635

Chapter 15

HYDRAULIC SUBSURFACE PUMPS

PHIL WILSON and GEORGE V. CHILINGARIAN (EDITOR)

INTRODUCTION

Subsurface hydraulic pumps are downhole pumps powered by high-pressure fluid

directed to them from the surface. There are two types in common use: (1) the
positive displacement piston pump, driven by a hydraulic reciprocating subsurface

-FLUID LEVEL

s ENGINE

- PUMP

Fig. 15-1. Schematic diagram of piston pump, free type

636

SHUT OFF PUMP IN 0PERAT E PUMP OUT

AND BLEED
fi A fi I

-
-
FLOW
LINE

J
t
STANDING STANDING
IA LV E VALVE
:LOSED CLOSED

Fig. 15-2. Schematic diagrams showing operation of parallel free pump.

engine directly connected to the pump, and (2) the jet pump. Only the piston-type
hydraulic pump is discussed here.
Figure 15-1 shows a typical hydraulic subsurface pump installation. Two strings
of tubing are shown: (1) for directing the high-pressure power fluid to the engine,
and (2) for conducting the return power fluid plus produced fluid to the surface. In
this type of installation, the pump is free to be circulated in and out of the well. T h s
“free pump” principle is a unique feature of subsurface hydraulic pumps and is
further illustrated in Fig. 15-2.
The “shut-off and bleed” function of the “free pump” system is shown at the left
in Fig. 15-2. The U tube is full of low-pressure power fluid, which is retained in the
tubing by the closed standing valve. The power fluid is shut-off at the surface and
the large tubing is opened at the top allowing the “free pump” to be inserted.
The next function shown is “pump in”, whereby the pump, with its packer and
nose assembly, is being circulated to bottom. The large tubing is closed at the top by
the insertion of the pump catcher which locks in place. The standing valve is still
closed and the 4-way valve at the surface is positioned to direct power fluid into the
large tubing and the return fluid into the flowline. The flow of power fluid down the
large tubing carries the pump to the bottom.
 631

8
Tubing -

Fig. 15-3.Complete hydraulic pumping system.

638

The “operate” function is shown next: The pump is seating at the bottom,
metal-to-metal, on the standing valve and at the top by an O-ring in a seal collar.
The flow of power fluid down the large tubing is operating the engine, while the
production, mixed with exhausted power fluid, is returning up the small tubing. The
standing valve is now open and its ball is being held off seat by a magnet.
The “pump out” function is shown at the right in Fig. 15-2: The power fluid is
directed down the small tubing, by the surface 4-way valve, thereby forcing the
pump off of the standing valve. When the pump unseats, the rush of fluid trying to
exit forces the ball off of the magnet and on the seat. With the standing valve now
closed, the U tube necessary to surface the pump is provided. The swab cups of the
packer and nose assembly provide the efficiency necessary to circulate the pump to
the surface, where the fishing neck of the assembly engages the pump catcher. With
the pump latched, the tubing strings can be bled off and the catcher used to remove
the free pump.
A complete hydraulic “free pump” system is shown in Fig. 15-3. The various
elements of this system are discussed in the order shown from A through F.

SUBSURFACE PUMPS-PISTON TYPE

Originally, the subsurface pump was designated “production unit”, but in

practice it was usually referred to as a pump. This caused confusion because the unit
consists of an engine as well as a pump, and it was continuously necessary to refer
to the operation of the engine separately from the operation of the pump. The
problem was solved by identifying the engine as the “engine-end’’ of the pump and
the pump as the “pump-end’’ of the pump. These commonly accepted terms are
used in the following discussion.
The engine-end of a Kobe type A pump is shown in Fig. 15-4. High-pressure
power fluid enters from the top and is shown being directed to the top of the piston.
Exhausted power fluid from the lower side of the piston is being directed by the
relieved area of the engine valve to the discharge port.
When the piston reaches the end of the downstroke, the reduced diameter at the
top of the valve rod allows high-pressure fluid to enter under the valve as shown in
Fig. 15-5. Inasmuch as the valve has a larger area at its bottom than at its top, the
high pressure causes it to move upwards.
With the engine valve in the up position as shown in Fig. 15-6, the flow paths to
the piston are reversed. The piston, therefore, begins the upstroke.
When the piston reaches the end of the upstroke, as shown in Fig. 15-7, the
reduced diameter near the lower end of the valve rod connects the area under the
valve to the discharge, or low-pressure, side of the engine. With high pressure on the
top of the valve and only exhaust pressure at the bottom, the valve will move to its
down position and the cycle will be repeated. The rate of flow of power fluid
determines the pump speed. Pump speed is measured in cycles per minute and is
referred to as “strokes per minute”.
 639
DOWNSTROKE END OF DOWNSTROKE

ENGINE
VALVE,

-
VALVE
ROD

ENGINE
PISTON -

ROD -
MIDDLE

CONNECTS TO PUMP PISTON

Fig. 15-4.Cross-section of engine-end: downstroke.

Fig. 15-5. Cross-section of engine-end; end of downstroke.
START OF UPSTROKE END OF UPSTROKE

Fig. 15-6. Cross-section of engine-end: start of upstroke.

Fig. 15-7. Cross-section of engine-end; end of upstroke.
640 DOWNSTROKE

EXHAUST
,VALVES

Fig. 15-8.Cross-section of pump-end; downstroke.

UPSTROKE

Fig. 15-9. Cross-section of pump-end; upstroke.

 641

DOWN STROKE UP STROKE

- ENGINE
PISTON-

- PUMP
PISTON-

Fig. 15-10. Cross-section of complete pump: downstroke and upstroke.

The pump-end of the unit is shown in Fig. 15-8 making a downstroke. This pump
is double-acting, i.e., it pumps on the upstroke and on the downstroke. The arrows
show that well fluid is entering on the left and filling the upper part of the cylinder,
while the well fluid below the piston is being discharged through the ball check
valve at the lower right.
On the upstroke, shown in Fig. 15-9, well fluid is filling the lower part of the
cylinder and is being discharged from the upper end.
The complete pump is shown in Fig. 15-10. The hollow rods serve two purposes:
(1) to balance the areas, and hence the forces, on the upstroke and downstroke; and
(2) to provide clean high pressure power fluid to the pump piston for lubrication
and for washing sand out of the piston-cylinder fit.
The Kobe type A pump is also shown in Fig. 15-11 along with a pump
specification table. Figures 15-12 through 15-24 show other pumps currently avail-
642

able from the various manufacturers. Some of these pump schematics are difficult to
analyze because of the various internal passageways and engine valve designs. A
simplified approach is shown in Fig. 15-25. T h s is the Kobe type A pump
previously covered. The engine valve, pump valves, and fluid passageways are all
shown external to the piston and cylinder. As a further simplification, the engine
valve is schematically illustrated as a rotating valve.
Figure 15-26 shows all of the various engine-ends and pump-ends in this
simplified format. The engine-ends at A , B , and C use a 4-way, 2-position, engine
valve, whereas those at D, E , F, and G use a 3-way, 2-position, engine valve. A
3-way valve requires the pressure in one end of the cylinder to be the same on the
upstroke and on the downstroke. The pressures for the upstroke are shown in the
left half of the cylinders and the pressures for the downstroke are shown in the right
half of the cylinders. In some of the pump-ends, the pump valves must be shown
internally.
The Kobe type A single pump-end pump (Fig. 15-11) is illustrated at A and H in
Fig. 15-26. The engine valve is at the top of the pump and is shifted hydraulically.
The top rod (called valve rod) acts as a pilot valve for shifting the main valve. This
pump is double acting, i.e., it pumps on the upstroke and on the downstroke.
The Kobe type A double pump-end pump (Fig. 15-12) is illustrated at A and I
in Fig. 15-26. It is similar to the pump in Fig. 15-11 except it has an added pump
piston. This piston is in parallel hydraulically with the other pump-end piston so it
doubles the pump-end volume capacity.
The Kobe type B single pump-end pump (Fig. 15-13) is illustrated at A and H in
Fig. 15-26. It is similar to the type A pump except some passageways that are
internal in the type A pump are external to the type B pump. This allows the type B
cylinders to be larger than the type A cylinders. Hence the type B pump has greater
capacity.
The Kobe type B double pump-end pump (Fig. 15-14) is illustrated at A and I in
Fig. 15-26. The comments regarding Figs. 15-11, 15-12, and 15-13 are applicable to
this pump also.
The Kobe type D single pump-end pump (Fig. 15-15) is illustrated at B and H in
Fig. 15-26. It has two engine pistons (in parallel hydraulically) for greater engine-end
capacity. The previous comments are applicable to this pump.
The Kobe type D double pump-end pump (Fig. 15-16) is illustrated at B and I
in Fig. 15-26. The previous comments are applicable to this pump also.
The Kobe type E pump (Fig. 15-17) is illustrated at C and J in Fig. 15-26. The
engine valve is in the middle of this pump and is shifted hydraulically. The rod acts
as a pilot valve for the main engine valve. It is somewhat awkward to refer to the
engine-end and the pump-end of this pump because the engine is in the middle. The
inboard ends of the pistons are the engine and the outboard ends are the pump.
More descriptive terms would be “upper and lower engines” and “upper and lower
pumps” or “ upper and lower pump-ends”.
The Guiberson Powerlift I1 pump (Fig. 15-18) is illustrated at C and J in Fig.
15-26 and is similar to the Kobe type E pump.
 643

SPECIFICATIONS-
KOBE TYPE A PUMP-SINGLE ENGINE, SINGLE PUMP END
DI LACEMENT Max.
At EPD Der SPM Rated
Rated Speed
Speed Eng. Pump (SPW
139 2 15 115 121
,............... 254 2 15 2 10 121
2x1-llle .............' 1546 393 2 15 3 25 121
2x11~-1 . . . . . . . . . . . . .I 647 254 3 30 2 10 121
393 3 30 3 25 121
256 5 02 2 56 100
367 5 02 3 67 100
492 5 02 4 92 100
703 5 02 7 03 100
492 7 13 4 92 100
703 7 13 7 03 100
486 9 61 5 49 87
646 9.61 7 43 87
821 9 61 9 44 87
1218 9 61 14 00 87
821 14 17 9 44 87
1218 14.17 14 00 87
1108 21 44 14 40 77
1617 21 44 21 00 77
2502 21 44 32 50 77
1617 32 94 21 00 77
2502 32 94 32 50 77

Fig. 15-11. Specifications and cross-section of a Kobe type A pump; single-engine, single-pump-end,
644

..j:j :j.
:;

@fl
:.: (I
:j :.:
.... ,

': 4

DISPLACEMENT Max.
PUMP SIZE At BPD per SPM Rated

DESCRIPTION RATIO Speed Eng.

2 x 1%. -1 x 1 . . .. . . .. . . 1.290 508 3 30
2xl%.-l%. X l ........ 1.647 647 3.30
z ~ i ~ ~ - -x li hv. ~ ~ ...... 2.000 786 3.30

,
3 x 134-1 % x 1% .. . . . . , , ,800 972 14.17 11.18
.. . ..,
.:.;.:
3 x 1%--1% x 1% , ,
3xl%-l%xl'h
31 l%-l% x 1%
........
. .......
~
1.351
1.675
2 000
~ lzli
2436
14.17
114.17
14 17
18.88
23.44
28.00
4 x 2'18-2 x 1% . . . . . . . . . . I I 1 32 94 35.40

1
1 094 2725
4 x 2W-2 x 2 . . . . . . . . . . . . 1.299 3234 32 94 42.00
4 x 2%-2H x 2 . . . . . . . . . . 1.850 4119 32.94 53.50
4x2%-2#x2h ........ 2.000 5005 32 94 65.00

Fig. 15-12. Specifications and cross-section of a Kobe type A pump; single-engine, double-pump-end.
 645

SPECIFICATIONS-
KOBE TYPE B PUMP-SINGLE ENGINE, SINGLE PUMP END

i
PUMPSIZE I At
Raled
DISPLACEMENT
1 BPDperSPM i Max.
Rated
Speed
1
DESCRIPTION RATIO Speed

544 4 54 4.50
744 10 96 7 44 100
1086 100

Fig. 15-13. Specifications and cross-section of a Kobe type B pump: single-engine, single-pump-end.
646

SPECIFICATIONS-
KOBE TYPE B PUMP-SINGLE ENGINE, DOUBLE PUMP END
DISPLACEMENT Max.
PUMP SIZE At BPD p e r SPM Rated
OR PIE Ribd Speed
DESCRIPTION RATIO Speed Eng. Pump (SPM)
2 x 1%-13% x 11%~ ...... 1.380 751 4.54 6.21 121
2xl%-l~hxl~h ,....... 1.680 913 4.54 7.55 121
2X1~l~-I~!~x1"~ ........ 1.980 1076 4 54 8.W 121
2% x 1%-1% x 1 % . . . .. . . 1.336 1452 10.96 14.52 100
... ...
2 % x 1%-1 114 x 1 'h , 1.652 1794 1096 17.94 100
2%x1~f4-lhxl~l, ....... 1.957 2136 10.96 21.36 100
3 x Z'h-178 x 1'18 ,.. . , . , , 1.454 2726 21.75 31.34 87
3x2'4-2'hxIh ........ 1714 3213 21.75 36.94 87
3~2'/~-2'hx2'/1 ........ 1.974 3700 21 75 42.53 a7

Fig. 15-14. Specifications and cross-section of a Kobe type B pump; single-engine, double-pump-end.
 641

DISPLACEMENT Max.
PUMP SIZE
OR
DESCRIPTION
PIE
RATIO
At
Rated
Sped
- BPD por SPM

En@. Pump
Rated
Speed
(SPM)
2 x 1%. x l 3 h - l a ~ e ... . . 407 381 7 79 3 15 121
Z x l S i i xl%--l'h ....... 581 544 7 79 4 50 121
2'hXl'li. X l ' A - l ' h ..... 411 744 17 99 7 44 100
2% x 1',e x I a A - I a A . .. . . 608 1086 1799 1086 100
3xl%x2%-1% ........ 449 1357 35 74 15 96 87
3 x 1% x 2%--2'h .. . ... .. 606 1874 35 74 21 55 87

Fig. 15-15. Specifications and cross-section of a Kobe type D pump; double-engine, single-pump-end.
648

SPECIFICATIONS-
KOBE TYPE D PUMP-DOUBLE ENGINE, DOUBLE PUMP END
DISPLACEMENT Max.
PUMP SIZE At BPD per SPM Rated
OR PIE Rated Speed
DESCRIPTION RATIO Speed Eng. Pump (SPM)
2 X 1 % 1 xI%-l%. ,802 751 7.79 6.21 121
.
Xl'h.
2 X I % # xl%-1% XlYw ,976 913 7.79 7.55 121
2x1'111 x l % - l W x l % .. 1,150 1076 7.79 8.90 121
2%X1%1 XI%-l%XlW. ,813 1452 17.99 14.52 100
2%xl%. x l U - l % x l ' l ~ , ,976 1794 17.99 17.94 100
2112 x IV?, x 1v+1*1, x 1 31, . 1.196 2136 17.99 21.36 100
3x1~/4x2H-I%x1% ... ,882 2726 35.74 31.34 87
3 x 1 % x 2'/1-2% x 1% . .. 1.039 3213 35.74 36.94 07
3x1Ux2%-2~/~x2% ... 1.197 3700 35.74 42.53 07

Fig. 15-16. Specifications and cross-section of a Kobe type D pump; double-engine, double-pump-end.
 649

I I

1
i PUMP SIZE
SPECIFICATIONS-
K 0 6 E TYPE E PUMP
DISPLACEMENT
EPD per SPM Rated
Rated Speed
DESCRIPTION RATIO

2397
4015

ICOUII~LY
Kobe Inc --Subsidiary 01 Baker lnlernslional Corp )

Fig. 15-17. Specifications and cross-section of a Kobe type E pump.

