift in actual versus
predicted dynamometer card shape.
3. Detect incorrect fluid level measurements due
to foam in gassy wells.
6.1 Understanding RODSTAR’s
Output
To maximize the benefit of using RODSTAR,
it is important to understand its output. After
RODSTAR runs, it displays the summary output
report page. Also, it shows buttons on the bottom
of the output window that allows you to access the
predicted dynamometer plot, torque plot, IRP plot
(if IPR data was entered), or return to the output
report as Figure 6.1 shows.
6.1.1 Dynamometer and Permissible Load Plots
When you click on the “Dynamometer” button
then you see the predicted surface and downhole
dynamometer card plots along with the permis-
sible load diagram as shown in Figure 6.2 . These
plots show the predicted surface and downhole
dynamometer cards, measured surface dynamom-

Figure 6.2 - Dynamometer plots and Permissible Load diagram


eter card from a RODDIAG or XDIAG file (if
you selected that option), and the permissible load
diagram. RODSTAR uses a permissible load
diagram that shows if the gearbox or structure
of the pumping unit are overloaded or if the
minimum polished rod load is negative. This
is different than the traditional permissible load
diagram that only shows whether the gearbox is
overloaded. This extended permissible load dia-
gram can be made up of curved lines only, combi-
nation of curved and straight lines, or straight lines
only. If the upstroke part of the predicted surface
dynamometer card exceeds the curved line of the
permissible load diagram this indicates that the
gearbox is overloaded at that point. If the dyna-
mometer card cuts into the straight line section of
the permissible load diagram on the upstroke, this
indicates that the structure of the pumping unit is
overloaded because the polished rod load is larger
than the structure rating of the unit.
For the exact numbers of peak net gearbox torque
Figure 6.3 - Torque plot
RODSTAR  | 61
and gearbox loading, look at the torque analy-
sis section of the printout. The permissible load
diagram corresponds to existing conditions if you
entered a counterbalance moment. If you did not
enter an existing max. CB moment then the pro-
gram shows a permissible load diagram for bal-
anced condition (for minimizing gearbox torque).
Note!: The above discussion about ROD-
STAR’s permissible load diagram refers to
beam pumping units. The permissible load dia-
gram for long stroke units such as the Rotaflex
will have straight line segments that corre-
spond to gearbox loading or structure loading.
Please look at the structure loading number
on the first page of the output and the percent
gearbox loading under torque analysis for the
exact percent unit loading.
In addition to showing whether the gearbox is
overloaded, the permissible load diagram also
shows how well the pumping unit matches the
load requirements of your system. If the predicted
62 |  Rod Pump System Design
polished rod dynamometer card fits nicely in the
permissible load envelope, this indicates a good
agreement between the pumping unit and the rest
of the system.
However, if the predicted surface dynamometer
card shows a trend that is opposite that of the
permissible load diagram, this shows that design
changes are necessary to avoid overloading the
pumping unit and to better match it to the rest of
the system. If the permissible load has a trend that
is opposite than the predicted dynamometer card,
it may indicate that the pumping unit you selected
is not the best geometry for this application. Or,
that you may have to change the spm, plunger size,
rod string design, or stroke length to get a better
Figure 6.4 - Inflow performance relationship (IPR) plot
match between the dynamometer card and permis-
sible load diagram.
Including prime mover speed variation and inertia
effects will alter the shape of the permissible load
diagram. The lines will be smoother if you do not
include prime mover speed variation. If you in-
clude speed variation the permissible load diagram
will tend to reflect changes in polished rod load.
This is because the permissible load diagram in
RODSTAR includes the effect of rotating and ar-
ticulating moments of inertia. As the prime mover
speed changes, this causes changes in polished rod
velocity and acceleration which in turn changes the
polished rod load and the distance between the dy-
namometer card and the permissible load diagram.

The output window has new buttons that allow
you to animate the calculated dynamometer cards.
