Computer Diagnosis ofDown-Hole
Conditions
In Sucker Rod Pumping Wells
S. G. GIBBS
MEM&9f AIMI?
A. B. NEELY
ASSOCIATE MEMBER AIME
ABSTRACT
Sucker rod equipment is the most widely used means
for artificially lifting oil wells. Owing to this wide applica-
tion, a large potential exists for increasing income through
better methods for analyzing and trouble-shooting sucker
rod installations. This paper describes a computer-oriented
method whereby subsurface dynamometer cards can be
determined from polished rod dynamometer data. The
sabsurjace cards are, useful in calculation of intermediate
rod stress, estimation of pump intake pressures, detection
of unanchored tubing and detection of leaking production
strings and down-hole plimps. To date, this method has
been used as a production engineering tool by Shell Oil
Co. in over 500 wells in the United States, Canada and
VenezueZa.
INTRODUCTION
Through the years the polished rod dynamometer has
been the principal tool for analyzing the operation of rod-
pumped wells. The dynamometer is an instrument which
records a curve of polished red load vs displaument. The
shape of this curve is affected by the down-hole operating
conditions. Ideally, these condhions would be apparent
from the dynamometer card by visual interpretation. OW-
ing to the complex behavior of sucker rod systems rmd
the diversity of card shapes, however, visual diagnosis of
down-hole conditions is not always possible, Though much
information can be gained from visual interpretation of
surface data, tits information is qualitative in nature.
Furthermore, the success in visual interpretation is directly
linked with the skill and experience of the dynamometer
analyst, and even the most experienced analysts are fre-
quently misled into an ineorreet diagnosis.
The analytical technique described in @is paper was
developed to bridge the gap which arises when visual in-
terpretation is inconclusive or when quantitative down-
hole data are needed. The method is based on a mathe-
matical model “of the prtmpirsg- system which is virtually
free from simplifying assumptions. The polished red data
are analyzed on a digital computer With a rigorous solu-
tion to the mathematical ,model. As a result, the technique
provides a rational, quantitative method for calculating
down-hole renditions which is independent of the skill and
SHELL DEVELOPMENT CO,
SHEIL 011 CO.
HOUSTON, TEK.
experience of the analyst, It is m ionger neeessary to
gUCSSat down-hole pump condition? on the basis ?f rec-
ordings taken several thousands of feet above at the pol-
ished rod. By use of the analytical method, direct calcula-
tions of subsurface conditions can be made.
The analytical method has been extensively used in field
operations. Discxtssed in this paper are calculation of inter-
mediate rod stresses, estimation of pump intake pressures,
detection of unanchored tubing, detection of exeessive rod
friction, detection of leaking pumps and production strings,
detection of gas separation problems and computation of
gearbox torque.
DEVELOPMENT OF EQUATIONS
The theory underlying the analytical method is not par-
ticularity simple but the basic idea behind it is. It is helpful
to think of the. sucker rod string as a transmission line. At
the lower end of the transmission line is a transmitter (the
down-hole pump) and at the upper end is a receiver (an
instrument installed at the polished rod). Information
about down-hole pump conditions. is transmitted along the
sucker red in the form of strain waves. These waves travel
at the acoustical velocity in the rod material (about 16,000
ft/see in steel). In its role as a transmission line, the
sucker rod eontinnrdly transmits information about down-
hole operations to the surface. But the information received
at the surface is in code. Information reeeivcd at the pol-
ished rod must be decoded so that quantitative deduct@s
regarding down-hole operating conditions can be made.
The technique of interpreting or decoding the informa-
tion reeeived at the polished rod is developed by solving
a boundary value problem based on the wave equation.%
The pertinent boundary conditions are the signals which
are received at the polished rod, namely, time histories of
polished rod load and displacement.
To develop the basic equations, let z(.z, t) be a complex
variable in the wave equation:
8Z(X;t)
a%(z, i) _ “a%(x, t)
(1)
af a-y “ c--m-”””
Assume product solutions Z(X,t)= X(x)T(t) and obtain the
ordinary different@ equations:
+ cT’(t) - A~a’T(t) = O,
T“(t) . . . . . , (2)
“: ---” ”X’’CW+-X;’X(X)-=
-O-* --.--’—:-- i -;--T “-T“”:“- -.– [3) -,-
*In Ref. 1, the wave equation is used as a basis for PW&titto the
beba ior of new PUIPDIW inata.llatione. Tbe reader mw no~ ~~s- ---=
tine4,on between the two mxotwhes in that the techniwze dlsm=+ —.
in this paper ertdne to andgsis of eziatinu. hmtaktims, wh-
~he~$:$in I?ef.11.s deskned for mdiotkm of .erform+nce in new
 J
6 .+,-.

