Ep Rod Pumping Basic Training PDF

eProduction Solutions Rod Pumping Solution Basic Training
Theory Of Rod Pumping Overview
Sucker Rod Pumping

Sucker rod pumping is one of the most commonly used methods of artificial lift in the world. It accounts for
approximately eighty percent of all artificially lifted wells in the United States. The advantage of sucker rod
pumping is its simplicity and visibility. By “visibility”, it is meant that the operator can look across the
horizon and see whether the pumping unit is going “up and down”. The operator can more readily visualize
what is happening than is possible with any other of the artificial lift systems. Perhaps the greatest
advantage of rod pumping is that it can reduce bottom hole pressures to a near “zero” condition, assuming
that there are not over-riding difficulties. Rod pumping is readily adaptable to one well or widely separated
wells, as each well installation is an entity unto itself. It is a relatively safe system in that no high-pressure
liquid or gas is required for operation. Sucker rod pumping, where it does not suffer from some of its
disadvantages, will almost always be the cheapest system that can be used to produce fluid from a well.
One disadvantage of sucker rod pumping is that the production rate that can be pumped is reduced quite
rapidly with increasing depth. Eventually, a depth is reached where no production can be obtained. The
vertical limits of the rod string are determined by simply raising and lowering the rod string itself. Rod
pumping is also quite susceptible to gas interference - and servicing the system requires a pulling unit to be
on the well location.
Rod Pumping Advantages / Disadvantages
Advantages of Rod Pumping:
• Easy to operate and service.

• Production rate can be changed easily by simply changing SPM or stroke length.
• Pump intake pressure can be reduced to near zero to obtain maximum production.
• It is often the most efficient artificial lift method.
• If electricity is not available, a gas engine can be used as the prime mover.
• Rod pumped controllers (RPCs) can be used to minimize fluid pound, electrical cost, and rod/tubing
failures.
• Beam pumped wells can be monitored remotely with central site software such as that provided by
Case Services’ csLIFT suite of products.
• Computer dynamometer analysis can be used to optimize all wells.
• Wells can be monitored and controlled remotely if RPCs are used.
Disadvantages of Rod Pumping:
• Rod pumped wells can be a problem if the cased hole is crooked.

• Rod pumping generally cannot be used offshore because of limited space for large surface equipment
and pump displacement limitations.
Louis Ray – Product Line Manager / Trainer / Consultant
22001 North Park Drive, Houston, TX 77339
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E-Mail: louis.ray@ep-solutions.com Website: www.ep-solutions.com
• Rod pumps cannot handle large volumes of sand.
• Gas compression (handling free gas) affects pump efficiency.
• Rod pumping is obtrusive in heavily populated areas.
• Depth affects displacement to a greater degree than with other artificial lift methods. (See the graphic
below)
Rod Pumping Range (Production vs. Depth)

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Typical Rod Pumping System

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Pumping Unit Types
Conventional Pumping Units
Advantages of Conventional Pumping Units:
• Lower maintenance costs (spare parts are easily available).

• Purchase cost is less than other unit types.
• Usually better to use with fiberglass rods than pumping units that use the “improved geometry”
configuration.
• Can be run either in a clockwise or counterclockwise direction.
• Can pump at a higher SPM than “improved geometry” units without operational problems.
• Requires less counterbalance than “improved geometry” units.
Disadvantages of Conventional Pumping Units:
• In some applications, conventional units may not be as efficient as “improved geometry” pumping units.
• Conventional units may require a larger gearbox than other pumping unit types (especially when steel
rods are used).

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Improved Geometry Pumping Units
Advantages of “Improved Geometry” Pumping Units:
• Gearbox torque is lower in most cases (with steel rods) as compared to conventional units under the
same or similar pumping conditions.
• May cost less (5% to 10%) as compared to next size conventional unit (more efficient than conventional
units in some cases).
Disadvantages of “Improved Geometry” Pumping Units:
• In many applications, an “improved geometry” unit cannot pump as “fast” as a conventional unit
because of its downstroke velocity - which is approximately 20% faster than the upstroke velocity (can
cause “rod fall” problems).
• Can be operated only in only one direction, either “clockwise” or “counterclockwise” depending on the
manufacturer of the unit.
• Because of increased downstroke velocity, more damage to the rod string and pump components in
case of “fluid pound” is likely.
• Can put the bottom rods of the rod string in severe “compression”, causing “buckling” failures.
• Can have higher gearbox torque as compared to conventional units when using fiberglass rods. Also,
“improved geometry” units unit may put fiberglass rods into “compression”.

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Air Balanced Pumping Unit
Advantages of an Air Balanced Pumping Unit:
• The unit is more compact and easier to “balance” than other pumping unit types.
• Shipping costs are lower than other units because of less total weight.
• Is manufactured with larger available gearbox sizes than any other pumping unit type.
• Can rotate either in a clockwise or counterclockwise direction.
Disadvantages of an Air-Balanced Pumping Unit:
• An air balanced unit is more complicated and thus requires more maintenance (air compressor, air
cylinder).
• Water condensation in the air cylinder can cause problems.
• Gearbox may be damaged if the air cylinder loses pressure.

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Important Pumping Unit Terms
Structural Unbalance (see the graphic on the next page) is the force needed at the polished rod to hold
the beam in a horizontal position with the pitman arms disconnected from the crank pins. This force is
"positive" when acting “down” and “negative” when acting "up". Structural unbalance is always negative for
Mark II units and can be either positive or negative for conventional units. The structural unbalance value is
available from the manufacturer.
Crank Off-set Angle (see the graphic on the next page) is the angle between the crank pin bearing and
the counterweight arm. This angle is positive for Mark II pumping units and negative for Baker Torqmaster
pumping units -- while conventional pumping units have an offset angle of “zero”. The purpose of this
angle is to help reduce gearbox torque by improving the timing between the polished rod load and the
counterweight moment.

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Sucker Rod Pumps
Sucker Rod Pump Valve Operation

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Tubing Pumps
Tubing Pump
Tubing Pump Advantages
• Greater capacity than standard rod

pumps.
• Simple, rugged pump for severe
service.
• Tubing protects casing against wear
and corrosion.
• Large fluid flow areas.
• Adaptable for producing viscous fluid.
Tubing Pump Disadvantages
• Tubing must be pulled to repair the

pump barrel.
• Added tubing means additional
installation cost.
• Gas compression ratio is less than with
an insert pump.
• In unconsolidated sands, larger
production rates may mean pump has
to handle more sand.

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Insert Pumps
Rod Pump - Stationary

Barrel, Bottom Holddown
Advantages
• Can be used in deep wells.

