Dynamometer Cards

Dynamometer Cards
(Surface and Downhole)

Dynamometer Cards (Surface and Downhole)
Surface Dynamometer Cards
Webster defines a dynamometer as an instrument used to measure force. In
terms of its use in the oil patch, a dynamometer records polished rod load in
relation to polished rod position. The result is a plot of load versus position
commonly called the surface dynamometer card that measure the amount of
work being done by the pumping system. Dynamometer systems allow the
user to record the necessary information to generate a surface card i.e.,
load and position data. This data can then be analyzed by any wave equation
driven diagnostic program. Analysis results include downhole cards, load/stress
calculations, counterbalance information, pump displacement, calculated fluid
levels, estimated electrical costs, etc. Through the years, the polished rod
dynamometer has been the principal tool for analyzing the operation of rod
pumped wells. The shape of the surface dynamometer card is determined by
changing downhole conditions. Ideally, these conditions would be apparent from
the surface dynamometer card by visual interpretation. However, because of
the complex behavior of the rod string and the great diversity of card shapes,
visual diagnosis is not always possible. Though much information can be gained
from visual interpretation of surface cards, success is directly linked to the skill
and experience of the analyst and even the most experienced analysts are
often misled into an incorrect diagnosis. The graphic shown in the next slide
illustrates how surface card shape relates to pump depth/size, SPM, stroke
length, and rod diameter.
eProduction Solutions
Page 1
LOWIS User Course

Beam Optimization
Dynamometer Cards
Polished Rod Load Points vs. Polished Rod Position

Points = Dynamometer Card
The Way It
Used To Be
Page 2
LOWIS User Course

Beam Optimization
Dynamometer Cards
Page 3
LOWIS User Course

Beam Optimization
Dynamometer Cards
Today
Todays Load Input Devices
Position Input Devices
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Raw Position and Load Values for Dynamometer

Card Generation
If these position points

points are plotted against the
load points
points what is the result?
A surface dynamometer card
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
The following several slides are a library of API 11L2

generated surface dynamometer cards and actual cards
gathered in the field.
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Calculated Downhole Pump Card

Bottom Hole Analysis
In the studies of surface dynamometer cards, it is understood that
one of the primary things that affect the shape of the actual
dynamometer card is the load condition at the bottom of the hole.
Therefore, bottomhole conditions such as crooked hole, paraffin,
scale, sand, and solids all affect the loads and the shape of the
card.In an effort to find out exactly what was happening at the
bottom of the hole, W. E. Gilbert and others designed a
bottomhole dynagraph that measured loads and displacements at
the bottom of the hole. His work, and a number of bottomhole
dynagraphs, was published in 1936. In 1967, Sam Gibbs received
a patent on a mathematical method for simulating the sucker rod
pumping system. His work and the work of others made it possible
to use a surface dynamometer card as a basis for a simulated
bottom hole card. In 1986 G. Albert designed an electronic
bottomhole analyzer which measured the bottom hole conditions
electronically in the same manner that W. E. Gilbert had measured
them mechanically. This tool confirmed that the mathematical
simulation from surface dynamometer cards does indeed give
accurate bottomhole loads and displacements.
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LOWIS User Course

Beam Optimization
Dynamometer Cards
The mysterious "black magic" of an experienced

surface card dynamometer analyst was and continues to
be based on a lifetime of observation and experience.
Today, with a thorough understanding of the principles
involved and aided by computer simulation, an accurate
analysis of the problem is possible in nearly every case.
To bridge the gap between interpretation of the
surface card (black magic) and quantitative downhole
data, todays diagnostic programs make use of a
mathematical solution based on a model of the rod
pumping system, known throughout the industry as the
wave equation. The resulting subsurface or downhole
card removes personal judgment and experience from the
diagnosis of downhole conditions.
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Page 21
LOWIS User Course

Beam Optimization
Dynamometer Cards
Rod Pumping Visualization
Load (Lbs)
Load (Lbs)
For Four of the Basic Downhole Pump Card Shapes
Full Pump
Net Pump Stroke (in.)
Gas
Interference
or
Compression
Load (Lbs)
Load (Lbs)
Pump-Off
Tubing
Movement
Click Anywhere to Continue

0.2
Rod
String
Tubing
Fluid
Level
Casing
Downhole Pump card
Top of Stroke
Pump
Hold-Down
Pressure
Above
Plunger
Pump
Barrel
Load (Lbs)
Maximum Fluid Load

Tubing
Anchor
Full Pump
Minimum Fluid Load
Fluid Load
On Plunger
Pump
Plunger
Pressure
Below
Plunger
Pump Stroke (Inches)

Polished rod in
the hole bottom
of stroke
Ball
Traveling Valve
Seat
Ball
Standing Valve
Seat
F1-03
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Tubing
Anchor
Pressure
Above
Plunger
Load (Lbs)
Start of Upstroke
Net Stroke (in.)
Pressure
Below
Plunger
TV Closed (loads increase to maximum)
SV Open Rods Support Fluid Column (load increases)

SV Closed Tubing Supports Fluid Column (load)
F2-04
Upstroke Completed
Pressure
Above
Plunger
Load (Lbs)
Pump moves up the hole

Tubing
Anchor
Net Stroke (in.)
Pressure
Below
Plunger
TV Closed (load @ maximum)
SV Open Rods Support Fluid Column (load)
F3-05
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Tubing
Anchor
Pressure
Above
Plunger
Load (Lbs)
Downstroke Begins
TV Closed
Net Stroke (in.)
TV Will Open (loads decrease)
Pressure
Below
Plunger
SV Open Rods Support Fluid Column

SV Will Close Tubing Supports Fluid Column (load)
F4-06
Tubing
Anchor
Pressure
Above
Plunger
Load (Lbs)
Pump Downstroke Completes
Pump moves down

TV Open
(loads @ minimum)
Net Stroke (in.)
Pressure
Below
Plunger
F5-07
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Pump Stroke Complete
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Full Downhole Pump Card
Net Stroke (in.)

