®

Beam Pump
p
Components
Show beam system
Show system
y component
p byy component
p
Show functionality of each component
Show nomenclature of each component to assist with following
sections on Design, Analysis and Trouble Shooting.
Beam Pump Components
S f
Surface E i t
Equipment
– Units
– Wellhead
– Polished Rods
– Motors
– Gearbox
– Sheaves
– B lt
Belts
– Transformers
Downhole Equipment
– Pumps
– Rods
– Tubing
Production Optimization
– Pump cards
P d
– Valve checks
– Pump Off Controller
– Power Measurement
– Downhole sensors

2
Pressure Profiles: Tubing / Casing

3
Surface Units
Types of units
Designations
L di
Loading
Design considerations
Maintenance

Conventional Unit

Mark Unit Air Balance Unit

®

4
Tower, Hydraulic Units

Tower Hydraulic

Long Stroke, more efficient Easy to control speed of up/down stroke

®

5
Smaller Hydraulically Powered Units:
These used for CBM wells and other.

Dynapump Dynasave Economizer VSH2

Economizer has no noticeable motion at
surface All are predicted to give more
surface.
required surface maintenance than regular
beam pumps. Details on all in report.

VSH2mini
®

6
Unico LRP

7
Multiple Zone Beam Completions

Two – in - One

Three – in - One

8
Surface Unit
Nomenclature

9
Surface Unit
Nomenclature

10
Surface Unit
Pumping Unit Designations

PK TORQUE RATING IN MAXIMUM STROKE

LENGTH IN INCHES
THOUSANDS OF IN-LBS

C-228D-246-86
A- AIR BALANCE
B – BEAM BALANCE
C – CONVENTIONAL POLISHED ROD RATING
IN 100’S OF LBF’S
M – MARK II
LP – LOW PROFILE
RM – REVERSE MARK See API Specification 11E
®

11
Surface Unit
C-912D-365-168 Conventional Unit

168”

912,000 in-lbs.

36500 lbs..
lb

Well on right: Designate CCW or CW rotation

rotation. Cranks fall towards Sampson Post is
called positive rotation as well. Negative for falling away from Sampson Post

12
Motors
Oil Field Motor Types
TYPE ~Efficiency
y SLIP STARTING APPLICATION
Full Load TORQUE
NEMA B ~92+ 2-3% 100-175% TRANSFER
PUMPS
NEMA C ~90+ 4% 200-250% POSITIVE
DISPLACEMENT
INJECTION PUMPS

NEMA D ~88% 8-13% 275%+ BEAM PUMPS

ULTRA HI- Lower 15-30% 275%+ SPECIAL

SLIP APPLICATION
BEAM PUMPS

SLIP=( No-load RPM – RPM under load) / (No-load RPM)

J. Lea, Texas Tech University
®

13
Motors
Torque Curves for
Motors

Motor Performance Curve

5 hp,
p, 1120 rpm,
p ,
220/440 V, 66/33 Amps,
3 Phase, 60 Hz
NEMA D, Squirrel Cage
Induction Motor
®

14
Motors
Balanced vs. Unbalanced Motor
– Torque (in-lbs) or kW (power) signatures of an electrically or
mechanicallyy unbalanced or balanced ppumping
p g unit:
– Balanced if the peak upstroke torque is equal to the peak down
stroke torque.

15
Motors
Two main methods for
determining motor HP
– Both based on calculating
Polished Rod Horse Power
(PRHP)
Computer Sizing

CLF × PRHP
Or
Motor HP =
U it Efficiency
Unit Effi i

Gault Method
Motor HP = 2 × PRHP
CLF = RMS Current/ Average Current
~ RMS T
Torque// Average
A Torque
T
~ RMS Power/ Average Power
®

16
Sheaves and Gearbox
The speed of a motor in
RPM can be calculated
from

Frequency ×120
Speed (rpm) =
No of poles
Typically beam pump
motors are running
1200 or 1800 rpm
Need a method to
reduce speed
p to get
g
down to approx 10 SPM
Use ratio of sheaves
and gearbox

17
How Sheaves and GB Reduce Speed

47” dia
di
298.7RPM
1170 RPM 30.12 GB Ratio
=9.92 SPM
12” dia

1170 x 12”/47” = 298.7 RPM

GB Ratio:
R ti 30.12
30 12

18
SPM Problem

Problem
–A bea
beam pupumpp has
as a motor
oto
sheave of 10 inches OD (254mm).
The gear-box
gear box sheave is 34 inches
(863.6mm). The gear box is
typical. The motor is a gas
engine turning at 500 rpm
average speed. What is the SPM
(strokes per minute) of the
pumping unit?
®

19
Belts

Purposes of belt
drive
– Adds additional
speed reduction
– Change pumping
speed
– Soft link in drive
train
– Moves motor away
from cranks

20
Gearbox
Most expensive part of
unit
Reduces rpm and
increase torque
– out/in by ~30:1
Requires servicing
Can last 20-30 + years
with care
Do not overload by
design
g or operation
p