• Less likely to have ruptures
caused by pressure than other
standard pump types.
• Good valve location.
• Preferred valve sizing.
• Good fluid flow design.
• Varied material selection.
• Better design where longer
pumps are necessary.
Disadvantages
• Valve rod is the weak link in

the sucker rod chain.
• Barrel tube is subjected to
sedimentation and corrosion.
• Part-time pumping may allow
sedimentation to take place in
and around working parts.
• Poor plunger leakage path.
• Requires more parts at a
generally higher cost than a
traveling barrel type.

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Rod Pump - Stationary
Barrel, Top Holddown
Advantages
• Good pump for sandy wells.

• Pump barrel can act as a gas
anchor.
• Excellent for low fluid level
wells, as the standing valve can
be submerged.
• Excellent fluid flow design.
• Preferred valve sizing.
• Good design where longer
pumps are necessary.
Disadvantages
• Valve rod is the weak link in the

chain of sucker rods.
• Not recommended for deep
wells because of bursting and
tensile loading on the barrel.
• Poor plunger leakage path.
• Part time pumping may allow
sedimentation to take place in
and around working parts.

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Rod Pump - Traveling
Barrel
Advantages
• Agitation keeps sand from

settling.
• Good plunger leakage path.
• Built in check valve.
• Both cages are the open
types.
• Rugged construction.
• Stronger pull tube instead
of the valve rod of
stationary barrel tubes.
• Usually costs less than
stationary barrel pumps.
Disadvantages
• Not recommended for

gassy wells.
• Not recommended for
longer pumps in deep wells.
• Poor valve placement.
• Poor fluid flow design.
Invites gas breakout.
• Poor valve sizing.

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25 –150 – R H T M 30 – 5 - 4
Tubing Size:
15 = 1.900 in. OD
Total Length of Extensions:
20 = 2 3/8 in. OD Whole Feet
25 = 2 7/8 in. OD
30 = 3 1/2 in. OD Nominal Plunger Length in Feet
Pump Bore (Basic): Barrel Length in Feet

125 = 1 1/4 in.
150 = 1 1/ 2 in
Seating Assembly Type:
175 = 1 3/4 in
C = Cup
178 = 1 25/32 in
A = Mechanical
200 = 2.000 in.
250 = 2 1/2 in.
275 = 2 3/4 in Location of Seating Assembly
A = Top
Pump Type: B = Bottom
R = Rod T = Bottom, Traveling Barrel
T = Tubing
Barrel Type for Metal Plunger H = Heavy Wall

Pump T = Thin Wall
Barrel Type for Soft-Packed S = Thin Wall Plunger
Pump P = Thin Wall
API Pump Designation Description

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Sucker Rods
Sucker Rod Nomenclature
Steel Sucker Rod Sizes:

Diameters:
1 1/8”, 1.0”, 7/8”, ¾”, 5/8”
Rod Length: 25' or 30’
Fiberglass Rod Sizes:

Diameters:
1 ½”, 1 ¼”, 1.2”, 1 1/8”

1”, 7/8”, ¾”
ROD LENGTH: 37.5'

(25' & 30' LENGTHS ALSO AVAILABLE)

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Fiberglass Rods
Advantages of Fiberglass Rods

• Because of their lighter weight, fiberglass rods reduce polished rod load (energy required) and gearbox
torque. Therefore, smaller pumping units can be used than when steel rod strings are installed.
• Because of their stretch characteristics, properly designed fiberglass rod strings can have a downhole
pump stroke substantially longer than the surface or polished rod stroke length.
• Fiberglass rods usually last longer than steel rods in corrosive environments.
Disadvantages of Fiberglass Rods

• Fiberglass rods are more expensive than steel rods and do not last as long as steel rods.
• Because of their stretch characteristics, an increased fluid load may cause the downhole pump stroke
to be smaller than the surface stroke - if the rod string is improperly designed.
• Because of their stretch characteristics, it is difficult to properly “space” the pump. The pump may start
hitting bottom when the fluid level is lowered - causing premature rod failure. Fiberglass rods cannot be
allowed to tag bottom or pound fluid.
• The surface of fiberglass rods is easily damaged when compared to the surface of steel rods.
Fiberglass rods cannot be twisted.
• Because fiberglass rods are made from individual glass fibers held together with epoxy, they cannot
support compressive loading . They must be carefully designed and monitored to ensure that they are
always in tension.
• In the past, fiberglass rods were temperature limited to about 240o F. Recent advances in materials and
manufacturing techniques have raised this limit to 300o F.
• Fiberglass rods are difficult to “fish” when they part.
• Fiberglass rods are not recommended for wells deeper than 4000' or for deviated wells.
• Handling fiberglass rods requires more education and supervision of operating personnel.
Fluid Pound
Pounding fluid can shorten the life of the rod string, as well as the pumping unit. When pounding fluid, the
rods and the fluid in the top portion of the downstroke act as a “free falling body” at the position of the
plunger. If the point of “fluid pound” is in the upper portion of the pump stroke, the plunger could hit with an
impact greater than the combined rod and fluid weight. Match well displacement to inflow or use “rod
pumped controllers” (RPCs) or percentage timers to prevent fluid pound.

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“Fluid Pound”, as experienced in a
rod pumping oil well, is caused by the
pump not completely filling with fluid on
the upstroke. As the downstroke
begins, the entire fluid and rod string
load moves down through a “void” until
the plunger “hits” the fluid level in the
pump barrel. The traveling valve
opens, suddenly transferring the load
to the tubing, causing a sharp
decrease in load that, in turn, transmits
a shock wave throughout the pumping
system. It is this shock wave that
damages the components of the
pumping system.

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Fluid Pound
Increases energy costs.
Increases wear and tear on downhole equipment.
Makes it almost impossible to counterbalance the pumping unit properly.
The counterbalance problem and the fluid pound "shock" increase gearbox wear and shorten unit
life.
Fluid Pound Control

