Rod Pump System Design

MODULE III
© 2006 Weatherford. All rights reserved.

Designing a Rod Pump System

Design Parameters
1. Production Casing:
1. Grade?
2. Size?
3. Weight?
2. Completion Type:
1. Deviated?
2. Cased?
1. Perforations?
3. Open Hole?
1. Starting Depth?

Design Parameters
1. Tubing:
1. Grade?
2. Size?
3. Weight?
4. Pump seating nipple depth?

Design Parameters
1. Production Requirements:
1. Barrels of fluid per day (BFPD)?
2. Barrels of oil per day (BOPD)?
3. Barrels of water per day (BWPD)?
4. Gas per day (MCF/D)?

Design Parameters
1. Fluid Properties:
1. Fluid Specific Gravity?
1. Oil, °API?
2. Water Specific Gravity (weight)?
3. Gas Specific Gravity?

Design Parameters
1. Corrosion?
1. Chlorides?
1. Parts per million (ppm)?
2. CO2?

3. H2S?

4. Fluid pH?

Design Parameters
1. Solids?
1. Paraffin?
2. Sand?
3. Scale?

Casing, Tubing and Pump Sizes
Oversize
Sucker Rod Size, RW Insert RH Insert TH Tubing
Casing Size Tubing Size, Max. Tubing Pump,
Max. Pump, Max. Pump, Max. Pump, Max.
Max.
2-7/8 in. 5/8 in., Slim-hole
1-1/2 in. Reg.
6.5 lb/ft Clpgs.
1-1/4 in. 1-1/2 in. 2 in.
3-1/2 in. 2-1/6 in. 3/4 in., Slim-
7.7 to 10.2 lb/ft Integral Jnt. hole Cplgs.
4 in. 7/8 in., Slim-
2-3/8 in. 1-1/2 in. 1-1/4 in. 1-3/4 in. 2-1/4 in.
9.5 to 14 lb/ft hole Cplgs.
4-1/2 in. 2-7/8 in. Spec.
9.5 to 12.6 lb/ft Clear Cplg. 1 in.,
2 in. 1-3/4 in. 2-1/4 in. 2-3/4 in.
5 in. Slim-hole Cplgs.
2-7/8 in.
11.5 to 20.3 lb/ft
5-1/2 in.
14 to 20 lb/ft
3-1/2 in. 1-1/8 in. 2-1/2 in. 2-1/4 in. 2-3/4 in. 3-3/4 in.
6-5/8 in.
20 to 28 lb/ft
7 in.
4-3/4 in.
17 to 29 lb/ft
4-1/2 in. 1-1/8 in. 3-1/4 in. 2-3/4 in. 3-3/4 in.
7-5/8 in.
5-3/4 in.
and larger
Design Parameters
1. Pumping Unit:
1. Type:
2. Size:

Design Parameters

Design Parameters
Include:
1. Prime Mover:
1. Type?
1. Electric
2. Gas
2. Size?

Designing a Pumping System
• Start with longest stroke available, slowest speed, and

smallest plunger size that will produce required number of
BPD.
• Design 25% over target production whenever possible.
• Design rods for maximum expected SPM and minimum

fluid level.

Surface Unit Considerations (continued)
• Several geometries and types of units available
• Air-balanced unit weighs less.
• Enhanced-geometry units with faster downstroke often

more efficient with less peak torque; can stack the rods
on high SPM unit.
• Other units include long-stroke or hydraulic units.

Surface Unit Considerations (continued)
• Gearbox Sizing
– Must be large enough to handle required torque.
– Gearbox is most expensive component.
– Should not be overloaded to preserve life.
– Manufacturers should have safety factor built in.
• Peak polished rod loading must not exceed unit rating.
• Most units have several stroke adjustments; longest stroke

helps efficiency.
Reducing Gearbox Torque
• Use shorter stroke length, and speed up unit.
• Use smaller pump plunger.
• Use lighter rod string by using either

high-strength steel or fiberglass rods.
• Use ultrahigh slip motor.