.
‘-- {

.
1
in which the & are separation constants. Anticipating
Fourier series expansions in t, assume periodic solutions u(d) = -!$ + 5 v. cosn@l-&sin tit . . (6)
~=1
$ILE$l ~ as T(t)= e’””’ from which the ~. can be evalu-
- -a. + i/3., n = 1,2,3, ..., wherein: In. order that the polished rod displacement condition be
satisfied, the choice of constants stemming from L@Jt) =
Re [z(OJ) ] is made. This results in:

U(OJ$= CJ + ‘Z v. cos wOt+ 8. sin rmr ,

and %=1
where the u and 8 are Fourier coefficients associated with
the measured polished rod dkplacement curve. The dis-
placement boundary condition will be satisfied if v. = 2&
rmd the coefficients are evaluated by the integrals
Eq. 3 is the harmonic equation and is satisfied by linear
eombmations of sin X.x and cos AA T
Semuate solutions are required for the case n = O. In
th@ instance, solutions of iritercst are J
“m=&
ir
o
L@) cos nddt , n = 0,1,2,00. ,

T(r):~ T

X(x):qx, g cs.
=+-J U(IAt)sin n~tidt , n = 1,2, . . . .
0
where & q and ~ are real constants.
To satisfy the load and displacement boundary condi- As before, the above integrals are evaluated numerically
tions, the product solutions chosen arw by harmonic analysis methods,
Whh the preliminary work of evaluating the constants
of integration @mpleted, the equations giving subsurface
2(x,?) = gqx -t & + 5 (% sin Lx -1- displacement and load may be developed. The formula
*=1
@. cos &x)e’”Wt ,, . , , . . . . . (4) for displacement at arbitrary depth and time U(XJ) is
,
bbtained by evaluating the real part of Eq, 4. This results
where iw.

% = –x. – ifin ,
‘“ + : o.(x) Cosmot +,
u(x,t) = — .,2> ,

,2;Ax+~ ..l
@.=v. —i8n .
P.(x)sinnd, . . . . . . . . (7)
The load signals which are received at the surface can be
represented by truncated Fourier series of the type where O,(x) = (K. cosh /3.x + S. sinh /l.x) sin LY.X
+ (p. sinh /3.x + v. cosh /3tix)cos a.x,
D(4 = ~ + ~~lu. cos nmf+r. sin twt . . , (5)
and P.(x) = (K. sinh @ -1-8,, cosh /3.x) cos a.x
Referring to Eq. 4, the load condition can be satisffed by
taking . - @. cosh ~.x -t v. sinh /3.x) sin ax.
F(xJ), the dynamic load at arbitrary depth and time,
““”=‘e[EA-l > n may be obtained from Eq. 7 and I-Iooke’s law: F(x,t) =

which leads to a choice of constants given by: EA au(x’r) These considerations yield:
T
u. = .?M(K&Y.
+ pnp.) , n =.1,2, “““,
To= Ez4(K.& — PKI.] , n =’1,2; . - i,
~(,x,t) = EA & -1- 5 on’(x) Cos no)t +
[ fi=l
2EA&7 ,
1
u. =
Pn’(x)sinnd , , , . . . . . . (8)
where the u and T are Fourier cocficients associated with
the load curve measured at the polished rod, These co- where
efficients are evaluated using harmonic analysis, i.e., by
numerical evaluation of the integrals
0.’(x] = “&,sinh /3.x + @J3. - v.a.) cosh &x “sin a.-x
T [
rrn=~ D(@ COS mid , tt = 0,1,2, -,-,
T J
o
-T
+ [ &
—cosh ~nX i- (I@ + &Y,) SiIIh @nX COS %x,
1 a.
and
— —________ &L=-+__._!!?@ @?n_@@_ _L&~!2?Z.~.”L .._
–- --&,(;i g- --’r,-. . . . .
J
o
~co%’ pnx + (K/X = Gi)-siiih-pk “-i35iGZz’”‘ ‘——
[ 1
‘l%e displacement of the pdiskd rod vs time is also a
boundary condition which must be satisfied. This condi- — -!ksinh pnx + (w& i- &a.) cosh ~~x sin U.X.
tion is representable by the truncated Fourier series: [ EA 1
9s JOURNAL OF PETROLEU?II TECENOLOGX
.. . . . . .. . . .. _-. ,. . . . . . .. . ... - ..”. “e. -. ... . . . ..- . . ..— . .._. . . . . . .. .

