PTP-7.

BEAM PUMP

PTP-7.2

PUMP OPERATIONS

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 TABLE OF CONTENTS

Page No.
1.1 Introduction
03

1.2 Beam Pump start-up operation 03

1.3 Beam Pump Dynamometer 07

1.4 Beam Pump monitoring 09

1.5 Beam Pump stopping operation 10

1.6 Beam Pump trouble shooting 10

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1.0 Beam Pump operation:

1.1 Introduction:
Most oil wells in the early stages of their lives flow naturally to the surface. These are
called ‘self flowing wells’. The basic pre-requisite to ensure flowing production is that
the pressure at well bottom be sufficient to overcome the sum of pressure losses
occurring along the flow path to the surface. When this criterion is not met, the well stops
flowing naturally and dies.

There are two main causes of a well’s dying: either the bottom hole flowing pressure
drops to a level at which it is no longer sufficient to overcome pressure losses in the well,
or the flowing pressure losses become greater than the bottom hole pressure necessary for
the well to produce. The first case happens due to the removal of fluids from the
underground reservoir and entails to gradual decrease in reservoir pressure. In the second
case, mechanical problems like, too-small tubing size, down hole restrictions etc. or a
change in the composition of the flowing fluid, normally a decrease of gas production,
tend to increase the flow resistance in the well. Surface conditions, such as separator
pressure or flow line size, also directly impact total pressure losses and can prevent a well
from flowing on it’s own.

One of the oldest and most common methods of artificial lift is the “Sucker Rod or Beam
Pumping System”. This system consists of mainly of four components: Beam Pumping
Unit, Power Unit, Sucker Rod String and subsurface Pump (called a ‘Sucker Rod Pump).

1.2 Beam Pump start-up operation:

These types of pumps are driven by some sorts of surface pumping unit to furnish power
to the sucker rods in the form of reciprocating motion. These surface units are mainly of
two types. It could be an overhead electric motor driven, drive pulley and belts type or
diesel or fuel gas driven engine type, which drives the generator for supply of electric
power to the motor. Therefore, start-up sequence of the unit depends upon the type of
power used to drive the beam pump. One of the main sources of surface pumping unit is
electric power motor driven method. Hence here, we will discuss regarding the same:

The surface power unit (in this case, electrical power driven motor) provides energy for
pumping the well. It also rotates the crankshaft and as the crankshaft rotates, pitman arms
lift and lower one end of the pivoted beam. One complete rotation of the crankshaft is
called a ‘Stroke’.
The beam seesaws up and down alternately lifting (up-stroke) and lowering (down-
stroke) the sucker rod string.

A beam pumping unit transfers energy from the power unit to a sucker rod string.
The string of sucker rods transmits the energy from the beam pumping unit to the
subsurface pump.

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These rods are selected to be the lightest weight that can be used and still be strong
enough to operate the pump efficiently.
The first sucker rod of the string is called the “Polished Rod”, and is usually very bright
and shiny.
The polished rod moves up and down inside a stuffing box that contains packing to form
a pressure-tight seal around the rod.
The function of a sucker rod pump is to lift the fluid to the surface.
As the sucker rod move downward, the pump moves downward allowing fluid to be
trapped by the pump.
When the sucker rods move upward (upstroke) the trapped fluid is lifted to the surface
through the tubing string.

1.2.1 Start Sequence:

Pre-start requirements are based upon, whether the start is after the initial well-
completion, process alarm trip, and major shutdown/maintenance:

a) Initial start-up after Well-completion:

1. Get the new opening-up program from Area Programmer.
2. Confirm all the mechanical, electrical, Instrument jobs are completed and the area is
clean and tidy.
3. Ensure that all discipline-crafts are available at site to assist start-up.
4. Conduct tool-box talks at site with co-workers as well as workers of other disciplines.
5. Check details of the equipment, especially the size of the pulley whether it is as per
the opening-up program.
6. Check the flow-line pressure and vibration switches for actual trip settings, also
whether they are lined-up properly.
7. Check line-up of the well flow-line to the required MSV’s/Manifold:
a) ensure flow-line vents and drains are closed
b) open the well-head master valve
c) open the well-head tubing wing valve
d) check sonolog connection is lined-up and casing wing valve is open
e) open the isolation valve to the MSV’s/Manifold
f) check well-head tubing, casing, flow-line etc pressure gauges are good and lined-
up.
8. Check and confirm electrical power is available and operating panel etc are energized.
9. Start the Pump, check all operating parameters (THP, CHP, Fluid level, amperage
current, dynograph reading, communication etc.) and observe for any abnormalities,
like, vibration due to unbalancing, any leaks etc.
10. In case of any abnormalities/malfunctions, arrange for remedial actions.
11. Carry-out the normal checking as per the commissioning check-list, if everything is
normal, hand-over the well to the Production Supervisor.

