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1.1 Introduction
Advantages
provides mechanical energy to lift oil efficient, simple and easy to operate pumps a well down to very low pressure applicable to slim holes, multiple completions, and high-temperature and viscous oils easy to change to other wells with minimum cost
Walking Beam
Fulcrum
Pitm an
Counter Balance
Walking Beam
Fulcrum
Pitm an
Counter Balance
Walking Beam
Pitm an
Force
Counter Balance
Fulcrum
Well Load
Figure 1-3: The pumping cycle: (a) plunger moving down, near bottom of stroke; (b) plunger moving up, near bottom of stroke; (c) plunger moving up, near top of stroke; (d) plunger moving down, near top of stroke (From Nind, 1964)
Figure 1-5
A C
P
R
I
Figure 1-6: Definitions of conventional pumping unit API geometry dimensions
API Unit Designation C-912D-365-168 C-912D-305-168 C-640D-365-168 C-640D-305-168 C-456D-305-168 C-912D-427-144 C-912D-365-144 C-640D-365-144 C-640D-305-144 C-456D-305-144 C-640D-256-144 C-456D-256-144 C-320D-256-144 C-456D-365-120 C-640D-305-120 C-456D-305-120 C-320D-256-120 C-456D-256-120 C-456D-213-120 C-320D-213-120
Torque Factor 80.32 80.32 80.32 80.32 80.32 68.82 68.82 68.82 68.45 68.45 68.45 68.45 68.45 58.12 57.02 57.02 57.05 57.05 57.05 57.05
C-228D-213-120 155 C-456D-265-100 129 C-320D-265-100 C-320D-305-100 C-228D-213-100 C-228D-173-100 C-160D-173-100 C-320D-246-86 C-228D-246-86 C-320D-213-86 C-228D-213-86 C-160D-173-86 C-114D-119-86 C-320D-245-74 C-228D-200-74 C-160D-200-74 C-228D-173-74 C-160D-173-74 C-160D-143-74 C-114D-143-74 C-160D-173-64 C-114D-173-64 C-160D-143-64 C-114D-143-64 C-80D-119-64 C-160D-173-54 C-114D-133-54 129 129 129 129 129 111 111 111 111 111 111 96 96 96 96 96 96 96 84 84 84 84 84 72 72
111.07 111.07 111.07 111.07 96.08 96.05 96.05 111.04 111.04 96.05 96.05 96.05 84.05 96.05 96.05 96.05 84.05 84.05 84.05 84.05 84.05 84.05 72.06 72.06 64 72.06 64
132 132 132 132 113 114 114 133 133 114 114 114 93.75 114 114 114 96 96 93.75 93.75 93.75 93.75 84 84 74.5 84 74.5
211 211 211 211 180 180 180 211 211 180 180 180 150.13 180 180 180 152.38 152.38 150.13 150.13 150.13 150.13 132 132 116 132 116
42, 36, 30 42, 36, 30 42, 36, 30 42, 36, 30 37, 32, 27 37, 32, 27 37, 32, 27 42, 36, 30 42, 36, 30 37, 32, 27 37, 32, 27 37, 32, 27 32, 27, 22 37, 32, 27 37, 32, 27 37, 32, 27 32, 27, 22 32, 27, 22 32, 27, 22 32, 27, 22 32, 27, 22 32, 27, 22 27, 22, 17 27, 22, 17 24, 20, 16 27, 22, 17 24, 20, 16
0 550 550 550 0 0 0 800 800 450 450 450 115 800 800 800 450 450 300 300 550 550 360 360 0 500 330
57.05 47.48 47.48 47.48 48.37 48.37 48.37 40.96 40.96 41.61 41.61 41.61 40.98 35.99 35.99 35.99 35.49 35.49 35.49 35.49 31.02 31.02 30.59 30.59 30.85 26.22 26.45
C-80D-133-54 C-80D-119-54 C-P57D-76-54 C-P57D-89-54 C-80D-133-48 C-80D-109-48 C-57D-109-48 C-57D-95-48 C-P57D-109-48 C-P57D-95-48 C-40D-76-48 C-P40D-76-48 C-P57D-89-42 C-P57D-76-42 C-P40D-89-42 C-P40D-76-42 C-57D-89-42 C-57D-76-42 C-40D-89-42 C-40D-76-42 C-40D-89-36 C-P40D-89-36 C-25D-67-36 C-25D-56-36 C-25D-67-30 C-25D-53-30
72 72 64 64 64 64 64 64 57 57 64 61 51 51 53 53 56 56 56 56 48 47 48 48 45 45
64 64 51 51 64 56.05 56.05 56.05 51 51 48.17 47 51 51 47 47 48.17 48.17 48.17 48.17 48.17 47 48.17 48.17 36.22 36.22
64 64 51 51 64 56 56 56 51 51 48 47 51 51 47 47 48 48 48 48 48 47 48 48 36 36