21
Gearbox
Factors Affecting GB Torque and Polished Rod
Loading
Gearbox should be loaded at least 50%
% to p
prevent
low efficiency

Factor Polished Rod Load Gearbox load

Increase rod string weight Increases PRL Increases load
Increase stroke length Minimal Effect Increases load
Increase pump diameter Increases PRL Increases load
Increase SPM Increases PRL Increases load
Out of balance Increases PRL Increases peak load
Pump off well Increases PRL Increases peak load
Oversized Motor Increases PRL Low Efficiency
Pump off well Increases PRL Increases peak load

22
Wellhead
Flowing/pumping well
Stuffing box
Bl
Blow outt preventer
t
Gas side check valve
Gas must be allowed
from casing back to
flowline through check
valve
l
Flowline pressure

23
Wellhead
Flowing vs. Pumping Well: Contrast the Two

24
Polished Rods

The polished rod is the connecting link between

the surface pumping unit and the downhole rod
string.
It’s surface is ground to close tolerances and has
an extremely smooth surface to provide a sealing
surface for the elastomer seals (packing) that
allow vertical movement of the polish rod
rod.

Recommended PR sizes:
Size of sucker rod Size of polished rod
5/8 inch 1-1/8 inch
¾ inch 1/1/8 inch
7/8 inch 1-1/4 inch
1 inch 1-1/2 inch
®

25
Polished Rods
• Polished Rod Liners
• Use polish rod or liner to
connect rods through
stuffing box:

Use sucker rod coupling

Use PR coupling
®

26
Tubing
Ranges from 1.05” to 4.5”
Pick appropriate size based
upon casing size and
production
Most common sizes for
beam pumping are2-3/8’s
and 2-7/8’s
The “most expensive” failure
for a downhole beam pump
system failure.
Set pump intake below the
perfs or as low as possible
Install an internally coated
joint above seat nipple
Decision TAC,, gas
g anchor,,
mud anchor, de-sander, etc.

27
Tubing
Seamless Tubing Construction
– Advantages: less susceptible to corrosion
– Disadvantages: more expensive than ERW
ERW, and less available

28
Tubing
Electro Resistance Welded (ERW) Tubing
Treating Choices
– Non-Normalized
– Seam Annealed
– Full Body Normalized (FBN)
– Full Body Normalized after upsetting (Best choice for
H2S Service))

29
Tubing
Tubing Grades
– Wide variety from H-40 (40 ksi min yield) to P-105
– More strength means more potential problems with
corrosion
– Most commonly used for rod pumping: J-55 and H-40
– J-55 is good choice considering both strength and
corrosion
H2S Precautions
– Max grade of L-80
– Do not use N-80 or P-105/110
– Specify full body normalization after upsetting
– In general high strength rods are not a good choice
with H2S presence

30
Tubing
Connections
– External upset (EUE) with
Beam
– Non-Upset (NU)
– Integral Joint (IJ)
– Special/Premium thread
¾ Sometimes used when
CO2 high for instance

31
Tubing
Use of Used Tubing
– Green Band tubing: 30-50% wall loss
– Blue Band tubing: 15-30% wall loss
– Yellow Band tubing: 0-15% wall loss
– Could use in 1/3’s
1/3 s of length of well
well, Green Band at the
top, Blue Band in middle, and Yellow Band or new
tubing at the bottom. This for a well where wear is a
problem.
– Even with 50% wall loss, the tensile strength is still
good for applications to 5000’
5000 .

32
Tubing Movement with No Anchor
Tubing movement and
buckling with no anchor

Guidelines for Anchor:

Set near pump
Set above perforations
Set within 200’ of seating nipple
Set 2 joints above seating nipple
if pumps stick
A tension anchor preferred
Calculate tubing pickup
Calculate min hookload for shear
pins on each anchor
Use proper tubing grade to
facilitate possible worst case
scenario

33
Tubing Anchor
Determine Tension to Set Anchor: On Disk

Buckling of Tubing in Pumping Wells, Its Effects and Means for

Controlling It.
Arthur Lubinski, K. A. Blenkarn; AIME Transactions
V l 210,
Vol 210 1957
1957, Ch
Chapter
t 3 3, V
Volume
l 1
Programmed by S. A. Wong

34
Tubing Failures
Acid Producing
Bacteria

Rod Guide Wear

35
Tubing Failures

Pump
p Joint – Protruding
g
ERW Seam

T bi - Pump
Tubing P J i t - Stagnant
Joint St tA
Area ((non coated)
t d)
Preferential Corrosion Along Seam
®

36
Sucker Rods
Sucker rods nominally
consist of 25 foot joints (30
ft in California) with a
th
threaded
d d pini (male)
( l )
connection on both ends.
Manufacturers furnish a
th
threaded
d d coupling
li (female
(f l
on one end of each rod).