 650

1 SPECIFICATIONS-

DISPLACEMENT Max.
PUMP SIZE At BPD per SPM Rated
OR PIE Rated Speed
DESCRIPTION RATIO Speed Eng. Pump (SPM)
2 Il%e.. ................ ,524 597 12.10 5.53 108
2 X f % . .................. ,725 826 12 10 7.65 106
2x .................. 1.147 1560 26.35 30.00 52
2% X l'h ................. ,725 1322 17.69 12.59
.................
2'h I l ' h
2% I 1% .................
503
1 146
918 1769 8.74 . 105
105
2500 43 97 50 50

Fig. 15-18. Specifications and cross-section of a Powerlift JI pump.

 651

SPECIFICATIONS-
P VERLIFT I PUMP . SINGLE ENGINE. SINGLE PUMP END

DISPLACEMENT Max .
PUMP SIZE At I BPD Der SPM Rated
I OR I P/E 1 ..
Rated I
RATIO Speed Eng .
2 x 14 x 1 ...............
............. ii 312 ~ 1508
645 35
35

!
2 x 1% x 1 ' 2 1 ~ 450 15 08
121 528 1508 1508 35
.............
............. :: 264
' 30 80

++J
2'2 x 2 x 1"l 467 30 80
.............
~

80 547 1 3080
............. I 93 637 I 30 80
............ 831 30 80 3080
3 x 272 x 1%
3
3
x
x
2% x 2
2h x
.............
21.4............ 98
643
840
1062
I' 43 71
4371
4371
2142
2798
3541
2 % x 2'h ............ 1
~

3 x 121 1711 I 4371 4371

4 ~ 2 x"2 ~. . . ~. . . . . . . . .
I 4 ~ 2 " ~ a x 2 h ............ 72
........... , .89
~ .57
. 1%
60 35
6035
2798
3541
30
30

........
4X2"/?8 X2'h 1311 60 35 4371 30
5290
4 2% ............ j 1810 60 35 8035 ~ 30
rCOurtesy Guibernon Division .D i e ~ ~ Industries
ei Inc I

Fig . 15.19 . Specifications and cross-section of a Powerlift I pump; single.engine. single.pump.end .

652

SPECIFICATIONS-
OILMASTER F, FE 6 FEE PUMPS

j C o ~ r I a l yARMCO-National Production Systems)

Fig. 15-20. Specifications and cross-section of an Oilmaster F, FE, and FEB pumps.
 653

SPECIFICATIONS-
OILMASTER VFR PUMP -
SINGLE ENGINE, SINGLE PUMP END
DISPLACEMENT Max.
PUMPSIZE At EPD pmr SPM Rated
OR PIE RIM SpHd
DESCRIPTION RATIO S W ~ng. Pump (SPM)
VFR201611 ............ 62 318 4 24 2 12 150
VFR201613 ............ 87 444 4 24 2 96 150
VFR 201616 ............ 1 32 673 4 24 4 49 150
VFR 252015 ............ 74 6% 8 89 5 25 120
VFR 252017 ............ 1 00 858 8 89 7 15 120
VFR 252020 ............ 1 32 1119 8 89 9 33 120
VFR 302424 ............ 1 28 1612 1299 1344 120

(Courtesy A R M C O - N ~ ~ I Production
O~~I System1

Fig. 15-21, Specifications and cross-section of an Oilmaster VFR pump; single-engine, single-pump-end.
654

DISPLACEMENT Max.
PUMP SIZE At BPD per spm Rated
OR PIE Wed Speed
DESCRIPTION RATIO Speed Eng. Pump (SPM)
VFR20181813 .......... 54 444 686 296 150
VFR 20181818 .......... 81 673 6 86 449 150
VFR25202015 .......... 41 630 I5 16 525 120
VFR 25202017 .......... 56 858 1516 715 120
VFR 25202020 .......... 73 Ill9 15 16 933 120

Fig. 15-22. Splecifications and cross-section of an Oilmaster VFR pump; tandem-engine, single-pump-end,
 655

SPECIFICATIONS -
OILMASTER V-11 PUMP-SINGLE ENGINE, SINGLE PUMP END

DISPLACEMENT Max.
PUMP SIZE At I BPD per SPM Rated
OR P/E Rated Speed
DESCRIPTION RATIO Speed Eng. Pump (SPM)
V-25-11-118 ................... 1.18 1419 5.33 6.31 225
V-25-11-095 ................... .95 1299 6.66 6.31 206
V-25-11-076 , , ,. . , , , , , , , , ,. , , ,
, 76 550 5.33 3 93 140
V-25-11-061 ................... .El 550 6.66 3.93 140
656

The Guiberson Powerlift I pump (Fig. 15-19) is illustrated at E and K in Fig.

15-26. The engine valve is in the engine plunger and is shifted mechanically at each
end of the cylinder. This pump does not use the upper rod (illustrated by dashed
lines at E ) . Power fluid is discharged through the (middle) rod. This pump is single
acting.
The Oilmaster F, F E and FEB pumps (Fig. 15-20) are illustrated at E and L in
Fig. 15-26. These pumps also do not use the upper rod. The engine valve is in the
engine plunger and is slufted hydraulically when the valve senses “no-flow’’ at the
end of each stroke. This pump is double acting.
The Oilmaster VFR single engine pump (Fig. 15-21) is illustrated at E and K in
Fig. 15-26. The engine valve is at the top of the pump and is shifted hydraulically.
The upper rod is the pilot valve for the main valve. This pump is single acting.
The Oilmaster VFR tandem engine pump (Fig. 15-22) is illustrated at F and K
in Fig. 15-26. This pump is similar to that illustrated in Fig. 15-21 except it has two
engine plungers. These are in parallel hydraulically for doubled engine capacity.
Comments regarding Fig. 15-21 apply to this pump.
The Oilmaster V11 pump (Fig. 15-23) is shown at E and M in Fig. 15-26. The
engine valve is at the top of the pump and is shifted hydraulically. The upper rod is
the pilot valve for the main valve. This pump is double acting.
The Oilmaster V21 tandem engine pump (Fig. 15-24) is shown at G and N in
Fig. 15-26. The engine valve is at the top of the pump and is shifted hydraulically.
The upper rod is the pilot valve for the main valve. The engine-end of this pump is
similar to Fig. 15-26F except that the underside of the bottom engine piston is
exposed to produced fluid rather than power fluid. This pump is double acting.
It is obvious that the pump-ends at H , I , and J in Fig. 15-26 are double acting
because they pump on the upstroke and on the downstroke. The pump-end at K is
obviously single acting because it pumps on the upstroke only. The pump-ends at L ,
M , and N are double acting, but this fact is not apparent because they pump only
on the downstroke; they are sometimes referred to as “differential double-acting’’
pumps. A simple way to determine if a pump is single or double acting is to divide
the pump-end displacement per SPM (from the specification table ) by the engine-end
displacement per SPM. If the result is equal to the value in the P / E column of the
specification table, then the pump is double acting (allow 2-3% variation for
operation of the engine valve of Kobe pumps). The results will be 20-30% less than
P / E for single-acting pumps. This test compares the pressure ratio ( P / E ) to the
volume ratio and is a measure of the unproductive work performed by the
engine-end.
Example problem 15-1
The pump-end displacement per SPM for the first pump in Fig. 1 5 - l l ’ i s 1.15 and
the engine-end displacement per SPM is 2.15; therefore:
1.15
volume ratio = -= 0.535
2.15
 651

SPECIFICATIONS-
OILMASTER V-21 PUMP-TANDEM ENGINE, SINGLE PUMP END

DISPLACEMENT
PUMP SIZE BPD per SPM Rated
Rated
DESCRIPTION
V-25-21-075 ...................
1072 10 00 6.31 170
550 8 38 3.93 140
V-25-21-041 ................... 550 10 00 3 93 140

(Courtesy ARMCO-Nation81 Production Syslernri

Fig. 15-24. Specifications and cross-section of an Oilmaster V-21 pump; tandem-engine, single-pump-end.
658

I-

UPSTROKE - - DOWNSTROKE

Pl=HIGH PRESSURE POWER F L U I D

Pz=EXHAUST PRESSURE POWER FLUID
P3=PRODUCTION DISCHARGE PRESSURE
P4=PRODUCTION INTAKE PRESSURE

Fig. 15-25. Simplified schematic diagram showing the operation of the Kobe type A pump.
 a
h

c
/ I
1-1

1 1 - 1

I
1
1
P
Y

L
7

==T
'
L

659
Fig. 15-26. Simplified schematic diagrams showing the opcrations of various engine-ends and pump-ends
660

This compares with the P / E value of 0.545. The 2%’ difference is the unproductive
power used to shift the engine valve.
The pump-end and engine-end displacement values for the first pump in Fig.
15-19 are 6.45 and 15.08, respectively; therefore:

6.45
volume ratio = -- 0.428
15.08
This compares with the P / E value of 0.52. The 21% difference is the unproductive
power used to make the downstroke of the pump.

PUMP SELECTION

Selecting a pump for a given well is a simple and straightforward process using
the specification tables in Figs. 15-11 through 15-24. One must select a pump (1)
that fits the given tubing size, (2) that has sufficient capacity for the well. and (3)
that will not operate at excessive pressure. Selection also involves price, brand
preference. mechanical feature preference, and delivery and service availability.
The “pump size or description” columns of the specification tables indicate what
size tubing the pump will fit in. For instance, the Kobe and Guiberson pumps start
with the nominal sizes:

Nominal size Tubing size

(in ) (In )
2 2: OD
2: 2 i OD
3 3; OD
4 4; OD

The Oilmaster pumps use the following code in the first two digits:

Code Tubing size

(in.)
20 2; OD
25 2; OD
30 3 f OD

The above information allows one to choose a pump to fit the given tubing size,
whereas the following equation allows one to choose a pump with sufficient capacity
for the well:

= Minimum pump displacement =

(Q, X B ) + Qs
(15-1)
Qp 0.85 x 0.85
 661

Example
Pump Intake Pressure = 400 psia
Oil Temperature = 100°F
Oil Gravity = 3 5 O API
Gas Specific Gravity = 0.7
Solution GOR = 65 scf/B

SOLUTION GAS-OIL RATIO A T PUMP INTAKE PRESSURE

( F r o m AIME Jour. Pet. Tech. T.P. 2931, 1950)

Fig. 15-27. Bubble point pressure correlation. (Modified after Borden and Rzasa, 1950, fig. 1, p. 346;
courtesy of the SOC. Pet. Eng. of AIME.)

where: Q, = required rate of oil production, Q6 = required rate of water production,

and B = formation volume factor.
When choosing a pump, it is good practice to choose a pump that will operate at
less than 85% of its maximum rated speed. In addition, a pump volumetric
efficiency, usually 85%, should be assumed to allow for fluid slippage due to the
pump wear over a period of time. These are the factors (0.85 X 0.85) in the
denominator of eq. 15-1.
The formation volume factor, B , should be obtained from actual PVT tests on
the particular well fluid to be pumped; however, in the absence of this data, Figs.
15-27, 15-28, 15-29, and 15-30 can be used. Hydraulic pumping installations can be
designed to require the pump to handle (compress) the free gas or they can be
designed to allow the free gas to be vented (through the casing annulus or through a
separate string of tubing) to the surface separately from the pumped fluid.
 PBOPERTIES OF NATURAL HYDROCARBON MIXTURES OF GAS AND LIQUlO

Formation Volurrrc of Bubble Poiot Irtprid m

m
N

EXAMPLE
GOR = 6 5 scf/B
Gas Sp. Gr. = 0.7
Oil Gravity = 3 5 0 API
Temperature = lOOOF
B = 1.037

Copyright 1947
Chevron Rerearch Corn-
Reprinted by Psrrnmnmon

B, FORMATION VOLUME of BUBBLE POINT LIQUID -

Fig. 15-28. Oil formation volume factors of California natural hydrocarbon mixtures of gas and liquid at bubble point. (After Standing, 1952; courtesy of
Reinhold Publishing Corp.)
 P R W f R T I E S OF NATURAL HYDROCAKEON MIXTURES OF GAS A N D LIQUIU

Form;rtion Volrimc nf Gas Plus Liquid Phases

EXAMPLE

GOR = 200 scf/B

Gas Sp. Gr. = 0.7
Oil Gravity = 350 API
Temperature = lOOOF
Pressure = 4M) psia
E = 1.1

m
m
w

Fig. 15-29. Total formation volume factors of California natural hydrocarbon mixtures of gas and liquid. (Alter Standing, 1952; courtesy of Reinhold
Publishing C'orp.)
664

THEORETICAL VOLUMETRIC EFFICIENCIES OF CASING PUMPS

Gas Gravity=0.8, Oil Gravity=40° API, Bottom Hole Temperature=150°F

3000

2500

2000
.
1500

8 1000
ui 900
I 800
3
VI
700
r
P 600
W
Y 500
6
+
z 400
P
I
2 300

250

200

150

I
FORMATION SHRINKAGE FACTOR - S
I .
01
.10 .20 .30 .40 .50 'I .60 .70 .80 .90
4
1.00

20 I
4

j
I
c .20 .30 .40 .50 .70 .80 .90 1.oo
3
, .60 ,
;
--d=
40 I
K .20 .30 .40 .50 .90 1.00
Lu
c .60 .80
a
B 60 : 4
.30 .40 .50 .60 .70 .a0 .90 1 .oo

80 + ; +
.40 .50 .60 .70 .80 .90 1 .oo

Fig. 15-30. Determination of theoretical volumetric efficiencies of casing pumps.