74.5 74.5 64 64 74.5 65.63 65.63 65.63 64 64 57.5 56 64 64 56 56 57.5 57.5 57.5 57.5 57.5 56 57.5 57.5 49.5 49.5
116 116 103 103 116 105 105 105 103 103 98.5 95 103 103 95 95 98.5 98.5 98.5 98.5 98.5 95 98.5 98.5 84.5 84.5
41 41 39 39 41 37 37 37 39 39 37 39 39 39 39 39 37 37 37 37 37 39 37 37 31 31
24, 20, 16 24, 20, 16 21, 16, 11 21, 16, 11 24, 20, 16 21, 16, 11 21, 16, 11 21, 16, 11 21, 16, 11 21, 16, 11 18, 14, 10 18, 14, 10 21, 16, 11 21, 16, 11 18, 14, 10 18, 14, 10 18, 14, 10 18, 14, 10 18, 14, 10 18, 14, 10 18, 14, 10 18, 14, 10 18, 14, 10 18, 14, 10 12, 8 12, 9
330 330 105 105 440 320 320 320 180 180 0 190 280 280 280 280 150 150 150 150 275 375 275 275 150 150
26.45 26.45 25.8 25.8 23.51 23.3 23.3 23.3 22.98 22.98 23.1 22.92 20.56 20.56 19.92 19.92 20.27 20.27 20.27 20.27 17.37 17.66 17.37 17.37 14.53 14.53
API Designation
C 228D 200 74. The first field is the code for type of pumping unit. C = Conventional units A = Air-Balanced units B = Beam Counterbalance units M = Mark II units. The second field is the code for peak torque rating in 1000 in.-lb. D stands for Double Reduction Gear Reducer. The third field is the code for polished rod load rating in 100 lb. The last field is the code for stroke length in inches.
Approximate Motion
Figure 1-7
If x denotes the distance of B below its top position C and is measured from the instant at which the crank arm and pitman arm are in the vertical position with the crank arm vertically upward, the law of cosine gives
( AB )
i.e.,
h = c + (h + c x ) 2c(h + c x ) cos t
2 2 2
so that
When t is zero, x is also zero, which means that the negative root sign must be taken. Therefore,
Acceleration is
a=
d x dt
2
Carrying out the differentiation for acceleration, it is found that the maximum acceleration occurs when t is equal to zero (or an even multiple of radians) and that this maximum value is
a max = c (1 +
2
c h
(1-1)
a min = c (1
2
c h
(1-2)
2N = 60
(rad/sec)
(1-3)
The maximum downward acceleration of point B (which occurs when the crank arm is vertically upward) is
a max
or
cN c = 1 + h 91.2
2
(ft/sec2)
(1-4)
a max
cN g c (ft/sec2) = 1 + 2936.3 h
2
(1-5)
Likewise the minimum upward (amin) acceleration of point B (which occurs when the crank arm is vertically downward) is
a min
cN 2 g c = 1 2936.3 h
(ft/sec2)
(1-6)
It follows that in a conventional pumping unit the maximum upward acceleration of the horses head occurs at the bottom of the stroke (polished rod) and is equal to
a max
d 1 cN 2 g c = 1 + (ft/sec2) d 2 2936.3 h
(1-7)
2cd 2 =S d1
where S is the polished rod stroke length. So if S is measured in inches, then
2cd 2 S = 12 d1
or
cd 2 S = d1 24
(1-8)
a max
SN g c = 1 + (ft/sec2) 70471.2 h
2
(1-9)
a max
SN 2 g = M (ft/sec2) 70471.2
(1-10)
M =1+
Similarly,
c h
(1-11)
a min
SN g = 1 70471.2
2
c (ft/sec2) h
(1-12)
(1-13)
(1-14)
Wr =
s DAr
144
(1-15)
144Wr Ar = sD
(1-16)
(1-17)
The above equation is often further reduced by taking the fluid in the second term (the subtractive term) as an API 50 with Sf = 0.78. Thus, Eq (117) becomes (where s= 490)
PRL max SN 2 M = S f (62.4) 0.1Wr + Wr + Wr 70471.2 144 DAp
or
PRL max
where
SN 2 M = W f + 0.9Wr + Wr 70471.2
W f = S f (62.4 ) DA p 144
(1-18)
and is called the fluid load (not to be confused with the actual fluid weight on the rod string).
