SRP Report

Sucker rod pumping is also referred to as ‘‘beam pumping.’’ It provides mechanical energy to lift oil from
bottom hole to surface. It is efficient, simple, and easy for field people to operate. It can pump a well
down to very low pressure to maximize oil production rate. It is applicable to slim holes, multiple
completions, and high-temperature and viscous oils. The system is also easy to change to other wells
with minimum cost. The major disadvantages of beam pumping include excessive friction in crooked/
deviated holes, solid-sensitive problems, low efficiency in gassy wells, limited depth due to rod capacity,
and bulky in offshore operations. Beam pumping trends include improved pump-off controllers, better
gas separation, gas handling pumps, and optimization using surface and bottom-hole cards.

Parts of SRP:

1) Prime Mover: an electric motor or an internal combustion engine. The modern method is to
supply each well with its own motor or engine. Electric motors are most desirable because they
can easily be automated.
2) The power from the prime mover is transmitted to the input shaft of a gear reducer by a V-belt
drive.
3) The output shaft of the gear reducer drives the crank arm at a lower speed (4–40 revolutions per
minute [rpm] depending on well characteristics and fluid properties).
4) The rotary motion of the crank arm is converted to an oscillatory motion by means of the
walking beam through a pitman arm.
 5) The horse’s head and the hanger cable arrangement is used to ensure that the upward pull on
the sucker rod string is vertical at all times.
6) The polished rod and stuffing box combine to maintain a good liquid seal at the surface.

Conventional pumping units are available in a wide range of sizes, with stroke lengths varying from 12 to
almost 200 in. The strokes for any pumping unit type are available in increments (unit size). Within each
unit size, the stroke length can be varied within limits (about six different lengths being possible). These
different lengths are achieved by varying the position of the pitman arm connection on the crank arm.

Types of pumping units:

Beam type pumping unit geometrics fall into two distinct classes:

(1) The Class I lever system which has its speed (gear) reducer rear-mounted with the fulcrum at mid
beam, represented by the conventional unit

Conventional Unit
(2) The Class III lever system, push-up geometry with its speed reducer front-mounted, represented by
the air balance and Lufkin Mark II units, where the fulcrum is located at the rear of the beam.

Lufkin Mark II Units:

Air Balanced Units:

The pitman arm and horse’s head are in the same side of the walking beam in these two types of
units (Class III lever system). Instead of using counter-weights in Lufkin Mark II type units, air
cylinders are used in the air balanced units to balance the torque on the crankshaft.

Sucker Rod Pumping Unit:

The American Petroleum Institute (API) has established designations for sucker rod pumping units
using a string of characters containing four fields. For example,

C-228D-200-74

 The first field is the code for type of pumping unit. C is for conventional units, A is for air-
balanced units, B is for beam counterbalance units, and M is for Mark II units.
 The second field is the code for peak torque rating in thousands of inch-pounds and gear
reducer. D stands for double-reduction gear reducer.
  The third field is the code for PRL rating in hundreds of pounds. Eg: 200: 20000lbs – Load
rating
 The last field is the code for stroke length in inches.

Different types of subsurface pumps:

The subsurface pumps can be divided into three main types:

1) Tubing pumps
2) Insert(rod) pumps
3) Casing pumps

All these three types of pumps consist of 4 main parts:

1) A working barrel
2) A plunger
3) An intake valve ( standing valve)
4) An exhaust valve( travelling valve)

1) Tubing Pumps: The working barrel is connected to the bottom of the tubing and is run into the
well as an integral part of the tubing string. One basic advantage of tubing pumps is that they
have a greater displacement than insert types because larger plunger diameters can be used
within the larger working barrels of tubing pumps. However, tubing pumps have the
disadvantage that the entire tubing string must be pulled from the well in order to service the
working barrel. For this reason, tubing pumps are generally used only when the production
desired cannot be obtained with an insert pump at the available stroke and speed combinations
on the pumping unit selected.

2) Insert Pumps: The working barrel is an integral part of the entire subsurface pump assembly and
is run as a unit on the sucker rod string inside the tubing string. The advantage of insert pumps is
that they connect to the sucker rod string, and the entire assembly can be removed from the
well merely by pulling the rod string. With this type of pump, the working barrel is lowered on
rods; consequently, some means must be provided to secure the barrel into the bottom of the
tubing in order to provide fluid packoff and to facilitate the relative motion of the working barrel
and plunger.

