Investigation of Sucker Rod Pumping Wells Performance

using Total Well Management Software

By
Said Kamel Elsayed Salem*
Abstract
The most popular artificial lift system is sucker rod pumping. Analysis of the performance of
sucker rod pumping wells is needed to decrease operating costs, improve oil production and
increase profit. Total Well Management (TWM) is the most widely used software for the
analysis and investigation the performance of an artificially produced well. The TWM version
for the personal computer (PC) can be used. The software can be downloaded for installation
and use on several numbers of PCs. In this paper, the TWM software was used to evaluate
the performance of sucker rod pumping wells. Field examples of sucker rod pumping wells
analyses are presented. Analyses show that the producing performance (Production
efficiency) is satisfactory. Also, analysis shows that the effective plunger stroke was much
lower. This could be a result of gas entering the pump or maybe some other unwanted
contaminants. Finally, the power system efficiency for the two wells is much lower. This could
be a result of unbalanced counter weights, undersized motors, etc. Economic analysis of the
result shows that oil production cost was too high. More study may result in increase of the
power system efficiency and reduce the cost per barrel of production.

Introduction
Analysis of the sucker rod pumping system is required to reduce operating costs,
increase oil production and increase net income. One of the cost-effective advantages
of an integrated analysis system is that the well data is entered only once into a data
file and the integrated system use the data to determine well performance 1. Acoustic
liquid level tests are performed successfully in analyzing producing oil and gas wells
throughout the world 2
An acoustic fluid level test is a diagnostic test that is performed on an oil or gas well,
proper analysis of the acquired acoustic and pressure data will aid in the diagnosis of
the wells problem and can be used to cure what is wrong with the well.
Dynamometer testing of sucker rod lifted wells is performed routinely in a safe and
efficient manner throughout the world 3. Experience from the analysis of many wells
has resulted in the development of a methodology: Total Well
Management 4. Application of this methodology to analyze a well insures that a proper
*Associate Professor, Faculty of Petroleum and Mining Engineering, Department of Petroleum
Engineering, Suez University, Suez, Egypt: E-mail:said.salem62@yahoo.com
1
McCoy, J. N., Podio, A. L.: "Modern Total Well Management - Sucker Rod Lift Case Study" Paper
SPE 68864 at the SPE Western Regional Meeting held in Bakersfield, California 26-30 March 2001
2
Rowlan, O.L., McCoy, J.N., Becker, D. and Podio, A.L.: Advanced Techniques for Acoustic LiquidLevel Determination, paper SPE 80889 presented at the SPE Production and Operations Symposium
held in Oklahoma City, Oklahoma, U.S.A., 2325 March 2003.
3
Rowlan, O.L. McCoy, J.N. and Podio, A.L.: Advances in Dynamometer Technology, presented at
the Southwestern Petroleum Short Course, Lubbock, TX, and Apr. 7-8, 2004.
4
Podio, A.L., McCoy, J.N., Becker, D., Rowlan, O.L., and Drake, B.: Total Well Management II,
paper SPE 67273 presented at the SPE Production and Operations Symposium held in Oklahoma City,
Oklahoma, U.S.A., 2427 March 2001.

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diagnosis of the wells operating conditions will be performed. Experience has shown
that this can be accomplished in a cost effective manner by establishing the well's
inflow performance (by measurement of the liquid level depth and casing pressure),
performing dynamometer analysis and measuring the overall efficiency of the
pumping system. It requires only the measurement of input power to the prime mover,
acquisition of polished rod load and position data, determination of the producing
BHP and accurate well test data 5, 6. Producing bottom hole pressure (BHP) is obtained
from a fluid level and casing pressure measurement and then computed taking into
account the effect of annular gaseous liquid column if present 7. The dynamometer
measurement is made with a polished rod transducer 8 which is easily installed in less
than a minute by technician. This provides at the well site the capability of also
determining the performance of the downhole pump. Overall efficiency is defined as
the ratio of the ideal power required to lift the produced fluids (oil and water from the
depth of the pump intake, taking into account the effect of the pressure at the Pump
intake) divided by the power supplied to the prime mover 9.
The most important objectives of this study is to:
1. investigate and evaluate the applicability of TWM software on two sucker rod
pumping wells performance,
2. establish the well's inflow performance using Vogel's IPR to determine if
additional production is possible,
3. evaluate performance of surface and subsurface installation equipments and
4. Design improvement of these pumping system.
Total Well Management Analysis Methodology
Table 1 to 6 shows the TWM software data requirements for the two field examples of
sucker rod pumping wells used in this study. These data include: surface data,
wellbore data and conditions data.