(1-19)
F1 =
SN 2 (1 +
c h
70471.2
(1-20)
(1-21)
70471.2
Wr
+ Wr Wr F2
(1-22)
SN F2 = 70471.2
c (1 h )
(1-23)
SN (1 + ) F2 = 70471.2
2 c h
(1-24)
1.4.3 Counterweights
The idea counter-balance load C is the average PRL. Therefore,
C=
1 2
C = 1 W f + 0.9Wr + 2
1 2
(F1 F2 )Wr
(1-25)
(1-26)
(1-27)
r d1 C = C s + Wc c d2
where Cs = structure unbalance, lbs Wc = total weight of counterweights, lbs r = distance between the mass center of counterweights and the crank shaft center, in.
(1-28)
T = 1 S [C (0.9 F2 )Wr ] 2
or
(1-29)
T = 1 S 1Wf + 2 2
or
1 2
(F1 + F2 )Wr ]
(in-lbs) (1-30)
T=
(1-31)
Maximum upstroke torque factor occurred when the crank is in the horizontal position Maximum downstroke torque factor occurred when the crank is in the horizontal position
TF2 =
TF1 (in.) 29 34 39 47 55 66 79
Maximum Permissible Pumping Speed As given earlier the maximum value of the downward acceleration is equal to
a max/ min =
SN g (1
2
c h
70471.2
c h
(1-32)
SN 2 (1
70471.2
(1-33)
or
N limit
70471.2 L = c S (1 m h )
(1-34)
For L = 0.5
N limit =
187.7 S (1 m
c h
(1-35)
The minus sign is for conventional units and the plus sign for air-balanced units.
There are two criteria used in the design of tapered rod strings:
1. Stress at the top rod of each rod size is the same throughout the string 2. Stress in the top rod of the smallest (deepest) set of rods should be the highest (~30,000 psi) and the stress progressively decreases in the top rods of the higher sets of rods.
The following geometry dimensions are for the pumping unit C 320D 213 86: d1 = 96.05 in. d2 = 111 in. c = 37 in. c/h = 0.33
If this unit is used with a 2 1/2 plunger and 7/8 in. rods to lift 25 API gravity crude (formation volume factor 1.2 rb/stb) at depth of 3,000 ft, answer the following questions:
a) What is the maximum allowable pumping speed if L = 0.4 is used? b) What is the expected maximum polished rod load? c) What is the expected peak torque? d) What is the desired counter-balance weight to be placed at the maximum position on the crank?
Solution:
The pumping unit C 320D 213 86 has a peak torque of gearbox rating of 320,000 in-lbs, a polished rod rating of 21,300 lbs, and a maximum polished rod stroke of 86 in. (a)Based on the configuration for conventional unit shown in Figure 1-5(a) and Table 1-1, thepolished rod stroke length can be estimated as:
N=
70471.2 L = c S (1 h )
= 22 SPM
(b) The maximum PRL can be calculated with Eq (12-17). The 25 API gravity has an Sf = 0.9042. The area of the 2 plunger is Ap = 4.91 in.2 The area of the 7/8 rod is Ar = 0.60 in.2 Then
(3,000)(4.91) = (0.9042)(62.4 ) = 5,770 lbs W f = S f (62.4 ) 144 144 DA p
s DAr
Wr
+ Wr + Wr F1
= 16,076 lbs
Wr
+ Wr Wr F2
C=
1 2
lbs
A product catalog of LUFKIN Industries indicates that the structure unbalance is 450 lbs and 4 No. 5ARO Counterweights placed at the maximum position (c in this case) on the crank will produce an effective counter-balance load of 10,160 lbs. That is,
which gives Wc = 11,221 lbs. In order to generate the ideal counter-balance load of C = 9,526 lbs, the counterweights should be place on the crank at
in.