If gas is to be vented, one can usually assume B = 1.0. To be precise, however,

one should use Fig. 15-27 to arrive at the solution gas,/oil ratio at pump intake
pressure. With this value, Fig. 15-28 can be used to determine the formation volume
factor, B , for the produced oil. (The formation volume factor for water is taken as
1.O.)
 665

Example:
If gas is being vented, pump intake pressure is 400 psi, oil has 35”API gravity,
the pump intake temperature is 100”F, and the gas gravity is 0.7. Fig. 15-27
indicates a solution gas/oil ratio of 65 scf/bbl. From Fig. 15-28, the formation
volume factor is equal to 1.037. If 100 bbl/D of oil and 100 bbl/D of water are to
be produced, the minimum required pump capacity from eq. 15-1 becomes:

100 X 1.037 + 100 = 282 B/D

Qpmin = 0.85 X 0.85

If free gas is to be compressed by the pump, Fig. 15-29 can be used to obtain the
formation volume factor of the oil plus free gas. For example, if the gas/oil ratio in
the above example is 200 scf/B and the free gas is not being vented, Fig. 15-29 gives
a formation volume factor of 1.7. Again, using eq. 15-1, minimum pump displace-
ment is equal to:

+
100 x 1.7 100 = 374 B/D
Qp min =
0.85 X 0.85

Figure 15-30 has been obtained from Fig. 15-29 at the specific conditions shown.
This chart takes into account the water produced but is made for “formation
shrinkage factor”, which is the reciprocal of formation volume factor. If symbol, S ,
is used for this shrinkage factor, eq. 15-1 becomes:

Q . = Qs’Q6
(15-1.a)
pmn (0.85 X 0.85) X S

In the above example, Fig. 15-30 gives a value of S of approximately 0.71. The
minimum required pump capacity thus becomes:

200
= 389 bbl/D
Qp = (0.85 X 0.85) X 0.71

When S is less than 0.5 or when [ ( Q , X B ) + Q 6 ]is more than [2 X (Q, + Q 6 ) ] ,it
indicates that the pump will be required to handle more gas than liquid. Under
these circumstances one should consider either (1)changing the tubing arrangement
to vent the gas or (2) allowing a greater pump intake pressure (flowing bottomhole
pressure).
Vogel’s reference IPR curve for solution-gas-drive reservoirs (Fig. 15-31) il-
lustrates that as the flowing bottomhole pressure is reduced, the incremental
increase in production rate is decreased. For example, a deep well with a static
reservoir pressure of 3000 psi (20.7 Pa) is to be produced at 1000 psi (6.89 Pa)
flowing bottomhole pressure. Figure 15-31 shows that at this pressure (pwf/p,
= $$$ = 0.3) one will be producing at 85-90% of the capacity of the well. To obtain
the 10-15% additional production rate may require considerable additional
666

1 .oo
VOGEL'S C U R V E FOR
INFLOW PERFORMANCE RELATIONSHIP
FOR SOLUTION-GAS D R I V E RESERVOIR

0.80

0.60

0.40

0.2c

I
C
3 0 40 0.60 0 80 '0
PRODUCING RATE AS A FRACTION OF MAXIMUM PRODUCING RATE
q,/iq,iMAX.

Fig. 15-31. Relationship between the bottomhole pressure (as a fraction of reservoir pressure) and
producing rate (as a fraction of maximum producing rate) for solution-gas drive reservoir.

equipment costs, because as the flowing bottomhole pressure decreases the value of
B increases rapidly.
It was discussed above how to choose a pump: (1) to fit the tubing and (2) with
sufficient capacity (displacement). Now one must (3) choose a pump that will not
require excessive surface pressure. The following equation, which is derived in a
later section, enables one to determine the surface power fluid pressure, ps:

(15-2)

where G4= fluid gradient of produced fluid, A p / h ; h , = pump setting depth;

h4 = height of fluid above pump; P / E = pressure ratio of pump; and Fp = friction
in pump.
 667

Solving this equation for pressure ratio gives:

P, - F p
P/E = (15-2.a)
G4(h1

Good practice is to select a pump that will not require over 3500 psi (24.1 Pa).
Pressures up to 4000 psi (72.6 Pa) are occasionally found in practice, but 4500 psi
(31.0 Pa) and above are rare. The quantity in the specification tables that relates to
surface operating pressure is found in the P / E column. This quantity is called the
“pressure ratio” or simply “ P over E”. It is the ratio of the effective pump area to
the effective engine area. Substituting ps = 3500 psi and Fp = 400 psi (2.76 Pa), an
average value, into eq. 15-2.a, one obtains:
3500 - 400 - 3100
P/E(max.) = (15-3)
G4(h1 - h4) G4hl - G 4 h 4

In SI units:
24.1 - 2.76 - 21.3
P/E (max.) = (15-3 .a)
G4(h1 - G4h1 - G4h4

The quantity ( h , - h,) is the net lift or working fluid level in the well. When the
pump is pumping from beneath a packer, there is no “working fluid level” in the
well. It is, therefore, helpful to expand the denominator to (G,h, - G4h,) as shown
in eq. 15-3. Flowing bottomhole pressure ( p4 = G4h4) can then be used instead of
working fluid level. Thus, the pump selection procedure can be summarized as
follows:
(1) Select a pump to fit the given tubing size.
(2) Select a pump to fit the given production rate (eq. 15-1).
(3) Select a pump to operate at less than 3500 psi (24.1 Pa) surface pressure (eq.
15-3).
Example problem 15-2
Given :
Oil production = 100 bbl/D (15.9 m3/D)
Water production = 100 bbl/D (15.9 m3/D)
GOR = 500 scf/bbl (90 m3/m3)
h , = 8000 ft (2440 m)
h , = 2000 ft (610 m)
G4 = 0.4 psi/ft (0.00904 Pa/m)
Tubing size = 29 in. O D (7.3 cm)
Find:
(A) The suitable pumps in Fig. 15-11 if gas is vented.
(B) The suitable pumps in Fig. 15-11 if gas is not vented.
668

Solution:
(A) Assume B = 1.0

Minimum p u q p displacement, Qp min = 2oo = 277 bbl/D

0.85 X 0.85
3100
P/E(max.) = = 1.29
0.4( 8000-2000)

According to Fig. 15-11, from 2i-in. pumps the second, third, fifth, and sixth
meet the above criteria. The fifth pump has the lowest P / E and, consequently, the
lowest surface operating pressure. Thus, it would probably be the ideal choice.
(B) Flowing bottomhole pressure = 0.4 (2000) = 800 psi
From Fig. 15-30, S = 0.62; thus:
200
Minimum pump displacement, Qp min = = 446 bbl/D
0.85 X 0.85 X 0.62
3100
P / E (max.) = = 1.29
0.4(8000) - 800

According to Fig. 15-11, three 2i-in. pumps meet these criteria.

If the well is 12,000 f t (3600 m) deep and the pump is set on bottom, the pump
submergence, h , , will become 6000 ft (1830 m). This does not affect the pump
selection if gas is to be vented. But if gas is not vented, a new value for p , and S (or
B ) must be found:
p4 = 0.4(6000) = 2400 psi
From Fig. 15-30, S = 0.95 (approximately); thus:
200
Minimum pump displacement, Qp min = = 291 bbl/D
0.85 x 0.85 x 0.95
3100
P / E (max .) = = 1.29
0.4(12000) - 2400

In this case, one can choose the second, third, fifth, or sixth pumps from Fig.
15-11. The maximum surface operating pressure and the maximum P / E value are
not altered by setting the pump deeper. This example shows why it is almost always
desirable to set hydraulic pumps as deep as possible. For a gas vented system, if the
working fluid level is say 6000 ft, the surface power fluid flow rate and pressure will
be the same whether the pump is set at 6000 ft, 12,000 ft or any other depth
(neglecting friction of course). When the pump is required to compress gas, deeper
setting depths provide higher pump intake pressures, which in turn provide higher
values for S (lower values for B ) , and, therefore, improved pump loading condi-
tions.
To select a surface pump, it is necessary to know the power fluid flow rate and
 669

TABLE 15-1
Pump selection procedure and the first approximation of surface power requirements

To find Use
Pump to fit in given tubing (size) Pump specification tables, Figs. 15-11 through 15-24
( Q 5 X B)+Q6 Q5+Q6
Pump with sufficient capacity or (eq. 15-1)
0.85 x0.85 0.85 X0.85 X S
Pump to operate below 3500 psi P / E (max.) = 3100/(G4h, - G 4 h 4 ) (eq. 15-3)
Surface power fluid pressure P , = G ~ ( ~ I - ~ ~ ) PFD /E+ (eq. 15-2)
( Q 5 B + Q 6 ) 91 - ( Q 5 +Q6)qi
Surface power fluid rate (eq. 15-4)
'I= 0.85x0.90xq4 0.85x0.90x9,xS

pressure required by the subsurface pump, or pumps, which have been selected.
Equation 15-2 will give a suitable first approximation for the surface pressure
required. (Equation 15-28 in a later section, with substitutions from Fig. 15-59, will
give the precise value of p,). The following equation (derived in a later section) will
give the value for power fluid flow rate, Q,:

(15-4)

where: q, = engine-end displacement factor; and q4 = pump-end displacement fac-

tor. Other quantities have been previously defined.
The downhole pump specification tables list the values for q, and q4 in bbl/D
per SPM (strokes per minute). In the denominator, the 0.85 is the pump-end
efficiency and 0.90 is the engine-end efficiency.
Table 15-1 summarizes pump selection procedure and the first approximation of
surface power requirements. If these calculations are 75% below surface and
subsurface pump maximum specification ratings, then it will usually be safe to omit
the precise calculations covered in a later section.
Example problem 15-3
Given: Same data as in Example problem 15-2 (B)
Assume: Fp = 400 psi
Find:
(A) Surface power fluid rate.
(B) Surface power fluid pressure.
( C ) Surface power required.
Solution:
In the solution of problem 15-2 (B) it was found that only one pump, the
2i-in. x l&-in. - l&-in., is suitable. This pump has a P / E = 1.0, q4 = 7.03, and
q1 = 7.13. S was found to be equal to 0.5.
670

(A) From eq. 15-4:

200 x 7.13
= 530 bbl/D
= 0.85 X 0.90 X 7.03 X 0.5
(B) From eq. 15-2:

p s = 0.4(6000)(1 .O) - 400 = 2000 psi

( C ) A useful hydraulic equation is:

Q (bbl/D) Xp (psi) X 0.000017 = Horsepower

530 X 2000 X 0.000017 = 18 H P

Class problems

(1) Given: Production rate = 700 bbl/D (no water)

Working fluid level = 7000 ft from surface
G4 = 0.36 psi/ft
Tubing size = 2i-in. O D
GOR = 500 scf/D
Pump setting depth = 12,000 ft
Maximum surface pressure p s = 3500 psi
Pump must handle all the gas.

Find: List the pumps capable of producing t h s well.

(2) Giuen: Same data as in Example problem 15-2 except pump setting depth = 10,000
ft.

Find: List the pumps capable of producing this well.

TUBING ARRANGEMENTS

The most common type of tubing arrangement is the casing “free type” shown in
Fig. 15-32. In this arrangement all the gas must be handled by the pump. For this
reason some of the following well conditions usually exist:
(1) Low gas/liquid ratio.
(2) Near-zero pump intake pressure is not required because:
(a) Excessive production rate may bring in too much sand.
(b) Excessive production rate may increase water/oil ratio.
(c) Incremental increase in oil production is not economically justified by
increased operating costs.
(d) Maximum well capacity (1)is not desired, (2) is not allowed, or (3) is beyond
equipment cap ability.
 671

The “parallel free” type system is shown in Fig. 15-33. This arrangement allows
the gas to be vented to the surface through the casing annulus. The size of tubing
string for returning the production and power fluid is usually smaller than the size
of power fluid tubing string because of casing size limitations. If the fluid flow rates
involved present an undue fluid friction problem, an arrangement such as the one
shown in Fig. 15-34 (reverse-circulation system) can be used. In t h s system, the
power fluid goes down the small string and production plus power fluid returns up
the large string. T h s requires a hold-down to keep the pump on seat while pumping
and requires that a releasing tool be dropped before circulating the pump out.
Another alternative, which is a “casing free” type system with gas vent, is shown in
Fig. 15-35. In this arrangement the small string is used to vent the gas to the surface.
Figures 15-36 and 15-37 can be used for calculating the amount of gas that can be
vented in t h s type of system.
Up to this point, the writer covered only the “open power fluid” (OPF) systems.
In Fig. 15-38, the “parallel free closed power fluid” (CPF) arrangement is shown. In
this system the power fluid is not commingled with the production-it is returned
to the surface through a third tubing string. This system and its slight variation as
shown in Fig. 15-39, is used extensively in California, U.S.A., for the following
reasons:
(1) Gas must be vented because near-zero pump intake pressures are required.
(2) Closed power fluid systems are used because:
(a) Fine sand is produced, which is difficult to remove by settling tanks.
(High pump repair costs result from solids in the power fluid.)
(b) Because many oil fields in California are in ecologically sensitive areas, water
is preferred as the power fluid. With hydraulic piston pumps (as opposed to
hydraulic jet pumps), usually a lubricant must be added to power water. The CPF
system conserves the lubricant, whereas in the OPF system the lubricant must be
continuously replenished. In many cases, fresh water is used as the power fluid.
Figure 15-40 shows a “casing free” CPF system, in which the produced fluid is
conducted to the surface through the casing annulus and power fluid is returned
through the side string of tubing. In this type of system, it is also possible to return
power fluid through the casing annulus and produce through the side string. This
latter arrangement would allow corrosion inhibitor in the power fluid to protect the
inside walls of casing.
Many combinations of the above arrangements are possible in dual-completed
wells. Figure 15-41 shows an arrangement where the two pumps are run in tandem
in one tubing string to produce a dual-zone well, whereas in Fig. 15-42 two pumps
are run in tandem to produce twice the capacity from a single-zone well. This is a
“casing free” OPF type system; however, all of the previously discussed arrange-
ments can be made to accommodate single-zone tandem pumps.
Figure 15-43 shows how a conventional subsurface safety valve can be used with
hydraulic pumps. This valve is the kind typically installed below the mud level in
offshore flowing wells. In this case, the valve is installed just above the packer. The
actuating line is connected to the power fluid tubing just above the pump (10-20 ft).
 8-n

CASING F R E E PARALLEL F R E E
r
r

rn
rn
rn

n
I13
%D
V

I-

Fig. 15-32.Casing free type system.