TV Open
TV Will Close
Pressure
Below
Plunger

F6-08

Fluid
Level
Pressure
Above
Plunger
Load (Lbs)
Tubing
Anchor
Downhole Pump Card
Gas
Interference
(high pressure gas)
Net Stroke (in.)
Pressure
Below
Plunger
Traveling Valve
Standing Valve
G1-09
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Start of Upstroke
Fluid
Level
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Net Stroke (in.)
TV Closed
(loads increase to maximum)
Pressure
Below
Plunger
SV Open Rods Support Fluid Column (load increases)

G2-10
Pump Upstroke Completes

Fluid
Level

Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Net Stroke (in.)
Pressure
Below
Plunger
TV Closed
G3-11
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Start of Downstroke
Fluid
Level
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Gas below pump must be compressed

before traveling valve can open
Net Stroke (in.)

TV Closed
Pressure
Below
Plunger

SV Will Close Tubing Supports Fluid Column (load)
G4-12
Downstroke (cont.)
Tubing
Anchor
Pressure
Above
Plunger
Load (Lbs)
Fluid
Level
TV Closed
TV Will Open
(loads decrease)
Gas Compression
Complete
Net Stroke (in.)
Pressure
Below
Plunger

G5-13
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LOWIS User Course

Beam Optimization
Dynamometer Cards

Fluid
Level
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Pump moves down

Net Stroke (in.)
Pressure
Below
Plunger
Traveling Valve Open

(loads @ minimum)
Standing Valve Closed Tubing Supports Fluid
Column (load)
G6-14
Bottom of Pump Stroke
Tubing
Anchor
Pressure
Above
Plunger
Load (Lbs)
Fluid
Level
Gas Interference
Card
Net Stroke (in.)

Pressure
Below
Plunger
Traveling Valve Closed

Standing Valve Closed Tubing Supports
Fluid Column (load)
G7-15
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Rod Pump Visualization

Downhole Pump Card
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Pump-Off
(low pressure gas)
Net Stroke (in.)
Pressure
Below
Plunger
Traveling Valve
Fluid
Level
Standing Valve
O1-16
Start of Upstroke
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Net Stroke (in.)
Traveling Valve Closed (load increases to maximum)
Pressure
Below
Plunger
Fluid
Level
O2-17
Standing Valve Will Open Rods Support Fluid

Column
Standing Valve Closed Tubing Supports Fluid
Column (load)
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Upstroke Continues
Top of Pump Stroke

Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Low
Pressure
Gas

(loads @ maximum)
Net Stroke (in.)
Pressure
Below
Plunger
Standing Valve Open Rods Support Fluid Column

Fluid
Level

O3-18
Start Downstroke
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Low
Pressure
Gas
Traveling valve must contact

liquid before it can open
Net Stroke (in.)

Pressure
Below
Plunger
Fluid
Level

Standing Valve Closed Tubing Supports Fluid Column
O4-19
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Downstroke (cont.)
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Traveling valve
opens late in the
downstroke
Net Stroke (in.)

(loads to minimum)
Pressure
Below
Plunger
Fluid
Level

O5-20
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Net Stroke (in.)
Pressure
Below
Plunger

(loads @ minimum)
Fluid
Level

O6-21
Page 31
LOWIS User Course

Beam Optimization
Dynamometer Cards
Bottom of Pump Stroke
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Pump Off Card

(low pressure gas)
Net Stroke (in.)

Pressure
Below
Plunger

Fluid
Level

O7-22
Rod Pump Visualization
Pressure
Above
Plunger
Downhole Pump Card

Tubing movement reduces effective pump stroke
Load (Lbs)
No
Tubing
Anchor
Fluid
Level
Tubing
Movement
Net Stroke (in.)
Pressure
Below
Plunger
Traveling Valve
Standing Valve
T1-23
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LOWIS User Course

Beam Optimization
Dynamometer Cards
No
Tubing
Anchor
Pressure
Above
Plunger
Load (Lbs)
Start of Upstroke
Lost effective pump stroke
Net Stroke (in.)
Pressure
Below
Plunger

(loads to maximum)
Tubing moves up due to rods now supporting the fluid load
T2-24
Upstroke Continues
Top of Pump Stroke
Pressure
Above
Plunger

Load (Lbs)
No
Tubing
Anchor
Traveling Valve Closed Net Stroke (in.)

(loads @ maximum)
Pressure
Below
Plunger

T3-25
Page 33
LOWIS User Course

Beam Optimization
Dynamometer Cards
No
Tubing
Anchor
Pressure
Above
Plunger
Load (Lbs)
Start Downstroke
Net Stroke (in.)
Pressure
Below
Plunger

T4-26
No
Tubing
Anchor
Pressure
Above
Plunger
Load (Lbs)
Downstroke (cont.)
Traveling Valve Closed Net Stroke (in.)

(loads decrease to minimum)
Pressure
Below
Plunger

Tubing moves down due to rods no longer supporting the fluid load
T5-27
Page 34
LOWIS User Course

Beam Optimization
Dynamometer Cards
No
Tubing
Anchor
Pressure
Above
Plunger
Load (Lbs)
Downstroke Completes
Pump moves down

Net Stroke (in.)
Pressure
Below
Plunger

(loads @ minimum)
T6-28
No
Tubing
Anchor
Pressure
Above
Plunger
Load (Lbs)
Bottom of pump Stroke
Tubing Movement
Card
Net Stroke (in.)
Pressure
Below
Plunger

T7-29
Page 35
LOWIS User Course

Beam Optimization
Dynamometer Cards
The following several slides show example calculated

downhole pump cards and explanations that are the
result of the wave equation diagnostic solution.
The shape of a downhole pump card showing full liquid fillage (with
anchored tubing) is approximately rectangular.
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Detailed Description
1. At point A, the traveling valve closes and the load begins to be
transferred from the tubing to the rods.
2. Between points A and B, tension in the pull rod is increasing as the
rods are picking up the fluid.
3. At point B, the entire fluid load is borne by the rods and the standing
valve opens.
4. Between points B and C, fluid is being lifted toward the surface. At the
same time, the pump chamber below the traveling valve is filling completely
with liquid through the open standing valve.
5. At point C, the top of the stroke has been reached and the downward
tendency of the pump motion causes the standing valve to close.
6. Between points C and D, the fluid load is being transferred back to the
tubing. Because the pump chamber has filled completely with liquid (nearly
incompressible) the pump cannot move downward until the entire fluid load
has been released. This is one of the reasons for the rectangular card shape.
The pump remains stationary (if the tubing is anchored) while the load is
being transferred back to the tubing from the rods.
7. At point D, the traveling valve opens and the pump begins to descend.
8. Between points D and A, the pump descends with the traveling valve
open (standing valve closed) through the fluid that entered the pump
chamber during the upstroke.
9. At point A, the traveling valve is closed by the tendency of the pump to
move upward. This action begins another pumping cycle.
Important Conclusion
When a pump fills completely with liquid (with anchored tubing), traveling and
standing valve actuation occurs at the top and bottom of the stroke with little
movement of the pump. This gives the downhole pump card a characteristic
rectangular appearance.
Page 37
LOWIS User Course