The computer program SuckerRodPumpingLoad.xls can be used for quickly seeking solutions to similar problems. It is available from the publisher with this book. Solution is shown in Table 1-2.
SuckerRodPumpingLoad.xls Description: This spreadsheet calculates the maximum allowable pumping speed, the maximum PRL, the minimum PRL, peak torque, and counterbalance load. Instruction: 1) Update parameter values in the Input section; and 2) view result in the Solution section. Input Data: Pump setting depth (D): 3,000 ft Plunger diameter (dp): 2.5 in. Rod section 1, diameter (dr1): 1 in. length (L1): 0 ft Rod section 2, diameter (dr2): 0.875 in. length (L2): 3,000 ft Rod section 3, diameter (dr3): 0.75 in. length (L3): 0 ft Rod section 4, diameter (dr4): 0.5 in. length (L4): 0 ft Type of pumping unit (1 = conventional; -1 = Mark II or Air-balanced): 1 Beam dimension 1 (d1) 96.05 in. Beam dimension 2 (d2) 111 in.
Crank length (c): Crank to pitman ratio (c/h): Oil gravity (API): Maximum allowable acceleration factor (L): Solution:
S = 2c
N=
d2 d1
85.52 in.
70471.2 L c S (1 h )
2 d p
22 SPM
Ap =
Ar =
4.91 in.2
4
= 0.60 in.
d r2
4
DA p 144
W f = S f (62.4 )
Wr =
5,770 lbs
s DAr
144
6,138 lbs
c SN 2 (1 h ) F1 = 70471.2
0.7940
Wr
+ Wr + Wr F1
16,076
lbs
280,056
lbs
0.40
Wr
+ Wr Wr F2
2,976
lbs
C=
1 2
9,526
lbs
Ap
(bbl/day)
q = 0.1484
A p NS p E v Bo
(stb/day)
l r =
W f Dr Ar E
(1-36)
l t =
W f Dt At E
(1-37)
The magnitude of the rod stretch due to acceleration is called plunger over travel:
Wr Dr l o = n (ft) Ar E
(1-38)
n=
SN (1
2
c h
70471.2
(1-39)
W r D r SN M (ft) l o = Ar E 70471.2
(1-40)
W r = s Ar D r
and S = 490 lb/ft3 with E = 30 x 106 lb/m2 Eq (1-40) becomes
(1-41)
S p = S l r l t + l o
or
1 SN 2 M Wr 12 D 1 Sp = S W f A + A 70471.2 A E r t r
(in)
(1-42)
If pumping is carried out at the maximum permissible speed limited by Eq (1-34), the plunger stroke becomes
12 D 1 1 1+ Sp = S W f A + A 1 E r t
c h c h
LW r Ar
(in)
(1-43)
1+ 1
c h c h
An empirical formula has been developed that can be used to calculate the slippage rate, qs (bbl/day), through the annulus between the plunger and the barrel.
qs =
k p (d b d p )
2.9
(d
+ d p ) p Lp
0.1 b
(1-44)
Ph = 7.36 10 q l LN
6
(1-45)
and
LN = H +
ptf 0.433 l
(1-46)
Pf = 6.3110 Wr SN
(1-47)
Ppm = Fs ( Ph + Pf )
(1-48)
A well is pumped off (fluid level is the pump depth) with a rod pump described in Example Problem 1-1. A 3 tubing string (3.5 OD, 2.995 ID) in the well is not anchored. Calculate (a) expected liquid production rate (use pump volumetric efficiency 0.8), and (b) required prime mover power (use safety factor 1.35).
Solution:
This problem can be quickly solved using the computer program SuckerRodPumpingFlowrate&Power.xls. Solution is shown in Table 1-3.