Fig. 15-33.Parallel free type system.

 PWR. FLD.
PWR. FLD.

PROD. +

Fig. 15-34. Parallel reverse-circulation type system.

Fig. 15-35,Casing free type system with gas vent,

674

PRESSURE-DROP IN P.S.I.
Pressure drop through 1 ” gas v e n t line I C O u r t e w A R M C O - N a t i o n a l Production SvrternP)

Fig. 15-36. Determination of pressure drop through 1-in. gas vent lines. (Courtesy of ARMCO-National
Production Systems.) Gas gravity = 0.60; average temperature = 150°F.
 615

PRESSURE-DROP IN P.S I
Pressure drop through 1-114" gas vent lines ICourtesy A R M C O - N a t i o n a l Production S y i f e m d

Fig. 15-37. Determination of pressure drop through 1:-in. gas vent lines. (Courtesy of ARMCO-National
Production Systems.) Gas gravity = 0.60; average temperature = 150'F.
676

CPF CPF
CPF
'y 'c -=
K

i
1
;i
i

\ I
Pump unseated
Pump Unseated - by power Gas
By Produced Fluid return fluid Pumped

PARALLEL FREE PARALLEL FREE CASING F R E E

Fig. 15-38. Parallel free closed power fluid (CPF) system. Pump is unseated by produced fluid.

Fig. 15-39. Parallel free closed power fluid (CPF) system. Pump is unseated by power return fluid.

Fig. 15-40. Casing free CPF system.

7 Y - I
m y >
b- r

TJ PWR. FLD. LWR. PUMP

?s EzZ
4 4 PWR. FLD. UPP. PUMP
2 3 =0
v y ? PROD. UPPER PUMP
Ei B N PROD. LOWER PUMP +
2 2 0 PWR. FLD. BOTH PUMPS
5' 5' $
Ei Ei
%
! e3 -
3 I
5' $
0 0
R m
2 L
PWR. FLD.-
:: fZ I Ez BOTH PUMPS
3 % $
Lu 2. rn PROD. + PWR. FLD.-
E N BOTH PUMPS
a 0
Ei6
4 ?
0
!-
678

S A F E T Y VALVE-,
requires high pressure
to open and to keep
open. Spring closes
valve when pressures
are balanced.

Fig. 15-43. Use of conventional subsurface safety valve with hydraulic pumps

When the pump is operating, the actuating pressure is the surface operating pressure
(1000-3500 psi). When the surface pump is shut down for any reason, the hydro-
static pressure in the tubing and casing equalize, and the valve closes, shutting-in the
tubing and casing at the packer. Some valves, sensitive to the pressure beneath
 619

B
L

OPF OPF $9
W Z

Gas
Pumped

!-Liquid
F I X E D INSERT FIXED CASING FIXED CASING
Fig. 15-44. Fixed insert type system.

Fig. 15-45. Fixed casing type system.

Fig. 15-46. Fixed casing type system with separate gas vent tubing string.
680

them, will remain open if the hydrostatic pressure in the actuating line and tubing is
above the pressure below them (bottomhole pressure). This does not present any
problem because the only possibility of the well flowing is when the bottomhole
pressure is greater than hydrostatic pressure, in which case these valves will close. If
the safety valve is for 2i-in. tubing and the pump and tubing above it is 2; in. in
diameter, the safety valve can be the wireline retrievable type.
Figures 15-44, 15-45, and 15-46 show “fixed” type pumps. These arrangements
require a tubing string to be screwed into the top of the pump and hence are not
“free pumps”. Figure 15-44 shows the so called “fixed insert”, i.e., the arrangement
used with the first hydraulic pump ever installed (Kobe pump, Inglewood, Cali-
fornia, 1932; now in the Smithsonian Institute). This arrangement is occasionally
used for one or both zones of a dual well. Figure 15-45 shows a “fixed casing” type
system, which is used where the required pump capacity cannot be obtained with a
pump that will fit inside the existing tubing. In Fig. 15-46, a “fixed casing” type
system with separate gas vent tubing string is demonstrated.

WELLHEADS

Wellheads for hydraulic pumps can be simple and compact with a low profile.
They can be closely spaced and can be below ground level. Wellheads are topped by
a 4-way valve that provides the following functions:
(1) Directs power fluid down the power tubing and production to the flowline
for the “pump-in and operate” position of the valve.
(2) Directs power fluid down the proper tubing (or casing) and returns fluid to
the flowline for the “pump-out’’ position of the valve.
(3) Provides a safety device to prevent high pressure from accidentally being
applied to the casing.
(4) Shuts surface line and provides a means to bleed pressure from the tubing for
the “shut-off and bleed” position of the valve.
(5) Provides a means to catch, hold, and release the pump.

COXTROL MANIFOLDS

A central control manifold is usually used to regulate the flow of power fluid to
the individual wells of a multiple-well installation. These manifolds are usually
located at a central location near the surface pumps, but can be located at satellite
locations. In some cases, the control valves are attached to each wellhead.
Control manifolds are available from the hydraulic pump manufacturers and
consist of modular header sections that can be readily added to or subtracted from
the manifold. Each header section has a “constant flow” control valve that auto-
matically compensates for pressure variations to keep the rate of flow of power fluid
to each well constant at the initial manual setting. In addition, the manifold
 681

contains high-pressure meters, gauges, and a back pressure regulator to keep a

constant pressure on the surface pumps.

SURFACE PUMPS

The surface pumps commonly used are designed specifically for power fluid
service and are supplied by the downhole hydraulic pump manufacturers. For
high-pressure clean oil service, these pumps usually use metal-to-metal plungers and
liners and ball-type valve components which require little or no maintenance. For
water service, plungers and liners with packing are usually used. Most pumps are
skid mounted with electric motors or gas engines and include relief valves, back
pressure regulators, gauges, safety switches and pulsation dampeners. Sometimes
suction charging pumps are used.
Suction lines are the most critical components of a surface pump installation.
These lines should be one size larger than the pump inlet connection. A flow
velocity of one foot per second is a good rule of thumb, and all valves should be full
opening. Bypass and relief lines from the high-pressure side of the pump should not
tie into the suction line, because t h s can cause pulsation (hammer) in the fluid end
of the pump due to gas flashmg out of solution. A pulsation stabilizer installed on
the suction side of the pump as close to the cylinders as possible is good insurance.
Many pump discharge pulses and vibrations are cured by a pulsation stabilizer on
the suction side of the pump. Charging or booster pumps are also an aid to proper
loading of surface pumps.
Elbows and tees should be kept to a minimum on the discharge side of the pump
also. These offer a reflecting surface for pressure pulse waves and are the source of
many vibrations. Sometimes just changing the geometry of discharge lines will
eliminate troublesome vibrations. This happens when the geometry of the lines
create a conduit tuned to a harmonic of the pulse wave length. Although most
system vibrations are hydraulic in nature, sometimes they are caused by misalign-
ment of the prime mover and pump or by loose foundation bolts.

POWER FLUID CLEANING SYSTEM

Power fluid quality, especially solids content, is an important factor contributing

to pump life and repair costs. Power fluid leakage through a pump’s fits and
clearances is a function of wear caused by abrasive solids and of the viscosity of the
power fluid. The permissible solids content varies somewhat depending upon the
definition of “acceptable pump life” and also on the viscosity; however, 10-15 ppm
is usually acceptable for 30-40” API gravity oils. For heavier oils, more wear and,
consequently, more solids may be tolerated, whereas for water, less wear and less
solids are usually the rule. The maximum particle size should not exceed 15 pm,
whereas the maximum salt content of oil should not exceed 12 lb/1000 bbl.
682

There are two basic types of power fluid systems:

(1) The closed power fluid (CPF) system, where the surface and subsurface
power fluid stays in a closed circuit and does not mix with the produced fluid.
(2) The open power fluid (OPF) system, where the power fluid mixes with the
production downhole and returns to the surface as commingled power fluid and
production.
The choice of oil or water for power fluid can be based on a number of factors.
Following is a list of most of the factors involved in this choice:
(1) Water is preferred for safety and environmental reasons.
( 2 ) For CPF installations, the addition of chemicals to power water for lubrica-
tion and corrosion control is not a large cost factor. (Fresh water is frequently used
in CPF installations.)
(3) For OPF installations, the addition of chemicals to power water can be a
significant cost factor because the power water is commingled with the produced
fluids. This requires continuous injection of chemicals which will add to the
operating costs.
(4) Treating power oil is seldom a large cost factor mainly because it seldom
needs chemical additives for lubricity. One exception is when high-gravity oils are
used at very h g h bottomhole temperatures. When these two factors produce a
viscosity below 1.0 centistoke (see Fig. 15-62) a lubricant may be necessary for long
pump life.
( 5 ) Maintenance on surface pumps is less when using oil, because metal-to-metal
plungers and liners are usually used instead of packing. Also valves last longer and
are usually ball-and-seat type rather than disc or poppet type, which are usually
used for water. Additionally, the low bulk modulus of water causes much larger
pressure pulses than oil, and these pulses are detrimental to pipe connections as well
as contributing to fatigue failures of pump components.
(6) Subsurface pumps are sensitive to viscosity and lubricating qualities of the
power fluid. Because water has practically no lubricating qualities at bottomhole
temperatures, it can, if not adequately treated, contribute to short pump life.
Leakage of power fluid past the various sliding fits in the pump is a function of the
viscosity and is greater with water than with most crude oils.
(7) Testing a well for oil production is subject to an added source of error when
oil is used for power fluid. (This statement is not true when using the “wellsite
power plant”.) In an OPF system, the power oil must be metered in and subtracted
from the total returned oil, and small errors in metering can be significant when the
ratio of power oil to produced oil is large, e.g., when the well is producing a large
percentage of water. For instance, if the ratio of power oil to produced oil is 10 : 1,
an error of 2% in the power oil meter translates into a 20% error in measuring the
produced oil.
(8) Usually the surface pressure required will be less when using power water as
compared to using power oil.
(9) Although hydraulic pumps handle viscous crudes (7-20”API) very well, it is
advantageous to use a higher gravity oil for power fluid and an OPF system. This
 683

-
S U R F A C E PUMP

WELLS

Fig. 15-47. Surface facilities of CPF system.

commingles the two crudes at the discharge of the pump, thus diluting the heavy oil
for ease in transporting it at the surface.

CPF SYSTEM

In the CPF system, an extra downhole conduit must be provided for returning
the spent power fluid to the surface. This causes the system to be more expensive
than the OPF system and consequently its use is not widespread. The bold lines on
Fig. 15-47 show the surface facilities for a CPF system. Because the power fluid
tank is relatively small, this system is popular for urban locations and offshore
platforms where surface space is at a premium. For example, it is quite popular in
California, U.S.A.,due to the many townsite and offshore well locations. Frequently
CPF systems use water for the power fluid because it is less hazardous and presents
fewer ecological problems than high-pressure oil. In the case of water, however,
corrosion inhibitors and lubricants must be added, and all oxygen must be removed
-considerations that add to the operating costs. Figure 15-47 shows two wells on
this system, but there is no reason that 30 or even 100 wells cannot be placed on a
system of this type.
Power jluid tank (CPF)

In most downhole pumps, the pump-end is lubricated with the power fluid and
consequently part (typically 2-10%) of the power fluid is purposely “leaked” to the
684

production. This loss of power fluid must be replaced with clean fluid. The purpose
of the power fluid tank in Fig. 15-47 is to remove abrasive particles from the
make-up fluid and part of the recirculated fluid.
One misconception concerning the CPF system is that the power fluid will
remain clean because it has no source of contamination. In actual practice, however,
this is not true due to the following reasons:
(1) The power fluid tank does not completely remove all of the solid particles
from the make-up fluid-cleanliness is relative, not absolute.
( 2 ) The power fluid is not completely non-corrosive. Again, this factor is relative,
not absolute. The products of corrosion are generally abrasive solids.
(3) When fluid containing solids, even a very small percentage of solids, is leaked
through a long closely-fitted clearance space as in a downhole pump, the solids tend
to be held back. This means that the fluid emerging from the fit is cleaner than the
fluid trying to enter the fit. The tendency, then, is for the power fluid circuit to lose
clean fluid and to retain the solid particles.
Over a period of time, the above three factors allow the power fluid in the closed
circuit to become “dirtier” than the fluid emerging from or the fluid entering the
closed circuit, unless a part (10% is reasonable) of the recirculated power fluid is
continuously cleaned, as in Fig. 15-47 by the power fluid settling tank. This
“continuous cleaning of part of the recirculated power fluid” is an important feature
in the design of the CPF system.
When water is used for the power fluid, filters may be used instead of settling
tanks for the cleaning process. These filters should remove particles down to 10 pm.
When oil is used, experience has shown that the settling tank should be large enough
to keep the upward velocity of the oil below 1 ft/hr for oils below 30”API gravity
and below 2 ft/hr for oils above 30”API gravity.