Figure 6.2 shows a “play” button (the one with the
double arrow) which causes small dots to move
around the surface and downhole dynamometer
cards; a “stop” button which makes the movement
stop; and a “step” button (the one with the single
arrow) which lets you move the dots one time-step
at a time, while holding the button down moves
the dots in slow motion. This facility can be used
to get a better understanding of rod stretch effects
and other phenomena such as the position and
speed of the pump plunger and how this relates to
the surface dynamometer card.
From this screen you can look at any other part of
the output by clicking the appropriate option at
the bottom of the screen. For example, to view the
torque plots click on Torque. Also, you can select
to view the report on screen, or you can send the
output to the printer. After you are done viewing
the output, close the screen by clicking on Close.
6.1.2 Torque Plot
When you click on the “Torque Plot” button
RODSTAR displays the net gearbox torque plots
for existing and balanced conditions. If you entered
an existing maximum counterbalance moment,
then you may see a plot with up to three curves:
one for existing conditions, one for balanced con-
ditions for minimum torque, and one for minimum
energy consumption. If there is no difference be-
tween the curve for minimum torque and the one
for minimum energy, then the program shows only
two curves (existing and balanced). If you selected
“unknown” max. CB moment then RODSTAR
will only show one curve if there is little difference
between balanced for min. torque vs balanced for
minimum energy consumption (see Figure 6.3).
Otherwise, it will show two balanced curves: one
for minimizing torque and one for minimizing
energy consumption.
RODSTAR  | 63
6.1.3 IPR Plot
When you click on the “IPR Plot” button, ROD-
STAR displays separate oil, water, and fluid pro-
duction versus flowing bottomhole pressure plots
as Figure 6.4 shows. Also, it shows a line with the
current bottom hole pressure and the test points
you entered. The line below the title of the plot
shows the correlation you selected to use for the
oil IPR and if you selected the Fetkovich method,
it shows the value of n. If you only enter one test
point, n is set to one. If you enter two or more test
points then RODSTAR calculates the value of n
by doing a log-log plot. For water, RODSTAR
uses a straight line IPR.
6.1.4 Report
To see the report, click on the “Report” button.
You can scroll this window using the mouse by
clicking or the up or down arrows at the top or
bottom of the range bar on the right edge of the
window.
Or, you can click and drag the range bar or the
report itself with the mouse.
Input and Output Summary
The summary report that appears when you first
run RODSTAR shows input data on the left side
of the page and calculated numbers on the right
size. The top part of the printout shows the com-
pany name, well name, user name, date of the run,
and comment. Following is a detailed explanation
of each item on the output.
Polished Rod Loads and Horsepower
The peak and minimum polished rod loads show
the polished rod load fluctuation predicted by
RODSTAR. The polished rod horsepower shows
how much work the pumping system is putting
into the rod string to lift the predicted production
from the present fluid level to the surface.
If you entered a target production or used IPR data
64 |  Rod Pump System Design
to determine the target production, RODSTAR
calculates the SPM required to get the target pro-
duction.
System Efficiency
The system efficiency is calculated by regarding
the whole pumping system as a black box with
electricity going in and produced fluid coming out.
This number shows how efficiently the system con-
verts electric power to work needed to lift the pro-
duced fluid to the surface. A system efficiency of
45% or above is excellent. In General, deeper wells
will have lower efficiencies than shallow wells since
deep wells have more rod-tubing frictional loses.
Efficiencies of 35%-45% are average, while system
efficiencies of less than 35% are poor and can usu-
ally be increased by using a longer, slower stroke
(with larger pump plunger).
Permissible Load HP
Permissible load horsepower is defined as the area
bounded by the upper permissible load line, lim-
ited by the structural rating of the pumping unit
and the lower permissible load line, limited by zero
minimum load.
The ratio PLHP/PRHP (permissible load HP
divided by polished rod HP) is a number that
should be as large as possible without overloading
the pumping unit. The larger this number is, the
more of the pumping unit potential capacity you
are using.