. ..—.
E@. “7 and 8 are the basic relations from which subsur-
face displacements and loads are deduced from data mea-
sured at the surface, IsI a sense, these are the equations
which permit the decoding of the subsw!face data which
has been transmitted through the sucker rod. T’hese equa-
tions can be easily generalized to represent the displace-
ments and loads in wells which have any number of
changes in rod cross-sectional area.
A COMPLETE EXAMPLE
The primary aim of a dynamometer analysis is to mea-
sure loads and displacements at the polished rod and, from
these measurements, deduce down-hale conditions. The
distinctive feature of the analytical technique described
here is the manner in which surface data are interpreted.
Rather than relying solely on visual interpretatio~ which
is dependent on personal judgment and experience, the
technique uses a digital computer to calculate subsurface
cards, thus furnishing quantitative results from which the
personal element has been largely removed.
To illustrate the technique, the polished rod data of
Pig, 1 is analyzed. These data are shown in the time
history form as measured by a special dynamometer and
pertain to an t3,525-ft well having a three-taper rod string
operated with a 74-in. conventional unit at 15.4 strokd
min. Measurement of polished rod data in time history
form is most convenient in view of the need for express-
ing these data in Fourier seriez as functions of time (Eqs.
26.00. ~
I
I I I 1 I I
0olt5 45678
FIG.1—TYPICALPOLISHSDROIILOADANtIDISPLACEMENT
HISTORIES.
20.000
OTM.G..P. C..D5 .1 SW?.CE,
2.,000 MB *UW, ,*Us, *NO PUMP
[
~ 152 BiD. ‘WELLTESTOF ONLY42 BID SIXX.WTS
Fm 2—CALCULATED
DYNAGRAFH
C,ws SUMMARIZING
OPERATING
i STATUSOF PUMPINGWELL.
,-.
5 and 6). Ordinates from these curves for one complete
cycle are r~d into the computer along with ,the pertinent
rod design daa pumping speed, damping factor, etc., to
yield the set of dynagrapli cards shown in Fig. 2. Consid-
erable diagnostic information can be gained from analysis
of these cards. Shown are the calculated dynagraph cards
at the surface, at junction points in the combination rod
string and at the pump. Peak stresses of 28,S00 psi in
the l-in. rods, 29,600 psi in the ?6-in. rods and 30,300
psi in ~the %-in, rods are indicated. This reveals a good
rod desi~ in which peak stresses are reasonably balanced
in each rod interval. The pump dynagraph card indicates
a gross pump stroke of 7.1 ft, a net liquid stroke of 4,6
ft and a fluid load of 3,200 lb. On the basis of the
gross and net strokes, a liquid volumetric etilciency of
65 per cent is calculated. From the fluid load and pump
size, an intake pressure of 690 psi is estimated. The
shape of the pump card indicates some down-hole gas
compression. The shape also indicates that the tubhg an-
chor is holding properly. A liquid displacement rate of
200 B/D is calculated which, when compared with mea-
sured production of 184 B/D indicates no serious tuling
or flowline leak.
This illustration indicates that a great deal of quanti-
tative down-hole information can be gained from a single
computer analysis. The whole’ operating status of a pump-
ing well can be diagnosed and summarized in a set of cal-
culated dynagraph cards (Fig. 2). The example is particu-
larly appropriate because of the odd shape of the polished
rod card. This is a graphic case in which visual inter-
pretation of the surface data would be difficult, because
the pump dynagraph card in no way resembles the sur-
face card.
DETECTION OF LEAKS IN PRdDLfCTION STRING
A Ieak in the production string is a serious problem in
any oil well. It is accompanied by a decrease in well pro-
duction, which can be the result of several deficiencies.
1
With this analytical technique, pump performance is
9
shown graphically. Thus, it tin be determined whether
a decrease is due to a tubing leak, a bad pomp or a de-
ficiency in the well itself. Actually, a tubing leak is in-
ferred when the indicated down-hole pump rate is much
larger than the surface test rate. This difference in rate
gives an immediate indication that all the liquid passing
through the pump is not reaching the surface. A speoific
examp!e is illustrated by Fig. 3. The calculated pump dyn-
agraph card indicatw excellent pump performance and a
liquid rate of 152 B/D. However, this well tested only
42 B/D, which indicated that much of the liquid which
passed through the pump was “getting lost” before it
reached the surface. By virtue of this comparison of li-
r
4000
. . ...= . .. ___ -.. -.— —--- —.. —.. —-— .—— —.-+ -.. . .—
–:7000
4 3 2 -1 -3 -4
PUhiP LilS:LACEMENT, -f:
FIG, &CALCULATE~PUMPCARUINmCATING LIQUti RATEOF
LEAK IN PRODUCTIONSTRING.
 J