37
Sucker Rods
API Specification 11b: Specification for SR’s
Couplings and Subcouplings
FRP (Fiberglass) Sucker Rods
St l S
Steel Sucker
k RRods
d
– Grade C
– Grade K
– Grade
G d D Carbon,
C b Grade
G d D Alloy
All and d Grade
G d D Special
S i l
Alloy (KD)
Polished Rods
P li h d Rod
Polished R d Clamps
Cl
Sinker Bars
Stuffing Boxes and Pumping Tees

N i
Norris
®

38
Sucker Rods
Connections

Coupling

Wrench Flats

Sucker
S k R Rod
d
Body

39
Sucker Rods

API 86 Rod String

8/8
1 5” P
1.5” Pump - 26.8%,
26 8% 27%
27%, 46
46.2%
2%

API Grade Rods

Equal Stress? C - 90,000 psi min. tensile
7/8
Not equal K - 90,000 psi min. tensile
stress. D - 115,000 psi min. tensile
Instead
equal
tendency
to fail from
g
fatigue.. 6/8
High strength rods - 140,000
140 000 psi min.
min tensile
Goodman
Diagram
®

40
Sucker Rods
Common Rod Grades
– Grade C rods are designed for light to medium loads (less than 25,000
psi fully loaded) in shallow to medium depth wells and non-corrosive or
effecti el inhibited well
effectively ell flfluids.
ids
– Grade K rods are designed to work under the same loading conditions as
C rods where corrosion is a problem and must be effectively inhibited.
– Grade D rods are designed for medium to heavy loads (up to 30,000 psi)
or deep wells with non-corrosive or effectively inhibited well fluids.
– KD rods are designed to be used where D rods are needed to handle the
loads but a higher level of corrosion resistance is required.
– High strength rods not covered by API grades but were designed to
handle extremely heavy loads (up to a maximum of 50,000 psi without a
safety
f factor)
f ) at any operating depth where corrosive fluids
f can be
inhibited.

corrosion.

41
Sucker Rods / Corrosive Conditions

Non-corrosive well fluid types are classified as follows:

Well fluids that have less than 25% water cut and a pH of 7.0 and above.
Well fluids that are effectively,
effectively chemically inhibited
inhibited, monitored and
documented.
Consider installing Type 30, Type 54, Type 78, or Type 97 sucker rods where
corrosion is not a problem. The specific type sucker rod must be determined
by the design loading conditions.

Acid Gas Corrosion

H d
Hydrogen S
Sulfide
lfid (H2S)
(H2S), either
ith as a gas or ffrom b
bacterial
t i l activity
ti it iin b
brine,
i iin
any amount.
Carbon Dioxide (CO2) as a gas between a partial pressure of 7 psi (.048
Mpa)
p ) to 30 p
psi ((.207 Mpa),
p ), or between 600 pp
ppm and 1200 pp ppm in brine.
Consider installing Type 40 or Type 90 sucker rods for service in corrosive
fluids. The specific type sucker rod
must be determined by the design loading conditions.

corrosion.

42
Sucker Rods
Rod Stress / Strain
Curve
– Sucker Rods should
operate in the linear portion
of the stress vs. stain curve
and never receive
permanent deformation
– However, fatigue will be
shown to be the design g
consideration for
continuous operation.

43
Sucker Rods
Original Goodman Fatigue Loading Diagram

44
Sucker Rods
Construction of Modified Goodman Diagram
T

Sa = (T/4+ .5625(Smin))(SF)

ΔSa= Sa – Smin Sy
Sa= max allowable
stress, psi
T/2 T/1.75
ΔSa = allowable range of
stress
.5625
5625 = slope
l off S
Sa curve
Sa
T/4
SF = Service Factor
T = Minimum tensile Sm
strength, psi

T 45
Sucker Rods
Service Factors
– Use C grade rods to SF of
1.35 before usingg D rods
– Use D rods to SF of 1.35
before going to high Service API-C API-D
strength
g rods (default) (default)
– Inhibit! Do not use case Non 1.0 1.0
Corrosive
hardened rods
¾ For Permian from failure Salt Water 0 65
0.65 09
0.9
control in rod pump
wells, SWPSC
H2S 0.5 0.7

46
Sucker Rods
Get Surface Rod Loads from Dyno Card

47
Sucker Rods
Modified Goodman Diagram: Grade D Rods
70000

Rod Loading = 60000

29768 - 15141
37267-15141
50000
= 66%
40000
Sa =(T/4+
=(T/4+.5625(Smin))(SF)
5625(Smin))(SF)
= 37267 psi
30000

20000
Smin = 15141 psi
10000
Pk Stress = 29768 psi
® 0 48
Sucker Rods
Modified Goodman Diagram: Grade D, SF=.8
70000

Rod Loading = 60000

29768 - 15141
29814 -15141
50000
= 99.7%
40000

30000
Sa =(T/4+.5625(Smin))(.8)
= 29814 psi
20000
Smin = 15141 psi
10000
Pk Stress = 29768 psi
® 0 49
Sucker Rods
Rod Loading Problem
– Grade D, one inch rods were used to generate the below
dyno
y card. The service factor is 1.0. The min tensile is
115,000 psi (792810 kPa)