McCoy, J. N., Podio, A. L, Kay Capps, J. West and J. Jennings: "Simplified Computer-Aided
Analysis of Electrical Current in Motors Used for Beam Pumping Systems," SPE 25447, Presented at
the Production Operations Symposium, March 21-23, 1993, Oklahoma City, OK
6
McCoy, J. N., Podio, A. L. Jennings, J. and Bill Drake, :"Motor Power, Current and Torque Analysis
to Improve Efficiency of Beam Pumps," Paper presented at the 40th Annual Southwestern Petroleum
Short Course, April 21- 1992. Texas Tech University, Lubbock, TX.
7
McCoy, J. N., A. L.- Podio and K. Huddleston," Acoustic. Producing Bottom Hole Pressures, SPE
14254, Annual Technical Conference and Exhibition, Las Vegas NV, September 22-25, 1985.
8
McCoy, J. N., Jennings, J. and Podio, A.L.:"A Polished. Rod Transducer for Quick and Easy
Dynagraphs," Paper presented at the 40th Annual Southwestern Petroleum Short Course, April 21-23,
1992. Texas Tech University, Lubbock TX.
9
Lea, J. F. and J. D. Minissale: "Beam Pumps Surpass ESP `Efficiency," Oil and Gas Journal May 18,
1992, pp. 72-75.

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Table 1: Surface data requirements for TWM Software (Well 1)

Input Information
a) Surface Units
b) Prime Mover

Surface
Equipment c) Electrical Motor
data
Parameters

Variable

Value

Pump Stroke Length

Motor Rating
Run Time
Full Load
Rated RPM
Voltage
Cycle frequency
3-Phase
Synchronous RPM
Consumption
Demand

120 in.
40 HP
24hr/day
45 Amps
1200 RPM
480V
60Hz
3-Phase
1300
5$/KWH
8$/KWH

Table 2: Wellbore data requirements for TWM Software (Well 1)

Input Information
a) Tubular

b) Pump

Wellbore
data

Variable

Value

Tubing

2.875"
6.00"

Casing
Anchor Depth
Plunger Diameter
Pump Intake Depth
Polished Rod
True Vertical Depth
Total rod length
Top Taper

c) Rod String Information

Taper 2

Taper 3

5200 ft
1.75"
5325 ft
1.5"
5300 ft
5300 ft
Rod Type: D
Length: 1200 ft
Diam.: 0.875"
Rod Type: D
Length: 3800 ft
Diam.: 3/4"
Rod Type: D
Length: 300 ft
Diam.: 0.625"

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Table 3: Condition data requirements for TWM Software (Well 1)

Input Information
a)Pressure:
SBHP
PBHP
b) Surface producing
pressure:
THP
CHP
Casing pressure build up,
dp/dt
Condition c) Production:
data
Oil
Water
Gas
d) Temperature:
Surface temperature
Bottom temperature
e) Fluid properties:
Oil gravity
Water gravity

Variable

Value

Estimated

1200 psi
198psi

Given
Given
Given

30 psi
40
0.3/2.3psi/min.