Fluid load on Pump
Fluid load on the pump shows how much fluid
load the plunger is carrying on the upstroke. This
is a function of pump depth, fluid level from sur-
face, and plunger size. Fluid load on the pump is a
function of pressure difference across the plunger
and pump plunger diameter.
Unit Structural Loading
Pumping unit Structural Loading indicates wheth-
er or not the pumping unit structure is overloaded.
This is a function of the peak polished rod load
and the structural capacity of the pumping unit
(the middle number in the API pumping unit
designation).
Buoyant Rod Weight
Buoyant rod weight shows how much the rod
string weighs in fluid. Since the rod string is im-
mersed in the fluid inside the tubing, it weighs
less than in air. You can compare this number to
a measured standing valve load. A good standing
valve check should be close to the weight of rods
in fluid as calculated by RODSTAR for a pump
that is in good mechanical condition. If these two
numbers differ by more than 10% and the standing
valve is in good condition, it may be an indica-
tion that the load cell is out of calibration or that
the standing valve load was incorrectly measured.
Also, the sum of the buoyant rod weight plus fluid
load on the pump should be close to the traveling
valve load for a good pump.
N/No’ and Fo/Skr
The dimensionless numbers N/No’ and Fo/SKr
are defined in API RP 11L . N/No’ is the ratio
of pumping speed to natural frequency of the rod
string. Fo/SKr is the rod stretch caused by the
static application of fluid load, as a percent of the
polished rod load stroke. In general, the higher
the Fo/Skr is, the shorter the pump stroke will be.
Also, the higher the N/No’ the larger the pump
stroke is. These numbers also relate to system ef-
ficiency. In general, the larger N/No’ is, the lower
the efficiency will be. The larger the Fo/SKr is,
the better the system efficiency is. However, this
relationship is not linear.
 API RP 11L (Third Edition) Recommended
Practice for Design Calculations for Sucker Rod
Pumping Units. American Petroleum Institute,
Dallas TX.

For low Fo/Skr numbers (below 0.25) fiberglass-
steel rod strings will have very low system efficien-
cies and should be avoided. For fiberglass rods try
to keep Fo/Skr above 0.3 and below .8 for best
results. Also for fiberglass rod strings, you should
keep N/No’ below 1.0 and above .4 for best results.
Prime Mover Speed Variation
If you select to have RODSTAR calculate the mo-
tor speed variation for you then this section shows
what this number is. For NEMA D motors this
number will vary from 2% to 14% depending on
motor size. For correctly sized ultra high slip mo-
tors it can be as high as 50%. If motor speed varia-
tion is not considered then this will be indicated
on the output report.
Figure 6.5 - Section of RODSTAR Output Report
RODSTAR  | 65
Pumping Unit Data
This section (see Figure 6.5) shows the pumping
unit you selected, the pumping unit ID, the calcu-
lated stroke length, the structural unbalance, the
crank offset angle, crank rotation with the well
to the right, and the crank hole number. If you
entered your own pumping unit dimensions for a
unit not in the program’s database, if the calculated
stroke length is different from what you think it
should be, check the pumping unit data to make
sure you entered the right dimensions. If you se-
lected to include speed variation and inertia effects
in the calculations, RODSTAR will also print the
rotating and articulating moments of inertia.
Torque Analysis and Electricity Consumption
In this section, the program prints the predicted
peak gearbox torque, percent gearbox loading,
66 |  Rod Pump System Design
cyclic load factor, maximum counterbalance mo-
ment, and counterbalance effect. Also, it calculates
electricity consumption. RODSTAR predicts the
KWH consumed per day, the estimated monthly
bill, and cost per barrel of fluid and per barrel of
oil per day. Use the cost per barrel numbers when
comparing system performance to ensure a valid
comparison. This is because a system that shows
a lower monthly bill may also be producing less
fluid.
If you enter a non-zero maximum counterbalance
moment the program calculates the above num-
bers for both existing and balanced conditions. If
the existing max. CB is unknown, it will calculate
the above numbers for balanced conditions only.