– What is the rod loading according to the percent of the

range
g of stress of the Modified Goodman Diagram?
g

50
Sucker Rods
Care
– Brochures Available from Norris

51
Sucker Rods

Recommendations for Sour / Corrosive

Service
–UUse C graded rods
d up tto a service
i ffactor
t off 1 1.35
35 bbefore
f
going to “KD” (alloy “D”) rods
– Use “KD” rods up to a service factor of 1.35 before
considering High Strength rods. Do you really want
HS rods in a sour, corrosive environment?
– Have an effective corrosion inhibition program to
reduce pitting, especially with HS rods.
– Do not use case hardened rods.
– Inspected
I t d rods
d are acceptable
t bl since
i mostt ffailures
il
originate from corrosion pits and the inspection
process is very good at identifying pits.

(Jim Curfew & John Patterson)

®

52
Sucker Rods
Types of Coupling

Note: Norris now

supplies
pp a hi-
strength coupling
for use with hi-
strength rods

Weatherford example products:

®

53
Sucker Rods: See API RP 11 BR
Correct Make-Up
Lubricate threads
before make
make-up
up

Scribed Measured
M d
Vertical Circumferential
Line Displacement
p

Hand Tight Joint Made up Joint

Made-up

54
Sucker Rods
Rods / Tubing / Casing / Pumps “Fit”
Table

2 3/8s

2 7/8s

55
Sucker Rods
Size Limitations
– 2 3/8’s
¾ 1 iinch
h fiberglass
fib l OK ( h
has 7/8’s
7/8’ coupling)
li )
¾ (All fiberglass rods have pins 1 size less)
¾ 7/8’s steel OK but can’t run overshot for fishing
¾ 7/8’s slim hole couplings can be run with steel coupled
rods
¾ Don’t run ½ inch in 2 3/8’s.. ((1/2 now discontinued))
¾ Don’t run 1 ½ wt bars in 2 3/8’s with less than 22 API
– 2 7/8’s
¾ Can run 1 “ w.w slim hole couplings
couplings.. Can fish
¾ Can’t run regular 1 1/8’s couplings
¾ Never run smaller than ¾” rods in 2 7/8’s

56
Sucker Rods
Rod Guides
– Use guides at wear
locations at dog-leg
g g
locations and/or at above
pump to reduce wear due
to fluid pound
– Molded guides tend to slip
less than hand installed

57
Sucker Rods
High Strength Rods

58
Sucker Rods
Fibreglass Rods
– Positive Features
¾ Rods are light weight, therefore reduce load on
surface equipment
equipment.
¾ Due to their elasticity characteristic, well designed
rod strings can have longer stroke down-hole than
surface stroke, over travel equal to increased
production
¾ Suitable for corrosive environments

Fibreglass Rods
– Negative Features
¾ Cost is higher then conventional sucker rods
¾ Due to excessive stretch characteristic, when fluid
load increases, down-hole pump stroke smaller than
su ace
surface
¾ Surface of rod damages quicker compared to steel
rods
¾ Due to fiber composite, they cannot support
compressive loads. Rods must always be in tension.
Design is critical and pump-off controllers are highly
recommended to eliminate any compression due to
unforeseen problem downhole
¾ Extremely difficult to fish when part
®

59
Sucker Rods
R d Rotators
Rod R t t
– Rod rotators are used in conjunction with rod
guides to remove paraffin deposition.
– A rod rotator should not be used when rods
can’t rotate freely. If the rods torque up,
backlash could cause the rods to unscrew.
– A leveling plate should be installed on the
carrier bar to prevent misalignment that could
cause side
id lloads
d ththatt could
ld result
lt iin a polish
li h
rod failure.
– A rotating tubing hanger and anchor system is
available that can be installed on wells that
have severe wear problems
problems.
– The entire tubing string can be slowly rotated to
distribute wear from rod contact, even if sides
loads keep the rod string in contact with one
side of the well.
well It is relatively expensive but it
can be justified if it eliminates one tubing failure
in a well.
– Use tubing rotator if tubing wears

60
Sucker Rods: Co-rod
No Couplings! Courtesy: Weatherford
Advantages
– Minimal Pin and Coupling Failures
– Minimal rod and tubing Wear
– Minimal torque and power
requirement
– Enhanced pump efficiency
– Simple,
p , quick
q installation and field
service

Disadvantages
– C
Costt couldld be
b up tto five
fi titimes
higher than comparable
conventional rod
– Service rig and welding unit must
b available
be il bl iin th
the area ffor
servicing
– Connection to polished rod and
pull rod critical

61
Sinker Bars
Heavier bars at bottom of
rod string to help rods fall
Sinker bars sized:
– by experience,
– use vendor formulas,
– using the “Z” factor or some
fraction of bars found from
this formula, (see Norris rod
handout) FLEX BAR INC