Accelerates oil recovery -
By detecting high fluid levels that cause back pressure on the producing formation and therefore
reduce fluid inflow into the wellbore.
By the detection of worn out pumps before production loss is otherwise noticed.
By early detection of any problem that might cause the well to stop pumping - necessary repairs
can be started immediately.
Saves energy -
“Rule of thumb” - Saves $600 per polished rod horsepower per year.
Requires a reduction of only “5” or “6” polished rod horsepower for a one year payout of the
equipment.
Extends the life of the downhole pumps and rod string -
Ten strokes per minute amounts to “5,250,000” strokes per year. The average life of a rod
string is about “20,000,000” strokes. The average life of a pump is about “5,000,000” strokes. If
a well’s runtime is reduced by “25%”, the rods will last one year longer and the pump will last
three months longer.
Eliminates downhole problems -
Eliminates rod failures at the pump by stopping rod "buckling" above the pump when the
plunger is “stopped” by fluid pound.
Eliminates low tubing splits because fluid pound control stops tubing wear caused by rod
“buckling”.
The elimination of about “1-3” low rod or tubing failures will justify the installation of a “rod
pumped controller” (RPC).
Theory of Rod Pumped Control
A common operating problem in a sucker rod pumping system is trying to match inflow into a well with a
pumping system that has a fixed displacement. Because the well inflow is constantly changing as the fluid
level in the well depletes or is re-charged, the displacement of the system never exactly matches the well
capacity. The well is either “under-produced” (which means that the maximum capacity of the well is not
being produced) or “over-produced” (which means that the pumping system displacement is larger than the
amount of fluid moving into the well).
Both of these conditions are very undesirable. “Under producing” results in loss of revenue because oil
that could be sold is not produced. “Over-producing” also has quite serious consequences. For example,
when the system has a capacity of one gallon per stroke but only one-half gallon flows into the well bore, a
fluid pound occurs when the downward moving plunger strikes the fluid in the half-filled rod pump chamber.

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The plunger instantaneously stops until the load is transferred, and the rods stack out on top of it. This
shock load is very damaging to the sucker rods, the bottom hole pump, and the pumping unit. Also, if the
unit is producing at the rate of one gallon per stroke but is only getting one half gallon per stroke, the
energy required is almost the same as if the system was producing one gallon per stroke.
Many devices have been used to try to match the system capacity and the well capacity. With gas engine
prime movers this is possible by regulating the engine speed. Systems that allow a variable speed drive
(VSD) to regulate SPM to match the well inflow performance are currently too expensive for general use.
A common method to match capacities is to size the system to have surplus capacity and then shut the unit
down for some period of time to allow fluid to build up in the well bore. At start-up, the unit pumps the fluid
that accumulated in the well bore in the idle time plus the fluid that is coming in. It then shuts down for
another idle time.
The most widespread device that is used for intermittent pumping is the time clock. It is inexpensive and
easy to understand. However, the minimum set time in most clocks is fifteen minutes and unless the
setting is changed to meet the changing fluid inflow, the same situation exists – “over pumping” or “under
pumping”. A variation on the time clock is the percentage timer. A percentage timer will allow the operator
to set a percentage of each fifteen-minute period as run time. Both devices require frequent attention from
the operator if they are to do any good at all. To find a reasonable setting, the operator must try a
particular time setting, check this setting against daily production and fluid levels, and then finally adjust the
setting. This process is never ending!
The best solution to the problem is to use a rod pumped controller (RPC) that detects when the well is
starting to pound fluid and then shuts the well down for a pre-determined period of time. Ideally, this idle
period should be based on specific well conditions so that the production lost due to backpressure is
minimized. The system starts pumping again after this idle period and pumps until the well starts to pound
fluid again.
There have been many attempts to develop a “pump off control” method that will do a precise job of
pumping all wells with maximum efficiency. The methods used to detect when the well should be shut
down range from: a simple “flow-no flow” paddle in the flow line, shock or impact sensing devices, motor
horsepower, motor speed, etc., etc. The most successful rod pumped controllers measure the polished rod
load and position for a qualitative or quantitative dynamometer card. This gives positive knowledge of what
is happening in the well. The introduction of the low cost PC computer has made it possible to combine
this information with the logic necessary to control the well completely in any situation. Bottom hole and
surface equipment analysis software packages that use this load and position information make this
package a complete pump off control and analysis system. The addition of radio, cellular phone, satellite,
or hard wire transmission of this information to a central location for analysis and action further expands the
utility of the system. This makes it possible to know the specific performance of every well at all times and
to take any necessary corrective action at the earliest possible instant.
The success of any “pump off control” method, even the sophisticated ones described above, is very
dependent on several factors. The most important being that the control logic is set up for that specific
well. The selection of idle times to minimize lost production depends on: 1. The reservoir pressure. 2. The
inflow characteristics of the well. 3. The size of the casing and tubing. 4. The pumping capacity of the
pumping unit.
Wave equation based analysis and predictive programs, such as csBeamAnalysis and csBeamDesign
provided by Case Services, greatly facilitate the setting up of load limits, pump off points, and all control
parameters. Well conditions can be simulated in a variety of normal and abnormal operating conditions.
The operator can also build a library of expected dynamometer cards covering most of the possibilities.
Then, a much more intelligent analysis of problems can be made when they occur.
Unfortunately, all wells cannot economically utilize a rod pump controller. In addition, some bottom hole
conditions or hardware make control with this type device impossible.

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Percentage Timers Vs. Rod Pumped Controllers
A percentage timer is a timing device used to control the operation of a pumping well. The timer can be set
to turn the motor “on” for part of a “15 minute” interval and then turn it “off” for the remaining portion of the
“15 minutes”. For example, a timer can be set to run a unit for five minutes and turn it off for ten minutes
(to pump “33%” of the time). Timers are simple, easy to use, and inexpensive. However, percentage
timers are effective only if the operator can keep them adjusted correctly based on well conditions. If a well
remains stable for a long time, a percentage timer may be sufficient to minimize fluid pound. However, a
well with fluctuating production will be very difficult to control with a percentage timer. In this situation, a
rod pumped controller is the only practical way to minimize fluid pound damage, while maintaining
maximum production.
A rod pumped controller (RPC) turns the unit off only if it detects fluid pound. Therefore, it automatically
adjusts pumping rate to changing well conditions. Rod pumped controllers can be thought of as "smart"
percentage timers. On the contrary, percentage timers are "dumb" devices because they turn the motor
“on” or “off” at the pre-set times regardless of well conditions. For example, if the well's inflow rate
increases due to a waterflood response, a percentage timer will continue to pump the well at the same rate
as before. This causes the fluid level to rise and may reduce production. For declining production, a
percentage timer that is not frequently adjusted will not prevent fluid pound. Therefore, system efficiency
and equipment life will decrease.
“Stand-alone” Rod Pumped Controller Systems
You can use modern rod pumped controllers either as a stand-along device or as part of a centralized
automation system. You can do this because modern controllers contain all logic needed to operate each
rod pumped well independently. However, when you use them as stand-alone devices, you must visually
inspect them for alarm lights and electronic malfunctions on a regular basis, usually daily. You also must
check the calibration of the load and position transducers periodically with a calibrated stand-alone
dynamometer system. Although stand-alone rod pump control systems require less capital than
supervisory centralized systems, they must be manually checked on a regular basis to ensure they are
functioning properly. Control logic parameters and start-up and shutdown dynamometer cards can be
reviewed or changed with a portable analyzer, usually a lap top computer. This portable analyzer plugs
into a port on the outside of the RPC box.
“Supervisory” Rod Pumped Control Systems
Supervisory rod pumped control systems represent the “state of the art” in pump off control application.
These systems consist of a central computer that communicates with several rod pumped controllers via
radio, direct cable, cellular telephone or even satellite telemetry. The operator of the central computer
system can monitor any single well or scan several wells using a specially designed software package
such as that provided by Case Services. The system can produce individual well performance reports that
show the average run time, present status of the well (“on”, “off”, “down”), alarms for load or runtime
violations, etc. Dynamometer cards can be transferred from the individual controllers to the central
computer for further analysis. A complete surface and downhole equipment diagnostic analysis can be
done at the central computer to detect problems. Also, RPC control parameters can be viewed or changed
via the central system. Centralized systems have higher capital costs than stand-alone systems and may
require drastic changes in field personnel job functions. However, since central systems can detect well
problems faster and more accurately than stand-alone systems, they help optimize manpower usage.
Instead of manually inspecting each well, field personnel can go only to problem wells. Software packages
such as Case Services' csBeamAnalysis also offer other functionality such as SPC trending of runtime,