3) Casing Pumps: It is just a larger version of the insert pumps and is set and operated in the same
manner. The casing pump is a large-volume, shallow-depth pump and is particularly suitable for
 installations where high production rates are required. This group of pumps includes all pumps
which use casing instead of tubing through which fluid is pumped to the surface. A casing pump
is run into the well on sucker rods, and a packer, either on the top or bottom of the working
barrel, provides the fluid packoff between the working barrel and the casings No tubing is used
in this type of installations.

The Pumping Cycle:

As the plunger is moved downward by the sucker rod string, the TV is open, which allows the fluid to
pass through the valve, which lets the plunger move to a position just above the SV. During this
downward motion of the plunger, the SV is closed; thus, the fluid is forced to pass through the TV. When
the plunger is at the bottom of the stroke and starts an upward stroke, the TV closes and the SV opens.
As upward motion continues, the fluid in the well below the SV is drawn into the volume above the SV
(fluid passing through the open SV). The fluid continues to fill the volume above the SV until the plunger
reaches the top of its stroke.

(a) Plunger moving down, near the bottom of the stroke

(b) Plunger moving up, near the bottom of the stroke
(c) Plunger moving up, near the top of the stroke
(d) Plunger moving down, near the top of the stroke

The designing parameters:

(1) Fluid level (net lift, ft): The depth or the distance from surface that the fluid in a well is capable of
flowing under static conditions.

(2) Pump depth, ft: The depth up to which the subsurface pump needs to be set in order to fill the
plunger barrel.
(3) Pumping speed, strokes per minute: The number of strokes the polished rod completes in one
minute. It determines the rate at which liquid is pumped.

(4) Length of surface stroke, in. : The surface stroke is the distance which polished rod travels at the
surface and it is different from pump stroke length due to the rod and tubing stretch and frictional
losses.

(5) Pump plunger diameter, in. : For a given pumping depth and volume of fluid to be produced, there is
an optimum size of pump bore which will result in effective pump plunger travel and maintain moderate
speed of operation. If the plunger is too large, unnecessarily high loads will be imposed upon the
equipment and plunger undertravel can result in inefficient operations. On the other hand, if the
plunger is too small, pumping speeds become too high and the increased acceleration (inertial) effects
can result in increased peak loads on the equipment.

(6) Specific gravity of the fluid : Specific gravity of fluid is one of the key parameter in deciding the
configuration of pump because more the specific gravity lesser will be the static level for the desired
flow rate and in that condition pump may run dry.

(7) The nominal tubing diameter and whether it is anchored or unanchored : The nominal tubing
diameter is decided on the basis of required flow rate at the surface and if the required flow rate is
higher tubing pumps are used. If the tubing is fixed at the bottom then it is said to be anchored
otherwise unanchored.

(8) Sucker rod size and design : Types of sucker rod pump to be used and its size depends on the
required flow rate at the surface

With these factors, the designer should be able to calculate, with some degree of reliability, the follow
ing:

(1) Plunger stroke, in. : A considerable difference can exist between the length of the stroke of the
polished rod and the actual length of travel of the pump plunger. The point of interest is the distance
that the plunger travels relative to the working barrel. This relative motion between the plunger and the
working barrel results in the net or effective plunger stroke, which differs from the motion of the
polished rod because of several factors such as Rod and tubing Stretch, Plunger overtravel, Vibrational
effects and frictional losses.

(2) Pump displacement, (BPD) : The basic factor in the selection of a suitable pump size is the volume of
fluid displaced by the pump per inch of each stroke. This volume displacement will depend upon the
diameter of the pump bore.

(3) Peak polished rod load, lb: The maximum amount of load on the polished rod occurs during
beginning of the upstroke which is due to the sum of static weight of the fluid and the sucker rods and
an additional factor which is a fraction of static weight of rod. Lifting maximum mass (weight of rods
and fluid) with high acceleration results in a greater rod and structural load, producing larger rod
stresses. Lifting the maximum load of rods and fluid off-bottom with reduced acceleration results in
lower structural loads and rod stresses. In this basic, inelastic system the bottom reversal loads the rod
string while the top reversal unloads it.