Beam Optimization
Dynamometer Cards
A downhole pump card with unanchored tubing (full liquid fillage) has a
parallelogram shape. The amount of tubing movement (in inches) can be
scaled off from the downhole card to determine the amount of pump
displacement being lost to unanchored tubing.
1. At point A, the traveling valve closes and the load begins to be transferred from
the tubing to the rods.
2. Between points A and B, tension in the pull rod is increasing as the rods are
picking up the fluid. The pump is moving relative to the casing as the fluid load is
being picked up. The pump is stationary relative to the tubing. Since the tubing
is not anchored, the tubing shortens as the load is removed from it. Because the
pump is riding along with the tubing, the pump moves relative to the casing. This
movement can be detected with the use of the wave equation diagnostic
solution. The horizontal distance between points A and B is the amount of
tubing stretch in inches.
3. At point B, the entire fluid load is borne by the rods and the standing valve
opens.
4. Between points B and C, fluid is being lifted toward the surface. At the same
time, the pump chamber below the traveling valve is filling completely with liquid
through the open standing valve.
5. At point C, the top of the stroke has been reached and the downward tendency
of the pump motion causes the standing valve to close.
6. Between points C and D, the pump load is transferred from the rods to the
tubing. As the load shifts to the tubing, the tubing stretches downward relative to
the casing. Thus, pump movement relative to the casing can be detected by the
wave equation diagnostic solution.
7. At point C, the traveling valve opens and the pump begins to descend.
8. Between points D and A, the pump descends with the traveling valve open
(standing valve closed) through the fluid that entered the pump chamber during
the upstroke.
9. At point A, the traveling valve is closed by the tendency of the pump to move
upward. This action begins another pumping cycle.
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LOWIS User Course

Beam Optimization
Dynamometer Cards
Page 39
LOWIS User Course

Beam Optimization
Dynamometer Cards
The shape of a downhole pump card with gas interference shows a

gas compression curve in the upper portion of the downstroke
(points C - D).
1. At point A, the traveling valve closes and the load begins to be transferred
from the tubing to the rods.
2. Between points A and B, tension in the pull rod is increasing as the rods
are picking up the fluid. If the fluid in the lower portion of the pump chamber is
compressible (very gassy), a slight upward movement of the pump may occur
during the load pick-up.
opens.
4. Between points B and C, fluid is being lifted to the surface. At the same
time, the pump chamber below the traveling valve is filling with a mixture of
liquid and high-pressure gas through the open standing valve.
5. At point C, the top of the stroke has been reached and the downward
tendency of the pump causes the standing valve to close.
tubing. Because of the compressible gas that entered the pump during the
charging cycle, the load transfer takes place along a compression curve. The
pump moves downward during load transfer which compresses the gas in the
chamber below the closed traveling valve. As the pressure in the gas below the
traveling valve increases, the load is removed from the rods.
7. At point D, the pressure in the compressed gas in the pump chamber is high
enough to offset the pressure in the tubing at which point the traveling valve
opens. The pump continues to descend.
(standing valve closed) through the fluid that entered the pump chamber
during the upstroke.
Page 40
LOWIS User Course

Beam Optimization
Dynamometer Cards
Fluid pound is a limiting case of gas interference. Pump intake pressure is

low and the incompletely filled (with liquid) pump contains almost
incompressible fluid. The load release thus takes place more abruptly than
the gradual transfer that occurs with gas interference does.
Page 41
LOWIS User Course

Beam Optimization
Dynamometer Cards
1.
2.
3.
4.
5.
6.
7.
8.
9.
At point A, the traveling valve closes and the load begins to be transferred
Between points A and B, tension in the pull rod is increasing as the rods
are picking up the fluid.
At point B, the entire fluid load is borne by the rods and the standing valve
opens.
Between points B and C, fluid is being lifted to the surface. At the same
time, the pump chamber below the traveling valve is filling with a mixture of
liquid and low-pressure gas. Liquid fillage can be much less than the volume
of the pump chamber.
At point C, the top of the stroke has been reached and the downward
tendency of the pump causes the standing valve to close.
Between points C and D, the fluid load is being transferred from the rods
to the tubing. Because the gas is under low pressure, little compression takes
place as the pump descends. Eventually, the plunger encounters nearly
incompressible liquid in the incompletely filled (with liquid) pump chamber. At
this point, the load is rapidly released from the rods and the pump is said to
pound fluid.
The traveling valve opens at point D and the pump continues to descend.
Between points D and A, the pump descends with the traveling valve
At point A, the traveling valve is closed by the tendency of the pump to
Page 42
LOWIS User Course

Beam Optimization
Dynamometer Cards
A worn traveling valve or plunger causes the pump to pick up the fluid load
slowly at the bottom of the stroke and to release it prematurely at the top of
the stroke.
1. At point A, the traveling valve closes and the load begins to be transferred
2. Between points A and B, tension in the pull rod is increasing as the rods
are picking up the fluid. The pump is moving slowly during this part of the
cycle thus its displacement rate is low. The pump slippage rate is a sizeable
portion of the displacement rate. This causes the fluid load pick-up to be
more gradual than usual.
opens.
4. Between points B and C, fluid is being lifted toward the surface. At the
same time, the pump chamber below the traveling valve is filling completely
with liquid through the open standing valve. In addition to this, fluids are
slipping back around the worn traveling valve or plunger into the chamber
below. This subtracts from the volume available for entry of new fluids from
the reservoir.
5. At point C, the pump speed has again slowed down enough so that the
slippage rate exceeds the displacement rate of the pump. This closes the
standing valve. In a worn pump of this type, the load release begins
prematurely near the top of the stroke.
tubing. The load is released with the pump still moving upward because of
slippage. This happens because the slippage rate exceeds the pump
displacement rate in this portion of the stroke.
7. At point D, the traveling valve opens and the pump begins to descend.
8. Between points D and A, the pump descends with the traveling valve
Page 43
LOWIS User Course