Table 1-3: Solution given by SuckerRodPumpingFlowrate&Power.xls SuckerRodPumpingFlowRate&Power.xls Description: This spreadsheet calculates expected deliverability and required prime mover power for a given sucker rod pumping system. Instruction: 1) Update parameter values in the Input section; and 2) view result in the Solution section.
Input Data: Pump setting depth (D): Depth to the liquid level in annulus (H): Flowing tubing head pressure (ptf): Tubing outer diameter (dto): Tubing inner diameter (dti): Tubing anchor (1 = yes; 0 = no): Plunger diameter (dp): Rod section 1, diameter (dr1): length (L1): Rod section 2, diameter (dr2): length (L2): Rod section 3, diameter (dr3): length (L3): Rod section 4, diameter (dr4): length (L4): 4,000 ft 4,000 ft 100 ft 3.5 in. 2.995 in. 0 2.5 in. 1 in. 0 ft 0.875 in. 0 ft 0.75 in. 4,000 ft 0.5 in. 0 ft
Type of pumping unit (1 = conventional; -1 = Mark II or Air-balanced): Polished rod stroke length (S) Pumping speed (N) Crank to pitman ratio (c/h): Oil gravity (API): Fluid formation volume factor (Bo): Pump volumetric efficiency (Ev): Safety factor to prime mover power (Fs):
Solution:
At =
d t2
4
2 d p
= 2.58 in.2
Ap =
Ar =
4.91 in.2
4
d r2
4
= 0.44 in.
W f = S f (62.4 )
DA p 144
= 7,693 lbs
Wr =
s DAr
144
c h
= = = = =
lbs
M = 1
12 D 1 1 SN 2 M Wr Sp = S W f A + A 70471.2 A E r t r
in. sbt/day ft
q = 0.1484
A p NS p E v
LN = H +
ptf
Bo
0.433 l
Ph = 7.36 10 6 q l LN
Pf = 6.3110 7 Wr SN
Ppm = Fs ( Ph + Pf )
= = =
hp hp hp
5) Calculate the length of each section of the rod string to the nearest 25 ft. 6) Calculate the acceleration factor. 7) Determine the effective plunger stroke length. 8) Using the estimated volumetric efficiency, determine the probable production rate and check it against the desired production rate. 9) Calculate the dead weight of the rod string. 10) Calculate the fluid load. 11) Determine peak polished rod load and check it against the maximum beam load for the unit selected.
12) Calculate the maximum stress at the top of each rod size and check it against the maximum permissible working stress for the rods to be used. 13) Calculate the ideal counterbalance effect and check it against the counterbalance available for the unit selected. 14) From the manufacturer's literature, determine the position of the counterweight to obtain the ideal counterbalance effect.
15) On the assumption that the unit will be no more than five per cent out of counterbalance, calculate the peak torque on the gear reducer and check it against the API rating of the unit selected. 16) Calculate hydraulic horsepower, friction horsepower, and brake horsepower of the prime mover. Select the prime mover. 17) From the manufacturer's literature obtain the gear reduction ratio and unit sheave size for the unit selected, and the speed of the prime mover. From this determine the engine sheave size to obtain the desired pumping speed.
A well is to be put on a sucker rod pump. The proposed pump setting depth is 3,500 ft. The anticipated production rate is 600 bbl/day oil of 0.8 specific gravity against wellhead pressure 100 psig. It is assumed that working liquid level is low, and a sucker rod string having a working stress of 30,000 psi is to be used. Select surface and subsurface equipment for the installation. Use safety factor of 1.35 for prime mover power.