Given

30 bbl/d
80 bbl/d
50 mscf/d

Given

75 o F
140 oF

Given

40 API
1.05

Table 1: Surface data requirements for TWM Software (Well 2)

Input Information
a) Surface Units
b) Prime Mover

Surface
Equipment c) Electrical Motor
Parameters
data

Variable

Value

Pump Stroke Length

Motor Rating
Run Time
Full Load
Rated RPM
Voltage
Cycle frequency
3-Phase
Synchronous RPM
Consumption
Demand

144 in.
30HP
24hr/day
50 Amps
1000 RPM
480V
60Hz
3-Phase
1100
6$/KWH
9$/KWH

Table 2: Wellbore data requirements for TWM Software (Well 2)

Input Information

a) Tubular

Variable

Value

Tubing

2.375"
5.5"

b) Pump

Casing
Anchor Depth
Plunger Diameter
Pump Intake Depth
Polished Rod
True Vertical Depth
Total rod length
Top Taper

c) Rod String
Information

Taper 2

Wellbore
data

Taper 3

6000 ft
1.5"
6125 ft
1.5"
6100 ft
6100 ft
Rod Type: FG
Length: 1600 ft
Diam.: 0.875"
Rod Type: FG
Length: 3700 ft
Diam.: 3/4"
Rod Type: FG
Length: 800 ft
Diam.: 0.625"

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Table 3: Condition data requirements for TWM Software (Well 2)

Input Information
a)Pressure:
SBHP
PBHP

Condition
data

b) Surface producing pressure:

THP
CHP
Casing pressure build up, dp/dt
c) Production:
Oil
Water
Gas
d) Temperature:
Surface temperature
Bottom temperature
e) Fluid properties:
Oil gravity
Water gravity

Variable
Estimated

Value
2000 psi
770 psi

Given
Given
Given

20 psi
70
0.2/2psi/min.

Given

80 bbl/d
120 bbl/d
100 mscf/d

Given

70 o F
150 oF

Given

30 API
1.05

The output results from TWM software are analyzed for Well 1 and 2 by sequentially
proceeding through the following graphs as described below.
Depth Determination
Figure 1 and 2 shows the depth determination curves of well 1 and well 2. In this
figures, a detail of the liquid level selection is displayed at the lower right corner of
the screen. A dashed vertical line is drawn through the liquid level signal. The liquid
level selection may be fine-tuned by returning to the select liquid level tab. As shown
in figures the depth to liquid level is 3130.9 ft and 4743.02 ft, respectively.

Figure 1: Well performance analysis diagram showing depth

determination of well 1

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Figure 2: Well performance analysis diagram showing depth determination of well 2

Bottom Hole Pressure Tab

Figures 3 and 4 show the bottom hole pressure (BHP) determination of Well 1 and Well 2. This
tab computes the BHP based on the measured acoustic fluid level and casing pressure data in
conjunction with the well and fluid data in the well file. The objective of this display is to
provide a complete analysis of the well conditions at the time of the measurement. The following
parameters are displayed on the BHP diagram and are labeled as follows: casing pressure, casing
pressure buildup, annular gas flow, % liquid, gas/liquid interface pressure, liquid level, formation
depth, pump intake pressure, producing bottom hole pressure (PBHP) and reservoir pressure
(SBHP). In the BHP screen, the wellbore schematic shows the position of the annular liquid
level as well as the position of the pump intake in relation to the formation depth.

Figure 3: Well performance analysis diagram showing BHP f Well 1

Figure 4: Well performance analysis diagram showing BHP of well 2

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Analysis of Individual Dynamometer Stroke

Figures 5 and 6 show the dynamometer stroke analysis of Well 1 and Well 2. In this
figures, the upper graph consists of a plot of polished rod load versus position for the
selected stroke. The corresponding downhole pump card is presented below the
surface card. The displacement shows downhole pump stroke. The downhole card
describes the effective plunger stroke. The program then calculates the equivalent
volume per day of fluid that should be displaced by the pump and the hydraulic
horsepower expended at the pump as shown in figures.