Beam Optimization
Dynamometer Cards
A worn standing valve causes the pump to prematurely pick-up load near
the bottom of the stroke. It also causes a delayed release near the top of
the stroke.
Page 44
LOWIS User Course

Beam Optimization
Dynamometer Cards
1. At point A, the traveling valve closes and the load begins to be transferred from the
tubing to the rods. The load transfer begins with the pump still on the downstroke. This
happens because the slippage rate past the standing valve exceeds the displacement
rate of the slowly moving pump as it approaches the bottom of the stroke. This closes
the traveling valve while the pump is still moving downward.
2. Between points A and B, tension in the pull rod is increasing as the rods are picking
up the fluid.
3. At point B, the entire fluid load is borne by the rods and the standing valve opens.
When the standing valve opens, slippage ceases.
4. Between points B and C, fluid is being lifted toward the surface.
5. At point C, the top of the stroke has been reached and the downward tendency of the
pump causes the standing valve to close.
6. Between points C and D, the fluid load is being transferred back to the tubing. The
load can be released with the pump moving down even with complete liquid fillage.
This can happen because slippage past the standing valve exceeds the displacement
rate of the slowly moving pump.
7. At point D, the displacement rate of the pump exceeds the slippage rate of the
standing valve and the traveling valve opens. The pump continues downward.
(standing valve closed) through the fluid that entered the pump chamber during the
upstroke. Slippage past the standing valve is occurring which decreases volumetric
efficiency.
9. At point A, the pump has slowed down enough so that the slippage rate past the
standing valve exceeds the displacement rate of the pump. This closes the traveling
valve and a new pump cycle begins.
Page 45
LOWIS User Course

Beam Optimization
Dynamometer Cards
Pumps can hit up or down or both. This hitting or bumping

condition can occur for any downhole situation gas interference, fluid
pound, unanchored tubing, etc. The case shown above has full liquid
fillage.
If the pump hits down, a load loss (compression) will be

shown at the lower left of the downhole card (at the bottom
of the stroke on the downhole pump card).
If the pump hits up, a load increase (tension) will be
shown at the top of the stroke (upper right on the downhole
pump card).
9 Pumps that are identified as hitting up or down should
be re-spaced to prevent equipment damage.
Page 46
LOWIS User Course

Beam Optimization
Dynamometer Cards
1.
2.
3.
4.
5.
6.
At point A, the plunger is below the bent section and the load
on the pull rod is the same as for a full pump.
At point B, as the plunger reaches the bend, the load on the
pull rod increases because the plunger must squeeze by this
portion of the pump barrel.
At point C, the load reaches a maximum value and then
decreases as the plunger moves away from the bend.
On the downstroke, the load on the pull rod is normal until the
plunger reaches the bad spot in the barrel at point E.
The load on the pull rod decreases until the plunger reaches
point F.
The pull rod load returns to normal after the plunger moves
away from the bent portion of the pump barrel.
Page 47
LOWIS User Course

Beam Optimization
Dynamometer Cards
1. At point A, the plunger is below the bent section and the load on
the pull rod is the same as for a full pump.

2. At point B, as the plunger reaches the bend, the load on the pull
rod increases because the plunger must squeeze by this portion of
the pump barrel.
3. At point C, the load reaches a maximum value and then decreases
as the plunger moves away from the bend.
4. On the downstroke, the load on the pull rod is normal until the
plunger reaches the bad spot in the barrel at point E.
5. The load on the pull rod decreases until the plunger reaches point
F.
6. The pull rod load returns to normal after the plunger moves away
from the bent portion of the pump barrel.
Page 48
LOWIS User Course

Beam Optimization
Dynamometer Cards
1.
2.
3.
4.
5.
6.
From point A to the worn place in the barrel, the load on the pull rod is
normal.
At point C, as the plunger moves through the bad portion of the barrel,
fluid leaks by the plunger and causes the load to decrease on the pull rod.
At point D, a good seal is again established between the plunger and the
pump barrel.
On the downstroke, as long as the traveling valve remains open, the load on
the pull rod appears to be normal.
If, however, the pump barrel is worn, it is possible that a corresponding
load increase will occur at the same place on the downstroke if the worn
spot causes enough pressure loss in the pump barrel for the traveling valve
to start picking up the fluid load.
The pull rod load returns to normal after the plunger moves away from the
worn portion of the pump barrel.
Page 49
LOWIS User Course

Beam Optimization
Dynamometer Cards
The graphic shown above helps to explain the downhole

pump card shape for a full pump experiencing upstroke
fluid inertia effects. This card shape is representative of
wells with large plungers, of shallow depth (usually less
than 4000), and a high water cut.
1.
2.
3.
4.
From points A to B, the inertia of the fluid in the tubing causes the
load on the pull rod to increase as the plunger moves on the upstroke
and accelerates the fluid above it.
At point B, the load on the pull rod reaches a maximum value.
Between points B and C, the pressure pulse travels up the fluid
column and the pull rod drops until the pressure pulse travels up
the tubing and reflects back down. When this reflected wave reaches
the plunger, it increases the pull rod load, but not as much as before.
The pull rod load returns to normal, assuming no further reflected
pulses are seen by the plunger.
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Dynamometer Cards
More Downhole Pump Card Examples
Combinations of the following conditions can occur

simultaneously.
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Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
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Beam Optimization
Dynamometer Cards
Things That Affect Calculated Downhole Pump Cards

Rod String Information:
9
9
9
9
9
9
9
Too short Too long Wrong length per rod Wrong taper length
Wrong weight per foot
Wrong Modulus of Elasticity
Wrong Speed of Sound -
The examples shown in this slide and the next show what can happen to the
calculated downhole pump card when input data is incorrect.
This example shows the downhole pump card shifted up and with a different shape
as a result of an incorrect number of rods in each taper of a three taper rod string.
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Beam Optimization
Dynamometer Cards
The example above shows what happens to the downhole pump card when
the weight per foot of each rod size is entered incorrectly in the database.
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Beam Optimization
Dynamometer Cards
Things That Affect Calculated Downhole Pump Cards