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production, card area, maximum/minimum load comparisons, etc. and reports of pertinent data to help the
user make timely operational decisions. csBeamAnalysis allows the user complete and easy access for
adding and changing wells, as well as data entry with a "point and click" Microsoft interface.
Communication
Communication protocol is typically “MODBUS RTU” or some form of “modified modbus” such as
“MODBUS ASCII”. Protocol may also be “native” – such as the eP RPC (CAC 8500 native) now provides.
Communication is most often accomplished through available dedicated radio frequencies or “spread
spectrum” radio technology. Cellular phones (CDPD) or satellite transmission are optional methods.
End Devices
eProduction Solutions provides all the end devices needed to complete the rod pumped automation
solution – including polished rod load cells, clamp-on load transducers, and position sensors of various
types. Other manufacturer’s end devices can be used in the solution – as well as instruments such as net
oil computers, flow control devices, and multi-phase flow meters.
Surface and Downhole Dynamometer Card Interpretation

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Surface Dynamometer Cards
Through the years the polished rod dynamometer has been the principal tool for analyzing the operation of
rod pumped wells. A dynamometer system gathers polished rod load and polished rod position or
displacement “points” and plots the resulting “curve” - which is commonly known as the “surface
dynamometer card”. The shape of this card is affected by changing downhole conditions. Ideally, these
conditions would be apparent from the surface 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 on the next page illustrates how “surface cards”
relate to the motion of the polished rod and the actions of the downhole pump.

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Card Area:
The term “Card Area”, as used in host software analysis systems, refers to the calculation of the area of a
selected surface card – measured in “ft-lbs.”. It represents the amount of work being done by the entire
pumping system. This calculation, with the assumption that maximum and minimum load from the RPC is
reasonably stable, is straightforward and will produce accurate values that can be tracked and trended for
recognition of changing downhole conditions.

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The example surface cards in the graphic below show what “API RP11L” generated surface cards look like
based on varying pumping system characteristics.
The following several pages are a library of “API 11L2” generated surface cards and actual cards gathered
in the field.

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The card on the left shows that the pump was leaking fluid throughout the upstroke, indicating that wear had
occurred in the lower portion of the barrel. Loss of load becomes more apparent at the top of the stroke
(characterized by the “blunt” end of the card) because the plunger is moving upward at a very slow rate of speed
(plunger is almost stationary) and slippage exceeds the displacement rate of the pump.
The card on the right shows that wear was confined to the top of the barrel. The field card compares favorably
with the API card until the top of the stroke is reached, at which point slippage becomes apparent (characterized
by the square end of the card) as the plunger comes in contact with the worn portion of the barrel.

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The “before and after” cards shown above dramatize clearly that when differences in the shape of
calculated and field cards are apparent, there are downhole problems --- conditions are abnormal.

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Downhole Dynamometer Cards
To bridge the gap that arises from knowing that visual interpretation of the surface card is often
inconclusive - and when good “quantitative” downhole data is needed, today’s 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. The “wave equation” solution can be used to
calculate a “downhole” card at any depth – see the example below.
The following several pages show example calculated downhole pump cards and detailed explanations
which are the result of the “wave equation” diagnostic solution.

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The shape of a downhole card showing full liquid fillage (with anchored tubing) is approximately
rectangular.
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

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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
In a pump that 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 card
a characteristic rectangular appearance.

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A downhole 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.
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.
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.

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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.

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The shape of a downhole card with gas interference shows a gas compression curve in the upper portion
of the downstroke (points “C” - “D”).
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.
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.
6. Between points “C” and “D”, the fluid load is being transferred back to the tubing. Because of the compressible
gas that entered the pump during the charging cycle, the load transfer takes place along a “compression curve”.

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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.

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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.
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 low-pressure gas. Liquid fillage can be much less than the
volume of the pump chamber.
valve to close.
6. 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

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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”.
7. The traveling valve opens at point “D” and the pump continues to descend.

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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.
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.
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.

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6. Between points “C” and “D”, the fluid load is being transferred back to the 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.

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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.
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.
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.
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.
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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.

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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.
¾ 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 card).
¾ If the pump “hits” up, a load increase (tension) will be shown at the top of the stroke (upper right on the downhole
card).
Pumps that are identified as “hitting” up or down should be “re-spaced” to prevent equipment damage.

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The graphic shown above helps to explain the downhole card shape for a bent or sticking pump barrel.
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”.

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6. The pull rod load returns to normal after the plunger moves away from the bent portion of the pump barrel.
The graphic shown above helps to explain the downhole card shape for a worn or split pump barrel.
1. From point “A” to the worn place in the barrel, the load on the pull rod is normal.
2. 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.
3. At point “D”, a good seal is again established between the plunger and the pump barrel.
4. On the downstroke, as long as the traveling valve remains open, the load on the pull rod appears to be normal.
5. 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.

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6. The pull rod load returns to normal after the plunger moves away from the worn portion of the pump barrel.
The graphic shown above helps to explain the downhole card shape for a full pump experiencing fluid
inertia effects. This card shape is representative of wells with large plungers, of shallow depth (less than
4000’), and a high water cut.
1. 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.
2. At point “B”, the load on the pull rod reaches a maximum value.
3. 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.
4. The pull rod load returns to normal, assuming no further reflected “pulses” are seen by the plunger.
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More Downhole Pump Card Examples
Combinations of the following conditions can occur simultaneously.