– or using the “neutral

neutral
buoyancy” concept.
– Example: 1.5" diameter
sinker bar lengths are 250-
250
300 feet, 2.875 tubing 1.5-
2.25” plungers and 5000 feet
deep. U
– Sinker bars have smaller pin
sized ~ 7/8’s
®

62
Rod Failures
Rod “Corrosion-Fatigue” Failure
– Mostly see (99%) corrosion-fatigue failures and not
“ l
“classic”
i ” metal
t l ffatigue.
ti
– Focus on pitting via improved chemical inhibition
program
p g & use rods with better fatigue
g p properties
p in
sour/corrosive environment
Corrosion - Fatigue -
y Small Pit in Wear Tract
Very

63
Rod Failures
Indication of Compression Flexing Failure
– Compression - double lipped failure
– Focus on eliminating fluid pound
– Pump slower, increase pump clearance, use sinker
bars or guide program above pump

Double Lip
p Failure - Flexing
g

64
Rod Failures
Loss of Circumferential
Displacement

Wear

65
Rod Failures
Inspection
– Recommend to inspect
new and used rods
Handling
– Critical!

66
The Downhole Pump

Plunger Traveling
Valve

Pump Barrel

Standing
Valve

Up Stroke Down Stroke

67
The Downhole Pump:

START PLUNGER
START OF DOWN FALLS THROUGH
OF UP STROKE FLUID FLUID
STROKE LIFTED TOWARD
From Harbison / Fischer SURFACE

68
The Pump
API Pump Designation
XX – XXX – XXXX - X - X –X - X

Length of
TBG SIZE
Extensions
PLGR SIZE Type of Pump & Length of Length of
Location of Barrel Plunger
Seating Assy

A 1-1/4in bore rod type pump with 10 ft. heavy wall

barrel and 1ft lower & upper extensions, a 4ft
plunger,
l andd a bottom
b tt cup type
t seating
ti assembly bl
for operations in 2-3/8” tubing, would be designated
as follows:
Weatherford
20-125-RHBC-10-4-1-1
®

69
The Pump
Rod Pump Top Anchor
– Advantages
¾ Eliminates sedimentation around barrel tube
¾ Reduces corrosive attack on exterior of barrel
¾ Pump barrel can act as gas anchor
– Disadvantages
¾ Valve rod is weak leak of sucker rod
¾ Not recommend for deep wells
¾ Part time pumping may allow sediments to fall on pump
Rod Pump Bottom Anchor
– Advantages
¾ Can be used in deep wells
¾ Good valve location
¾ Better design where long pumps necessary
– Disadvantages
¾ V-rod weak link in S-rod chain
¾ Barrel tube subject
j to sedimentation
¾ Part-time pumping may allow sediments to fall on pump

70
Bottom / Top Holddown Insert Pumps

Bottom holddown Top holdown

has no place for
has pressure particulates to
p
equalized
li d across th
the accumulate but
barrel of pump – But outside of
particulates can barrel exposed
accumulate
accu u a e be
between
ee to low well
barrel and tubing pressure and
and stick pump on could split at
removal. So need deep depths. So
has shallower
top seal or bottom depth
discharge pump limitations

71
The Pump
Ball and Seat Pull Rod/tube Plunger Metallurgy
– Steel – Steel – Steel
– Stainless steel – Stainless steel – Monel or electroless nickel
– Cobalt alloy – Brass coated
t d pins
i
– Tungsten carbide – Coatings
– Titanium carbide Barrel Metallurgy ¾ Chrome plated
– Nickel carbide – Carbon Steel ¾ Spray
S Metal
– Ceramic – Stainless steel ¾ Boron impregnation
– Silicon nitride – Brass
Cage – Monel
– Steel – Treatment/coating
– Monel ¾ Heat treated
– Stellite hardened ¾ Chrome plated
– Four piece insert ¾ Nickel carbide

72
The Pump
Plunger Length
– Rule of thumb:
¾ 3 ffeett ffor d
depths
th less
l than
th 3000 ft
¾ 3 feet long plus 1 ft/1000 ft to 6000 ft
¾ 6 feet long in deeper wells
¾ Industry recommendations: Slippage should be 2-5% of
production to reduce pump galling and provide
lubrication.