OPF SYSTEM

In the OPF system, only two downhole paths are needed, one for conducting
power fluid to the engine and one for conducting spent power fluid plus production
to the surface. These conduits can be two strings of tubing or one tubing string and
the tubing-casing annulus. Simplicity and economy are the important features of
the OPF system. When water is used for power fluid in the OPF system, the
chemicals added (for lubrication, corrosion inhibition, and oxygen scavenging) are
generally lost when mixed with the production and, consequently, must be added
continuously. The bold lines on Fig. 15-48 show the surface facilities for an OPF
system with two wells. Central plants of this type can be used for any number of
wells. Usually, the triplex pump and control manifold are located at the central tank
battery, whereas control manifolds can be located at satellite locations. Even triplex
pumps can be located at satellite locations if a small pump is used at the battery to
get the fluid to the suction of the triplex pump. Satellite manifolds and satellite
pumps reduce the length of high-pressure surface power fluid lines.
Fig. 15-48. Surface facilities of OPF system.

Power fluid tank (OPF)

The OPF power fluid tank shown in Fig. 15-49 has been proven over the years to
represent an excellent design. This design and one with a slight modification are
almost universally used.
Oil generally enters the gas boot in surges and contains gas not removed in the
treater, i.e., gas that was in solution at the 30-psi treater pressure. The purpose of
the gas boot is to remove the last remnants of gas which would otherwise keep the
tank stirred up. The top section of the boot should be 36 in. in diameter to be
effective; however, even with this diameter, surges frequently occur that cause the
oil to be carried over the top through the gas line. To prevent this oil carry-over
from going into the top of the tank, and thereby bypassing the settling process, a
loop with riser is used to tie the boot gas line to the tank gas line.
Dead oil (gas-free) then enters the bottom of the tank which should have a level
spreader. The oil entering here is power oil plus production. At the vertical
midpoint, production is drawn off through the outside riser that keeps the tank full.
From the midpoint up, the power oil settling process takes place. The settling out
light solids are carried with the production to stock, whereas the heavier particles
which settle to the bottom must be removed periodically.
The one modification sometimes used is to allow the production to be taken off
the boot or between the boot and the tank, but still with a riser to keep the tank full.
This modification allows full use of the tank for power oil only, but imbalances in
the column weight of the riser and of the tank can occasionally cause seemingly
strange fluid level variations in the tank. With this modification, the solids should
 GAS BOOT
3 BOLTED SECTIONS 8 x 2 0 SWAGED TO TOP 8' x
36' SFCTION TOP SECTION SHOULD HAVE SIDE
DPFNlNG IY M I N D I A I LOCATED I N CENTER.
CLOSED EXCEPT
.
,
'// O I L FROM TREATING PLANT
FROM TRIPLEX RELIEF
IPRODUCTION LINE TO TANK
r MINIMUM DIAMETER 1' ABOVE BOTTOM OF
TANK R I M V A L V E MUST BE F U L L OPENING END OF
TRIPLEX SUPPLY LINES
T MINIMUM DIAMETER TWO LINES ARE FLANGED
X TO 7 FROM TOP OF TANK, R U N 1 ' APART, JOINED
ABOUT 5' FROM BOTTOM OF R I M GATE VALVES ARE
F U L L OPENING FLANGES SHOULD BE AS FAR
FROM SlOCK DRAW OFF AS POSSIBLE NOT LESS
T H A N 90 DEGREES AROUND TANK
Fig. 15-49. Power fluid settling tank in OPF system.
4 MINIMUM DIAMETER CONNECTED TO T A N K 12
FROM BOTTOM RISES TO 18 IBOTTOM OF
CONNECTION) FROM TOP AND THEN TO STOCK AS
WITHDRAWAL LINE
3" DIAMETER MOUNTED 3" OFF BOTTOM INSIDE
TANK, LINE SHOULD GO TO CENTER OF TANK AND
HAVE DROP PIPE DOWN I N SUMP TO 6 OFF
BOTTOM OUTSIDE LINE SHOULD BE CONNECTED
BOTH WITH STOCK TANK IAS SHOWN UNLESS
POWER
STOCK T A N K IS HIGHER THAN 1 6 ) A N D PIT I F F L A T OIL TANK
BOTTOM TANK I S USED. INSIDE LINE SHOULD
HAVE B U L L HEADED TEE MOUNTED HORIZONTALLY
I N CENTER OF TANK
SPREADER
ROUND WITH SERRATED OR PERFORATED SKIRT
8 MINIMUM DIAMETER MOUNTED LEVEL 2' ABOVE
BOTTOM R I M OF TANK
 687

Fig. 15-50.Wellsite power plant unit. (Courtesy of Kobe, Inc., subsidiary of Baker International Corp.)

be drained from the bottom more frequently. The boot can be placed inside the
tank; however, experience has shown cases of pitting and corrosion at the fluid
level. The outside location, therefore, is preferred.
In order to assure adequate particle settling, the power oil tank should be sized to
allow the upward velocity in the top half to be less than 2 ft/hr. This velocity is
equivalent to 1500 bbl/D in a 750-bbl, 24-ft high tank. The velocity should be lower
for oils heavier than 30"API gravity and for operations in extremely cold climates.
Treating the oil for sale to the pipeline must be done ahead of the power oil tank.

INDIVIDUAL WELLSITE POWER PLANT

The use of individual wellsite power plants is becoming more and more popular,
and these units are competitive with other types of artificial lift. Typical wellsite
units are shown in Figs. 15-50 and 15-51.
A wellsite power plant is a package of components, installed at or near a wellsite,
that accomplishes the functions normally performed at a central plant. The basic
components consist of a liquid-gas separator, centrifugal separators for removing
solids from the power fluid (oil or water), and a surface pump. These units are
portable, require a minimum of installation labor, and eliminate the need for
advance long-range planning of a central power plant. Although they are always
used with an OPF tubing arrangement, they have one feature similar to a CPF
688

Fig. 15-51. Wellsite power plant unit. (Courtesy of Guiberson Division, Dresser Industries, Inc.)

system: the net production from the well goes into the flowline while the power
fluid is recirculated at the wellsite. This feature simplifies well testing and does not
increase the load on the treating system at the tank battery. Wellsite power plant is
simple, flexible, compact, and portable, features that are of great interest to the
design engineer, the production foreman, and the lease operator.
Generally, there is a choice of having either a central system or an individual
wellsite system. Some choices are obvious, as in the case of a central system for an
offshore platform or any cluster of wells (such as in a downtown area or islands
constructed for that purpose). For those wells that are isolated or widely spaced, the
individual wellsite system will probably be preferred.
Flow schematics in Figs. 15-52, 15-53, and 15-54 show models of Kobe (Solo
Unit), Oilmaster (Unidraulic), and Guiberson (Econodraulic) wellsite power plants.
The important functions these units must perform are:
(1) Provide gas-free fluid to the surface pump.
(2) Provide means to choose oil or water for the power fluid.
(3) Remove the solids from the power fluid.
(4) Provide surge and reserve capacity for circulating a subsurface pump to the
surface after a pump failure. (Vessel sizes range from 40 in. X 10 ft to 5 ft X 20 ft.)
If a well produces 600 bbl/D of water, 200 bbl/D of oil, and uses 2000 bbl/D of
power water, these flow rates are shown on the simplified schematics of Figs. 15-55,
15-56, and 15-57.
 689

RELIEF VALVE

Q
FROM
WELL
0
'
I \ RELIEF VALVE
I
TO
WELL

FLOW LINE-

-P O -METER
a - P D METER

CLOSED CLOSED

t OPEN FOR RESERVE POWER O I L SUPPLY

OTHER V A L V E S SHOWN
I A I FLOAT.OPERATED DUMP V A L V E
(61 VESSEL BACK-PRESSURE V A L V E
ICI M E T E R BY-PASS V A L V E

Fig. 15-52. Kobe Solo wellsite power plant unit.

ACCUMULATOR

RESERVOIR

ANK
ERY

Fig. 15-53, Oilmaster Unidraulic wellsite power plant unit.

690

CHECK
VALVE

L
-.
29

DAMPENER CHECK
POWER
FLUID
PUMP

MOTOR - 1- ::NTROL PANEL

Fig. 15-54. Guiberson Econodraulic wellsite power plant unit.

r
I
'
I \I I
2000

Fig. 15-55. Flow rates (flow diagram) in a Kobe Solo unit, assuming water production of 600 bbl/D, oil
production of 200 bbl/D, and use of 2000 bbl/D of power water.
 691

I I I
-1 I I -9

2000
- - 2000

Fig. 15-56. Flow diagram in an Oilmaster Unidraulic unit, assuming water production of 600 bbl/D, oil
production of 200 bbl/D, and utilization of 2000 bbl/D of power water.

Removing solids from the power fluid is usually accomplished by cyclone

centrifugal separators (Fig. 15-58). These cyclones require 30-60 psi pressure drop
from inlet (feed) to top outlet (overflow). The ratio of overflow to underflow out of
the apex of the cone is controlled by the relationslup of overflow pressure to
underflow pressure. Usually, the overflow must be 5-10 psi greater than the
underflow pressure to insure a positive rather than a negative underflow rate. The
cyclone internals, feed nozzle, vortex finder, and apex can be sized to accommodate
various rates of flow.

I \ 2200

1
0

wELb
0
N
0
800
-- 600

L - 2000 -- 2000

Fig. 15-57. Flow diagram in the Guiberson Econodraulic unit, assuming water production of 600 bbl/D,
oil production of 200 bbl/D, and utilization of 2000 bbl/D of power water.
692

OVERFLOW
(CLEAN LIQUID)

VORTEX FINDER -L

FEED NOZZLE (2)

LIQUID ROTATION DEVELOPS
H I G H C E N T R I F U G A L FORCES
THROUGHOUT CYCLONE

(1) /
FEED INLET
PRESSURIZED L lQ U l D
ENTERS T A N G E N T I A L L Y

CONE A N G L E

(4)
LIQUID MOVES INWARD SUSPENDED SOLIDS
A N D UPWARD AS S P I R A L L I N G DRIVEN TOWARD W A L L
VORTEX A N D DOWNWARD I N
ACCELERATING SPIRAL

UNDERFLOW
(SOLIDS A N D LIQUID)

Fig. 15-58. Cyclone centrifugal separator

In Fig. 15-55, the underflow rate is controlled by valve number ( I ) . Valve

number ( 2 ) , a pump internal relief valve, is used to adjust the pressure drop across
the cyclones to 40-50 psi, which produces optimum rates through the cyclones. This
4
unit is designed to continually recycle approximately of the cleaned power fluid
back through the cyclones for additional solids removal.
In Figs. 15-56 and 15-57 the underflow is controlled by valve number ( I ) .
Cyclone internals are changed to obtain pressure drop for wells with different flow
rates.
Disposing of the underflow (solids) can be a problem on low-volume wells. In the
Kobe Solo Unit system, if the underflow is set at a rate that is constantly, or even
occasionally, greater than the production rate, the excess will go back to the vessel
and has to be separated by the cyclones a second time. In the Oilmaster Unidraulic
system, these conditions can cause the underflow to be shut-off and thereby cause
the cyclone to be ineffective. In the Guiberson Econodraulic system, these condi-
tions can cause the level in the vessel to drop.
 693

POWER FLUID RATE CALCULATIONS

The pump specification tables list the engine- and pump-end displacement
factors, q1 and q4, in bbl/D per SPM. At 100% efficiency, the power fluid rate
would be ( q1 X S P M ) . Usual practice is to assume 90% engine-end efficiency so that
power fluid rate'Q, is equal to:
q1 x S P M
(15-5)
= 0.90
The pump-end displacement is ( q4 X S P M ) . As discussed in a previous section, one
must take into account the formation volume factor, B, and usually assume 85%
pump-end efficiency. Pump-end displacement, therefore, becomes:

q4 x SPM =
QsB + Qi (15-6)
0.85
(In eq. 15-1, an additional factor, 0.85, was used in order to choose a pump that
would operate at less than 85% of its maximum rated speed.)
By combining eqs. 15-3 and 15-6, one obtains eq. 15-4:

POWER FLUID PRESSURE CALCULATIONS

The various pressures, friction losses, and fluid densities involved in CPF and
OPF systems are shown in Fig. 15-59. Figure 15-60 illustrates those cross-section
areas of the Kobe Type A pump which are involved with the various pressures.
(Other pumps have different configurations.) On adding the upstroke forces on this
pump and assigning the plus sign to upward-acting forces, one obtains:

-PIA, -P2 - 'Pi -AR) -P3 ( - A R ) 'P4 ( -AR) + p l A R =

(P1 - P 2 ) ( A E - A R ) - ( P 3 - P 4 ) ( A P - A R ) =

Pump friction, Fp,is not shown in Fig. 15-60, because it does not operate against
an area. It is a function of pump speed and fluid passageways in the pump.
Inasmuch as it opposes motion it will have a negative sign and the above equation
becomes:
 PRESSURES & FRICTION LOSSES AFFECTING HYDRAULIC PUMPS

694
m
W
P

'L-
-

0
ln
c
P, Surface Operating Pressure, PSI

8
u

8
I
c
m
2
=

PPR Surface Power Return Back Pressure. psi

a:
c
E
=

m
Y
v)

e
PFL Surface Flow Line Back Pressure, psi

m
3

"
=

F1, Fp, F g = Fluid Friction in Tubing, psi

8
C
Fp = Friction in Pump, psi

GI, G2, G3. G4 ~ Fluid Gradient

rn
hl = Pump Setting Depth, ft. E
=-

ln
P
5
h4 Pump Submergence, ft.

u
P

E
P
C
5
= L

P
P

f '1

i
;1

1
r '1

,-

5-
U
a"

tI
c
c
I
c?

P2 P3
U

5
'7,

P3 h l G 3 + F3

+
PFL
+

U
I,

m
+

1
m

U
1

Closed Power Fluid System P4 = h4G4 P4 = h4G4 Open Power Fluid System

Fig. 15-59. Pressures and friction losses affecting hydraulic pumps.

 695

PRESSURES ACTING ON A KOBE TYPE A PUMP

Net
Pressure Pressure
Cross-section
Upstroke Downstroke
Area

AR

AE - AR

AR

Fig. 15-60,Pressures acting on a Kobe type A pump.