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b) After the process alarm trip:
i) check/identify the cause of the trip, if still ready to run signal is not
obtained, re-check the pre-start requirement and rectify or report fault
found until it is identified/normalized. Once ready to run signal obtained,
Press Start Button.
ii) If after a pre-set time limit the main motor started and tripped again, check
further for electrical power supply and other safe-guarding system, like
vibration/high pressure switch(flow-line valve status).
iii) Further check for flow-line valves (may be valve closed, causes high
pressure) or check due to high vibration.

7.2 Beam Pump Operations

Start sequence of Motor Driven Beam Pump after Process Alarm Trip:
Unit on Process
Alarm Trip

Pre-start check,
Identify Problem

Ready to run
obtained

Within pre-set time

Press Start Button
limit, unit started
and tripped again

Ready to run obtained, Checked flowline valve

press start button and vibration switch

Unit run normal

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c) If after the major shutdown maintenance; check for all normal formalities,
like PTW, isolation/de-isolation, all well valves are lined-up as per requirements, electric
power supply normalized, all control, protection and safe-guarding-systems are lined-up
and are healthy. Once pre-start requirements are completed and if the ready to run
obtained, Press Start Button.

7.2 Beam Pump Operations

Start sequence of Motor
Driven Beam Pump
after Major Shutdown: Unit after Major
Shutdown

Pre-start check,
PTW, isolation/de-isolation,
all valves, electric supply,
all control & sage-gaurding etc

Ready to run
obtained

Press Start Button

Unit run normal

1.3 Beam Pump Dynamometer:

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1.3.1 General
The dynamometer is presently the instrument most frequently used to analyze the
performance of a beam pump. It is positioned between the polished rod clamp and wire-
line hanger, actuated to take the whole weight of the sucker rod assembly, and then used
to produce a graph (dynograph) of the forces acting on the polished rod during the
pumping cycle.
Interpretation of dynograph requires experience, but the information that can be revealed
by a dynograph include:-

Minimum and peak load on the polished rod.

Polished rod load at each point on the stroke cycle.
Fluid leakage past the standing valve.
Fluid leakage past the travelling valve.
Sticking plunger.
Restriction in the well.
Gas lock.
Over or under travel of the plunger in the barrel (i.e. hitting down/pulling out).

1.3.2 Use of Instrument:

1. Stop the beam pump at the bottom of the down stroke and engage hand brake.
Lock off the pump power supply.
2. Attach clamp-on amperage meter to the external cable supply loop.
3. Ensure a safe position, then pick up the Dynamometer by the two handles,
holding them almost horizontal.
4. Slide the dynamometer into the space between the polished rod clamp and the
collar with a downward rotating motion.
5. Attach safety chain around the wire rope to prevent the accidental loosening
of the instrument.
6. Develop pressure inside the instrument by pumping lever quickly up and
down. This is a double-acting plunger.
7. As you pump, the two pistons will lift the carrier off the collar of the Leutert
attachment and the total sucker rod string load is transferred to the
dynamometer. Keeping on pumping until no more resistance is felt. At this
point, the full weight is on the dynamometer.
8. Engage stylus by lifting lever, pull wire to draw static load base line on chart
and dis-engage stylus again by lifting lever.
9. Attach hook of pull wire to Blow Out Preventer (BOP) or stuffing box.
10. Start the beam pump unit and allow a minimum of 10 strokes before engaging
the stylus and drawing the dynograph.
11. Record high and low readings from the clamp-on ammeter.
12. Engage the stylus by pulling lever, with the red knob, to the left. Leave it
engaged for three strokes.
13. Dis-engage the stylus by pulling lever, with the black knob, to the left until the
spring-loading of lever locks it back. Leave the pull wire connected.
14. Stop the beam pump, apply hand brake and lock off.