RODSTAR has the capability to balance pumping
units for minimum torque and minimum energy. If
the maximum counterbalance moment for mini-
mum energy equals the one for minimum torque
then the program shows only one recommendation
for balanced conditions. However, if the two values
are more than 2% different then it shows two bal-
anced columns: One for minimum torque, and one
for minimum energy. The torque plots show how
net gearbox torque changes throughout the pump-
ing cycle for existing and balanced conditions.
Figure 6.6 - System cost analysis
To maximize gearbox life you must keep gearbox
loading less than 100%. The cyclic load factor
indicates how smooth the gearbox torque is. The
smaller this number is, the more uniform the net
gearbox torque is. Also, a smaller cyclic load factor
will result in higher system efficiency because of
less thermal losses in the motor.
Tubing, and Pump Information
Here you see the tubing inside and outside di-
ameters, the anchor depth, the calculated tubing
stretch, the upstroke and downstroke rod-tubing
friction factors you entered or that were calculated
by RODSTAR, pump load adjustment., etc. Also,
this section shows the pump depth, the pump
type, and plunger size.
RODSTAR uses the pump volumetric efficiency
you enter to calculate the expected production rate.
When you ask the program to calculate the spm
by entering a target production, it will calculate a
larger spm if you enter 80% pump efficiency than
when you enter 90% pump efficiency.

Figure 6.7 - IPR report
Tubing, Pump and Plunger Calculations
This section shows tubing stretch and production
loss due to tubing stretch, gross pump stroke, the
pump spacing recommendation, minimum re-
quired pump length, and recommended plunger
length. The pump spacing recommendation should
be used as follows:
After working on the well and before you
are ready to restart the pumping unit, make
sure the tubing is full of fluid. Then lower the
rod string slowly until it tags bottom. Then
raise the rod string a distance equal to the one
recommended by RODSTAR next to: “Pump
spacing (in. from bottom): ” Then, attach the
polished rod to the bridle with the unit stopped
at the very bottom of the downstroke.
Please note that the working fluid level makes a
big difference in pump spacing and pump length.
This is especially true for fiberglass rods since the
plunger travel is strongly dependent on fluid load
on the plunger.
Rod String Design and Stress Analysis
This section shows the rod string design and ser-
vice factor you selected, the calculated percent rod
loading for each rod section, the maximum and
minimum stresses at the top, and the bottom min-
imum stress for each rod section. To ensure your
rods are in tension, do not include buoyancy effects
(this should always be the case for steel rods).
Then, make sure there are no negative stresses on
RODSTAR  | 67
any other rod section other than the sinker bar sec-
tion on the bottom of the rod string.
If you are using fiberglass rods you would not want
to use a design with a negative bottom minimum
stress on the fiberglass section even with buoyancy
effects included. Compressive loading will cause
fiberglass rods to part. Also, to maximize rod
life, stress loading must be less than 100% in all
cases. For sinker bars, RODSTAR calculates stress
loading, top maximum and top minimum stresses
based on the elevator neck or pin undercut diam-
eter of the sinker bars. However, RODSTAR still
uses the full body diameter in the calculation of
stress at the bottom of the sinker bar section.
Rod String and Pumping Unit Cost Analysis
This section shows the cost of each rod section as
well as the total rod string cost (see Figure 6.6).
Also, below the rod string cost is the pumping
unit cost. RODSTAR shows the cost information
only if you select this option in Setup. You must
first enter rod string and pumping unit cost data in
Setup before RODSTAR can show you accurate
cost information here.
Inflow Performance Relationship Information
This section shows the correlation used for oil
IPR, mid-perf depth, the static bottomhole pres-
sure, and the bubble point pressure (if entered) or
whether the well is producing below the bubble
68 |  Rod Pump System Design
point pressure. Also, it shows a table of input test
point data of flowing bottomhole pressure versus
measured production, and a table of pressure vs.
production table. As Figure 6.7 shows, this table
shows separate oil, water, and fluid production
rates for different pump intake pressures.