Maximum Strokes per Minute
A good rule of thumb:
• The stroke length multiplied by the strokes per minute should not be more than 1400
• 168” stroke at 10 spm = 1680 Too fast
• 120” stroke at 10 spm = 1200 Acceptable
Maximum allowable pumping unit speed

(strokes per minute) is to keep the maximum
polished rod velocity below 240 ft/min.
Maximum allowable pumping unit speed:

(SPM x SL x 2)
12

One Stroke Per Minute
• 1,440 strokes per day
• 10,108 strokes per week
• 43,800 strokes per month
• 525,600 strokes per year

Save Energy Costs
• Lower energy costs by using larger pump and slower

pumping speed.
• Counterbalance unit properly.
• Avoid fluid pound.

Modified Goodman diagram
MINIMUM TENSILE STRENGTH T
Goodman conducted series

of tests to determine
1 maximum load which can be
----
2
T
----- cyclically applied without
1.75
breaking the rod.
T
+ ---- T
3 ----- This graph illustrates
-
4 maximum allowable stress.
450
1. SA = ( T/4 + M SMIN) SF
2.
SA = (.25T + 0.5625 SMIN) SF
T 3.
?SA = SA – SMIN
- ------
3 When:
SA = MAXIMUM AVAILABLE STRESS, PSI
?SA = MAXIMUM ALLOWABLE RANGE OF STRESS, PSI
M = SLOPE OF SA CURVE = 0.5625
SMIN = MINIMUM STRESS, PSI (CALCULATED OR MEASURED)
SF = SERVICE FACTOR
T = MINIMUM TENSILE STRENGTH, PSI
Design
API RP11L Design Method:

– The original analog work was done in the late 1950’s
by the Midwest Research Institute for an oil
consortium group and given to the American
Petroleum Institute (API) in the early 1960’s.
– No additional research has been done since.

API RP11L Design Method
• Assumes vertical well bore.

• Assumes tubing is unanchored or anchored at the seating
nipple.
• Not accurate in wells under 2,000 feet.
• Only good with high slip electric motors.

API RP11L Design Method
• Only good with conventional geometry pumping units.

– Pumping unit is assumed to have zero structural unbalance.
• Only good for API tapered rod strings.
• Only good for steel API class sucker rods.
• Only gives rod load for the top sucker rod in the rod string.
• Only good for complete pump fillage.

Modified RP11L Design Method
• Allowed the use of Mark Pumping Units.

• Allowed the use of modified API tapers (weight bars) but
still gives rod load for the top rod – only.
• Allowed the use of high strength steel sucker rods.

Modified Goodman Diagram Calculations
8,225
SMIN   10,477
API D Rods, T = 115,000 .785
MPRL = 8,225 23,916
PPRL = 23,916
SMAX   30,466
.785
Rod String = 86
Service Factor = .90
 115,000 
SA    .5625 10,477   .90
1. SA = ( T/4 + M SMIN) SF  4 
2.
SA  (28,750  5,893)  .90
SA = (.25T + 0.5625 SMIN) SF
SA  31,178PSI
3.
∆SA = SA – SMIN SA  31,178PSI - 10,477
SA  20,701 PSI
When:
SA = MAXIMUM AVAILABLE STRESS, PSI As such : SA  SMAX therefore in  range
∆SA = MAXIMUM ALLOWABLE RANGE OF STRESS, PSI 31,178  30,466
M = SLOPE OF SA CURVE = 0.5625
SMIN = MINIMUM STRESS, PSI (CALCULATED OR MEASURED) 30,466
 100  97.7%
SF = SERVICE FACTOR 31,178
T = MINIMUM TENSILE STRENGTH, PSI

Wave Equation Design Method
Wave Equation Design Programs:

• Wave equation programs solved the same fundamental
wave equation, as done by Midwest Research, but with a
digital computer. They offer much more flexibility in
modeling well conditions and have been continuously
improved for 35+ years.