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Solution Overview
Rod Pumped Controller Components
Model 8800 RPC Description and Specifications

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Model 2000 RPC Description and Specifications

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ePIC RPC Description and Specifications

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♦ Event and time based control language.
♦ Read/modify any numeric parameter, execute
command parameters.
♦ Integer math - add, subtract, multiply, divide,
modulus.
♦ Logical operators - AND, OR, XOR, NOT. Both
Boolean and binary (bitwise) forms available.
The controller, using patented automatic idle time
optimization, can be used to continuously optimize
cycle time, even adjusting for power outages, pump
wear, tubing leaks or production "kicks". Air balance
control automatically balances pumping units. The
Intelligent Rod Pumping Control for peak energy control option can inhibit well operation
Production Optimization during peak periods of higher energy costs. The power
Access to accurate, timely information is the key to fail recovery method allows wells to pump down high
preventing an uninformed, costly decision. fluid levels after power failures, and the motor restart
eProduction Solutions (eP) has developed the ePIC protection function prevents motor restart when
rod pump controller (RPC) as part of eProduction condensation is present on motor windings.
Solutions' mission to provide improved decision When a pumping system malfunction or alarm is
making opportunities for operators of today's oilfields. detected either by the well site RPC or the host
The ePIC RPC is part of eP's complete rod pump software, the controller can be configured to respond
solution. eP provides the unique combination of in a number of ways - from illuminating a flashing
intelligent hardware controllers, communication light on the controller box to shutting the well down.
systems, advanced desktop analysis, training and The ePIC clearly defines both the identified fault and
support. the action taken by the controller so that the operator
can quickly and easily analyze the situation. Time
consuming trouble-shooting guesswork is eliminated.
Exceptional Intelligence and Well Site
Control
eP's proven technology has been expanded and Dynamic Interaction with Analytical
enhanced in the ePIC RPC to provide the following Tools
advanced functions: The registers are all available for analytical tools to
♦ Well site alarms and system diagnostics. read and write. This makes the results of any program
♦ Selected pumping system alarms based on host written in the controller available to host-based
analysis of well conditions. analytical programs. The accuracy derived from this
♦ Card area alarms for deep rod part detection and architecture allows for more exact analytical control at
downhole friction identification. the well site and more exact analysis at the desktop.
♦ Programmable Intelligent Control Language The ePIC gross fluid production calculation includes
(PICL) that provides users the flexibility to user-defined pump efficiency values for both deep and
modify control mechanism to adapt to site and shallow wells as well as utilizing the calculated
well specific conditions. downhole pump stroke information from host
♦ Well site valve checks and CBE determination, software analysis of deep wells.
available to host analysis systems.
♦ Improved data storage and trending. Simplified Setup and Maintenance
♦ Enhanced data-logging function that allows any ♦ Improved and expanded well site configuration
register to be logged and used in application logic. screens.
PICL is a simplified way to create well site ♦ New three step load sensor calibration method.
applications that provide well site intelligence.
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♦ Improved RPC interface access to "Energy
Management" feature, communication diagnostics, Backwards Compatibility
continuous position sensor diagnostics, and load
cell setup and diagnostics. The ePIC RPC is fully compatible with all generations
of eP RPC products. This design feature allows the
ePIC to be installed using existing register
Enhanced I/O Configuration configuration as a base. The configuration can then be
The ePIC includes programmable I/O for unique expanded with the new features.
analog, meter, and discrete monitoring and control
applications. With the ePIC, operators can fine-tune
their wells using operational set points and are Software Interfaces
notified of load-based and other alarms immediately. The ePIC is highly integrated with many of the
♦ Simple new I/O configuration menu. industry leading host-based monitoring and analysis
♦ Improved analog I/O logging method. software packages (i.e. Case Services csLIFT, Shell
♦ Auto-acting I/O functions provide easily Services International, Theta XSPOC™, SOFS, etc.).
configured control capabilities. It also can be integrated directly to HMI applications
♦ Expanded event action options. such as Wonderware and Intellution®. With multiple
communication protocols available, eP's ePIC is easily
integrated into any host system.
Field-Proven Technology
eP is known worldwide for manufacturing and
supporting reliable, stable, and accurate
electronics. The ePIC rod pump controller takes
the knowledge and experience gained from the
CAC line of rod pump control products and
combines them with new, innovative features to
create a state-of-the-art RPC. Much of the ePIC
technology is included in eP's CAC product line
currently used by over 22,000 wells world-wide.
With inventive manufacturing processes based on
years of experience, eP has made this controller
both robust and affordable. It provides the stability
and durability needed for harsh operating
environments without sacrificing the latest
technological advances for advanced rod pump
control.
Open Technology
ePIC controls virtually any rod pumped lift system,
including improved geometry pumping units, long
stroke units (Rotaflex) and even wells using two stage
downhole pumps.

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Advanced Features for Intelligent Control
Features Benefits
Control
Patented air balance control Automatically optimizes and controls air cylinder pressure on air-balanced
units.
Peak energy control functionality Inhibits well operation during peak periods of high energy cost as
determined by the operator.
Motor restart protection Prevents motor restart when condensation is present on motor windings.
Power fail recovery method Inhibits selected load alarms following a loss of power to allow a well to
pump down a high fluid level.
Programmable (auto-acting) I/O Unique monitoring and control applications using analogs, meters, and
discretes.
Multiple control methods Point or quadrant, for lower right or upper left hand portions of the surface
cards, and reverse pump-off.
Automatic idle time optimization Improved determination of idle time adjusted for inflow based production.
Pump-up delay timer Eliminates immediate pump-off due to incomplete pump fillage following
well idle time.
Monitor only mode Monitor dyno cards without regard for control setpoints or speed ranges.
Ideal for dyno card generation with VFD controlled pumping system.
Works with all kinds of wells Companies can standardize on one controller for heavy oil, sand, deviated
holes, etc.
Analysis
Gross fluid or inferred production Accurate estimates of total fluid production from shallow and deep wells
calculations without complex well site configuration.
Available ESP operating mode Allows the RPC to monitor submersible pump controllers.
System load analysis Host based detection of load cell drift on changing downhole conditions.
Cycle and run time buffers Easy access to historical data at the well site or using the host software.
Dynamometer card buffers Access to event cards (Full, Current, Shutdown, etc.) and several cards
stored leading up to the event.
Expanded alarm features Host based alarms (torque, stress, pump efficiency, prime mover size,
unbalance, etc.).
New stored card types and Card Area Alarm; Excessive Card Areas; and Hi-Hi, Hi, Low-Low, and
associated alarms Low loads.
Alarm
Extensive communications Capable of analyzing data at the well site to diagnose data transmission
debugging capabilities problems due to faulty radios, etc.
System Configuration
Improved well site configuration Simple menu for configuration, data management, system diagnostics, and
load cell calibration.
Upgradeable modular hardware Auxiliary I/O, communications, and local user interface options can be