(4) Minimum polished rod load, lb : The Minimum Polished Rod Load (MPRL) results from the maximum
downward inertial force component being subtracted from the static weight of the rods Minimum load
occurs near the top of the stroke just a the rods ire starting down, because this is the point o maximum
downward acceleration. The greater the downward acceleration the greater the inertial force
component and, when subtracted from the static weight of the rods, results in the minimum polished
rod load.

(5) Peak (crank) torque, in-lb or ft-lb: The net crankshaft torque of a beam pumping unit is the difference
between well load torque and counterbalance torque at any position of the crank. This net crankshaft
torque is the actual torsional load ‘seen” by the prime mover and gear box during the crank cycle. The
maximum net torque is referred to as peak torque and is the value to which the gear reducer is
designed. Thus, in any pumping installation the actual peak torque occurring during the pumping cycle
must not exceed the maximum torque rating (capacity) of the gear box or speed reducer. On the
conventional unit, the peak torque generally occurs twice during each revolution of the crank where the
difference between the well load moment and the counterbalance moment (or vice-versa) is maximum.
This normally occurs near the middle of the stroke (Sf2). Consequently, the gear reducer must be
designed to handle this peak torque. All else equal, peak net torque is a function of the difference
between peak and mini mum polished rod loads, i.e., the rod load range

(6) Polished rod horsepower

(7) Counterweight required, lb: In a beam pumping system, the amount of polished rod work needed to
lift the fluid column is required only during the first half of the crank cycle, i.e., during the upstroke. If
the beam pumping unit were not counterbalanced, the prime mover would have to do all of its useful
work during the upstroke portion of the cycle. This would require a relatively large prime mover and
speed (gear) reducer and would produce fluid in a most ineffective, inefficient manner.

Dynamometer Cards
Introduction

Surface Card: displays the load on the Polished Rod (PR) over a pump cycle. The card shape is a
function of PPU geometry, SPM x SL, pump depth, rod string design and elasticity, fluid load on
pump, etc.
Wave Equation: mathematically models the elastic nature of the rod string (assuming a
downhole friction factor), & allows the Surface Card data to be converted to pump card.
Pump Card: displays the fluid load on the pump plunger (F0) over a pump cycle. The size and
shape of the card indicate the operating conditions and performance of the pump

Physical Interpretation of Dynacard

Interpreting dynacards :

Baseline Actual
Dynacards – 100%
Pump Fill

Baseline Actual
Dynacards – 75%
Pump Fill

Error in pumping unit

identification:
 Tilted Actual
Dynacards
condition may be
caused by a tight
or uneven pump
barrel

Actual Downhole
Dynacard Rests
Below Zero
Rod weight
parameter is too
large because rod
length, rod
diameter, or other
rod makeup
Parameters are
incorrect; rod
friction and/or oil
gravity parameter
values may also be
in error.

Actual Downhole
Dynacard Rests
Above Zero
Rod weight
parameter is too
small (incorrect
rod makeup
settings), or hole in
tubing is causing
increased buoyant
rod weight, or rod
friction or oil
gravity parameter
 is incorrect

Downhole
Dynacard Too Thin
– Rod Friction
Actual rod friction
is less than the rod
friction parameter

Downhole
Dynacard Too
Thick – Rod
Friction
Actual rod friction
is more than the
rod friction
parameter.

High Casing Fluid

Level caused by
high casing fluid
level. This could
also simply
indicate a new
startup – no fluid
to the surface yet
Free Flowing Well /
Stuck Traveling
Valve / Deep Rod
Part caused by
very high casing
fluid level, free-
flowing well, a
stuck or broken
traveling valve,
deep rod part, or
an unseated pump.
This could also
simply indicate a
new startup – no
fluid to the surface
yet
Fluid Not to
Surface / Tubing
Leak
Caused by no fluid
to the surface
(tubing not full), or
a leaky tubing. This
could also simply
indicate a new
startup no fluid to
the surface yet.
This could also
indicate the
presence of gas in
the tubing. The
hallmark of this
condition is an
uncharacteristicall
y high downstroke
load associated
with a loss of
buoyancy on the
rod.
 Stuck or broken
Standing Valve