Incorrect Surface Loads
9 Strain gauge
9 Bad calibrated load cell, load cable / connections
Poor Position Data
9 Position switch (TOS / Simulated Data Input)
9 Bad real position device /cable
9 Improper position device installation
Damping Factor values control the amount of work from the surface
dynamometer card that is applied to the calculated downhole pump card.
9
Increasing the Damping Factors results in smaller downhole cards/fluid

loads.
Decreasing the Damping Factors results in larger downhole cards/fluid

loads.
Note: Changing the Damping Factors is one way to help

model conditions such as excessive friction or entrained
gas.
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Beam Optimization
Dynamometer Cards
The example below also demonstrates the effects of increasing the Damping
Factors:
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Dynamometer Cards
Class Exercise Dynamometer Cards

Refer to the exercise handout. Record your observations in the
space provided below each card or card pair.
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Beam Optimization
Dynamometer Cards
Extreme pump off (gut pumped)

Bad pump off set-point?
Restricted pump intake? ...
Pump off, gas compression ...
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Beam Optimization
Dynamometer Cards
Pumping unit rolling ...
Pumping unit rolling ...
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Beam Optimization
Dynamometer Cards
No pump valve action

Tubing leak ?
TV not closing properly

Possible ring valve pump ?
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Beam Optimization
Dynamometer Cards
Load cable short / connection? ...
SV hung open ...
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Beam Optimization
Dynamometer Cards
TV hung open then slams shut ...
Parted rod string

Inoperative pump valves ...
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Beam Optimization
Dynamometer Cards
Worn pump - upstroke leakage (TV or

bbl./plunger fit) ...
SV wear, upstroke tight spot? ...
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Beam Optimization
Dynamometer Cards
Rod part ...
Stuck pump valves - trash, well not

pumping ...
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Beam Optimization
Dynamometer Cards
Load cable - possible radio antenna problem ...
No tubing anchor or not enough TAC

tension ...
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Beam Optimization
Dynamometer Cards
Upstroke pump wear ...
Hole in pump barrel or split pump barrel ...
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Beam Optimization
Dynamometer Cards
Upstroke pump wear ...
Timing problem RPC SPM ...
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Beam Optimization
Dynamometer Cards
Position input problem: Proximity switch /

simulated position, bad inclinometer /
potentiometer, bad real position device ...
Full pump fillage - looks good ...
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Beam Optimization
Dynamometer Cards
Timing RPC SPM too high

Calibration / Data input ...
Pumped off, some gas compression ...
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Beam Optimization
Dynamometer Cards
Sticking SV, load cable problem, load

cell problem ...
Pump valves not working - trash ? ...
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Beam Optimization
Dynamometer Cards
Load cable
Bad position input
Tight spot in pump - sticking on downstroke ...
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Beam Optimization
Dynamometer Cards
Position input - device shaking from

fluid pound or unstable foundation? ...
Bumping bottom - with reflections on

upstroke ...
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Beam Optimization
Dynamometer Cards
RPC problem with stroke closure ?

Unit rolling ?
Likely pumping unit gearbox wear ...
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Dynamometer Cards
Hitting on the upstroke
Comments? Questions?
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Beam Optimization
Pumping Unit Counterbalance

** The most overlooked component of rod pumping systems? **
Why Worry About Pumping Unit Counterbalance?
Practical field-based experience indicates that 75% of all pumping units are improperly
counterbalanced. Incorrect counterbalance has two main drawbacks:
o Reduced gearbox life
o Excessive energy usage
Remember that balancing a pumping unit is primarily aimed at the reduction of loading
on the gearbox and thus will not always reduce energy requirements. In some cases,
energy usage may actually increase slightly. However, in cases where the unit is badly out
of balance, energy usage will usually be reduced. One case study has shown an average
energy use decrease of 7%-9% per unit balanced. Perhaps the most important aspect
of gearbox overloading caused by improper counterbalance is the effect on the life of the
gearbox. A rule of thumb is that the life of a gearbox is reduced as the cube of the
gearbox overload amount.
Example: A 320,000 in-lbs. gearbox has a calculated maximum torque of 456,000 inlbs. (43% overload). Thus, 320000 / 456000 = (.7) cubed = 0.33 = (1/3) of the rated
life of the gearbox (with ideal maintenance).
A 10% overload reduces expected gearbox life by 25%
A 20% overload reduces expected gearbox life by 42%
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What is Counterbalance?
Cranks & Counterweights (Primary / Auxiliary)
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Essentially, counterbalance stores energy on the downstroke and then gives it up

on the upstroke all to reduce the required gearbox torque.
A pumping unit is said to be weight heavy if it has more counterbalance
than is required the weights are too big, are positioned too far out on the
crank arms, or in some cases the crank arms themselves may be too large.
When referred to as rod heavy, a pumping unit does not have enough
counterbalance just the opposite of the weight heavy description.
Remember that these out of balance conditions or a balanced situation will
remain constant only if the well conditions do not change because of fluid level,
pump wear, downhole friction, etc. If the pumping unit is located in a waterflood
or steam injection response area, changing downhole conditions mean more
frequent checks and adjustments best accomplished through the use of RPCs
and central site software programs.
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Torque is the product of a measured force (F) and the radial

distance from the point of the forces application (R) to the object
rotated. (See below.)
What is torque as it
relates to pumping unit
gearboxes?
The unit of torque measurement is pounds of force times inches of

distance resulting in inch-pounds of torque.
When considering a pumping unit gearbox, the gear reducer is subjected

to two simultaneous torques. One is the torque applied by well loads at
the polished rod transmitted through the walking beam and pittman arms.
The other is the torque applied by the counterweights. (See below.)
The net torque is the algebraic

sum of these two torques because
they act in different directions. To
complicate matters, these applied
torques are continually changing.
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The angle of the crank is changing, thus changing the length of the
moment arm of the counterbalance weights. (See below (A) (C).)
The angle of the walking beam at the tail bearing changes continuously
(R1) and the direction that the pittman arms pull on the walking beam
changes (R2), together causing both the lever arm length and the applied
forces to change at the tail bearing. Compare B in the graphics above.
because these forces and lever arms are changing continually, complicated
geometrical relationships are necessary to solve them todays wave
equation based torque analysis software programs handle this situation
easily.
Pumping unit structural unbalance also plays a part

in determining the torque load on the gearbox.
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Net Gearbox Torque (in-lbs) = TF * (W - SUB) M SIN 0