73
The Pump
1.25" 1.5" 1.75" 2" 2.25" 2.5" 2.75"
Pump Type Steel Barrels
Top
p Hold-down,, Thin
Wall RWA 6,394 5,520 - 3,732 - 3,183 -

Bottom Hold-down,
Thin Wall RWB 16,936 14,705 - 9,727 - 6,362 -

Travel Barrel, Thin

Wall RWT 16,936 14,705 - 9,727 - 6,362 -

Top Hold-down,
Heavy Wall * RHA 8,321* 8,818* 6,749* - 4,876* - -

Bottom Hold-down,
H
Heavy W
Wall
ll * RHB 27 148*
27,148* 24 249*
24,249* 21 897*
21,897* - 18 323*
18,323* - -

Travel Barrel, Heavy

Wall * RHT 27,148* 24,249* 21,897* - 18,323* - -

Tubing Pump TH - - 10,019 - 7,763 - 6,262

Oversized Tubing
Pump THOS - - 10,019 - 7,763 - 6,262

* If using extensions RHA 7,568 6,118 4,706 - 3,824 - -

RHB 25728 28,714 20,708 - 17,294 - -

Weatherford
®

74
The Pump
Latest Slippage Equation : Desire at least 2-5% of
production rate leaking (slipping) back between
plunger/barrel
DPC1.52
Slippage = [(0.14 ⋅ SPM ) + 1]453
Lμ
– Based on this work and previous work, the following minimum
pump clearances are recommended for a 48”48 Plunger with a “+1
+1
Barrel”.
– These clearances have become widely used in the Permian
Basin for well depths up to 8000 feet
feet.
¾ 1.25” pump = -3 to -4 plunger (0.004” to 0.005” total clearance)
¾ 1.50” pump = -4 to -5 plunger (0.005” to 0.006” total clearance)
¾ 1.75
1 75” pump = -5
5 to -6
6 plunger (0.006
(0 006” to 0.007
0 007” total clearance)
¾ 2.00” pump = -6 to -7 plunger (0.007” to 0.008” total clearance)
®

75
The Pump
Pump / Tubing / Casing / Rods Chart

76
Anchors
Mud Anchors
– Used to protect pump & part of gas anchor
– Same size restriction as tubing
– Can be short joint or multiple joints
– Can cut slots in the top of the joint or use a perforated
nipple
– Recommend that end be orange g p peeled rather than a
bull plug
– If severe corrosion, consider coating OD and ID

77
Anchors
Gas Anchors
– Gas interference can
drastically reduce the pump
efficiency
– Gas should be separated
downhole and vented up
the casing
– A natural gas anchor with
the seat nipple below the
perforations is the best
option
– If no rat hole
hole, then
determine the best gas
anchor for the well

78
Beam Monitoring and Optimization
Optimization of a Beam System requires getting
most production at lowest power cost.
Parameters that effect the system that are checked /
monitored are:
– Fluid pound
– G Interference
Gas f
– Valve Leaks
– Worn Plunger / Barrel
– Incorrect Spacing
– Overloads (Rod, Unit, Primemover)
– Pump Fillage
– Runtime
– Prod rate vs Pump Volume = Volumetric Efficiency
– Motor oversized
– Efficiency of system
– Fluid levels or intake pressure
®

79
Beam Monitoring and Optimization
In order to produce the
maximum with a beam
pump
– The fluid level should be as
low as possible
– However this can result in fluid
pound and gas interference
– A typical practise is to switch
the pump off and let fluid level
build up again and then run
pump again.
– This can be done using
¾ Pump Off Controllers
(POCs)
¾ Timers

80
Beam Monitoring and Optimization
Pump Card (Cycle with Pump Full of Liquid) on left
and partial gas fillage on the right

81
Beam Monitoring and Optimization
The Pump Card
– Pump off occurs when the
pump
p p begins
g fill with
increasing amounts of gas
instead of liquid.
– It is up
p to the operator
p to
decide what degree of
pump off is allowed before
shutting off the unit.
– Common practice is to
allow pump-off to the point
where pump fill age with
liquid is about 85 to 90
percent

82
Beam Monitoring and Optimization
Pump Off Controllers
– A well with a high static pressure and a low PI is a
good d wellll ffor POC
POC.
– This is because during the down-cycle, the well will
continue to flow into the well annulus.
– The pumping unit should be designed such that the
unit will pump about 140% of the maximum that the
wellll will
ill make.k
– This means that the well will pump about 18 to 20
hours a day
– Beam system is only AL method where POC used
extensively! Unit has to be designed to pump
f t th
faster than reservoir i produces
d to
t pump-off.
ff

83
Beam Monitoring and Optimization
Pump Off Controllers
– Typical cycles are about 1 hour for many wells. This
means about a 15 min idle time and 45 minute
pumping time.
– If the pumping hours decrease when idle time is
increased then production is being lost
increased, lost. The idle time
should then be decreased again.
– Pumping hours are an excellent measure of
production,
d ti sometimes
ti even bbetter
tt than
th a wellll ttestt iin
many fields.
Potential Benefits
– 20% reduction in energy costs
– 25% reduction in pulling expense
– 1 to 10% increase in production
®

84
Beam Monitoring and Optimization
Automated Well with POC
A well can have a
little or a lot of
control. This well
figure shows
many y controls.

85
Beam Monitoring and Optimization
Timers
– A timer can be used to determine when the unit
operates
t / switches
it h offff
– Two style of timers are used in the oilfield.
¾ A percentage timer controls the percentage of time that
the pumping unit operates.
¾ An interval timer controls the time intervals (usually 15
min)) which
c tthe
e pu
pumping
p g unit
u t operates.
ope ates
– They can cost from $25 to $200 each.