Solution:
(1) Assuming volumetric efficiency of 0.8, the required pump displacement is (600)/(0.8) = 750 bbl/day. (2) Based on well depth 3,500 ft and pump displacement 750 bbl/day, Figure 1-8 suggests API pump size 320 unit with 84 in. stroke, i.e., a pump is selected with the following designation: C - 320D 213 - 86
(3) Table 1-4 (g) suggests: Tubing size: 3 in. O.D., 2.992 in. I.D. Plunger size: 2 in. Rod size: 7/8 in. Pumping speed: 18 spm (4) Table 1-1 gives d1 = 96.05 in., d2 = 111 in., c = 37 in. and h = 114 in., thus c/h = 0.3246. Spreadsheet program SuckerRodPumpingFlowRate&Power.xls gives qo = 687 bbl/day > 600 bbl/day, OK Ppm = 30.2 hp
(5) Spreadsheet program SuckerRodPumpingLoad.xls gives PRLmax = 16,121 lbs PRLmin = 4,533 lbs T = 247,755 lbs < 320,000 in.-lbs, OK C = 10,327 lbs The cross-sectional area of the 7/8 in. rod is 0.60 in.2 Thus the maximum possible stress in the sucker rod is
(6) If a LUFKIN Industries C - 320D 213 86 unit is chosen, the structure unbalance is 450 lbs and 4 No. 5ARO Counterweights placed at the maximum position (c in this case) on the crank will produce an effective counter-balance load of 12,630 lbs. That is,
= 12,630 lbs
Wc = 14,075 lbs. In order to generate the ideal counterbalance load of C = 10,327 lbs, the counterweights should be place on the crank at
in.
(7) The LUFKIN Industries C - 320D 213 86 unit has a gear ratio of 30.12 and unit sheave sizes of 24 in., 30 in. and 44 in. are available. If a 24 in. unit sheave and a 750 rpm electric motor are chosen, the diameter of the motor sheave is
(18)(30.12)(24) de = (750)
= 17.3 in.
2,500 Curve Pump Displacement (bbl/day) 2,000 A B C D E F G H API Size 40 57 80 114 160 228 320 640 Stroke 34 42 48 54 64 74 84 144
1,500
1,000
500
Figure 1-8: Sucker rod pumping unit selection chart (After Kelley and Willis, 1954)
Table 1-4: Design data for API sucker rod pumping units
(a) Size 40 Unit with 34-inch Stroke Plunger Size Rod Sizes (in) Tubing Size (in) (in) 2 3/4 3 7/8 2 1/2 3 7/8 2 1/4 2 1/2 3/4 2 2 1/2 3/4 1 3/4 2 1/2 3/4 1 1/2 2 5/8-3/4 1 1/4 2 5/8-3/5 1 2 5/8-3/6 (b) Size 57 Unit with 42-inch Stroke Tubing Plunger Size (in) Size (in) Rod Sizes (in) 2 3/4 3 7/8 2 1/2 3 7/8 2 1/4 2 1/2 3/4 2 2 1/2 3/4 1 3/4 2 1/2 3/4 1 1/2 2 5/8-3/4 1 1/4 2 5/8-3/5 1 2 5/8-3/6
Pump Depth (ft) 1000-1100 1100-1250 1250-1650 1650-1900 1900-2150 2150-3000 3000-3700 3700-4000
Pumping Speed (stroke/min) 24-19 24-19 24-19 24-19 24-19 24-19 22-18 21-18
Pump Depth (ft) 1150-1300 1300-1450 1450-1850 1850-2200 2200-2500 2500-3400 3400-4200 4200-5000
Pumping Speed (stroke/min) 24-19 24-19 24-19 24-19 24-19 23-18 22-17 21-17
(c) Size 80 Unit with 48-inch Stroke Pump Depth (ft) 1400-1500 1550-1700 1700-2200 2200-2600 2600-3000 3000-4100 4100-5000 5000-6000 Plunger Size (in) Tubing Size (in) 2 3/4 2 1/2 2 1/4 2 1 3/4 1 1/2 1 1/4 1 3 3 2 1/2 2 1/2 2 1/2 2 2 2 Rod Sizes (in) 7/8 7/8 3/4 3/4 3/4 5/8-3/4 5/8-3/5 5/8-3/6 Pumping Speed (stroke/min) 24-19 24-19 24-19 24-19 23-18 23-19 21-17 19-17
Pump Depth (ft) 1700-1900 1900-2100 2100-2700 2700-3300 3300-3900 3900-5100 5100-6300 6300-7000