• Models rod loading in both vertical and deviated wells.

– Predicts side loads for rod guide applications.
• Models tubing movement relative to the tubing anchor depth and the
pump seating nipple depth.
• Accurate for both shallow and deep wells.
• Allows the use of all types of prime movers.

• Allows the use of advanced geometry pumping units.

• Allows the use of modified tapered rod strings with both fiberglass
and high strength steel sucker rods.
• Gives the rod load at any point in the rod string.
– Predicts the neutral point in the rod string.
– Predicts rod buckling tendencies.

• Models incomplete pump fillage.

– Fluid pound.
– Gas interference.
– Pump leakage.
• Models system inefficiencies.
– Prime mover.
– Pumping unit.
– Rod sting.

Design
In designing the rod string, a minimum load of 2,000 pounds should

be kept at the top of each taper. Since most wave equation
programs give this load in stress (psi), the minimum stress
should be at least:
• 1 1/8” – 2,000 psi.
• 1” – 2,500 psi.
• 7/8” – 3,300 psi.
• 3/4” – 4,500 psi.
• 5/8” – 6,500 psi.

Design
• For API class sucker rods, the value at the bottom of the interval for
the last taper should not exceed a minimum stress of more than –
2,000 psi.
• For high tensile strength N&T sucker rods, the value at the bottom of
the interval for the last taper should not exceed a minimum stress of
more than –1,500 psi for 7/8” and 3/4” sucker rods.

Rod Pump Selection

Required Data
• Minimum amount of information

must be provided (or assumed):
– Fluid level
– Pump depth
– Production requirements
– Length of surface stroke

Pump Design Considerations
Pump Pump metallurgy (barrel, plunger, balls and seats) is selected for corrosion and wear.
Metallurgy Materials selected to resist corrosion, perhaps in conjunction with a corrosion treatment
plan, must be considered. Barrels could be carbon steel, stainless steel, brass, monel, or
chrome plated, for example. Plungers could be plain steel, chrome- or nickel-plated, popular
spray metal, or other options.
Balls and seats can be stainless steel (440C, specially treated, 329, other) balls and seats, K
monel balls and seats, bronze balls, tungsten carbide balls and seats, silicon nitride balls, or
other. Cages for the balls can be of various materials.
Pump The pump size determines the pumping rate. The largest pump (lowest SPM) will provide
Sizing the most energy efficiency, but also the biggest loads to the equipment. The optimum choice
is the biggest pump with no overloads on the rod, unit or motor.
Spacing Pumps should be spaced to maximize the pump compression ratio for gas handling. The
pump should be built and spaced so that the traveling valve comes close to the standing
valve on the downstroke to help prevent gas lock. This may not be practical for fiberglass
rods since they are widely spaced to prevent possible compression and destruction on the
downstroke.
Pump Type, For deeper applications, the outside of the barrel should withstand exposure to produced
Holddown fluid pressure (bottom hold down) and thicker wall (heavy wall) pumps are used.
For shallower applications, the outside of the barrel should withstand exposure to suction
fluid pressure (top hold down). This eliminates sediment problems around the barrel.
Production Specialty pumps are designed for sand, gas, viscous oil, and other problem situations.
Problems

Determine Pump Displacement
Determine Pump Displacement
PD= Ap(in.2) x Sp(in./stroke) x N(stroke/min.) x 1440 min/day

9702 in3/bbl
PD = 0.1484 ApSpN
TABLE OF PUMP CONSTANTS

Plunger Area of
Diam Plunger sq in. Constant
in. (A p ) (K)
1 0.307 0.117
1-1/16 0.442 0.132
1-1/4 1.227 0.182
1-1/2 1.767 0.262
1-3/4 2.405 0.357
2 3.142 0.466
2-1/4 3.976 0.590
2-1/2 4.909 0.728
2-3/4 5.94 0.881
3-3/4 11.045 1.640
4-3/4 17.721 2.630