quid rates, a leak in the production string was suspected,

Investigation showed that the check valve which connect-
,0,000

r
8000
F
ed the annulus to the flowline was defective, and part of
the production was being recycled down the casing. Re-
pair of this valve increased the production rate to 140
B/D. This type of malfunction is fairly common and has
been encountered on severaI occasions in applications of
the technique.
-2000
I I I I 1 1 I J
DETECTION OF UNANCHORED TUBING 3 z ,
PUMP 01S?LAGE61 CM-;, f f
-z -3 -4

Defective tubing anchors sire frequently not discovered m PARbi-Ltt06W4 w-mm wdP Mm m wm row UfJbfKKIRED ruwm

until after they have caused damage to tubular goods in

the well. Many types of tubing anchors normally in use
cannot be checked unless the well is pulled. Even then sow
r’
there is no way to prove conclusively whether or not the i
anchor was working during producing operations. .Owing ~ 4000 -

to an unexpected circumstance, it was found that the com- g

puter technique offers a means of checking the effective- g 2003 -

ness of a tubing anchor while the well is on production 2

and without the well having to be pulled. The method is 0

{_ _

most reliable for sensing tubing movement in installations I I I I I 1 I

-1000
which have little free gas passing through the pump. St
P“II’P msPLn:EMm;,’ ft
-z -s

A special feature of the mathematical development per-

mits sensing of tubing movement. The movement of tub- IL) 171CWNIJLAR .SH4PE PUMP CAZD IN HELL WIH ,iNC”CSEO l“BwG.

ing affects the manner in which the fluid load is trans-
ferred to and from the rod string. This is manifested in
the polished rod data, where it can be detected with the
analytical technique. In the mathematical development the
displacements of the pump are measured with respect to
a coordinate system fixed in the ground. If the tubing is
unanchored and moves relative to the ground, then the
pump dynagraph card referred to a tubing coordinate
system will ha~ a dKferent shape from the card referred
to the ground coordinate system, For a pump dynagraph
card which is rectangular with respect to the tubing (saY,
a card measured with the Gilbert dynagraplf which rides
along with the tubing) the technique will indicate a paral-
lelogram-shaped card. The parallelogram shape is mused
preferences tiven at end of paper.
I% 5—EFFECTOF Tumixc MOVEMENT
ONPunrr CASDSXAFE
release are not always as straight as those in Fig. 4, Also,
by the stretching and contracting of the unanchorcd tub-
ing during the period when the fluid load is bein’g trans-
ferred to and from the tubing. The sequence of events
shown in Fig. 4 depicts the movement of the pump and
the shape of the pump card relative to both coordinate
systems for a high-efficiency well which has negligible free
gas passing through the pump.
The sequence in Fig. 4 has been idealized for clarity.
It should be noted that the tubing is an elastic body
which, when unanchored, vibrates during intermittent ap-
plication of the fluid load .Thus, in cards calculated with
respect to ground, the segments during load pickup and

( /“”8’”

@ @ @

I
PIMP HAS !?EACHEO LOAD TRANSFERAL EN7cZL FL”’U LOAD
“lGMES? PC$N7 fiND rROLt mm 10 S.,P.WED B, T“BAG
$ 0CSCENC8VG. FLUID T“B’\o &LW05T 7“9 h$ MM s? RETCWD
Lou Is mt!o mANs- co!fPLcrE Tumo w tin., cwmsr
FE.WtO FROX RODS CON18N”ES 70 WW3T” P“UP ,s DE-
10 1uB6NG. TuWK IS STRETCH. Scmom, 6 m WI Ms.fa
Slnclc”tldt. Pull? !5 10 601. GRVWD ANO
DESCCf10’N& m, mm 7“wW COOiW,liATC
TO G80W0 W tS SYSTEMS.
51&Tt0NBRV Wil “
RE6PCCT ‘IO T*
Tlmho.

10&ma
. i- u.. e F
.—-. —..— . . .._ ._ ._.
--i-4-li===7--”---

l%. 4-SEQUENCE OF EVENTS SHOWINGEFFECTOF TUBINGMOVEMENTON COMPUTED PUMP CARD. .