Where
W = Polished Rod Load (lbs.)
SUB = Structural Unbalance (lbs.)
TF = Torque Factor (at current crank position)
M = Maximum Counterbalance (CBT, in-lbs)
0 = Crank Angle (degrees)

Counterbalance can be defined as the measurement of the
torque applied to a pumping unit gearbox by the unit cranks and
counterweights. Basically, the term CBE (counterbalance effect)
refers to the value of this torque as measured in the field in
pounds. CBT (counterbalance torque, sometimes referred to as
counterbalance moment) refers to this value when calculated in
in-lbs of torque.
If a pumping unit gearbox had to supply all the force or torque
necessary to operate the entire pumping system, it would have to
be extremely large. The purpose of counterbalance (cranks and
weights) is to help reduce the amount of work or torque that the
gearbox has to provide to operate the system. Counterbalance
helps the gearbox to handle the polished rod load on the upstroke
and on the downstroke the gearbox moves the counterbalance
using the rod load to help.
The Next Slide Illustrates Crank and Counterweight

Counterbalance Effects
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A pumping unit is said to be balanced when gearbox torque on the

upstroke and on the downstroke is equal because the proper amount of
counterbalance (cranks and counterweights) has been applied to the
system.
Improperly balanced pumping units can and often do result in
overloading the gearbox or prime mover leading to excessive energy
usage or expensive failures.
To determine if a pumping unit installation is balanced, use a
diagnostic program that is capable of doing a torque analysis of the unit
gearbox.
A less desirable method is to record the amps being using by the
pumping unit on the upstroke and downstroke. Because amps are also a
direct measurement of the torque requirements on the gearbox, unit
balance or unbalance can be easily seen from such a measurement of
amps for conventional pumping units.
Peak amp measurements are very difficult to accurately determine
from improved geometry units (multiple peak amp readings in a single
stroke).
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Using data taken from an API torque analysis calculation has major
advantages, especially if the information is generated by a good
computer analysis software program:
Counterbalance effect is easily calculated using data stored in the
analysis software database - no potentially dangerous field
measurements are necessary.
Counterweight placement based on calculated optimum
counterbalance requirements eliminates "trial and error" positioning of
weights when using amps as a guide. Weights are simply positioned
according to analysis software calculations, greatly reducing time and
cost considerations.
The risk of injury is reduced because the counterweights are
handled only one time.
Using Measured Motor Amps vs. API Torque Analysis

Balancing beam pumped wells has traditionally been done using an
amp meter or amp clamp, which requires a "trail and error" approach.
This method is based on the fact that the current drawn by the electric
motor is directly proportional to the work being done by the motor.
The well is assumed to be balanced when the peak amps drawn on the
upstroke, by the electric prime mover, is equal to the peak amps
drawn on the downstroke. This method has several disadvantages:
It can be very time consuming (Remember, time is money) - weights may
have to be adjusted several times and/or weights may have to be added or
removed.
It likely will be inaccurate - the nature of using amp measurements to balance
a pumping unit requires that the well be shut down for an extended period of
time (likely more than once). This means a fluid level rise will occur in the
casing, thus changing conditions from normal and likely causing incorrect amp
readings. Also, improved geometry units are very difficult to balance because of
multiple amp peaks during a single stroke.
It is dangerous - weights are heavy and not easy to handle, increasing the
possibility of injury - especially if weights have to be removed or added to the
pumping unit cranks.
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When Does It Become Necessary to Balance a Pumping Unit?

One rule of thumb suggests a 10% difference between the
calculated upstroke and downstroke peak gearbox torque. This
percentage should be refined based on torque reduction and
decreased energy use for a particular operating area.
Whenever necessary to reduce unacceptable torque levels on the
gearbox.
Counterbalance Measurement:
The most accurate method to measure counterbalance in the field is to
use a calibrated load cell to record the polished rod load (lbs.) when a
conventional pumping unit is stopped as close to 90 or 270 degrees
(wellhead at the observers right) as possible with the brake off. For a
Mark II unit, stop the unit at the six oclock position.
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In most cases, however, a pumping unit will not stop in these positions
and remain motionless (without using the brake) because of unit
unbalance or other well conditions. In these situations, a chain must be
used to tie off the polished rod to the wellhead and the unit
counterbalance propped up or tied off, as appropriate, before a
measurement of counterbalance can be recorded.
Note: This method can be dangerous and should be undertaken only if
absolutely required and only under the most rigorous of safe practices.
Field calculation of counterbalance is much safer, relatively simple to
accomplish and provides acceptable accuracy - if the user is properly
trained, and if the needed crank and weight information or counterbalance
charts have been requested from the pumping unit manufacturer. There
are three common scenarios that are usually encountered when
determining counterbalance in the field.
Method One - Formula or calculation based counterbalance

measurement:
CBT (inlbs) = CBTC (inlbs) (cranks) + CBTW (inlbs) (weights)
CBTC (cranks) value is available from manufacturer information based on the
individual crank identifier as observed from the cranks on each pumping unit. If this
value is not provided in inlbs., but in lbs., use this formula to convert to inlbs:
W (lbs.) x C.G = CBTC (inlbs.), where W is the weight of both cranks in pounds
and C.G is the distance to the center of gravity of the cranks (in inches). The
pumping unit manufacturer provides the W and C.G values.
CBTW (weights) = (M - X) (NW + nZ) where
M = Maximum distance from the center of the gearbox crankshaft to the center
of gravity of the weight (inches)
X = Distance the weights are located from the long end of the cranks (inches)
N = Number of master weights
W = Weight of each master weight (pounds)
n = Number of auxiliary weights
Z = Weight of each auxiliary weight (pounds)
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1. At each pumping unit, note the ID of each master and each auxiliary
weight (if installed) and physically measure the distance from the end of
the crank to the leading edge of each master weight (X).
2. Then, based on the ID of each weight refer to the proper
manufacturers data for the M distance and for the weight in pounds of
each master (W) or auxiliary weight (Z).
3. Use the formula to calculate the CBT value of the counterweights. Add
the CBTC (cranks) value to the CBTW (weights) value.
This is the CBT value to be entered into whatever rod pumping analysis
program is being used.
Important: If more than one size of counterweight is used on a pumping
unit, repeat the entire calculation for each different size counterweight.
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Beam Optimization
Counterbalance Class Exercise 1