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 15. Release the hydraulic pressure by pressing lever.
16. When the pressure has been released, engage the stylus to draw a further base
line by pulling the static load pull wire.

1.3.3 Completion:
2. Remove the pull wire from the hook on the recorder unit and allow to Slowly
retract into unit.
3. Replace safety chain and take the Dynamometer out of the Leutert attachment
by pulling the two handles.
4. Remove the chart from the chart-holder, enter the date, time, and other data
requested on the chart. Take care to prevent further scratches on the chart.
5. Remove the clamp-on ammeter.
6. START the beam pump.

Notes:
1. Different springs require to be fitted to the dynamometer depending on
the depth of the well. Ensure that the correct spring is fitted.
2. A dynograph should be taken in conjunction with a casing fluid level reading
(ECHOMETER) for correct evaluation.
3. The dynamometer should be routinely maintained every month.

1.3.4 Beam Pump Maintenance:

General
Production maintenance crews will carry out a half yearly preventive maintenance on all
beam pumps as listed below:

1. Checks whilst the unit is running

1.1 Abnormal noise
1.2 Excessive vibration
1.3 Amperage down and needs balancing
1.4 Horse-head alignment and polished rod alignment

2. Maintenance Checks
2.1 Stop beam pump at 6 o’clock position.
2.2 Apply hand brake and insert brake latch (Lufkin).
2.3 Provide padlock on switch lever.
2.4 Remove gearbox inspection cover and check gears.
2.5 Check gear-box oil level, top up if necessary.
2.6 Check for evidence of oil leaks, and replace seals/gaskets as necessary.
2.7 Take oil sample, check of contamination if required by 2.4 above.
2.8 Clean gear-box breather.
2.9 Horse-head and polished rod alignment.
2.10 V-belt tension and alignment.
2.11 Check brake cables and balance, as well as brake shoe condition and
replace/adjust as necessary.

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 2.12 Balance unit if amperage is unstable.
2.13 Grease all bearings
2.14 Check hold down bolts.
2.15 Check rotor foundation bolts.
2.16 Check and tighten all other bolts.
2.17 X-mas tree wing valve greasing and bolt tightness check.
2.18 Check B.O.P.
2.19 Stuffing box packing and victolic joint.
2.20 Location valve/drain valve condition, check operation and grease.
2.21 Pressure switch cut-off.
2.22 Air compressor belt and guard (both units).
2.23 Air cylinder and airline connection (both units).
2.24 Diesel lube oil, fuel filter, radiator (both units).
2.25 Apply lube oil on wire rope.
2.26 Check general condition.
2.27 Clear unit for start-up.

Note: Most Preventive Maintenance checks on beam pumps are co-ordinates with
maintenance Department (Instrument, Electrical and Mechanical).

1.4 Beam Pump Monitoring :

After start-up of a beam pump, the following parameters are to be monitored during the
next couple of hours:
1. Check for any leaks in the unit, sucker rod travelling stuffing box, flow-line etc.
2. Check number of strokes per minutes.
3. Flow-line and casing wellhead pressure.
4. Motor current amperage reading.
5. If the pump is running on timer, check timings.
6. Motor winding and bearing temperature.

1.4.1 Typical Daily Checks:

a) Check for leaks, flow-line pressure.
b) Electrical power supply amperage reading of the drive motor.
c) Lube oil crank-case level check.
d) Battery charger and batteries.
e) Observe and listen for any unusual noise or vibration.
f) Record a full set of readings.
g) Compare the readings taken, with known normal operating conditions.
h) Record all known problems and report to the concerned department for corrective
action.

1.5 Beam Pump stop sequence:

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As it is motor driven beam pump unit, stopping the unit for operation and maintenance,
there are very few points to be considered. If it is programmed for minor maintenance,
proper isolation(electrically as well as mechanically) are to be done. If it is major
maintenance or work-over repairs of the well, then the isolation procedure should be
accordingly, like isolation (electrically as well as mechanically by spading or positive
isolation by spool removal and blinding), then drive motor is stopped.