6.2 RODSTAR-D Output
In addition to the output quantities discussed
above, RODSTAR-D calculates and prints num-
bers and plots that are related to wellbore devia-
tion. Following is an explanation of these outputs
that are unique to RODSTAR-D.
Figure 6.8 - RODSTAR-D First Displayed Page
6.2.1 Deviation Plots
After RODSTAR-D runs, it will display the
summary output page as shown in Figure 6.8.
When you click on the “Dev. Plot” button on
the bottom. It will display the first deviation
related plot as shown in Figure 6.9. This plot
shows side load as a function of measured depth.
All deviation plots show colored lines that
correspond to different sections of the rod string.
The calculated side load affects is used by the
program to determine the number of rod guides
and their spacing, using rod guide manufacturer
recommendations. Click on the “Next” button
on the bottom of this plot to see the rest of the
deviation-related plots.
The next plot is the maximum and minimum axial

Figure 6.9 - Side Load Plot
loading. This plot shows how the maximum and
minimum rod loads change as a function of mea-
sured depth.
The buckling tendency shows the buckling ten-
dency load as a function of measured depth. It is
generally accepted that buoyancy does not cause
buckling. The bottom of the rod string is sub-
jected to negative loads because of pump friction
and other frictional effects due to wellbore devia-
tion. According to a paper titled “Interpretation of
Calculated Forces on Sucker Rods” by J.F. Lea and
P.D. Pattillo, published in SPE production and Fa-
cilities, February 1995, the critical load necessary
to buckle a rod string is calculated as follows:
RODSTAR  | 69
Where:
w = rod weight in fluid
I = moment of inertia of cross section (in4)
E= elastic modulus of rod = 30.5x10⁵ psi for steel
The Moment of inertia of the rod section (“I”
above) can be calculated as follows:
In the same paper referenced above, the author
shows a table of critical forces and length that will
cause rods to buckle. According to this table, a 3/4”
rod would buckle if it subjected to a negative load
of only 37.2 lbs and if at least 26.1 feet of the 3/4”
section is in compression. For 7/8” rods, buckling
would occur if the negative force on the bottom
is 56.2 lbs and the negative portion is longer than
70 |  Rod Pump System Design

28.9 feet long. As these examples show, the only them in tension.
way to be sure the rods will not buckle is to keep The Dogleg severity in degrees per 100 feet, rep-

Figure 6.10 - RODSTAR-D Deviation plot page


resents the rate of change in the inclination and
azimuth of the bore hole with respect to measured
depth. Dogleg severity is not used to calculate side
load. The Dogleg severity plot is a useful guide
that shows how sharply the curvature of the well-
bore changes. The same dogleg severity close to the
surface of the well will result in a larger side load
as compared to the same dogleg severity close to
the bottom of the hole. This is because the tension
in the rods is much higher at the surface and thus,
it results in larger side loads as compared to the
bottom of the rod string where axial load is much
lower and therefore the rods can go around the
bent more easily.
The rest of the deviation plots show different views
of the wellbore.
If you click on the “Report” button shown in
Figure 6.8, the program will show you a one-page
summary of all the deviation plots as shown in
Figure 6.10. This page looks exactly the same as
the printed page when you print the report. You
can also page up or down using the up or down ar-
row keys at the top of the report page to see all of
the report pages, including the rod guide spacing
recommendation pages.
6.2.2 Rod Guide Recommendation Output
RODSTAR-D shows rod guide spacing recom-
mendations depending on the calculated side load
and the type of rod guides you selected in Setup as
shown in Figure 6.10. These are the last pages of
the output report.