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design added in the field.
Flexible, expandable I/O Three options available to allow the best match for individual well site
applications.
Backward compatible parameter Prevents incompatibility issues with older eP RPC equipment.
structure
Basic three level password Provides security for access to critical RPC setup parameters and well
protection scheme control commands.
Optional enhanced graphic Menu driven user interface for configuration and review of system data
display and keypad including dyno cards, valve checks, and run times.
Available ESP operating mode Allows the RPC to interface to submersible pump controllers.
Local graphic display Provides readily understood messages relating to pump system conditions.
Digital rod load calibration Operator no longer has to manually adjust potentiometers to calibrate the
load sensor.
Automatic beam mounted load Simply enter the correct maximum and minimum loads, no complex multi-
calibration step program required.
Integrated “single package” Simplifies installation with all components in one unit.
design
Rugged hardware design Manufactured to strict standards to ensure long life and reduced cost of
ownership.
Sensor options Position switch, continuous position sensor, polished rod load cell, and
beam mounted sensor.
ePIC Rod Pump Controller Highlights

♦ Controller commissioned with minimal effort
♦ Improved gross fluid calculations
♦ Advanced integration with host surveillance systems
♦ Robust data logging and trending capabilities
♦ Programmable Intelligent Control Language (PICL)
♦ Valve checks and CBE determination
♦ Compatible with all eP RPC products

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ePIC RPC Specifications
Rod Pump Controller

Enclosure NEMA 4
Weight Approximately 22 pounds
Input Voltage Range 120/240-Vac or 12- 24-Vdc
Frequency 47- to 63-Hz
Relay Output 12-Vdc
Operating Temperature -40° to +185°F (-40° to +85°C)
Printed Circuit Boards Conformally coated to protect against moisture, H2S, and salt air
Communication Protocol Operator selectable, CAC 8500 native, Modbus™ RTU, or Modbus ASCII
Transient Protection
Over voltage/Transient Meets ANSI/IEEE C37.90.1-2989 protection specifications
Dynamometer Card
Resolution Samples and stores load and position data at 20 times-per-second for downhole
analysis
Analog-to-Digital
Conversion Monolithic, successive approximation 12-bit A/D converter
Oilfield Sensors
Clamp on Beam Load Transducer (Beam Sensor)
Operating Temperature -60° to +212°F
Temperature Effect on Zero ±0.19uV°F
Temperature Effect on Output ±0.0008% of full scale/°F
Combined Accuracy 0.5% to 1.0% full scale
DPS (Dual Position Sensor)
Analog Output 0- to 5-Volts
Tilt Range ±45° to ±22°
Accuracy 0.1 degree of tilt
Filters Four selectable digital filters
Input Voltage 8- to 15-Vdc @ 14-mA
Polished Rod Load Cell
Class Quantitative strain gauge
Range 0- to 30,000-lb. or 0- to 50,000-lb.
Maximum Error ±0.5% full scale
Operating Temperature -70° to +190°F (-55° to +88°C)

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Expansion I/O Boards
Board Analog Digital Digital Analog
Number Inputs Inputs Outputs Outputs
1 2 2 2 0
2 4 4 4 0
3 8 4 4* 1

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CAC EXS-1000 RPC with Continuous Variable Speed Drive
Description and Specifications

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RPC End Devices – Load Sensors
Polished Rod Load Cell

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Beam Mounted Load Cell

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RPC End Devices – Position Sensors
Dual Position Sensor

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Position Potentiometer Sensor

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Position Switch Sensor

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Host Software Component
Case Services’ csBeamAnalysis Software

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Case Services’ csBeamDesign Software
Other Software Solutions
eP’s total solution allows the use of other software interfaces such as WonderWare
(shown above).

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Typical Field Installation
pipeline
Production/
Artificial Lift RTU
Reservoir
Applications Engineers Communications
Corporate (Radio, Satellite,
Web Site and Cellular)
Management
RTU
WAN
Application Server Downhole
Beam Suite Sensor
ESP Suite
PCP Tool
Gas Lift Suite
Monitor
LAN
Production Suite
Field Injection Tool
Applications General Monitoring
Control Client
Dial Up
Design OPC
Analyze
Production Client
Optimization
Existing SCADA
or DCS Systems
Rod Pump Control Benefits to the Customer
Key RPC Benefits:

• Maximize production
• Minimize equipment failure / fatigue
• Minimize power usage to obtain desired production
Direct RPC Benefits:

• Reduction or elimination of the causes of lost production
• Reduced maintenance costs by protecting pumping system components
• Minimize power usage
• More efficient manpower utilization
• Maximize well production
Indirect Benefits:
Detection of --
• Worn pumps
• Leaking standing or traveling valve
• Tubing leaks
• Rod parts

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• Stuck pumps
• Rod string overload / underload
• Plugged or restricted pump intake
Pump Off Control Justification And Economic Benefits

Justification
Rod Pumped Controllers (RPCs) can help reduce operating costs and increase
production by providing production operators and well analysts information
necessary for performance analysis, problem diagnosis and equipment
optimization. Early designs merely sensed “pump off” and were most effective
with wells that could be over-pumped. The newer RPCs can also be justified for
wells that do not “pump off” because the tool enhances well surveillance and
allows identification of operating problems more quickly.
Rod pumped controllers improve profitability in many ways. When these
controllers are integrated with a computer assisted operations (CAO) system,
field-operating profitability can be enhanced even further.
Benefits Of Rod Pumped Added Benefits Of

Profit Category
Controllers CAO
Changes in inflow capacity

Maximizes oil recovery by
Optimize short-term can be recognized sooner,
matching pumping time to well
cash flow allowing corrective action
inflow capacity
to be initiated more quickly
Operators can readily

review and adjust
Less unscheduled downtime
alarm/shut-down limits,
because of abnormal operating
pump-off parameters, etc.
conditions (excessive fluid pound,
to help reduce failures.
excessive high or low loads, etc.)
Failures can be easily
Problems can be recognized and
recognized when they do
the unit shut down before severe
occur and corrective action
damage occurs
can be initiated more
quickly
Operators can review and

select optimum idle times
Reduces energy cost because
and pump-off limits to
wells are not pumped when the
maximize energy savings
barrel is partially filled
while assuring that
production is not deferred

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Predictive beam pump
Equipment can be run closer to design modeling can be
Minimize capital operating limits if continuously calibrated with observed
investment monitored and shut down if the conditions to help optimize
operating limits are exceeded changes in equipment
design and selection
Downhole pump cards can