Figure 5: Well performance analysis diagram showing dynamometer

cards of well 1

Figure 6: Well performance analysis diagram showing dynamometer

cards of well 2

Power Torque Analysis

Figures 7 and 8 show the power torque curve analysis of Well 1 and Well 2. In these
figures, the left half of the screens are plotted two torque curves as a function of time;
the dashed line matches to the calculated actual torque while the solid line
corresponds to the balanced torque. The tabulated torque analysis gives the upstroke
peak and the downstroke peak torque values in thousands of inch-lb that occur during
the stroke. The difference between these values is a measure of the unbalance of the
system. If the upstroke peak is greater, the unit is under balanced or "rod heavy". If

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the down stroke peak is greater, the unit is overbalanced or "crank heavy." The torque
that would be qualified if the counterbalance were adjusted so that two peaks were
equal is displayed as the balanced peak value.

Figure 7:Well performance analysis diagram showing power

torque of well 1

Figure 8: Well performance analysis diagram showing power torque of well 2

Power Use and Efficiency Tab
Figures 9 and 10 show the information related to energy utilization of well 1 and well
2. At the bottom left, power and current are displayed as a function of time. Time
increases from left to right. Thus the first half of the plot corresponds to the up-stroke
and the second half to the down-stroke. The horizontal dashed line corresponds to
zero power and current. Values below this line indicate electrical generation.

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Figure 9:Well performance analysis diagram showing power results of well 1

Figure10 Well Performance Analysis Diagram Showing Power Results of Well 2

Discussions of Results
The results show that the producing efficiency is considered satisfactory. The
production efficiency using the Vogel IPR method for the two wells ranged from
89.7% to as low as 82.3%. This indicates that the wells are near their maximum daily
production. The efficiency decreases as the plunger stroke effectiveness and the
power efficiencies are investigated. Since the actual Echometer test data was not
available for the well, it is impossible to say how accurate these results are. There are
other important pieces of information noted earlier that were also estimated, such as
the producing BHP, SBHP, producing tubing and casing pressure, etc. The most
important result is that the program has been used and familiarized with and it is
actually quite simple.
The effective plunger stroke was much lower, at around 54.3%. This could be a result
of gas entering the pump or maybe unwanted contaminants such as asphaltines or

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paraffins. A suggestion for this result would be to either set the pump below the
perforations/producing interval (which is not possible), or to install gas separators.
The power system efficiency for the two wells is much lower, about 40.1 % and 69.4
% respectively. This could be a result of unbalanced counter weights, undersized
motors, etc. From the program outputs, a recommendation is made to move
counterweights in 6.0 inches for well 1 and 6.2 inches for well 2. This could help the
performance assuming we have used the correct counterweight size by reducing the
work on the motor.
Economic analysis of the results shows that oil production cost were 36.6 $/bbl and
17.6 $/bbl respectively. Further study may result in increase of the power system
efficiency and reduce the cost per barrel of production. After that, consideration might
be given to installing a more efficient pump in terms of gas separation.
The cost efficiency of the changes that would be required in order to improve the
efficiency of the system needs to be evaluated. This analysis must include both the
expected increases in production as well as the reduction in operating expenses either
as a result of improved efficiency or reduced energy costs.
Conclusions
The results presented in this study lead to the following conclusions:
1. The most important result is that the program has been used and familiarized
with and it is actually quite simple after a short learning curve.
2. The results for this analysis in Total Well Management show that the
producing performance (Production efficiency) is satisfactory.
3. The effective plunger stroke was much lower, at around 54.3%. This could be
a result of gas entering the pump or maybe unwanted contaminants such as
asphaltines or paraffins
4. The power system efficiency for the two wells is much lower, about 40.1 %
and 69.4 respectively. This could be a result of unbalanced counter weights,
undersized motors, etc.
5. Economic analysis of the results shows that oil production cost were 36.6
$/bbl and 17.6 $/bbl respectively. Further study may result in increase of the
power system efficiency and reduce the cost per barrel of production.
6. The mainly significant output obtained from TWM program is power torque
which is very considerable for optimizing of Sucker rod pumping wells
performance.
Nomenclatures
SBHP:

Static Bottom Hole Pressure

PBHP:

Producing Bottom Hole Pressure

THP:

Tubing Head pressure

CHP:

Casing Head Pressure

RPM:

Revolution per Minuets

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