86
Beam Monitoring and Optimization
Summary: POCs and Timers
– Electrical and maintenance costs will be reduced with a properly
operating
p g timer or POC.
– The recommended 15 minute percentage timer technique for
reducing electrical costs and maintenance costs is a relatively
simple
p techniqueq and inexpensive
p p
procedure for reducingg
operating costs in a well which have a pumping capacity
exceeding the wells’ producing capacity.
– POC is a more sophisticated
p method of control and is very
y
common.
The main idea is to keep the fluid level low without
requiring a lot of service time from field personnel
personnel.
Other gains such as reduced energy, reduced
damage, and more production are also possible.

87
Beam Monitoring and Optimization
System Efficiency
– Single well meters allow some measure of diagnostics for the well
including
g the calculation of p
power efficiency.
y
¾ Actually few determine the power efficiency below but if they do
it is useful diagnostic.
¾ With high prices for oil, the main concern is “how to maximize
production”.
– Master meters for a group of well give the company credit for
regeneration of the motors when they act as generators. Single
well meters with a rachet do not.

0.00000736(bpd )(lift )γ liq useful power

η= =
kW / 0.746 input power

88
 Additional Reference
Slid Follow
Slides F ll that
th t are
Included for your
Information that may y not
be Presented in Class

89
The Pump
The “Sandbar” Top Seal Uses a Brush Seal:
Other type rubber expandable seals exist

90
The Pump
The Bottom Discharge Valve is placed
above the bottom seating assembly of
a bottom
b tt anchor
h pump.
On the downstroke, a portion of the
fluid from the pumping chamber is
discharged into the annulus around
the pump, providing and upflow to
keep sediment from accumulating.
This valve is an alternate to use of the
top seal assembly for type “B” insert
pumps.

91
The Pump
API Documents
– API Spec 11AX Specification of Subsurface Sucker
R dP
Rod Pumps and d Fitti
Fittings
– API RP 11AR Recommended Practice for Care and
Use of Subsurface Pumps p

92
Surface Unit
Standard API Unit Sizes
API Gearbox Ratings API Structural Ratings API Standard Stroke’s, in

80 48
114 143 54

160 173 64
228 200 74
320 213 86
456 246 100
640 256 120
912 305 144
1280 365 168
1824 427 192
2560 470 216
240

93
Gearbox
Care
1. Keep the loading within the manufacturer’s rating.
2. Ensure unit balanced (counterbalance)
3
3. A id flfluid
Avoid id pound
d (thi
(this d
down h
hole
l condition
diti causes severe shock
h k
loading on the entire pumping unit as well as on the reducer)
4. Ensure belts not too tight (results in high shaft stresses)
5. Use correct lubricant (manufacturer recommendations)
6. Periodically change rotation (conventional units can be run in both
directions). Allows opposite tooth surfaces exposed to contact loading.

Lubrication: Wiper Comments

1. Lufkin wipers work equally well in both direction of rotation (+ & -).
2. If you run at < 5 SPM Lufkin recommends you add an extra set of
wipers on the high speed gear
gear.
3. Never have to adjust the wipers as they use gravity to continually
adjust as they wear with time (the wiper is hinged to allow gravity to
adjust)

94
API Documents
Spec 11E Specification for Pumping Units
RP 11G Installation and Lubrication of Pumping
Units
API STD 11E Pumping Units
API BUL 11L4 Curves for Selecting Beam Pumping
Units
API spec 1B for guidelines of V belts

95
Tubing Best Practices
Perform Wellhead tubing scanning on wells
where excessive rod wear is found and on
problem wells.
wells Scan all the tubing
tubing, including
that below the TAC.
For wells 3500' or less in depth
p with historic
wear problems, pull and replace entire tubing
string when there is a tubing failure.
Ch
Change outt entire
ti tubing
t bi string
t i (regardless
( dl
of the type of failure) once the tubing string
has reached the average g age
g of tubing g life for
that particular field.

F ll i 4 slides,
Following lid MB
Brock
k BP)
®

96
Tubing Best Practices
Lay down tubing on all wells having 2 tubing
failures in 12 months or less.
– Exception to this would be where all tubing failures
have historically been right above the pump in which
case you should replace the bottom 10 joints.
IIn wells
ll with
ith tubing
t bi failure
f il due
d tot external
t l
pitting, lay down all pitted joints and test
tubing back in hole
Wellhead scan tubing on the first tubing
failure after tubing has been replaced with
new or yellow band pipe.
– The information is an excellent diagnostic tool for
evaluating the current rod design
design.