Equipment will not require be analyzed by the
premature replacement because operator to optimize the
of damage caused by abnormal setting of pump-off control
operating conditions parameters to minimize the
effects of fluid pound
In addition to alerting the

operator to anomalies in
measured parameters at a
Operating parameters are
central location, the
continuously monitored to detect
Improve surveillance system can monitor
anomalies in beam pumping
calculated parameters
performance
(e.g. rod stress, peak
torque, pump efficiency, or
out of balance)
Operators can quickly

focus attention on problem
wells by using exception
reports to screen analysis
results and identify wells
needing review and
corrective action
Being aware of problems

as soon as they occur will
permit quicker prioritization
and scheduling of
corrective action
Accurate downtime is
Information monitored by the well collected on each well
Improve production head controller can be used to every day. In conjunction
accounting improve reporting of unscheduled with accurate well tests,
downtime for allocation purposes this information can be
used to highlight deferred

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production and help
prioritize corrective action
Wells can be stopped if monitoring Wells can be stopped and

Improve safety and devices that can be installed started remotely. This can
environmental indicate unsafe conditions (e.g. be tied in with critical
protection high flowline pressure, leaking production facility alarms to
stuffing boxes, or tank levels) shut down wells
Rod pumped controllers with central site monitoring capabilities can improve the
quality of well tests in locations that have automatic well testing by monitoring
well performance during the well test.
Economic Benefits
Previous results have documented the following economic benefits from the use
of RPCs:
Analog Stand-alone Rod Rod Pumped
Controller Pumped Controller Controller with
CAO
Energy savings 20% 21% 22%
Pulling cost savings 25% 28% 35%
Net operating cost ----- $50-300 /well/yr. $300-800 /well/yr.
savings
Production acceleration 1% 1% 2%
Given this magnitude of savings, any field with beam pumping should be a
candidate for effective microprocessor based beam pump controllers and a
central site monitoring system unless there is a very compelling reason not to do
so.
Well Site Intelligence
Standard RPC Well Site Intelligence
• Multiple operator interface options

• Communications options for radio or hardwire applications up to 19,200 baud
• “Gross Fluid Production” calculation for both deep and shallow wells
• Shutdown based on configurable high and low loads, low average load, low load
span, and card area

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• Pump off cycle length alarms
• “Software Timer” and “Manual Timer” operating modes
• Load sensor calibration
• “Monitor only” mode for display of current load, position, and speed data without
regard for control setpoints or speed ranges
• “Real Time” dynamometer card display
• Load based alarm functionality: “Card Area Alarms” (high and low) and “high-
high” / “high” / “low-low” / “low” loads with configurable actions
• RPC interface access to I/O point configuration
• RPC interface access to “Energy Management” feature, communication
diagnostics, continuous position sensor diagnostics, and load cell setup and
diagnostics
Unique RPC Well Site Intelligence
• Multiple well control methods for a variety of well operating conditions and
pumping equipment types
• “Automatic Idle Time” determination
• “Peak Energy Control” for reduced well operation during periods of high energy
cost
• Expandable / Programmable I/O for unique point monitoring and control
applications
• “Motor Re-start Protection” to prevent motor restart in case the motor windings
are wet
• “Power Fail Recovery” method automatically pumps a well down following power
outages
• “Air Balance Control” option automatically balances air balanced units
• TV / SV checks and CBE value determination – both available for use by a host
analysis system
• “Run Time” data storage and trending – 6 segments of 4 hours
• Analog point and RPC parameter value logging capabilities: Hourly averages
stored for each 24-hour period and daily averages stored for 30 days
Desktop Intelligence
Host Rod Pumped Software - Main Selling Points
Case Services’ csBeam Suite:

– csBeam (basic well operation/status/control/alarms)
– csBeamAnalysis (adds detailed downhole analysis and diagnostics)
– csBeamDesign (optimize wells through “what if” scenarios)

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Case Services’ csBeam Application
9 Does not require a proprietary hardware platform

9 Simple well configuration
9 Client/server architecture
9 In addition to daily access to application software “at the office”, user access
is available through “dial in” capability at home or on the road
9 Support personnel can "dial in", using a modem, to each location for software
updates or problem solving, eliminating the need for site visits in most
instances
9 Supports multiple protocols on a single communication frequency
9 External physical point I/O and alarm configuration
9 Calculated “point” and alarm configuration
9 Current well status screens, trends of key operational data, and pre-
configured reports - including communication statistics and other important
data
9 Built-in security levels for “read/write” privileges
9 Host interface to well site controller for status, control and alarms
9 Access to all well site controller parameter registers
9 Access to surface dynamometer cards
9 Configurable automatic collection of surface dynamometer cards
9 Trends and reports of important well operating information
9 Well management by “exception”
9 Manual or automatic well shutdown by selected group
9 Automatic collection of downtime data
9 Reference library for storage of important surface – annotated by the user
9 Ability to “export” or “import” dynamometer card data
9 E-mail eP, Case or anyone else from the application interface – send
dynamometer cards, reports, trends, or ??
Case Services’ csBeamAnalysis Application
9 Integrated software package allows vital data to be shared between all

applications – beam/beam design, subs/subs design, well testing, production
allocation, facilities, injection, plunger lift, PCP, etc.
9 Does not require a proprietary hardware platform
9 Simple well configuration (add, change, or delete)
9 Client/server architecture
Tel: 281 348-1167 Fax: 281 348-1284 Mobile: 903-647-6777
9 In addition to daily access to application software “at the office”, user access
is available through “dial in” capability at home or on the road
9 Support personnel can "dial in", using a modem, to each location for software
updates or problem, eliminating the need for site visits in most instances.
9 Supports multiple protocols on a single communication frequency
9 External physical point I/O and alarm configuration
9 Calculated “point” and alarm configuration
9 Current well status screens, trends of key operational data, and pre-
configured reports - including communication statistics and other important
data
9 Built-in security levels for “read/write” privileges
9 Host interface to well site controller for status, control and alarms
9 Access to all well site controller parameter registers
9 Open pumping unit and sucker rod database (add, change, or delete)
9 Intelligent alarms
9 Well management by “exception”
9 Manual or automatic well shutdown by selected group
9 Automatic collection of downtime data
9 Trends and reports of important well operating information
9 Access to surface dynamometer cards, downhole pump cards, and the
downhole analysis (torque, rod stress, pump efficiency, etc.)
9 Configurable automatic collection of surface dynamometer cards with on-line
analysis
9 Ability to “export” or “import” dynamometer card data
9 Reference library for storage of important surface and downhole cards –
annotated by the user
9 Card calibration feature which allows an over-plot comparing actual well
based dynamometer cards and predicted dynamometer cards
9 “Rotate the Card” feature to check RPC “top of stroke” settings and tubing
anchor tension
9 “Balance the Unit” feature which uses API torque analysis to calculate the
correct placement of counterweights on the crank arm for optimum unit
balance
9 Performance grids: Vital information based on measured surface data, well
test history, or downhole calculation for a selected group of wells
9 Well diagnostics: A user configurable comparison of selected measured data
from each well and predicted values based on well configuration – card
pattern matching – and other well operating parameters