(d) Size 114 Unit with 54-inch Stroke Plunger Size (in) Tubing Size (in) Rod Sizes (in) 2 3/4 3 7/8 2 1/2 3 7/8 2 1/4 2 1/2 3/4 2 2 1/2 3/4 1 3/4 2 1/2 3/4 1 1/2 2 5/8-3/4 1 1/4 2 5/8-3/5 1 2 5/8-3/6
Pumping Speed (stroke/min) 24-19 24-19 24-19 23-18 22-17 21-17 19-16 17-16
Pump Depth (ft) 2000-2200 2200-2400 2400-3000 3000-3600 3600-4200 4200-5400 5400-6700 6700-7700
(e) Size 160 Unit with 64-inch Stroke Rod Sizes Plunger Size (in) Tubing Size (in) (in) 2 3/4 3 7/8 2 1/2 3 7/8 2 1/4 2 1/2 3/4-7/8 2 2 1/2 3/4-7/8 1 3/4 2 1/2 3/4-7/8 1 1/2 2 5/8-3/4-7/8 1 1/4 2 5/8-3/4-7/8 1 2 5/8-3/4-7/8
Pumping Speed (stroke/min) 24-19 24-19 24-19 23-18 22-17 21-17 19-15 17-15
(f) Size 228 Unit with 74-inch Stroke Rod Sizes Pump Depth (ft) Plunger Size (in) Tubing Size (in) (in) 2400-2600 2 3/4 3 7/8 2600-3000 2 1/2 3 7/8 3000-3700 2 1/4 2 1/2 3/4-7/8 3700-4500 2 2 1/2 3/4-7/8 4500-5200 1 3/4 2 1/2 3/4-7/8 5200-6800 1 1/2 2 5/8-3/4-7/8 6800-8000 1 1/4 2 5/8-3/4-7/8 8000-8500 1 1/16 2 5/8-3/4-7/8
Pumping Speed (stroke/min) 24-20 23-18 22-17 21-16 19-15 18-14 16-13 14-13
(g) Size 320 Unit with 84-inch Stroke Rod Sizes Pump Depth (ft) Plunger Size (in) Tubing Size (in) (in) 2800-3200 2 3/4 3 7/8 3200-3600 2 1/2 3 7/8 3600-4100 2 1/4 2 1/2 3/4-7/8-1 4100-4800 2 2 1/2 3/4-7/8-1 4800-5600 1 3/4 2 1/2 3/4-7/8-1 5600-6700 1 1/2 2 1/2 3/4-7/8-1 6700-8000 1 1/4 2 1/2 3/4-7/8-1 8000-9500 1 1/16 2 1/2 3/4-7/8-1 (h) Size 640 Unit with 144-inch Stroke Pump Depth (ft) 3200-3500 3500-4000 4000-4700 4700-5700 5700-6600 6600-8000 8000-9600 9600-11000 Plunger Size (in) 2 3/4 2 1/2 2 1/4 2 1 3/4 1 1/2 1 1/4 1 1/16 Tubing Size (in) 3 3 2 1/2 2 1/2 2 1/2 2 1/2 2 1/2 2 1/2
Pumping Speed (stroke/min) 23-18 21-17 21-17 20-16 19-16 18-15 17-13 14-11
Pumping Speed Rod Sizes (in) (stroke/min) 7/8-1 18-14 7/8-1 17-13 3/4-7/8-1 16-13 3/4-7/8-1 15-12 3/4-7/8-1 14-12 3/4-7/8-1 14-11 3/4-7/8-1 13-10 3/4-7/8-1 12-10
Figure 1-10: Pump dynagraph cards: (a) ideal card, (b) gas compression on down stroke, (c) gas expansion on upstroke, (d) fluid pound, (e) vibration due to fluid pound, (f) gas lock (From Nind, 1964)
The surface dynamometer cards record the history of the variations in loading on the polished rod during a cycle. The cards have three principal uses:
a. To obtain information that can be used to determine load, torque and horsepower changes required of the pump equipment. b. To improve pump operating conditions such as pump speed and stroke length. c. To check well conditions after installation of equipment to prevent or diagnose various operating problems (like pounding etc).
Correct interpretation of surface dynamometer card leads to estimate of various parameter values.
Maximum and minimum PRLs can be read directly from the surface card (with the use of instrument calibration). This data then allows for the determination of the torque, counter balance, and horsepower requirements for the surface unit. Rod stretch and contraction is shown on the surface dynamometer card. This phenomena is reflected in the surface unit dynamometer card and is shown in Figure 1-11 (a) for an ideal case.