696

The quantity [ ( A , - A R ) / ( A , - A R ) ] is the ratio of net pump area to net engine

area and, for this pump, is the same for the downstroke and the upstroke. This
quantity is sometimes referred to as the pressure ratio, but more commonly it is
called the P over E ratio. The numerical values for P / E ratio are listed in the
specification tables. Inasmuch as the algebraic equation relating pump areas to P / E
ratio is different for different pumps, one must substitute P / E in the above
equation to arrive at the following general CPF equation for all hydraulic pumps:
(15-7)

Some pumps have an additional term in their CPF equation that is a function of
( p z - p 3 ) , but this term is always ignored because it is very small. For Fig. 15-13,
the term is:

Inasmuch as the value of ( p 2 - p 3 ) is usually less than 500 psi, this term is usually
less than 35 psi. (For OPF system p 2 = p 3 , so this term drops out.)
As shown in Fig. 15-59:

PI =hF1- Fl + Ps
P2 = hlG, + F2 + Ppr

P3 = hlG4 + ‘3 +Pwh
P4 = h4G4

Substituting these relationships into eq. 15-7 and assuming fluid friction, F,, F2,
and F3, and wellhead back pressure, ppr and pwh to be zero, eq. 15-7 becomes eq.
15-2:
p , - ( hlG4 - h 4 G 4 )P / E - Fp = 0

T h s is the equation which was used in a previous section to get a first approxima-
tion of surface pressure and to arrive at a maximum value for P/E (eq. 15-3).
Inasmuch as in the OPF system p 2 = p 3 , the general OPF equation for all
hydraulic pumps becomes:

(PI - P 3 ) - (P3 -P4)P/E- Fp=0 (15-8)

where (as shown in Fig. 15-59):

PI = hlG1 - 4 + Ps
P3 = h l G 3 + F3 +Pwh
P4 = h4G4
 691
PRESSURE INCREASE DUE TO MECHANICAL AND
HYDRAULIC FRICTION I N PUMP AND BOTTOM HOLE ASSEMBLY
vs
PERCENT OF RATED SPEED
200c

1500

1000
9oc
800
700

600

500

400

300

EXAMPLE
200
PUMP - Flg 15 - 13
SPEED - 50%
VISCOSITY - 1 0 C S
SP GR. - 0 8
A P = 270 x 8 = 216 PSI

100

PERCENT OF R A T E D SPEED

FIG 13- 1 7 , 1 5 - 1 9

FIG 1 5 - 1 6 t l 5 - 2 4

FIG 1 5 - 1 5 , 1 5 - 2 3

FIG is- 12,15-22

FIG 15- 1 7 15-18,15-21

Fig. 15-61. Relationship between the percent of rated speed and pressure increase due to mechanical and
hydraulic friction in pump and bottomhole assembly.
 0 20 40 60 80 100 120 140 160 B3 200 220 240 260 280 300
Temperature - degrees Fahrenheit

-
Gtavity Gravity
API Field Line ’API Field
9.5 Boscan, Venezuela 8 306 Ventura, Calif.
10.7 Boscan, Venezuela 9 31 1 Kettleman Hills, Calif.
14.0 Maricopa, Calif. 10 364 Oklahoma City, Okla.
15.0 Wilrnington, Calif. 11 346 Kettlernan Hills, Calif.
19.8 Sansinena, Calif. 12 440 Denton, New Mexico
25.6 Scholern Alechern, Okla. 13 50 7 Kettlernan Hills, Calif.
7
- 26.8 Seal Beach, Calif.