.
,.. %. JOURNAL OF PETROLEUM TECHNOLOGY
-.- .. . . . .. ____ .. . . .... . ... . . . . . ,~-.,~ _,-- -,- .. —-- . . ...
 ., .-.

the fluid load is quickly applied; therefore, the tubing
stretch indicated by the calculated card will usually ex-
ceed the stretch calculated on the basis of a statically or
SIOWIy app]jed fluid load. An cxample is shown in Fig. 5a
for a well with 4,oOO ft of unanchored 2Y2 -in. tubing.
The parallelogram shape is evident.
In wells having effective anchors, the tubing is re-
strained from moving. As a result, pump cards are the
same with respect to both coordinate systems. Fig. 5b
shows a calculated pump card in “a deep well in which
“a tubing anchor is installed. The rectangular shape of the
card indicates that the anchor is operating properly,
It can be seen that the method of detecting tubing move-
ment just described becomes less conclusive in wells which
have considerable free gas passing through the pump. In
these wells the expansiori-compression effects of the free
gas can be confused with tubing movement. Fortunately,
it is frequently possible to distinguish between tubklg
movement and gas expansion-compression etiects by the
shape of the pump card. Good pump spacing minimizes
gas expansion effects during rod load pickup; hence, ex-
cessive movement of the pump during this period can imp-
ly tubing movement.
It is interesting to note that use of the analytical meth-
od for detection of tubing movement was not anticipated
but grew out of attempts to understand why some com-
puted pump cards had a parallelogram shape rather than
the expected rectangular shape.
CHARACTERISTIC DYNAGRAPH CARDS
FOR LEAKY PUMPS
In a number of instances, badly leaking pumps have
been indicated by calculated subsurface cards. When a
pump is leaking due to a bad traveling valve or plunger,
it is slow to pick up the fluid load at the beginning of the
upstroke and tends to release the load prematurely before
the downstroke begins. The load pickup is slow because
plunger velocity is low, and the leak rate is almost as
large as the plunger displacement rate, Near the end of
the upstroke the plunger velocity is again low, and the
plunger displacement rate becomes smaller than the leak
rate. Thus, the load transferal begins while the pump is
still ascending, These effects give the pump card a-n arched
top. A typical calculated pump card which indicates a
leaky pump is shown in Fig, 6a. In this card the slow load
pickup and premature release are evident, A1l pumps
leak to a certain extent, but when the leak becomes large
enough to give an arched top to the pump card, remedial
action is usually warranted.
Fig. 6b shows a calculated pump card for both a leaky
pump and an unanchored tubing string. On load pickup
the effects of tubing-shortening and the leaky pump are
additive, Near the top of the stroke the effects of tubing
stretch and the leaking pump cancel. Thus, the parallelo-
gram shape of the unanchored-tubing card combines with
the arched-top shape of the leaky-pump card to yield a
pumping well is its intake pressure. There are several
methods for determining pump intake pressqre, both direct
and indirect, Direct methods include use of a pressure
bomb which. is lowered down the annulus, and various
electrical transducers which transmit pressure data up from
the pump via electrical cables strapped to the tubing.
When the direct methods are not stymied by inadequate
annular clearances or cabling troubles, they are the best
and most precise methods to use. The most common in-
direct method involves measurement of annular fluid lev-
els by acoustical means. Once the fluid level is known,
the intake pressure is calculated by assuming an effective
gradient for the fluid in the annulus. However, if the an-
nular clearance is inadequate, acoustical measurement of
the fluid level may be impossible, and intake pressure esti-
mates in this manner may not be obtainable,
Another indirect method for estimating intake pressure
is provided by the analytical technique described herein,
This method is not hampered by space limitations or elec-
trical cabling troubles, because all down-hole data are
transmitted through the sucker rods. Though not capable
of great precision in determination of pressures, the meth-
od can be used to obtain engineering estimates of intake
pressure which oftentimes are adequate.
Determination of pump intake pressure by the ana-
lytical technique is based on the equation:
P,= Pr, –~. . . ..L. . . (9)
v
The meaning of this equation is illustrated in Fig. 7. The
term P, denotes pressure above the pump caused by the
head of fluid in the tubing. The terms W, and A,, denote,
respectively, fluid load and pump area. Their quotient.
W,/AP denotes the, pressure ditlerence across the pump.
Thus, the intake pressure P, (the pressure beneath the
pump) is found by subtracting the pressure difference
1 I I I
.1 0 -1
Fufd. DrS.PLACE!/E N,, F,
[al QYNAGRAPH ctm FOR LEAKING PLW.GER CR TRAVELING VALVE.
-looo~,
P~14P DIs PLfi CEMENT, f!

card with different, slopes on the ends.