6.3 Rod Pump System Design
Guidelines
When designing a rod pumping system you
must specify the equipment, strokes per minute,
and stroke length required to get the desired
production at the lowest possible cost. In your
efforts to select the best system design for your
well you will be mostly concerned with the
RODSTAR  | 71
following parameters:
♦ Production Rate
♦ Capital costs
♦ Rod loading
♦ Gearbox loading
♦ System efficiency and power costs
Ideally, the system you select will give the highest
present value profit after tax, considering capital
and operating costs. Up to now, rod system design
was a tedious trial and error process that usu-
ally resulted in a system that could be far from
ideal. Since achieving an optimum design requires
equipment and data that may not be available, only
the most obvious system parameters are usually
considered. In most cases production rate is of
highest priority, followed by rod loading, gear-
box loading, and energy cost. If electricity cost is
high, you can lower it by using a larger pump and
a slower pumping speed. However, a large pump
will increase rod loading and gearbox torque.
Also, a large pumping unit must be used. This will
increase capital cost. On the other hand, a small
pump demands a faster pumping speed and longer
stroke to maintain production. This increases ener-
gy consumption but reduces the required pumping
unit size. Usually, you must reach a compromise
between efficiency, rod loading, pumping unit size,
and cost.
A very important aspect of system design is pump-
ing rate. If you know the maximum production
rate you can expect then design the pumping sys-
tem for a production rate a little higher than that.
This ensures enough pump capacity to account for
normal pump wear and inaccurate data. However,
if the pumping rate is substantially higher than
what the well is capable of producing, then the
well will pump off. Fluid pound is a problem that
results from the common practice of over-design-
ing the pumping capacity. Fluid pound is damag-
ing to pump, rods and pumping unit. If you do not
take steps to minimize fluid pound it will reduce
efficiency and equipment life. You can reduce fluid
pound by slowing down the unit, shortening the
72 |  Well Information
stroke length, using a smaller pump, or by install-
ing a percentage timer or pump off controller.
Because RODSTAR can simulate fluid pound,
you can use it to see what will happen if the well
pumps off.
6.3.1 Shallow, High Rate Well Simulation
RODSTAR can simulate any pumping unit geom-
etry and gives accurate results for any pump depth
or production rate. This is especially significant
for shallow well applications because conventional
design computer programs such as the API RP
11L and other wave equation programs give poor
results. This is because at shallow depths, polished
rod load is increasingly dependent on the dynamic
effects of fluid in the tubing. This is especially
true for high production rate shallow wells (pump
depth less than 4000 feet with larger than 2.00”
plunger).
To accurately simulate these wells, RODSTAR uses
two wave equation models simultaneously, one for the
rod string and one for the fluid in the tubing. This
unique capability allows very accurate predictions.
RODSTAR can predict the expected surface and
downhole dynamometer card shapes common to
shallow, high rate wells. When designing shal-
low high rate wells it is recommended that you
use pump efficiencies of 90%-95% to avoid un-
der-predicting peak polished rod load, torque, etc.
This higher pump efficiency will result in higher
fluid velocity in the tubing and higher fluid iner-
tia forces on the plunger. However, when you are
trying to “history match” an existing system, you
may need to use a pump efficiency of less than 90%
to better match the actual pump slippage of your
system.
6.3.2 Selecting the Target Production
To avoid severely over-sizing the displacement
capacity of your pumping system, design it with a
pump efficiency of 80%-85% or even 75% if you
expect the downhole pump to wear out quickly.
This ensures that you will get your production
without grossly over-designing the system.
To minimize energy consumption and stress load-
ing, use the largest plunger diameter and slow-
est pumping speed combination possible without
overloading the rod string and pumping unit. If
you have to make a choice between stress loading
and power consumption, opt for lower stress load-
ing especially if you are close to 100% since rod
breaks are more costly than a slightly lower system
efficiency.
Note that these are only general guidelines. Eco-
nomics and local field conditions may require a
different design philosophy than the one described
above. Regardless of your objectives and design
philosophy, with RODSTAR you can design rod
pumping systems faster and more accurately than
with any other computer program.