Fig. 15-62. Relationship between viscosity of crude oils and temperature

 699

0 100 200
Temperature -degrees Fahrenheit

Fig. 15-63, Relationship between viscosity of water and temperature at 0 psi

The unknowns in eq. 15-8 are pump friction, Fp;fluid friction, Fl and F,; and
the fluid gradient in the return column, G,. Pump friction, Fp, is obtained from Fig.
15-61 after obtaining SPM from eq. 15-6. The fluid gradient in the return column is
calculated after obtaining the ratio of power fluid flow rate, Q,, and produced fluid
+
flow rate, (Q, Q 6 ) ,in this column. Thus, it is necessary first to calculate Q,, by
using eq. 15-5 or 15-4. Fluid friction in the tubing is then found by use of Figs.
15-65 through 15-98.
The value of p 3 may be obtained from multiphase flow corrections; however, in
this chapter the equation p , = h,G3 + F3 +pwh is used. This equation does not
account for gas in the return column, but it offers a conservative procedure that will
provide a safe design.
Pump friction is obtained from Fig. 15-61, which represents the mechanical and
hydr'aulic friction in the pump. From the curves in Figs. 15-62 and 15-63, the power
fluid viscosity at the bottomhole temperature can be obtained to use with the pump
friction chart. Conversions from API gravity to specific gravity can be made from
Fig. 15-64. The values obtained from Fig. 15-61 show maximum values based on the
largest pump piston operating at 100% pump-end efficiency. When the fluid flow
rate through the pump-end is reduced by smaller pistons, or by gas, the total friction
will be somewhat lower than that predicted by the chart. This discrepancy is due to
700
Specific G r a v i t i e s a n d U n i t Pressure of Oil Columns
Note-First line opposlte each API gravity IS sp gr at 60'F. Second line is column pressure in psi/ft
~~~ -
Degrees
A P I 0 I .2 .3 4 .5 6 7 .8 .9

10000 9993 9986 9979 9972 9965 9958 9951 9944 ,9937
10 4331 43'8 4325 4322 4319 4316 4313 4310 4307 4304
9930 9923 9916 9909 9902 9895 9888 9881 9674 ,9888
11 4301 4295 4295 4212 4289 4286 4282 4279 4276 ,4274
9861 9854 9847 9840 9833 9826 9820 9813 9808 ,9799
12
4271 4268 4265 4262 4259 4256 4253 4250 4247 4244
9792 9786 9779 9772 9765 9759 9752 9745 9738 ,9732
13 "238 $235 4232 4229 4226 4224 4221 4218
424' 4215
9725 9718 9712 9705 9696 9692 9685 9679 9672 ,9685
14 $212 4209 4.06 4203 4200 4198 4195 4192 4189 4186
9659 9652 9646 9639 9632 9626 9619 9613 9606 ,9600
15
~183 41.80 4178 4175 4172 4169 4166 4163 4160 4158

9593 9587 9580 9574 9567 9561 9554 9548 9541 9535
16 4155 4152 4139 *'46 4143 4141 4138 4135 4132 4130
,9529 9522 9516 9509 9503 9497 9490 9484 9478 9471
17 4127 4124 6121 4118 4116 4113 4110 4108 4105 4102
,9465 ,9459 9452 9446 9440 9433 9427 9421 9415 9408
18
4099 4097 4094 4091 4088 4085 4083 4080 4078 4075
,9402 ,9398 9390 9383 9377 9371 9365 9358 9352 9346
19 4072 4069 C067 4361 4061 4059 4056 4053 4050 4048

20 9340 ,9334 9328 9321 9315 9309 9303 9297 9291 9285
4045 4043 GO40 4037 4034 4032 4029 4027 4024 4021
-. ~...~. ~ ~ ~~~~ ~ __
9279 ,9273 9267 9260 9254 9248 9242 9236 9230 9224
21 4015 4016 501 I 4038
4014 4005 4003 4000 3998 3995
9216 9212 9206 9200 9194 9188 9182 9176 9170 9165
22 3932 3933 3987 3985 3982 3979 3977 3974 3972 3969
9159 9153 9147 9141 9135 9129 9123 9117 9111 9108
23
3967 396.: ??6? 3959 3956 3954 3951 3949 3946 3944
,9100 ,9094 9088 9082 9076 9071 9065 9059 9053 9047
24 394; 3933 3936 3333 3931 3923 3918
3929 3926 3921

25 ,9042 9036 ,9030 9024 9016 9013 9007 9001 8996 8990
39:6 3913 33! I 3x8 3906 3934 3901 3898 3896 3894
__
8984 8978 8973 8967 8961 6956 8950 8944 8939 8933
26 339! 3858 3886 3883 3881 3579 3876 3874 3871 3869
8927 ,8922 ,8916 891 1 8905 8899 8894 8888 8883 8877
27 3566 3861 3832 3859 3857 3854 3852 3849 3847 3845
8871 ,8668 8860 8855 8849 6844 8838 8833 8827 8822
28 3847 38;0 3837 3835 3833 3823
3830 3828 3826 3821
,8816 981 1 8605 8800 8794 8769 8783 8779 8772 8767
29 3818 3815 3813 381 I 3809 3807 3804 3802 3799 3797

30 9762 6756 ,8751 8745 8740 8735 8729 8724 8718 8713
3795 3792 3790 I 3787 3785 3783 3781 3778 3776 3774

8708 8702 6697 8692 8686 8681 8676 8670 8685 8660
31 3'71 3/60 3767 3'65 3762 3760 3758 3755 3753 3751
8654 8649 8644 8639 8833 9628 8623 8618 8612 8607
32 3748 3746 3744 3742 3739 3737 3735 3732 3730 3728
6602 8597 8591 8586 8581 8576 8571 8585 8560 8555
33
3726 3723 3771 3719 3716 3714 3712 3710 3707 3705

34 8550 8545 8540 8534 8529 8524 8519 8514 8509 8504
3703 370' 3b99 3696 3694 3692 3690 3687 3685 3683

35 8498 6493 9488 8483 8478 8473 8468 8463 8458 8453
3680 3678 3676 3674 3672 3670 3667 3665 3663 3661

Fig. 15-64a Conversion table-'API gravity (10-35) to specific gravity and pressure gradient in psi/ft.
 701

S p e c i f i c G r a v i t i e s and U n i t Pressure of O i l C o l u m n s
Note-First line opposite each API gravity is s p gr at 60°F. Second line is column pressure in Psl/tt

.4 .5 .6 .7 .I .9
___
,6448 ,6443 ,8438 ,4433 .M28 ,8423 .a418 ,8413 ,8408 ,8403
38 ,3659 ,3657 ,3654 ,3652 ,3650 ,3648 ,3646 ,3644 ,3642 ,3639
.098 ,8393 ,8388 ,8383 ,8378 ,8373 ,8368 ,063 ,8358 ,8353
37 3629 3626 ,3624 3622 ,3620 ,3618
,3637 ,3635 ,3633 ,3631

38
.ma ,8343 ,8338 ,033 ,83211 ,8324 ,8119 ,8314 ,8309 ,8304
,3616 ,3613 ,3611 3609 ,3607 ,3605 3603 3601 ,3599 ,3596
,8299 ,8294 ,8289 ,8285 .I280 ,8275 ,8270 ,8265 ,1260 ,8256
39
,3594 ,3592 ,3590 ,3588 3586 ,3584 ,3582 ,3580 ,3577 ,3576
,8251 ,8248 ,8241 ,8236 ,8232 ,8227 ,8222 ,8217 ,8212 ,8208
40 3557 ,3555
,3574 ,3571 ,3569 ,3567 ,3565 ,3563 ,3561 3559

,8203 .Il9B ,8193 ,8189 ,8184 ,8179 ,8174 ,8170 ,8165 ,8160
,3553 ,3551 3548 3547 3544 ,3542 3540 3538 ,3536 3534
,8155 ,8151 ,8146 ,8142 ,8137 ,8132 ,8128 ,8123 ,8118 ,8114
,3532 ,3530 3528 3526 3524 3522 ,3520 3518 3516 3514
,8109 ,8104 ,8100 8095 ,8090 ,8086 ,8081 ,3016 ,8072 ,8067
3512 ,3510 3508 3506 3504 3502 3500 ,3498 3496 ,3494
,3063 ,8058 .SO54 ,8049 ,8044 ,8040 ,8035 .5031 ,8026 ,8022
,3492 ,3490 3488 3486 3484 3482 3480 ,3478 ,3476 ,3474
.a017 ,8012 ,8008 ,8003 ,7999 ,7994 ,7990 ,7985 ,7981 ,7976
,3472 3470 3468 3466 3454 ,3462 3460 ,3458 ,3457 ,3554

,7972 ,7987 ,7963 ,7958 ,7954 ,7949 ,7945 ,7941 ,7936 ,7932
46 ,3453 ,3451 ,3449 ,3447 ,3445 3443 3441 3439 3437 ,3435
,7927 ,7923 ,7919 ,7914 ,7909 ,7905 ,7901 ,7896 ,7892 ,1887
47 3918 3416
,3433 ,3431 ,3429 3428 ,3425 ,3424 ,3422 3420
.7883 ,7879 ,7874 ,7870 ,7865 ,7861 ,7857 ,7852 7848 .1a44
48 3397
,3414 3412 ,3410 ,3408 ,3406 3405 ,3403 3401 3399
,7839 ,7835 ,7831 ,7826 ,7822 ,7818 ,7813 ,7809 ,7805 ,7800
49 ,3395 ,3393 ,3392 ,3389 ,3388 ,3386 3384 3382 3380 3378
,7796 ,7792 ,7788 ,7783 ,7779 ,7775 ,7770 ,7766 7762 ,7758
50
,3376 ,3375 ,3373 ,3371 ,3369 3367 ,3365 3363 3362 ,3360
-
,7753 ,7749 ,7745 ,7741 ,7736 ,7732 7128 ,7724 ,7720 ,7715
51 3358 ,3356 ,3354 3353 3350 3349 3347 3345 3344 ,3341
,7711 ,7707 ,7703 ,7699 ,7684 ,7690 ,7686 ,7582 7618 ,7674
52 ,3324
3340 ,3338 3336 3334 3332 3331 3329 3327 3325
,7669 ,7665 ,7861 ,7657 ,7653 7649 ,7645 ,7640 ,7636 ,7632
53 3307 3305
3321 ,3320 ,3318 3316 ,3315 3313 3311 3309
,7628 ,7824 ,7820 ,7816 ,7612 ,7608 ,7603 ,7599 ,7595 ,7591
54 328P
3304 ,3302 ,3300 3298 ,3297 3295 3293 3291 3289
.7W ,7583 ,7579 ,7575 ,7571 ,7567 ,7563 7559 ,7555 ,7551
55
3286 ,3284 ,3282 3281 ,3279 3277 3276 3274 3272 ,3270
~

,7547 ,7543 ,7539 ,7535 ,7531 ,7527 ,7523 ,7519 ,7515 ,7511
56 ,3269 3267 ,3265 ,3263 ,3262 3260 ,3258 ,3256 3255 3253
,7507 ,7503 ,7499 ,7495 ,7491 ,7487 ,7483 ,7479 ,7475 ,7471
57
,3251 ,3250 ,3248 ,3246 ,3244 3243 ,3241 ,3239 3237 ,3236
,7467 ,7463 ,7459 ,7455 ,7451 ,7447 ,7443 ,7440 ,7436 ,7431
58
,3234 ,3232 ,3230 ,3229 ,3227 3225 ,3224 ,3222 ,3221 ,3219

59 ,7428 ,7424 ,7420 ,7416 ,7412 ,7408 ,7405 ,7401 ,7397 ,7393
,3217 ,3215 ,3214 ,3212 ,3210 3208 ,3207 ,3205 ,3204 ,3202
.7389 ,7385 ,7381 ,7377 ,7374 ,7170 ,7366 ,7362 ,7358 ,7354
80
,3200 ,3198 ,3197 ,3195 ,3194 3192 ,3190 ,3188 ,3187 ,3185

Fig. 15-64b. Conversion table-"API gravity (36-60) to specific gravity and pressure gradient in psi/ft.
702

PRESSURE DROP IN PIPE

STANDARD
’?” PIPE (0.62” I.D.)

Fig. 15-65. Relationship between the fluid flow and pressure drop in a +-in. standard pipe (0.62 in. I.D.).

the fact that approximately 25% of the total friction is in the pump-end of the
pump. This value is not well documented for all pumps, but can be used to estimate
the reduction in pump friction due to actual pump-end liquid flow rate. In equation
form, the A p from Fig. 15-61 is equal to:

where Fee= engine-end friction = 0.75 A p , and Fpe= pump-end friction = 0.25 A p .
 703

PRESSURE DROP IN PIPE

3h” STANDARD PIPE (0.82’’ I.D.)

01 05 10 50 10 50 0

PRESSURE DROP-PS1/1000’-MULTIPLY BY SPEC GRAV

Fig. 15-66. Relationship between the fluid flow and pressure drop in a :-in. standard pipe (0.82 in. I.D.).

In the example shown in Fig. 15-61, the A p is 216 psi; therefore:

Fee = 0.75 X 216 = 162 psi

Fpe= 0.25 X 216 = 54 psi

If it is a 2t-in. pump from Fig. 15-13 (29 in.X l a h-1: in. pump-the largest
2t-in. pump), which is operating at 100% pump-end efficiency, the Fpe= 54 psi is
correct. If, however, it is a 2 t in. x l a in-1; in. pump operating at 80% pump-end
704

PRESSURE DROP IN PIPE

1” STANDARD PIPE (1.05” 1.0.)

1000

100
-
il
u
N
P
n
a
m
I
%
s
P
3
10

10

PRESSURE DROP-pS1/1000 -MULTIPLY BY SPEC G R A V

Fig. 15-67. Relationship between the fluid flow and pressure drop in a I-in. standard pipe (1.05 in. I.D.).

efficiency, Q4 will be less than that used to construct the chart. Because the
correction to Fpe is a small quantity, it is customary to ignore it. The error thus
introduced is on the safe side. On assuming:

Fp= A p (from Fig. 15-61)

the procedure for calculating ps in the OPF system is:

 705

PRESSURE DROP IN TUBING

1-%”EU API TUBING

1000

100
-
Y
0
N
z
n
m
1
3
s
0
LL
J

10

10

PRESSURE DROP-PSI/lOOO -MULTIPLY BY SPEC G R A V

Fig 15-68 Relatlonahp between the fluid flow and pressure drop in a l i - i n EU API tublng

Find From
Step 1: Formation volume factor, B Figs. 15-27, 15-28 or 15-29
or
Step 1: Formation shrinkage factor, S Fig. 15-30
Step 2 : Pump speed, SPM eq. 15-6
Step 3: Pump friction, Fp Figs. 15-61 and 15-62 or 15-63
Step 4: Power fluid rate, Q1 eq. 15-4 or 15-5
Step 5 : Power fluid tubing friction, Fl Figs. 15-65 through 15-98
706

PRESSURE DROP IN TUBING

1-kz” EU API TUBING

0.1 05 10 50 10 50 too

PRESSURE DROP-PSl/lOOO’-MULTIPLY BY SPEC G R A V

Fig. 15-69. Relationshp between the fluid flow and pressure drop in a 1:-in. EU API tubing.

GiQi + G5Q5 + G6Q6

Step 6: Return fluid gradient, G, G, =
Qi + Q, + 426
Step 7: Return fluid tubing friction, F3 Figs. 15-65 through 15-98

One can now calculate p , after rearranging eq. 15-8 to:

Step 8: ps = p 3 ( l + P / E ) - p 4 ( P / E ) + Fp- hlGl + F,

 707

PRESSURE DROP IN TUBING

2-1/16" API TUBING

10 000

1000
-
Y
U
N
f
n
m
n
I
B
s
D
3
100

10
01 05 10 50 10 50 100

PRESSURE DROP-PSI/lOOO'-MULTIPLY BY SPEC GRAV

Fig. 15-70. Relationship between the fluid flow and pressure drop in a 2&-in. API tubing.

+
Inasmuch as Q4 = Q , Q 6 , where Q, is the flow rate of produced oil and Q6 is the
flow rate of produced water:

G, = G5Q5 G 6 Q 6 ,where Q,
+ + Q6 = Q4 (15-9)
Q 5 + Q6
708

PRESSURE DROP IN TUBING

2-910" EU API TUBING

10 000

1000
-
Y
c7
N
9
a
0
m
I
3
s
0
3
100

10
01 05 10 50 10 50 100

PRESSURE DROP-PS1/1000'-MULTIPLY BY SPEC. GRAV

Fig. 15-71. Relationship between the fluid flow and pressure drop in a 22-in. EU API tubing.

Example problem 15-4

Given:
Q, = 200 bbl/D of 40"API gravity oil
Q6= 100 bbl/D of 1.03 sp. gr. water
p 4 = 600 psi
h , = 10,000 ft
Power fluid: 40"API gravity oil
pwh= 1 5 psi
Bottomhole temperature = 180°F
 709

PRESSURE DROP IN TUBING

2-78'' EU API TUBING

' - --- I

0.1 0.5 1.o 5.0 10 50 0

PRESSURE DROP-PSl/lOOO'-MULTIPLY BY SPEC. GRAV

Fig. 15-72. Relationship between the fluid flow and pressure drop in a 2 i - h . EU API tubing.

Assume:
252016 pump from Fig. 15-20 OPF parallel free type installation using 24-in. OD
power tubing and 2i-in. OD return tubing, with gas to be vented to the surface
through the casing annulus.
B=l.
Find:
(A) Surface horsepower using first approximation method.
(B) Surface horsepower using method outlined in this section.
From Fig. 15-20: P / E = 0.64, q 1 = 16.5 bbl/D per SPM, q4 = 10.6 bbl/D per
SPM.
710

PRESSURE DROP IN TUBING

3-%” EU API TUBING

10 000

1000
I

Y
u
N
I
0
a
m
I
3
s
D
LL
_I

100

10
01 05 10 50 10 50 100

PRESSURE DROP-PSI/lOOO’-MULTIPLY BY SPEC GRAV

Fig. 15-73. Relationshp between the fluid flow and pressure drop in a 3:-in. EU API tubing.

Solution:
(A) From eq. 15-9:

(0.8251) (0.433)(200) + (1.03) (0.433)(100)

G, = = 0.386 psi/ft
300

From eq. 15-2:

p , = (0.386 X 10,000 - 600)0.64 + 400 = 2490 psi

 71 1

PRESSURE DROP IN TUBING

4-'P EU API TUBING

0.1 05 10 50 10 50 0
PRESSURE DROP-PS1/1000'-MULTIPLY BY SPEC GRAV

Fig. 15-74. Relationship between the fluid flow and pressure drop in a 4:-in. EU API tubing.

From eq. 15-4:

300 16*5 = 610 bbl/D

0.85 x 0.90 x 10.6
Hydraulic horsepower = 2450 X 610 x 0.000017 = 25.4 HP
(B) Step 1: was given; B = 1.0
Step 2: From eq. 15-6:
300
SPM = = 33.3 SPM
10.6 X 0.85
712

PRESSURE DROP IN TUBING

FLOW BETWEEN P a ' ' EU TUBING & %" (1.050" O.D.) PIPE

1000

100
-
Y
a
N
If_
0
m
I
z
s
2
3
10

10
01 05 10 50 10 50 100

PRESSURE DROP-PSI/lOOO'-MULTIPLY BY SPEC GRAV

Fig. 15-75.Relationship between the fluid flow and pressure drop when flow occurs between 2i-in. EU
tubing and :-in. pipe (1.050 in. O.D.).

Step 3: From Fig. 15-62, viscosity of 40"API gravity oil at 180°F is between lines 11
and 12 at approximately 1.5 centistokes. From Fig. 15-64, specific gravity is equal to
0.825, whereas from Fig. 15-20, rated speed is 51 SPM.
Percent rated speed = 33.3/51 X 100 = 65%
From Fig. 15-61, A p is equal to approximately 410 psi, whch if multiplied by
specific gravity gives Fp:

Fp= 410 X 0.825 = 338 psi

 713

PRESSURE DROP IN TUBING

FLOW BETWEEN 2-'a" EU TUBING L 1" PIPE ( 1 . 3 l S ' O . D . )

0.1 0.5 1.o 5.0 10 50 100

PRESSURE DROP-PSl/lOOO'-MULTIPLY BY SPEC. GRAV.

Fig. 15-76. Relationship between the fluid flow and pressure drop when flow occurs between 2i-in. EU
tubing and 1-in. pipe (1.315 in. O.D.).

Step 4: From eq. 15-5:

33.3 X 16.5
= 610 bbl/D
0.9

Step 5 : In step 3, viscosity of the power fluid was found at bottomhole temperature;
however, to be precise for tubing friction calculations, one should estimate the
average temperature of the fluid from the bottom to the surface. If the fluid reaches
714

PRESSURE DROP IN TUBING

FLOW BETWEEN 2 - 7 w 3 II i - 1 EU
~ API TUBING

01 05 10 50 10 50 100

PRESSURE DROP-PS111000'-MULTIPLY BY SPEC GRAV

Fig. 15-77. Relationship between the fluid flow and pressure drop when flow occurs between 2 i - h and
1f -in. EU API tubing.