[b) UIVAORAFH CIiRD SKWU5 COIAIXMED EFFCCT% w UrlAtlCllOREO TIMING AND LEAklt@
Fig. 6C shows a calculated card for a pump with a PLWIGER CM TRAVELING V~<E

leaking standing valve. The action is just the reversal of

the leaking traveling valv~ fhat is, the pump is quick to
pick up the load and slow to release it. This gives the

-~’b ---
pump card an arched bottom.
The diagnosis of leaking pumps in field tests has been
-–—-contlrmed-by- mechanical--inspection- after-fhepurnp-was––

-2 -1 0 -3 -4
ESTIMATION OF ~PUMP INTAKE PRESSURE PUMP D15PLACEUENT, f!

One of the most valuable diagnostic ciues about a FIG.6-TYPICAL DYNAGRAPIiCARDSFoa LBAKINGPUMPS.

JANUARY, 1966 9s
. .....-_ ______ -. .._ -. ...,. ._ ----- ,, ----------- . . . .._ .- .._. . . . . . .. . .. .... .... . . . . . . ... ... . ------ . _-_,----- ___

... . .... .. . . . . .. . .. .. . . . . . ..
 . .

—. -.. .

across the pump W1/AP from the pressure above it PD.The
‘ fluid load WI is read directiy from we calculated pump
dynagraph card. The pressure above the pump may be
inferred from gradient considerations or from a two-
phase-flow pressure traverse. Determination of pressure
over the pump is the primary factor which limits the ac-
curacy of this indwect method,
To illustrate the use of Eq, 9 in estimating intake pres-
sure, the data of Figs. 1 and 2 are anaiyzed, From the
calculated pump card, a fluid load WI of 3,200 lb is de-
termined. For the 1.5-in. pump in die well (AP = 1.67
sq in.), the pressure d~erence across the pump is W~/AP
= 1,810 psi. The pressure above the pump P. is deter-
mined from a pressure traverse as being approximately
2,500 psi. FinaIiy, according to Eq. 9, the pump intake
pressure is estimated to be P, = 2,500- 1,S10 ==690 psi.
Fortunately, it is not necessary in many cases to know
the intake pressure with great accuracy, Much about the
potential proctti tivity of the well can be inferred from
the shape of the calculated pump card. A well having a
rectangular-shaped pump card is not pumped off-regard-
less of its intake pressure. The PVT properties of the pro- “
duced fluid can also be of use. For example, a pump
card which indicates gas compression signifies that the in-
take pressure is below the bubble point pressure, which
is known from the PVT properties of the crude.
Another useful procedure is to calci.rlate an upper limit
@ the intakb pressure. This is done with Eq. 9, in which
the pressure over the pump is computed on the assump-
tion that all of the fluid in the tubing is ~il and water in
the proportions indicated by a weli test. It is then known
that the actual intake pressure is. less than this upper iim-
it, because any gas in the tubing acts to decrease the
prewure over the pump. It is tiseful to note that the ana-
lytical method provides the oniy known means for de-
termining intake pressures in tubingkss completion wells,
In these wells there is no annulus for determination of a
fluid level, nor is there any tubing on which to attach
electrical cabl+ for pressure transducers. The technique
can also be used to estimate pressurea in wells being
A.
&l&z
I narily, the steel sucker rod transmits these data with great
TUBING HEAD PRESSURE
\ for data to be transformed and distorted while traveling
pumped under packers.’ In such we[ls, fluid levels cannot
be obtained because of the packer in the casing-tubing
annulus,
DETECTION OF GAS SEPARATION PROBLEMS
A sucker rod pump is a relatively poor gas compres-
sor. Consequently, it is desirabie to minimize the free gas
which the pump must handie because this gas decreases
the volume in the pump available for liquid, causing a
diminution in the pump volumetric efficiency. To provide
adequate down-hole separation so that free gas, passing
through the pump will be minimized, it is desirable to
know the severity of any existing down-hole gas separa-
tion problems. The shape of the pump dynagraph card is
one of the best intilcators of such problems,
As the analytical technique provides the shape of the
pump card, the severity of down-hole gas separation prob-
lems is readily apparent. A pump card which is generaliy
rectangular (Fig. 8a) indicates a negligible amount of free
gas passing through the pump. The rectangular shape
arises because the fluid in the pump chamber is virtually
incompressible;, hence, the load transferal at the top and
bottom of the stroke occurs with negligible movement of
the pump. If there is free gas in the purrsp, on the other
hand, the fluid in the chamber is not incompressible and
the pump does not remain stationary during ioad trans-
feral. Pig. 8b ,shows a typical pump card which indicates
compression and expansion segments for the entrained gas.
The distahce that the pump travels during the expansion
and compression phases is lost stroke insofar as liquid
production is concerned. The expansion curve at the be-
ginning of the upstroke is strongly affected by pump spac-
ing. To minimize stroke loss due to gas expansion, the
pump should be spaced with the minimum” practical clkar-
ance at the bottom of the stroke.
EFFECT OF EXCESSIVE ROP FRICTION
As previously mentioned, a convenient way of regard-
ing the sucker rod analytical technique is by analogy with
a communication line. Data indicative of down-hole op-
erating condhions are received at the polished rod after
traveling up from the pump along the sucker rod. Ordi-
fidelity. However, if the data are somehow garbled en
route, they may “not be suitable for computer anaiysis. In-
deed, the oniy conceivable way for the technique to fail is
through the sucker rods. A factor which can create this