6.3.3 Avoiding Rod Compression
RODSTAR calculates rod stresses at the top and
bottom of each rod section. It calculates the maxi-
mum and minimum stress at the top of each rod
section in order to calculate the percent stress load-
ing. It also calculates the minimum stress at the
bottom of each rod section. The bottom minimum
stress shows if the rods are in compression.
Steel rods can tolerate some compressive force but
fiberglass rods cannot tolerate any compression
at all. This is why fiberglass rods must have steel
rods or sinker bars at the bottom. The weight of
the sinker bars overcomes the opposing hydrostatic
force and pump friction. If correctly designed, the
sinker bars or steel rods ensure that the fiberglass
rods are always in tension.
Although steel rods can be subjected to some com-
pression without adverse effects, excessive negative
stresses can cause buckling problems. The recom-
mended way to use RODSTAR to determine if
your rods may be subjected to compression is to
run the program without including buoyancy
effects. Then, add sinker bars or sinker rods to
overcome the negative stresses at the bottom
section of the rod string (above the sinker bar
section) . Other ways of minimizing buckling

problems include using smaller pumping speeds
and avoiding use of small diameter rods such as
5/8” or even ¾”.
6.3.4 Minimizing Power Consumption
In general, the slower the pumping speed and the
larger the pump plunger size, the less energy the
pumping system will use. However, minimizing
energy consumption must not be the sole purpose
of system design because a large pump plunger
diameter will result in large polished rod load and
gearbox torque. This will require the purchase of a
larger unit, larger rods and bigger prime mover. To
come up with the best pumping system design you
must consider the economics of the whole system
and whether you plan to use existing equipment or
buy new ones.
RODSTAR’s power and ease of use allows you
to get the most economic pumping system based
on your economic criteria. Because RODSTAR
calculates the predicted energy consumption, rod
sizes, rod loading, and recommends a pumping
unit size, it provides you with the data you need for
sound economic decisions.
6.3.5 Reducing Gearbox Torque
Sometimes, using the largest unit stroke may not
be the best way to maximize production since it
can result in severe gearbox overload. If this oc-
curs you may be able to use the next smaller unit
stroke and speed up the unit to get your produc-
tion without overloading the gearbox. Another way
of reducing gearbox loading is by using a smaller
pump plunger. Another way is to use a lighter rod
string by using either high strength steel or fiber-
glass rods.
Also, you can reduce gearbox torque with an ultra
high slip motor. RODSTAR-V can predict the
gearbox torque depending on the pumping unit
size and ultra high slip motor size. Also, ROD-
STAR-V can calculate the motor speed variation
and power consumption very accurately.
RODSTAR  | 73
6.3.6 Using RODSTAR for Correct Equipment Sizing
When designing a new rod pump system you must
ensure that the system you select has sufficient ca-
pacity to produce the well under the heaviest loads
possible during its operating life. For most systems
this will occur when the fluid level is at the pump.
Therefore, even if you do not expect the fluid level
to be at the pump, it is a good idea to design the
pumping system (especially when using steel rods)
for fluid level at the pump. This ensures that the
equipment you plan to use will not be overloaded if
the fluid level drops in the future.
For systems with fiberglass-steel rod strings, you
may get higher gearbox torque loads and higher
polished rod horsepower when the fluid level is
above the pump. This occurs because fiberglass rods
are very sensitive to fluid load. When the fluid
level is above the pump, the fluid load on the pump
is reduced. This causes a longer pump stroke which
in turn affects the shape of the surface dynamome-
ter card making it fatter. This in many cases brings
the predicted surface dynamometer card closer to
the permissible load diagram causing the gearbox
load to increase. Also, when the area of the surface
dynamometer card increases, the system requires
a larger motor size. This means that when you use
fiberglass rods you should run system simulations
using different fluid levels (within the expected
fluid level range) to see which fluid level results in
the highest loads and largest required motor size.