A Lufkin conventional pumping unit has 5456B cranks.
Installed on the cranks are four # 5ARO master weights and
two # 5A auxiliary weights, all measured at 6 (average
distance) from the end of the cranks. From the Lufkin pumping
unit catalog: CBTC = 70,303 inlbs., M = 40.1, W = 913
lbs., and Z = 366 lbs. Calculate the CBT for this unit.
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Beam Optimization

A Lufkin conventional pumping unit has 5456B cranks. Located
on the cranks are four # 5ARO master weights and two # 5A
auxiliary weights, all measured at 6 from the end of the cranks.
From the Lufkin catalog: CBTC = 70,303 inlbs., M = 40.1,
W = 913 lbs., and Z = 366 lbs. Calculate the CBT for this
unit.
CBT (inlbs) = CBTC (inlbs) (cranks) + CBTW (inlbs) (weights)
CBTW
CBTW
CBTW
CBTW
CBTW
(weights) = (M - X) (NW + nZ)

= (40.1-6) * {4(913) + 2(366)}
= (34.1) * {(3652) + (732)}
= (34.1) * (4384)
= 149,494 inlbs.
CBT = 70,303 + 149,494

CBT = 219,797 inlbs.

Using the same information available from exercise 1, calculate
where to position the counterweights calculate (X) if the optimal
CBT is 260,000 inlbs.
Was there a problem with the result?
X = M {(OCBT-CBTC) / (NW + nZ)}
X = 40.1 {(260,000-70,303) / (4*913 + 2*366)}
X = 40.1 {(189,697) / (3652 + 732)} = 40.1 - {189,687 / 4384}
X = 40.1 43.3
X = - 3.2
Yes the negative calculation of X indicates that additional
counterbalance needs to be added to this pumping unit in order to
achieve the goal of 260,000 inlbs. of counterbalance. What is the
solution?
Re-calculate X by adding an third auxiliary weight -X
X
X
X
=
=
=
=
M {(OCBT-CBTC) / (NW + nZ)}

40.1 {(260,000-70,303) / (4*913 + 3*366)}
40.1 {(189,697) / 3652 + 1098
40.1 39.9 = 0.2
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Method Two Manufacturers Chart-based Counterbalance

Determination
Some pumping unit manufacturers provide counterbalance tables to enable the
user to determine CBT (inlbs.) or CBE (pounds), rather than calculating CBT as
explained and exercised in method one.
Crank and weight information still must be physically gathered from each
pumping unit. Under this scenario, the cranks will have some type of position
scale marked off on each crank.
o The counterweights will have a pointer or arrow that points to their position
on the crank. Record the ID of the cranks and of each weight and weight
position as indicated by the pointer.
o Determine the average value of the position of all installed counterweights.
o Then, use the appropriate manufacturers chart to retrieve the CBT values for
the cranks and counterweights.
This is the value to be entered into an available analysis program. If the
manufacturer provides only CBE (pound) charts, determine this value in the same way
as described above. Analysis programs may require the conversion of CBE to CBT
before calculating gearbox torque.
3.5 + 3.5 + 9.5

+ 9.5 = 26 / 4 =
6.5
Average Position
Once the average position of all installed counterweights is

calculated, charts similar to those shown in the following slides
can be used to determine the correct CBT (Maximum
Moment) or CBE (Effective Counterbalance) value.
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CBT (in.lbs.)
Counterbalance
Chart
CBE (lbs.)
Counterbalance
Chart
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An American pumping unit with KA-117-53 cranks has two RJ
master weights at position 2 and two RJs at position 10. From the
table provided on the next slide, calculate the existing CBT. (Note:
The column labeled Position of Counterweights refers to the average
position of all counterweights on the cranks.)
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An American pumping unit with KA-117-53 cranks has two RJ master
weights at position 2 and two RJs at position 10. From the table
provided on the next slide, determine the existing CBT. (Note: The table
column labeled Position of Counterweights refers to the average position
of all counterweights on the cranks.)
2 + 2 + 10 + 10 = 24 / 4 = 6.0 average position
From the counterbalance table: CBT is 1,145,480 inlbs.
Note that the CBT and CBE values shown in

manufacturers counterbalance sheets apply only to situations
where there are four installed counterweights. If there are one
two or three counterweights, these values will require
adjustment based on the number of counterweights actually
installed on the pumping unit.

Normally, Position of Counterweights will very seldom be calculated as an
even number. What changes would be required in the calculations if
average position were calculated to be a decimal? (Ex: Not 6.0, but
6.4)
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From the Counterbalance Chart:
Position 6.0 = 1,145,480 & Position 7.0 = 1,189,400
1,189,400 1,145,480 = 43,920 / 10 = 4,392 per decimal fraction.
Thus, an average Position 6.4 = 1,145,480 + (4 * 4,392)
6.4 = 1,145,480 + 17,568 = 1,163,048 inlbs.
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Using Counterbalance CBE Charts For Beam Balanced Pumping

Units
Visit the wellsite and note the number and type of beam weights attached to
the walking beam.
Using the correct manufacturers API data sheets, refer to the effective
counterbalance portion of this information to determine the CBE value in pounds
based on the number of beam weights installed.
Method Three Host Software-based CBT Determination
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Converting CBE (pounds) to CBT (inlbs.)

Sources of CBE values:
From a recent wellsite dynamometer survey measurement
From the pumping unit manufacturers counterbalance sheets
From CBE values determined by using wellsite RPC functionality
Use this formula to manually convert CBE to CBT then

enter the CBT value directly into an analysis program:
CBT = (CBE SU) x TF, where CBT = Counterbalance torque in inlbs.
CBE = Counterbalance effect at the polished rod in lbs.
SU = Structural unbalance in lbs. - defined as the force required at the
polished rod to hold the unit walking beam in a horizontal position with the
pitman arms disconnected from the crank arms. This force is positive when
acting up on the polished rod or negative when exerting a downward pull. This
value is included in the manufacturers API dimensional data sheets.
TF = Torque factor (ins.) can be defined as the number that, when multiplied
by the load at the polished rod, results in the gearbox torque from that polished
rod load. The pumping unit manufacturers can supply torque factor tables for
each size unit. In addition, the number can be calculated from the units
geometric dimensions, but the calculations are complex and best done by a
computer application.
Note: Use the torque factor at 90 degrees for clockwise unit rotation or the
torque factor at 270 degrees for counter-clockwise unit rotation.
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Given: CBE = 17,000 lbs.
TF = 68.450
SU = 480 lbs.
Calculate: CBT in inlbs.