97
Tubing Best Practices
Verify the wellhead scanning tool was calibrated on
location before and after the job against a known
tubing sample and verify the pipe is pulled at the
proper speed.
– Some tools have a speed scale on the chart.
Consistent speed is very important in scanning
tubing.
– When approaching
pp g the TAC crews tend to slow down several
stands before the TAC to keep from pulling it into the wellhead.
– It is recommended that when the pulling unit operator feels he
must start slowing
g down (g
(generally
y 7 to 10 stands above the
TAC) that he stops scanning and stands back the remaining
tubing down to the TAC, remove the TAC, rerun the stands not
scanned, and then scan the rest of the string out at the
appropriate speed.

98
Tubing Best Practices
When running tubing, always use a new or
yellow band joint in the wellhead slips.
Always replace the seating nipple plus the
blast joints / internal plastic coated joints /
etc in pump discharge or dead space with
etc.
new or yellow band when tubing pulled.
Tag bottom for fill where applicable when
pulling tubing.
See below paper , SWPSC 1998 for tubing
practices in detail:

99
Sucker Rods
API Practice 11BR: Care and Handling of
Rods
– Selection Of API Steel Sucker Rods
– Transportation, Storage and Handling
– Corrosion Control By Chemical Treatment
– Allowable Sucker Rod Stress Determination Utilizing
Range
g Of Stress
– Sucker Rod Joint Makeup Utilizing Circumferential
Displacement
– Methods
M h d Of Inspection
I i anddRRequired
i dEEquipment
i
– Installation Of Polished Rod Clamp On Polished Rod

100
Sucker Rods
Rod Spacing (wells that are 8000-9000 feet deep typically with
very low fluid levels)
– Run pump in hole until tag seating nipple.
– Space out polish rod/pony rods
– Load tubing w/ fluid.
– Stroke pump x check for action.
– Put gauge in pumping tee and
– stroke w/ rig.
– Tag plunger on barrel x PU about 18 inches. PU horsehead x hang off
rods.
– Put well pumping x let pump fluid level down.
– Check for bumping and respace pump as necessary. Check pump
spacing with dyno to make certain pump is not bumping also.
– 18 inch spacing has been working pretty good for Hackberry
Hackberry. This
spacing is for steel rods only w/ no fiberglass. Fiberglass spacing will
be different.
Note: gas problems PU will be much less… only inch or two
and then recheck if bumping and respace..

101
Rod Failures
Corrosion due to Turbulence Past Rod Guide?
– SPM x SL (inches) < 1500Fluid velocity between coupling OD (d)
and tubing ID ( D) is: Velocity
Velocity, ft/sec = 0 02384 BPD/(D-d) < 4
fps
– Newer guides more streamlined.
– Guides must be removed in inspection process to look for
underlying corrosion!!

Corrosion In Turbulent Area - Rod Guide

102
Sucker Rod Best Practices (after Brock, BP)
When running rods, remove one rod and replace
with 13' of rod subs above pump and 12' of rod subs
at the top of the well to move the wear pattern.
On subsequent pulls reverse procedure. (Assuming
the pump length remains the same).
All rod strings should be carded when run in the
hole. Should card every taper and/or 10 - 12 triples
Replace rod taper section following the second
failure in 12 months in that taper.
Replace
p entire rod string
g on second failure in 12
months if failures occurred in two different tapers.
(another operator 4th in 24 months)

103
Sucker Rod Best Practices (after Brock, BP)
R l
Replace ti steel
entire t l rodd string
t i after
ft an estimated
ti t d
20,000,000 cycles.
If used inspected rods are utilized, 15,000,000 cycles
since
i last
l t inspected
i t d goodd rule
l off thumb.
th b
When looking at replacing fiberglass rods, need to
consider the loading the rods have been under.
Loading on fiberglass
f rods is inversely proportional
to cycle life. The higher the percent rod loading, the
shorter the rod life.
P bli h d data
Published d t for
f fiberglass
fib l rods
d indicates
i di t the
th
number of cycles to first failure to be:
– 30 million cycles at 80% rod loading,
– 15 million cycles at 85% rod loading
loading,
– 10 million cycles at 92% rod loading
– 7 million at 100% loading.

104
Beam Monitoring and Optimization
Travelling Valve Test
– Stopping the pump on the
upstroke
p will have the fluid
load plus the weight of rods
in fluid on the polished rod.

TV, load = Wra ( 1- 0.128 x

SG) +
+ 0.340
0 340 x SG x D2 x H
Where:
Wra = weight of rods in air
SG = specific
ifi gravity
it off fluids
fl id
D = pump diameter , inches
H = depth, feet

105
Beam Monitoring and Optimization
Standing Valve Test
– Stopping the unit on the
downstroke will have only
th weight
the i ht off rods
d iin fl
fluid
id
on the polished rod.

SV, load
= VOL x 487.5 - VOL x 62.4
x SG
= Wra
W ( 1 - .128 128 x
SG)
Where:
VOL = volume of rod string
487.5 = density of steel,
lbs/cu.ft
62 4 = water density,
62.4 density lbs/cu.ft.
lbs/cu ft
Wra = weight of rods in air
®

106