Using different fluid levels also affects the calculat-
ed pump stroke length and therefore the required
pump length and pump spacing . RODSTAR can
recommend a NEMA D motor size based on the
fluid level or pump intake pressure you enter.
TIP: You can speed up your system design consid-
erably by asking RODSTAR to design a rod string
for you. Even if you do not plan to use the design
RODSTAR recommends, it is easy to “grab”
RODSTAR’s recommended design and modify
it. To do this, after the program runs, go to the
rod string entry screen and select the “Manual rod
string entry” option. The program will default to
the rod string it calculated, and it will display this
74 |  Well Information
data as if you had entered it yourself. So, you can
simply change only the data you want to modify.
Please keep in mind that RODSTAR expects the
length of the rod string you enter to be within 50
feet of the pump depth. However, it cannot be
longer than the pump depth.
6.3.7 Using RODSTAR for Diagnostic Analysis
Although RODSTAR is primarily a design tool it
can be a very powerful diagnostic aid, when used
in conjunction with RODDIAG or XDIAG. This
is due to the powerful overlay feature that allows
direct comparison of predicted versus measured
dynamometer cards.
Using RODSTAR’s Dynamometer Overlay Feature
This feature has many different uses. For example,
it can help you figure out if your load cell is out
of calibration, if the fluid level you measured was
incorrect, etc. RODSTAR can help you find these
problems by comparing the shape and load range
of the measured dynamometer card versus the one
predicted by the program. Also, it can help verify
downhole problems such as a worn pump, leaking
traveling or standing valves, deep rod parts, stuck
pump etc. You can simulate a worn out pump or a
deep rod part by entering a fluid level of zero feet
from surface. This will result in zero fluid load on
the pump plunger.
RODSTAR cannot simulate a traveling valve leak,
a hole in the pump barrel, or a sticking pump.
But, it can predict what the dynamometer card
should look like if there were no problems. Then,
by comparing the actual dynamometer card shape
with the theoretical shape, you can have more
confidence in your diagnosis of the problem. For
example, if you have a traveling or standing valve
leak or a worn out pump, then the pump will be
doing less work and the surface dynamometer card
will have less area than the theoretical polished rod
dynamometer card.
If the pump is sticking, or if there is more friction
than normal between rods and tubing (due to par-
affin, scale, etc.), the measured dynamometer card
will be fatter than normal. The theoretical polished
rod dynamometer card predicted by RODSTAR
(for average friction calculated by the program)
will be smaller than the measured dynamometer
card. By entering a larger rod-tubing friction coef-
ficient you can get a better match between actual
and predicted dynamometer cards. This technique
helps you figure out what rod-tubing friction factor
to use for better simulation of your rod pumping
wells.
Rod-tubing friction is especially important
for fiberglass rods. Higher friction than
normal may actually reduce the area of the
predicted surface dynamometer card because
it causes the rods to stretch which results in a
small stroke at the pump.
RODSTAR-D allows you to change the rod-tub-
ing damping coefficients for upstroke and down-
stroke and also the friction coefficient between
rods and tubing for each section in the rod string.
This allows you to better simulate use of different
rod guides, or more exactly match the correct fric-
tion between rods and tubing for a better match
with the measured dynamometer card.
6.3.8 Using RODSTAR-D for better Wellbore Designs
RODSTAR-D can be a very useful tool in helping
you optimize the wellbore trajectory of your
deviated wells to minimize side loads, rod-tubing
wear and buckling, and to reduce lifting costs by
improving system efficiency.
The optimum wellbore path will be different for
each well, but by using RODSTAR-D you can
determine which is the best wellbore trajectory
by trial and error. Normally, wellbores that avoid
sharp turns and abrupt builds to the deviated sec-
tion will produce better results.
With careful planning and wellbore path control,
deviated well design can be improved with ROD-
STAR-D.
Theta Oilfield Services, INC., 1901 E. Lambert Rd. Suite 108 La Habra, CA 90631 USA
Telephone #: (562) 694-3297, Fax #: (562) 694-8641 www.gotheta.com