Figure 1-11: Surface Dynamometer Card: (a) ideal card (stretch and contraction), (b) ideal card (acceleration), (c) 3 typical cards (From Nind, 1964)
Acceleration forces cause the ideal card to rotate clockwise. The PRL is higher at the bottom of the stroke and lower at the top of the stroke. Thus, in Figure 1-11 (b), point A is at the bottom of the stroke. Rod vibration causes a serious complication in the interpretation of the surface card. This is result of the closing of the TV and the pickup of the fluid load by the rod string. This is of course the fluid pounding.
Figure 1-13: Surface to down hole cards derived from surface dynamometer card
Problems
1-1. If the dimensions d1, d2 and c take the same values for both conventional unit (Class I lever system) and airbalanced unit (Class III lever system), how different will their polished rod strokes length be? 1-2. What are the advantages of the Lufkin Mark II and airbalanced units in comparison with conventional units? 1-3. Use your knowledge of kinematics to proof that for Class I lever systems, (a) the polished rod will travel faster in down stroke than in upstroke if the distance between crankshaft and the center of Sampson post is less than dimension d1. (b) the polished rod will travel faster in up stroke than in down stroke if the distance between crankshaft and the center of Sampson post is greater than dimension d1.
1-4. Derive a formula for calculating the effective diameter of a tapered rod string. 1-5. Derive formulae for calculating length fractions of equal-top-rod-stress tapered rod strings for (a) two-size rod strings, (b) three-sized rod strings, and (c) four-sized rod strings. Plot size fractions for each case as a function of plunger area. 1-6. A tapered rod string consists of sections of 5/8 and rods and a 2 plunger. Use the formulae from problem 1-5 to calculate length fraction of each size of rod. 1-7. A tapered rod string consists of sections of , 5/8 and rods and a 1 plunger. Use the formulae from problem 1-5 to calculate length fraction of each size of rod.
1-8. The following geometry dimensions are for the pumping unit C 80D 133 48: d1 = 64 in. d2 = 64 in. c = 24 in. h = 74.5 in. Can this unit be used with a 2 plunger and rods to lift 30 API gravity crude (formation volume factor 1.25 rb/stb) at depth of 2,000 ft? If yes, what is the required counter balance load?
1-9. The following geometry dimensions are for the pumping unit C 320D 256 120: d1 = 111.07 in. d2 = 155 in. c = 42 in. h = 132 in. Can this unit be used with a 2 1/2 plunger and -7/8-1taperd rod string to lift 22 API gravity crude (formation volume factor 1.22 rb/stb) at depth of 3,000 ft? If yes, what is the required counter balance load?
1-10. A well is pumped off with a rod pump described in Problem 12-8. A 2 tubing string (2.875 OD, 2.441 ID) in the well is not anchored. Calculate (a) expected liquid production rate (use pump volumetric efficiency 0.80), and (b) required prime mover power (use safety factor 1.3). 1-11. A well is pumped with a rod pump described in Problem 1-9 to a liquid level of 2,800 ft. A 3 tubing string (3.5 OD, 2.995 ID) in the well is anchored. Calculate (a) expected liquid production rate (use pump volumetric efficiency 0.85), and (b) required prime mover power (use safety factor 1.4).
1-12. A well is to be put on a sucker rod pump. The proposed pump setting depth is 4,500 ft. The anticipated production rate is 500 bbl/day oil of 40 oAPI gravity against wellhead pressure 150 psig. It is assumed that working liquid level is low, and a sucker rod string having a working stress of 30,000 psi is to be used. Select surface and subsurface equipment for the installation. Use safety factor of 1.40 for prime mover power. 1-13. A well is to be put on a sucker rod pump. The proposed pump setting depth is 4,000 ft. The anticipated production rate is 550 bbl/day oil of 35 oAPI gravity against wellhead pressure 120 psig. It is assumed that working liquid level will be about 3,000 ft, and a sucker rod string having a working stress of 30,000 psi is to be used. Select surface and subsurface equipment for the installation. Use safety factor of 1.30 for prime mover power.