CBT
CBT
CBT
CBT
=
=
=
=
(CBE SU) x TF
(17,000 480) * 68.450
16,520 * 68.450
1,130,794 inlbs.
This would be the value to be entered into a rod pumping

analysis software program.
Field Determination of Rotaflex Counterbalance

Total CBE = Standard Minimum CBE + Auxiliary CBE
Standard Rotaflex CBE:
800DX and 900 Series = 9400 lbs.
1100 Series = 9800 lbs.
Auxiliary Rotaflex CBE:
The auxiliary counterweights are supplied in properly
dimensioned metal blocks of varying thickness.
o To calculate the weight (lbs.) of the installed auxiliary
counterweights, measure each stack of auxiliary
counterweights (four). Measure the height, width, and depth of
each stack. (See pictures on the next slide.)
Use this formula to calculate the CBE value for each
counterweight stack: (H x W x D X 0.2833).
Add these four values together plus the standard CBE value
for the installed Rotaflex unit size to obtain total installed CBE
(lbs.).
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Converting CBE to CBT in Host Analysis Software
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Manual Calculations for Balancing a Pumping Unit Using

Optimum Counterbalance Torque Calculations or a
Counterbalance Chart
The best and most accurate method of properly balancing a pumping
unit is accomplished with a diagnostic torque analysis evaluation from a
wave equation driven analysis program. Torque analysis programs
calculate the degree of unbalance and the increased gearbox load caused
by any unit unbalance. Also calculated is the optimum counterbalance
torque needed to balance the pumping unit, the correct weights
needed, and the proper position of the counterweights.
Once optimum counterbalance torque value is available, the position
of the weights (X) to achieve the optimum counterbalance torque can
be manually calculated and thus balance the pumping unit.
X = M {(OCBT-CBTC) / (NW + nZ)} }, where X is defined as the overall average

distance the weights are from the end of the cranks when all weights are the same size
(Refer to the previous explanation of terms other than OCBT is optimum CBT)
To solve for X when one or more of the counterweights are a different size:
Q = Required counterbalance torque
To move one weight:
X = (CBTC Q) + {M1*(W1+Z1)} + {M1*(W1+Z1)} + {M1*(W1+Z1)} ) + {M1*(W1+Z1)} (W1 + Z1)
To move two weights:
X = (CBTC Q) + {M1*(W1+Z1)} + {M1*(W1+Z1)} + {M1*(W1+Z1)} ) + {M1*(W1+Z1)}
(W1 + Z1) + (W2 +Z2)
To move three weights:
(W1 + Z1) + (W2 +Z2) + (W3 + X3)
To move four weights:
(W1 + Z1) + (W2 +Z2) + (W3 + X3) + (W4 + Z4)
If X is calculated to be a negative value, add more counterweight. If X is calculated to be

more the value of M, reduce the amount of counterweight.
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Important:
Always move lead and lag weights to the same
distance from the end of the crank arms to prevent
changing the phase angle of the cranks which could
affect gearbox torque calculation and correct
counterbalance determination.
In addition, it will be necessary to use the manufacturers counterbalance

charts when the X position cannot be calculated as indicated previously
by using a formula solution.
For example:
An American pumping unit has KA-117-53 cranks with three RJ
counterweights located at position 5 on the cranks. It has been
determined that in order to balance the pumping unit - 1,100,000 in-lbs.
of counterbalance is needed.
Where must the three counterweights be re-positioned to achieve this
amount of counterbalance and thus balance the pumping unit?
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From the chart above, note that the two KA-117-53 cranks and four RJ
counterweights at position 5 have a value of 1,101,560 in-lbs. The value of the
cranks alone is 551,200 in-lbs. To calculate the value of a single counterweight,
subtract the value of the cranks from the total value and divide by four:
(1,101,560 551,200) / 4 = 137,590 in-lbs. per counterweight. This means that
the maximum value of the cranks and three counterweights at position 5 is:
551,200 + 3(137,590) = 963,970 in-lbs. By subtracting this number from the
calculated optimum value, it can be determined how much addition
counterbalance is needed: 1,100,000 963,970 = 136,030 in-lbs.
Note that the counterbalance value difference between each position

(1 to 2, 2 to 3, 3 to 4, etc.) is 43,920 in-lbs. To find the
counterbalance value for a single counterweight, divide this number by
four: 43,920 / 4 = 10,980 in-lbs.
Knowing that an additional 136,030 in-lbs. of CBT is needed to
balance the unit, calculate how much position to add the current
counterweight position of 5 for the three RJ counterweights: X =
136,030 / (3 X 10,890) = 4.1. Therefore, 5 + 4.1 = 9.1 is the
final calculated counterweight position for the three RJ
counterweights.
Page 29
LOWIS User Course

Beam Optimization
API Torque Analysis Counterbalance Adjustment Benefits

Studies have shown:
Peak gearbox torque is reduced an average of 17% per well

Power cost is reduced an average of 8% per year
COUNTERBALANCE IS IMPORTANT !!!
Page 30
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Beam Optimization

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Polished Rod Load Points vs. Polished Rod Position

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Position Input Devices

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Raw Position and Load Values for Dynamometer

If these position points

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The following several slides are a library of API 11L2

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Calculated Downhole Pump Card

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The mysterious "black magic" of an experienced

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Rod Pumping Visualization

For Four of the Basic Downhole Pump Card Shapes

Net Pump Stroke (in.)

Net Pump Stroke (in.)

Net Pump Stroke (in.)

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Rod Pumping Visualization

Downhole Pump card

Maximum Fluid Load

Pump Stroke (Inches)

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Net Stroke (in.)

TV Closed (loads increase to maximum)

SV Open Rods Support Fluid Column (load increases)

Pump moves up the hole

Net Stroke (in.)

TV Closed (load @ maximum)

SV Open Rods Support Fluid Column (load)

Click Anywhere to Continue

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SV Open Rods Support Fluid Column

Pump Downstroke Completes

Pump moves down

Net Stroke (in.)

SV Closed Tubing Supports Fluid Column (load)

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Pump Stroke Complete

Full Downhole Pump Card

Net Stroke (in.)

SV Closed Tubing Supports Fluid Column (load)

Rod Pumping Visualization

Downhole Pump Card