the surface at loo", which will give an average temperature of 140"F, from Fig.
15-62 the average oil viscosity is found to be approximately 2.1 centistokes. From
Fig. 15-72, at Q, = 610 bbl/D and oil viscosity of 2.1 centistokes, the pressure drop
is approximately equal to 1.6 psi per 1000 ft. Upon multiplying it by specific
gravity, Fl is found to be:

F, = 1.6 X 10 X 0.825 = 13 psi

 715

PRESSURE DROP IN TUBING

FLOW BETWEEN 3-”2”&1-”r”EU APl TUBING

05 10 50 10 50 100

PRESSURE DROP-PS1/1000’-MULTIPLY BY SPEC GRAV

Fig. 15-78. Relationship between the fluid flow and pressure drop when flow occurs between 3:-in. and
1:-in. EU API tubing.

Step 6:

G, =
(610) (0 3 2 5 ) (0.433) + (200) (0.8250) (0.433) + (100)(1.03) (0.433)
610 + 300

= 0.367 psi/ft

Step 7: The viscosity of water at 140°F from Fig. 15-63 is equal to 0.46 centistokes.
716

PRESSURE DROP IN TUBING

FLOW BETWEEN 3-'z"6 1 - ' 2 " EU API TUBING

I " I
01 05 10 50 10 50 1 I0

PRESSURE DROP-PSI/lOOO'-MULTIPLY BY SPEC, G R A V

Fig. 15-79. Relationship between the fluid flow and pressure drop when flow occurs between 3i-in. and
1:-in. EU API tubing.

The average viscosity in the return string, v3, is equal to:

(610)(2.1) + (200)(2.1) + (100)(0.46)

v3 = = 1.92 centistokes
910

From Fig. 15-71, at 910 bbl/D and viscosity of 1.92 centistokes, the tubing friction
in the return string of 2i-in. tubing is 11 psi per 1000 ft. Upon multiplying it by
 PRESSURE DROP IN TUBING
FLOW BETWEEN 3-w a z-J/s~*
EU API TUBING

1000

100
-
v)

a
l3
N
0
0
a
m
I
B
s
P
3
10

10

Fig. 15-80. Relationship between the fluid flow and pressure drop when flow occurs between 3;-in. and
2i-in. EU API tubing.

specific gravity, F3 is found to be:

F3 = 11 X 10 X -
0.367
0.433
= 93 psi

Step 8:

p 3 = (10,000 X 0.367) + 93 + 75 = 3838 psi

718

PRESSURE DROP IN TUBING

FLOW BETWEEN 4 - 1 ~ 3 . 32-31~33 EU API TUBING

10.000

10

Fig. 15-81. Relationship between the fluid flow and pressure drop when flow occurs between 4:-in. and
Zi-in. EU API tubing.

From eqs. 15-8 and 15-9:

ps = (3838)(1.64) - (600)(0.64) + 338 - (10,000 X 0.825 X 0.433) + 13 = 2690 psi

Hydraulic horsepower = 2690 X 610 X 0.000017 = 27.9 HP
By using the first approximation method (Solution A), one arrives at a surface
hydraulic horsepower requirement that is about 10% low. [One could easily add
+
pWh(l P / E ) = 75(1.64) = 123 psi and improve the accuracy.] If the first approxi-
 119

PRESSURE DROP IN TUBING

FLOW BETWEEN 4-‘2” 6 2 . ’ ~ ” EU API TUBING

10 000

1000
-
Y
s
5
n
P
m
I
3
E:
P
2
100

10
0.5 1.o 5.0 1’0 50 100

PRESSURE DROP-PS111000’-MULTIPLY BY SPEC. GRAV.

Fig. 15-82. Relationship between the fluid flow and pressure drop when flow occurs between 4:-in. and
2;-in. EU API tubing.

mation method yields a power requirement 20% less than a standard size surface
pump, it is usually safe enough to ignore the more precise calculations outlined in
this section.
Class problems
(1) Given: Same problem as example problem 15-4, except power fluid is water
having specific gravity of 1.03.
Find: Surface hydraulic horsepower and compare to example problem 15-4A and
15-4B.
720

PRESSURE DROP IN TUBING

FLOW BETWEEN S”,l a # CSG. 6 2-’/a” EU API TUBING

10 ooc

1 OO(

-
Y
0
N
p1
n
a
m
I
3
s
0
Y
_I

1O(

11

Fig. 15-83. Relationship between the fluid flow and pressure drop when flow occurs between Sin., 18-lb
casing and 2 i - h EU API tubing.

( 2 ) Giuen: Same problem as class problem 1 above, except: return tubing string is 1$
in. in diameter.
Find: Surface hydraulic horsepower.

BOTTOMHOLE PRESSURE CALCULATIONS

Equations 15-7 and 15-8 are frequently used to calculate the flowing bottomhole
pressure, p 4 , in existing hydraulic pumping installations. This calculation is similar
 721

PRESSURE DROP IN TUBING

FLOW BETWEEN 5-”2”, 20# CSG. 6 2-%” O.D. EU TUBING

0.1 05 10 50 10 50 100

PRESSURE DROP-PSI/lOOO’-MULTIPLY BY SPEC G R A V

Fig. 15-84. Relationship between the fluid flow rate and pressure drop when flow occurs between Sf-in.,
20-lb casing and 2;-in. O.D. EU tubings.

to finding p,, except steps 1, 2, 3 and 4 are eliminated because SPM and Q, are
given. Often the last-stroke method is used. The procedure for this method is to
close the valve on the power fluid supply line to the well and record the pressure
when the pump stops stroking. This last-stroke pressure is the operating pressure at
zero pump speed and zero fluid flow. It is the pressure where Fp, Fl and F3 are
zero. Inasmuch as it takes less than a minute for the pump to stop stroking, p4 and
h,G, do not change appreciably from their producing values. If p , , is the last-stroke
122

PRESSURE DROP IN TUBING

FLOW BETWEEN 5-’2’’, 14# CSG. (L 2-’a” O.D.EU TUBING

- I

0.1 0.5 1 .o 5.0 10 50 3

PRESSURE DROP-PSl/lOOO’-MULTIPLY BY SPEC. G R A V .

Fig. 15-85. Relationshp between the fluid flow rate and pressure drop when flow occurs between 5+-in.,
14-lb casing and 2;-in. O.D. EU tubing.

pressure, eqs. 15-7 and 15-8 become:

P I S - Ppr
For CPF system: p4 = ~ - hlG4 -pwh (15-10)
P/E

(15-11)
 123

PRESSURE DROP I N TUBING

FLOW BETWEEN S - l r " . 22# CSG. & 2-'s" EU TUBING

Fig. 15-86. Relationshp between the fluid flow rate and pressure drop when flow occurs between the
5;-in., 22-lb casing and 2 i - h . EU tubing.

Use of these equations eliminates the need for calculating the various friction
losses in the system. This last-stroke method must not be used with a severely worn
pump, however, because fluid slippage in the pump-end of the pump can cause the
pump to continue strohng past its balance pressure.
If precise bottomhole pressure data is required, a pressure bomb can be attached
to most hydraulic pumps to record actual producing bottomhole pressures while the
pump is operating. This method is preferred to calculations based on eqs. 15-7, 15-8,
124

PRESSURE DROP IN TUBING

FLOW BETWEEN 5 - 3 4 ' , , 22# CSG. & 3-12'' EU TUBING

10 000

1000
-
Y
u
N
z
n
n
1
3
s
il
LL
J

100

10
01 05 10 50 10 50 100

PRESSURE DROP-PS1/1000 -MULTIPLY BY SPEC GRAV

Fig. 15-87. Relationship between the fluid flow rate and pressure drop when flow occurs between the
5:-in., 22-lb casing and 3;-in. EU tubing.

15-10, or 15-11. The principal sources of error in calculations using these equations
are:
(1) Pump friction values are obtained using eqs. 15-7 and 15-8. Values for Fp
using Fig. 15-61 are sometimes 200-400 psi high. This is due to the fact that pump
friction varies with clearance, concentricity, and surface finish of the sliding parts,
which vary due to manufacturing tolerances and to pump wear. The values shown
on the chart are purposely on the high side of the range to allow a safety factor for
 125

PRESSURE DROP IN TUBING

FLOW BETWEEN 8 - 5 8 " , 28# CSG. 6 3-'2'' EU TUBING

10 000

01 05 10 50 10 50 0

PRESSURE DROP--PS1/1000 -MULTIPLY BY SPEC G R A V

Fig, 15-88. Relationship between the fluid flow rate and pressure drop when flow occurs between the
6:-in., 28-lb casing and 3i-in. EU tubing.

design purposes. Using eqs. 15-10 and 15-11, solves this problem, but G, and G,
become sources of error as explained below.
(2) When gas is present in the production column, multiphase flow correlations
must be used with eqs. 15-7 and 15-8, because even a 300 scf/bbl, gas/liquid ratio
will reduce p 3 by 600-1200 psi at depths below 5000 ft. Although this error provides
a safety factor when designing an installation, it is intolerable for bottomhole
pressure calculations. Equations 15-10 and 15-11 eliminate the error in Fp, but they
also eliminate tubing friction, F3. Inasmuch as multiphase flow correlations include
7 26

PRESSURE DROP IN TUBING

FLOW BETWEEN 6-50", 28# CSG. & 4-'r" E U TUBING

10 000

01 05 10 50 10 50 0
PRESSURE DROP-PSI/lOOO'-MULTIPLY BY SPEC GRAV

Fig. 15-89. Relationship between the fluid flow rate and pressure drop when flow occurs between the
6:-in., 28-lb casing and 4:-in. EU tubing.

tubing friction. a separate calculation must be made to determine tubing friction,

which must then be subtracted out of the multiphase flow value.

SAMPLE PROBLEM AND QUESTIONS

(1) The following well is to be equipped with a subsurface hydraulic bottomhole

piston pump, whch will operate off of the existing lease open-power oil system. A

The help extended by Charles E. Arnold is indeed greatly appreciated by the authors
 727

PRESSURE DROP IN TUBING

FLOW BETWEEN 7”, 26# CSG. h 2%” O.D. EU TUBING

100,000

10,000
-
u5
2a
N
P
n
0
m
I
e
s
P
3
LL

1ooc

lot
0.1 0.5 1 .o 5.0 10 50 100

PRESSURE DROP-PSI/IOOO’-MULTIPLY BY SPECIFIC GRAVITY

Fig. 15-90. Relationship between the fluid flow rate and pressure drop when flow occurs between the
7-in., 26-lb casing and 2;-in. O.D. EU tubing.

casting type free pump installation is desired using available 2i-in. O.D. API
tubing. Design the whole system.
Given :
(a) Well depth (both vertical and measured) = 6000 ft
(b) Pump setting depth = 5900 f t
(c) Pumping fluid level (from surface) = 5000 ft
(d) Gross production = 400 bbl/day
(e) Water cut = 25%
728

PRESSURE DROP IN TUBING

FLOW BETWEEN 7”, 2 w CSG. a 2-7s” O.D. EU TUBING

10 000

1000
-
I_J
n
a
N
9
0
Q
m
I
3
2
0
Y-
2

1oc

1(

PRESSURE DROP-PSI/lOOO -MULTIPLY BY SPEC GRAV

Fig 15-91 Relationship between the fluid flow rate and pressure drop uhen flou occurs between the
7-1n. 26-lb and 2 i - i n 0 D EU tubing

( f ) Oil gravity = 33” API

(8) Oil viscosity at 100 OF = 46 SSU
(h) Water specific gravity = 1.05
(i) Gas/oil ratio = 0
6) Casing size and weight = 7-in., 32-lb
(k) Flowline back pressure = 60 psi
(1) Static fluid level (from surface) = 3700 ft
 129

PRESSURE DROP IN TUBING

FLOW BETWEEN 7”, 26# CSG. (I 3 - ’ P O.D. EU TUBING

3
PRESSURE DROP-PSl/lOOO’-MULTIPLY BY SPEC. GRAV.

Fig. 15-92. Relationshp between the fluid flow rate and pressure drop when flow occurs between the
7-in., 26-lb casing and 3i-in. O.D. EU tubing.

Also solve this problem using gas/oil ratio of 200 cu ft/bbl.

(2) What are the four basic components in every type of artificial lift system?
(3) What is the primary advantage and disadvantage in a free-casing OPF
hydraulic pump system?
(4) What are the two basic power fluid systems?
( 5 ) Name the basic components of a hydraulic pumping system.
(6) What are the two main disadvantages of a Jet Pump? (Consult literature on
jet pumps, e.g., Trico Industries, Inc.)
730

PRESSURE DROP IN TUBING

FLOW BETWEEN 7”, 30# CSG. 6 4-’h” EU TUBING

10.000

1000
-
r:
ff
N
P
0

I
3
s
0
3
100

10
05 10 50 10 50 100

PRESSURE DROP-PSI/lOOO-MULTIPLY BY SPEC GRAV

Fig. 15-93. Relationship between the fluid flow rate and pressure drop when flow occurs between the
7-in., 30-lb casing and Of-in. EU tubing.

(7) Engine valve is shifted (check correct answer):

(a) Mechanically by piston. (b) Hydraulically by valve rod. (c) Automatically by
packer nose.
(8) Normal power fluid loss expected in a hydraulic pump system (check correct
answer):
(a) None, (b) 20%,and (c) 5%.
(9) Running the pump too fast for the well’s production often results in (check
 731

PRESSURE DROP IN TUBING

FLOW BETWEEN S’h”, 43%# CSG. 6 2%” O.D. EU TUBING

100,000

100
0.1
1 ’ ’ I

PRESSURE DROP-PSI/lOOO-MULTIPLY BY SPECIFIC GRAVITY

Fig. 15-94. Relationship between the fluid flow rate and pressure drop when flow occurs between the
9;-in., 43;-lb casing and 2;-in. O.D. EU tubing.

all that apply):

(a) Pounded production valving. (b) “Governed” engine valve assembly. (c) More
production than expected. (d) Excessive wear and damage to pump. (e) Short pump
runs. (f) Pump unseating while running.
(10) What is the hydraulic horsepower (HHP) if the pump requires 1250 bbl/D
of power fluid at 3000 psi operating pressure?
732

PRESSURE DROP IN TUBING

FLOW BETWEEN 8-5s”, 43-’r# CSG. 6 3 - l ~ ”O.D. E U TUBING

01 0.5 1 .o 5.0 10 50 100

PRESSURE DROP-PS1/100O-MULTIPLY BY SPEC. GRAV.

Fig. 15-95. Relationship between the fluid flow rate and pressure drop when flow occurs between the
9;-in., 43i-lb casing and 3 i - h . O.D. EU tubing.

(11) When considering jet pump sizing:

(a) What ratio gives high lift capacity?
(1) “A” ratio, (2) “C” ratio, (3) “E” ratio, (4) “H” ratio.
(b) What amount of submergence is probably necessary?
(1) 5 % , (2) 20%, (3) 50%, (4) None.
(12) If minimum surface horsepower is important, which type of pump should be
chosen?
 133

PRESSURE DROP IN TUBING

FLOW BETWEEN 9-%", 43-'z# CSG. & 4-'z" O.D. EU TUBING

01 0.5 10 50 10 50 100
PRESSURE DROP-PSI/lOOO -MULTIPLY BY SPEC G R A V

Fig. 15-96. Relationship between the fluid flow rate and pressure drop when flow occurs between the
9;-in., 43i-lb casing and 4;-in. O.D. EU tubing.

(13) Which of the following are advantages of hydraulic pumping?

(a) Wide production range (flexible). (b) No large equipment over wellhead. (c)
Requires no attention. (d) Operating pressure allows pump intake pressure to be
accurately estimated. (e) Directional wells do not present problems.
(14) (a) For piston pumps, is the P/E ratio used to determine maximum pump
setting depth or not?
(b) They should be sized so that maximum operating speed is:
(1) Used only by foreman. ( 2 ) Is no more than 85% of maximum rated speed. (3)
134

PRESSURE DROP IN TUBING

FLOW BETWEEN lo%’’, 40.5# CSG. & 3%”O.D. EU TUBING

PRESSURE DROP-PSl/lOOO’-MULTIPLY BY SPECIFIC GRAVITY

Fig. 15-97. Relationship between the fluid flow rate and pressure drop when flow occurs between the
loi-in., 40.5-lb casing and 3i-in. O.D. EU tubing.

Within local speed limit. (4) Within OSHA specifications.

(15) (a) A nozzle to throat ratio of 1OC in jet pumps means throat is a No. -
throat.
(b) Power fluid cleanliness is less or more important in the case of jet pumps than
with a piston pump?
(c) Describe several throat materials available according to the type of service.
 735

PRESSURE DROP IN TUBING

FLOW BETWEEN lo%”,40.5# CSG. 6 4%” O.D. EU TUBING

I
01 0.5 1.o 5.0 10 50 1 3

PRESSURE DROP-PSI/lGOO’-MULTIPLY BY SPECIFIC GRAVITY

Fig. 15-98. Relationship between the fluid flow rate and pressure drop when flow occurs between the
lOi-in., 40.5-lb casing and 4i-in. O.D. EU tubing.
736

Fig. 15-99. Grid for Figs. 15-65 through 15-98.

REFERENCES

Coberly, C.J., 1961. Theoiy and Application of Hydraulic Oil Well Pumps. Kobe Inc., Huntington Park,
Calif., 127 pp.
Borden, Jr., G. and Rzasa, M.J., 1950. Correlation of bottom hole sample data. Trans. A.I.M.E., 189:
345-348.
Neely, B., Gipson, F., Clegg, J., Capps, B. and Wilson, P., 1981. Selection of artificial lift method. 56th
Annu. Fall Tech. Conf. and Exhibition of the SOC. Pet. Eng. of A.I.M.E., San Antonio, Tex., Oct. 5-7,
SPE 10337,6 pp.
Standing, M.B., 1952. Volumetric and Phase Behavior of Oil Field Hydrocarbon Systems. Reinhold, New
York, N.Y., 122 pp.
Wilson, P.M., 1976. Introduction to Hydraulic Pumping. Kobe Inc., Huntington Park, Calif., 103 pp.