Tel: 281 348-1167 Fax: 281 348-1284 Mobile: 903-647-6777
9 Pattern matching feature: Pattern library is completely open to the user - add,
change, or delete cards and their descriptions. Any card in the library can be
observed or overlaid for comparison at any time
9 Configurable “sessions” of user selected information
9 E-mail eP, Case or anyone else from the application interface – send
dynamometer cards, reports, trends, or ??
Case Services’ csBeamDesign Application
9 Directly linked to the csBeam database for current well configuration

9 Makes use of a “shadow” database to allow users to change well
configuration for design purposes without changing the analysis database
9 Users can run multiple design scenarios within a single design case
9 Users can change over 100 parameters and observe the result of each
change
9 “Design Option” scenarios can be based on expected well production, “What
If” SPM changes, or design of a new or improved rod string
9 User can display the predicted card and associated calculated data for any
design case
RPC System Case Study – Rocky Mountain Region
Decreased Pump Cycles

Strokes/Day - Before & After RPC
Pump Off Controller Test/C-13 Test Point
Salt Creek LOU/Crew 3
20000
20000
Strokes per Day
15000
15000
10000
10000
5000
5000
00
18WC2SE36
18WC2SE36 16WC2NE01
16WC2NE01 6WC2NE01
6WC2NE01 33WC2SE36
33WC2SE36 29WC2SE36
29WC2SE36
Before
BeforePOC
POC POC
POCInstalled
Installed
Average 47.5% Decrease in Strokes/Day

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Decrease in KWH
KiloWatt Hours/Day - Before & After RPC
500
500
KWH Consumed, KWH/Day

400
400
300
300
200
200
100
100
00
18WC2SE36
18WC2SE36 16WC2NE01
16WC2NE01 6WC2NE01
6WC2NE01 33WC2SE36
33WC2SE36 29WC2SE36
29WC2SE36
Before
BeforePOC
POC POC
POCInstalled
Installed
Electrical Use = 14.1% Decrease in KWH
Increased Production
Oil Production, BOPD - Before & After RPC
40
40
Oil Production, BOPD
30
30
20
20
10
10
00
18WC2SE36
18WC2SE36 16WC2NE01
16WC2NE01 6WC2NE01
6WC2NE01 33WC2SE36
33WC2SE36 29WC2SE36
29WC2SE36
Before
BeforePOC
POC POC
POCInstalled
Installed
Total Oil Production Increase = 23-BOPD

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Decreased Fluid Level
Fluid Levels - Before & After RPC
1000
1000
900
900
800
800
700
700
Fluid Level, FOP
600
600
500
500
400
400
300
300
200
200
100
100
00
18WC2SE36
18WC2SE36 16WC2NE01
16WC2NE01 6WC2NE01
6WC2NE01 33WC2SE36
33WC2SE36 29WC2SE36
29WC2SE36
Before
BeforePOC
POC POC
POCInstalled
Installed
Average 201-Ft. Decrease in Fluid Level

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Product Overview
Rod Pumped Controller Solution

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RPC Solution Concepts

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Tel: 281 348-1167 Fax: 281 348-1284 Mobile: 903-647-6777
Tel: 281 348-1167 Fax: 281 348-1284 Mobile: 903-647-6777
Tel: 281 348-1167 Fax: 281 348-1284 Mobile: 903-647-6777
Tel: 281 348-1167 Fax: 281 348-1284 Mobile: 903-647-6777
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Theory Of Rod Pumping Overview

Sucker Rod Pumping

Rod Pumping Advantages / Disadvantages

Advantages of Rod Pumping:

• Easy to operate and service.

Disadvantages of Rod Pumping:

• Rod pumped wells can be a problem if the cased hole is crooked.

Rod Pumping Range (Production vs. Depth)

Louis Ray – Product Line Manager / Trainer / Consultant

Louis Ray – Product Line Manager / Trainer / Consultant

Conventional Pumping Units

Advantages of Conventional Pumping Units:

• Lower maintenance costs (spare parts are easily available).

Disadvantages of Conventional Pumping Units:

Louis Ray – Product Line Manager / Trainer / Consultant

Advantages of “Improved Geometry” Pumping Units:

Disadvantages of “Improved Geometry” Pumping Units:

Louis Ray – Product Line Manager / Trainer / Consultant

Advantages of an Air Balanced Pumping Unit:

Disadvantages of an Air-Balanced Pumping Unit:

Louis Ray – Product Line Manager / Trainer / Consultant

Louis Ray – Product Line Manager / Trainer / Consultant

Sucker Rod Pump Valve Operation

Louis Ray – Product Line Manager / Trainer / Consultant

Tubing Pump Advantages

• Greater capacity than standard rod

Tubing Pump Disadvantages

• Tubing must be pulled to repair the

Louis Ray – Product Line Manager / Trainer / Consultant

Rod Pump - Stationary

• Can be used in deep wells.

• Valve rod is the weak link in

Louis Ray – Product Line Manager / Trainer / Consultant

• Good pump for sandy wells.

• Valve rod is the weak link in the

Louis Ray – Product Line Manager / Trainer / Consultant

• Agitation keeps sand from

• Not recommended for

Louis Ray – Product Line Manager / Trainer / Consultant

Pump Bore (Basic): Barrel Length in Feet

Barrel Type for Metal Plunger H = Heavy Wall

API Pump Designation Description

Louis Ray – Product Line Manager / Trainer / Consultant

Sucker Rod Nomenclature

Steel Sucker Rod Sizes:

1 1/8”, 1.0”, 7/8”, ¾”, 5/8”

Rod Length: 25' or 30’

Fiberglass Rod Sizes:

1 ½”, 1 ¼”, 1.2”, 1 1/8”

ROD LENGTH: 37.5'

Louis Ray – Product Line Manager / Trainer / Consultant

Advantages of Fiberglass Rods

Disadvantages of Fiberglass Rods

Louis Ray – Product Line Manager / Trainer / Consultant

Louis Ray – Product Line Manager / Trainer / Consultant

Fluid Pound Control

Theory of Rod Pumped Control

Louis Ray – Product Line Manager / Trainer / Consultant

Louis Ray – Product Line Manager / Trainer / Consultant

“Stand-alone” Rod Pumped Controller Systems

“Supervisory” Rod Pumped Control Systems

Louis Ray – Product Line Manager / Trainer / Consultant