1.6 Basic problems and trouble-shooting in such well operations:

This section outlines a recommendation for identification and solution of typical Beam
Pump Well Operations problems. The only way a failure can be analyzed and its cause
determined is by data collection. When a problem occurs you simply cannot have too
much information.

Information that should be routinely compiled on each such well includes production data
(such as water, oil, and gas), run life, unit starts and stops, dynamic and static fluid level,
and pump setting and perforation depth. Information also should be obtained on sub-
surface equipment like, dynamometer readings/cards, visual observations of equipment
and Bottom Hole Temperature.

When a Beam Pump Well is first put on production, data should be collected daily for the
first week, weekly for the first month, and a minimum of monthly after the first month.
Production data during the first month are very important because they will indicate
whether the pump is performing as designed. If a down hole pressure instrument is
installed, operating Bottom Hole Pressure is equally important.

The major source of information when troubleshooting a well is the dynamometer

readings. In addition, there are other problems pertaining to these types of wells which
are as given below:

1.6.1 Gas Anchors (Down-hole Gas Separators):

Where conditions are such that there is considerable free gas in the well fluid at the pump
intake, it is desirable to prevent as much gas as possible from entering the pump and
permit the gas to rise to the surface through the casing annulus rather than through tubing.
Numerous so-called gas anchors are in use that is designed to separate the free gas and
deflect it up the casing annulus. A common type of gas-anchor arrangement in which the
well fluid must enter the perforated nipple and circulate downward at a low velocity
before entering the gas-anchor tube, which is attached to the pump intake. This gives the
free gas an opportunity to separate and rise to the uppermost ports in the perforated
nipple where it may return to the casing. A large portion of the gas will rise through the
casing before passing through the perforated nipple.
1.6.2 Corrosion:
In some areas resistance to corrosion of materials used in subsurface pumps is of major
importance. A wide variety of alloys iron, steels, nonferrous alloys, and elements have
been used to combat corrosive conditions in various locations. Some of the corrosive
agents commonly found in various locations are hydrogen sulfide, carbon dioxide, salt
waters containing sodium chloride, calcium chloride, magnesium chloride, and other

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salts. Chemical corrosion inhibitors are now widely used by many operators. Such
inhibitors are fed either continuously or intermittently down the casing into the well.
Protective films are formed on the tubing and rods, as well as on pump parts. However,
since protective films cannot form on wearing surfaces, the closely fitted pump parts in
rubbing contact are not protected as well as the rods and tubing by corrosion inhibitors.
For this reason it is more important to use corrosion-resistant materials in the
construction of subsurface pumps.
1.6.3 Effects of Gases and Vapors:
In selecting pumping equipment for oil wells remember that in a majority of cases some
of the constituents of the fluid being pumped are above or near their boiling points at the
pressure and temperature conditions existing within the pump. These conditions may
cause release of large volumes of dissolved gases and vapors with a slight drop in
pressure of the well fluid, in addition to the free gas initially in the fluid. For this reason it
is very difficult to pump some wells down. Many wells apparently will pump off with
several hundred feet of fluid standing in the hole because the condensable vapors and
gases occupy the entire displacement volume of the pump. Under these conditions,
without a relatively high intake pressure, which decreases compression ratio, the pressure
below the plunger cannot be raised to the tubing pressure. (This is necessary before the
traveling valve can open and deliver oil to the tubing). On the down stroke the vapors
may condense and occupy a very small volume without an appreciable increase in
pressure, and only the permanent gases are effective in increasing the pressure in
accordance with the gas laws.

There are two precautions to take to minimize the adverse effects of vapors and gases:
1. The compression ratio should be made as high as possible. This is accomplished by
using a closed-cage-type valve below the plunger with a stationary-barrel pump or a
valve above the plunger with a traveling-barrel-type pump. It is also important to
space the pump so the traveling valve and standing valve come as near to each other
as possible at the lowest position of the rods without making contact, and to use as
long a stroke as possible with the equipment available.
2. Flow velocities and turbulence at the pump inlet should be kept at a minimum. Using
the largest standing valve possible and a suitable gas anchor with the largest possible
flow passages accomplish this.

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