Step II. Determine Severity of Corrosion
*NACE Standard MRO176-2000

Plunger Length & Clearance
Depth
Size 2000’ 3000’ 4000’ 5000’ 6000’ • Plunger Length
*1-1/16, 1-1/4 2' 3' 4' 5' 6'
1-1/2" 2' 3' 4' 5' 6'
1-3/4" 2' 3' 4' 5' 6'
2 2' 3' 4' 5' 6'
2-1/4 2' 3' 4' 5' 6'
2-1/2 2' 3' 4' 5' 6'
2-3/4 2' 3' 4' 5' 6'
3-3/4 2' 3' 4' 5' 6'
4-3/4 2' 3' 4' 5' 6'
5-3/4 2' 3' 4' 5' 6'
Plunger Length
Plunger size Fit (Ft)
*1-1/16, 1-1/4 -.001" 2
1-1/2" -.002" 2
• Clearance 1-3/4", 2 -.003" 2
2-1/4, 2-1/2 -.004" 2
Add .001” to fit size for additional foot of
2-3/4, 3-3/4 -.005" 2
length up to 4’
4-3/4, 5-3/4 -.007" 2
Calculate Barrel Length
Calculate Barrel Length
BL = S + PF + RS
Where:
S = Surface Stroke
PF = Pump fitting (12"
RS= Rod Stretch (18-24")

Select Fittings and Accessories

25-150-RHBC-20-5-1-1

Rod Pump System Design

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MODULE III

© 2006 Weatherford. All rights reserved.

© 2006 Weatherford. All rights reserved.

© 2006 Weatherford. All rights reserved.

© 2006 Weatherford. All rights reserved.

© 2006 Weatherford. All rights reserved.

© 2006 Weatherford. All rights reserved.

1. Parts per million (ppm)?

1. Parts per million (ppm)?

© 2006 Weatherford. All rights reserved.

© 2006 Weatherford. All rights reserved.

© 2006 Weatherford. All rights reserved.

© 2006 Weatherford. All rights reserved.

© 2006 Weatherford. All rights reserved.

• Start with longest stroke available, slowest speed, and

• Design 25% over target production whenever possible.

• Design rods for maximum expected SPM and minimum

© 2006 Weatherford. All rights reserved.

• Several geometries and types of units available

• Air-balanced unit weighs less.

• Enhanced-geometry units with faster downstroke often

• Other units include long-stroke or hydraulic units.

© 2006 Weatherford. All rights reserved.

– Must be large enough to handle required torque.

– Gearbox is most expensive component.

– Should not be overloaded to preserve life.

– Manufacturers should have safety factor built in.

• Peak polished rod loading must not exceed unit rating.

• Most units have several stroke adjustments; longest stroke

• Use shorter stroke length, and speed up unit.

• Use smaller pump plunger.

• Use lighter rod string by using either

• Use ultrahigh slip motor.

© 2006 Weatherford. All rights reserved.

A good rule of thumb:

Maximum allowable pumping unit speed

Maximum allowable pumping unit speed:

© 2006 Weatherford. All rights reserved.

• 1,440 strokes per day

• 10,108 strokes per week

• 43,800 strokes per month

• 525,600 strokes per year

© 2006 Weatherford. All rights reserved.

• Lower energy costs by using larger pump and slower

• Counterbalance unit properly.

• Avoid fluid pound.

© 2006 Weatherford. All rights reserved.

Goodman conducted series

API RP11L Design Method:

© 2006 Weatherford. All rights reserved.

• Assumes vertical well bore.

© 2006 Weatherford. All rights reserved.

• Only good with conventional geometry pumping units.

© 2006 Weatherford. All rights reserved.

• Allowed the use of Mark Pumping Units.

© 2006 Weatherford. All rights reserved.

© 2006 Weatherford. All rights reserved.

Wave Equation Design Programs:

© 2006 Weatherford. All rights reserved.

• Models rod loading in both vertical and deviated wells.

© 2006 Weatherford. All rights reserved.

• Allows the use of advanced geometry pumping units.