Parted Rod
The depth of the
part can be
determined by the
pump load. The
lower the load, the
higher the rod
part. If the surface
card rests on zero,
the rod part is near
the surface. If the
downhole card
rests on zero, the
rod part is deep,
near the pump

Actual Downhole
Dynacard Has
Sloping Sides
caused by either
an unanchored or
loose tubing
anchor, or by rod
stiffness less than
predicted
 Erroneous
Oscillations in
Downhole
Dynacard
caused by high
rod/pump friction
causing stick/slip
behavior, or by an
improper rod mass
calculation,
possibly caused by
incorrect rod
makeup data

Gas Interference &

Gas Lock

Sticking Pump
Indicates a stuck or
sticking pump,
possibly caused by
scale or paraffin
buildup.
 Undertravel
because of too
much stress on rod

Sticking or Floating
Rod possibly
caused by scale or
paraffin buildup

Damaged Pump
Barrel
 Fluid Pound
Sudden Impact
Load. Inefficient &
very damaging to
the pump, rods,
tubing and the
Gearbox. The
impact load causes
rod buckling.

Worn Pump
Slow to pickup and
quick to release
the fluid load due
to TV leaking or
plunger/barrel
wear

Bent
barrel/Sticking
pump

Worn Standing
valve
 Worn Travelling
Valve or Plunger

Pump hitting at top

and bottom

Load Transducers
Horseshoe Loadcell

-Indicate actual load and is most accurate with an accuracy of 0.5% or better of its rated load

-Placed between polished rod load and carrier bar

-It contains strain gauges distributed cylindrically around polished rod which provides an averaging
effect

Disadvantages

-Pumping unit must be stopped while placing dynamometer on polish rod

-while moving cell on top of carrier bar the rod string must be raised by 3” which changes the downhole
spacing of plunger which may bring about changes in pumping conditions and dynamometer card
obtained will not represent normal pumping operations.

Polished Rod Transducer

-Measure changes in diameter of polished rod load due to pumping load using solid state stain gauges.
-Transducer is slightly clamped to polished rod below carrier bar by tightening it’s screw.

-It contains strain gauges measuring the loads as well as accelerometer to determine the load postion.

Advantages

-Easy application

-Spacing of downhole pump is not affected because polished rod does not needs to be spaced

NOTE :

It must be noted that dynamometer surveys for the six cases investigated have to be made using
horseshoe transducers because PRTs always force the bottom of the pump card to lie on the zero load
line.

Deep Rod Part

Pump card lies on the zero load line and is very flat because the
bottom of the string is not loaded. The polished rod loads lie close
to the buoyant weight of the rod string, Wrf, since there is no fluid
load applied by the pump to the rod string.

Shallow Rod Part

Surface loads are less than the calculated buoyant rod string
weight, Wrf, because the lower part of the string is missing. The flat
pump card shifts below the zero load line by the buoyed weight of
the missing rod sections.
Standing Valve Stuck Open
In this condition prevents the transfer of the fluid load from the
traveling valve to the standing valve during the downstroke. Since
the traveling valve never opens, polished rod loads are close to the
sum of the buoyant weight of the string plus the fluid load. The
pump card is flat because the plunger carries the fluid load during
both the up- and the downstroke.

Traveling Valve Stuck Open

Since there is no pumping action due to the permanently open traveling
valve, pump loads are close to zero and the pump card lies around the
zero load line. The loads on the surface dynamometer card are equal to
the buoyant rod string weight.

Blocked Pump Intake

Barrel does not fill with liquid during the upstroke or can even become
empty. Due to the blocked intake the pressure inside the barrel during the
upstroke goes down to zero and the plunger carries a load much higher
than the load calculated from the measured fluid level. The flat pump card
lies very close to the maximum possible fluid load. The surface card shows constant load equal to the
sum of the buoyant rod string weight and the maximum possible fluid load.

Deep Hole in Tubing

If the tubing leak is big enough, the tubing above the depth of the hole is
practically dry. Due to this the measured weight of the rod string
considerably increases because most of the string operates in air, the
buoyancy force for the dry section is missing. The pump card is shifted
above the zero load line by the load equal to the missing buoyancy force.
Fluid load on the plunger, as compared to previous cases, is considerably
greater but much lower than normal because the pump lifts liquids up to
the tubing leak only. The surface card similarly to the pumpcard is not flat
and is situated above the buoyant rod string weight.