\
“m
— t
g FL._iIdu 54

[0) Nf.OLIBIBLE
3210
.PvUP

FREC
DISPLACEMENT,

GAS IN PUMP
-1-2-3
ft
-4-5

-\ :- STROiiE LO.3S DuE

TO EXPANSION
STROKE LOSS LwE
70 COMPRESS1OU
~ P P Y
.6030
2
EXpANSION
SUBSURFACE 5 k
---- -..—. PumF-r

~o
54 3 -2 -s -4 -5
P&!P D: SPLAC:MBN;,’ ft
PRESSU8E
(b) M00CR6TE FREE !lAS IN PUMP
FIG.7%SCIIEMATICOF DEPTSi.PRIISSURE
RELATIONSHIP
IN
PUMPINCW%LL, FIG. 8--EFFECT OF FSLSE
GAS ONPuiwP CARD SHAPE.

. 96 JOURNAL OB’ PETROLEUM TECENOLOGlf .

-... . .. . . ... .. . . . ,_ .-, .+.i.- -. . . . . ..— . . ..- . . . . . . ... . . . “... L. . . ... . . . . . -,.
-.=—.;:”
: ..-, ~ , ~ . . .. . .-. -.>.... .,, .-—-. ,.e,:. ..=, . .. . . . .. . . . . . .- .,.-. ______
-,=;_=, .,. =.,. ---- .“-, -.-,. . ..-. ... &;---.,-:. .. . .
,. .,>. .
;++ ,;:. -b-am. : ?.e.. .,.. >,,,%. .>*4,.,.—:----~.= ,..,:,,-.,.-.,. . “....*.:..=: L
 —. ,.. .,. . .-

garbkg effect is excessive friction on the rods caused by
crooked holes or corkscrewed tubing.
Striking proof of the adverse effect of excessive rod
friction is shown in Fig. 9a. These cards were calculated
in a well in which a packer was used for a tnbhg anchor.
The calculated pump card is unrealistic and uninterpre&-
able. When thh card was calculated, it was surmised that
rod friction garbling was occurring. Later, when the well
was pulled, severe rod coupling wear was noted. This in-
dicated that the tubing was corkscrewed by its own weight
as it rested on the packer. When the well was placed back
on production, it was equipped with a tension-type tubing
anchor. Fig. 9b shows the polished rod card and pump
card after the tension anchor was installed. As indicated,
surface loads are less severe and the calculated pump card
is reasonable.
When the analytical technique is correctly applied with
reliabIe data, the only way that it can produce an incor-
rect pump card is for excessive rod tilction to be present.
Therefore, an uninterpretable and unrealistic pump card
frequently implies adverse rod friction which should be
corrected if possible,
DETERMINATION OF TORSIONAL
The applications discussed so far primarily concern the
determination of subsurface operating conditions. Aiso of
great importance is loading on the surface equipment, par-
ticularly torsional Ioading on the pumping unit gearbox.
It is therefore desirable to be able to determine both sub-
surface and surf ace operating conditions” in a single com-
puter analysis. A brief description is given which illustrates
how polished rod data required for computation of sub-
surface Conditions c-m also b: used to deter@ne gearbox
torques at the surface.
The net torque on the gearbox is composed of the
torque caused by the well load, and the opposing torque
created by the counterweights. ,The torque arising from
the well load depends on the torque factor which in tum
depends on the geometry of the pumping unit. Normally,
the torque factor is determined by a solution which in-
volves all of the linkage dimensions of the unit. However,
if the assumption of constant crank angular velocity is
made, the simple relationship between poiished rod veloc-
ity and torque factor can be derived:’
TF= ~ . . . . . . . . . . .. (10)
U
This relationship is particularly well suited to the method
described here because the polished rod velocity is easily
derived from the displacement function (Eq, 6) already
required for computation of subsurface conditions. Thus,
the torque factor may be determined from Eqs. 6 and 10
as
TF = j –tzv. sin mot -f- rd. cos not . . (11)
~= ~
The complete formula for net torque can now be written
W
LOADING Net Torque = TF[D(.]t) + W,] – C sin (d + ~), (12)
from which a torsional analysis can be made. A typical
torque analysis is presented in Fig. 10. This pertains to a
4,724-ft well being produced with a 168-in. unit operating
at 9.5, strokes/rein. Fig. 10a shows computed dynagraph
cards and Fig, 10b shows corresponding net torque and
counterbalance torque curves developed from Eq, 12, As
indicated, the unit is reasonably well counterbalanced with
the peak torsional loading being about 520,000 in.-lb.

25,000

.20,000
n
~- I 5,000
u
0
~ I 0,000
a lb
s
~
-1 6000
I \ PUMP CARO \

o.
1 I I I I I
4 3 2 -3 -4
Put!P OIS:LACE;~NT , %
[0) WELL EOUIPPEO WITH SET - 00WN PACKER

. . .,-,.
25,000
r
.$ x+ /-

n
z
~
5000
PUMP CARD

2
o Lf --
 -. ---

SUMMARY depth and time, lb

The sucker rod analytical m~thod has been applied in n = number of terms in truncated Fourier series
P, = pump intake pressure, psi
over 500 installations to date and haa proven to be a use-
P, = pressure over the pump, psi
ful production engineering tool, The technique is capable
t = time, sec
of providing quantitative data regarding down-hole operat-
T= pumping period, sec
ing conditions. Since the method ii artathematical in na-
TF = torque factor, ft
ture, personal judgment required for analysis of subsurface
U(x,t) = displacement of sucker rod at arbitrary depth
operating conditions is minimized. It is no longer neces-
and time, ft
sary to speculate about down-hole operating conditions—
these conditions can be calculated with the analytical
U(ust)‘= measured polished rod displacement curve, ft
method.
w, = static weight of rods, lb
w, = fluid load, lb
When good data are used, the method should rarely x = distance measured from top of unstrained
fail, When it does break down, excessive rod friction is sucker rod string, ft
usually the reason. When excessive rod friction is occur- 2(X,4 = complex form of u(x,t), ft
ring, the force signals are garbled during transmission v, 8 = Fourier coefficients for polished rod displace-
within the sucker rod, and the method usually produces ment, ft
an unretdktic pump card. This in itself is a useful diag-
nostic clue because it indicates an adverse down-hole fric- # = phme angle which orients counterbalance ef-
fect with respect to p@hed rod stroke,
tion condition which should be corrected, if possible. rad
In view of the widespread application of rod pumping U, 7 = Fourier force coefficients, lb
equipment, good methods of analyzing and troubleshoot- w = angular frequency, rad/sec
ing pumping wells are an economic necessity, It is hoped
that this method will prove useful to the industry in maxi- ACKNOWLEDGMENT
mizing the effectiveness of rod pumping equipment.
The authors wish to thank Lufh Foundry & Machine
NOMENCLATURE Co, (who hold a Shell Development Co. license for indus-
trial application of the method) for permission to publish
a = velocity of stress wave propagation, ft/see” this paper,
A = area of sucker rods, sq in. 1

A, = area of pump, sq in. REFERENCES

= damping coeticient, see-’ ‘
~ = maximum counterbalance moment, ft-Ib
D(oJt) = dynamic polished rod load function (found
by subtracting static rod weight from meas-
ured polished rod load), lb
E = modulus of elasticity, psi
F(x,t) = dynamic, load on sucker rods’ at arbitrary
1.Gbbs. S. G.: “Predicting tke 13elnwior of Sucker Rod PuMp-
ing Systems”, low. Pet. Tech. (July, 1963) 763.
2. Gilbert, W. E.: “An Oil Well Pump Dymgmplr”,Drill. & Prod.
Prac., API (1963).
3. Gray, H, E,: ‘Kinematics of Oil Well Pumping Units”, DrilL &
Prod, Prac., API (1963).
*