Jakarta06-SPE-02
PROCEEDINGS, JAKARTA2006 INTERNATIONAL GEOSCIENCES
CONFERENCE AND EXHIBITION
Jakarta, August 14 – 16, 2006
AN APPROACH FOR SUCKER ROD LIFT WELL PERFORMANCE OPTIMIZATION
August J. P*
E. Patrick T.**
SUMMARY
Throughout the world, the most commonly used
method to artificially produce oil wells is known as
sucker rod lift. Sucker rods have been the primary
artificial lift method used in ‘Y’ field operated since
1933. This mature field is currently produced
utilizing the Enhanced Oil Recovery (EOR) method
known as a water flood.
This study emphasizes an approach which has been
used to improve performance and optimize wells
produced with sucker rod lift in a field with limited
data available for analysis. Field ‘Y’ is a mature
field, but has extremely inadequate data for
optimization such as dynamometer and motor
power surveys.
The available data consists of acoustic liquid level
and daily production rates. The limited data set is a
direct result of an operating philosophy where costs
have been minimized because of the low oil
production rate.
Sucker rods pumps have been operating for some
time without any management review. After a long
period of operation, the mechanics of the pump
system have changed. Aspects of friction,
acceleration, buoyancy, polished road load, service
factor, and fluid weight have all changed from their
original design condition.
To improve the economics of the field, an approach
was developed to study sucker rod well
performance optimization. This approach involved a
mathematical knowledge of linear equations,
quadratic equations, and a numerical method
solution. Correction factors due to pressure and
depth relationships were developed to give accurate
pump intake pressure values which were used for
the optimization study. As a result of this study,
optimization can be done by calculating the stroke
* Trisakti University
length configurations and pump speed for an
expected producing bottom hole pressure and oil
production rate. These calculations were done for 3
wells (Well X-024, Well X-235 and Well X-258).
The rates for these three wells can be increased
from initial production. The approach used in this
study can be helpful to solve sucker rod lift well
performance optimization problems due to lack of
survey reports data.
INTRODUCTION
Sucker rod lift is the most commonly used artificial
lift method in order to pump oil from the
subsurface. The objective of this paper is to give
information on how to apply nodal analysis to
design, optimize and analyze sucker rod
performance for artificial lift. In the design of
sucker rod lift systems for a well, it is recommended
that the well is initially treated as if it were a
flowing well. The problem which often happens is
inefficient energy use in the sucker rod lifted wells.
Due to the inefficiencies of the various components
of the sucker rod lift system, energy losses occur in
lifting the liquid to the surface. Therefore, better
maintenance is needed to improve efficiencies. The
first step in this method is to perform nodal analysis
of sucker rod lift performance, and then adjust the
setting depth to analyze the optimum production
performance. By using pressure relationships and
depth, a correction factor for the nodal analysis can
be obtained. Afterward, the next step is to determine
possible flow rates from each pump intake pressure
by using a quadratic curve of dimensionless IPR
corrected with P3/PBHP. The maximum flow rate
can be calculated using Vogel’s equation when the
well is in multiphase flow well. The supporting
calculation provides the constant value of a, b and c
in pump intake pressure equations for sucker rod
pumps. Following these steps, the optimization
study can be done to increase oil production rates to
the maximum incremental oil production rate.
METHODS
Analysis and optimization of well performance
study : proposed new approach
Nodal analysis of sucker rod lift performance is an
intersection of 3 lines (an IPR line and 2 pump
intake curves). The lines represent a combination of
stroke length and pump speed. Ideally, if the setting
depth is being placed at formation depth, there is no
difference between pump intake pressure and
PBHP. Figure 1 illustrates the ideal condition
calculated using nodal analysis. In real conditions of
a sucker rod lift wells, common setting depths are
not placed at formation depths. This is due to
several reasons such as setting depth being placed
above formation depth to avoid sand problems or
setting depth being placed below formation depth
for natural gas separation. Figure 2 shows nodal
analysis of a sucker rod lift well with its setting
depth above the formation depth. This condition can
be improved if the node point is being placed at the
pump intake depth. Pump intake depth or setting
depth has a relationship with PBHP and pump
intake pressure. This will happen when the pump
setting depth is lowered gradually. If the pump
intake depth is at the formation depth, the pump
intake pressure has the same value with PBHP.
Pump intake pressure is the lesser value from PBHP
if the pump intake depth is above the formation
depth, but if the pump intake depth is set below the
formation it has greater value than PBHP
(Figure 3). From this gradient relationship, we can
predict the value of PBHP and pump intake pressure
by formation depth. Pump intake pressure increases
along with depth, while PBHP decreases with
formation depth. Below the formation depth, PBHP
value will remain constant. The relationship
between setting depth (SD) and PBHP to SBHP
(from above the formation depth down to the
formation depth) can be described as a reversal
relationship: (PBHP/SBHP)n at SDn = SDi/SDn x
(PBHP/SBHP)i. The setting depth to formation
depth ratio (SD/FD) is related to pump intake
pressure and PBHP ratio (P3/PBHP). Figure 4
describes a SD/FD of 0.7 with P3/PBHP of 0.8. The
relationship line meets SD/FD of 1 and P3/PBHP of
1 when setting depth meets formation depth. This
relationship can be used as a correction factor for
nodal analysis when the setting depth is not at the
formation depth or pump intake pressure is different
from PBHP. Using pressure relationships and depth
as mentioned before, two values of pump intake
pressures with the same sucker rod pump
configuration (stroke length and pump speed) at two
setting depth can be generated. Possible flow rates
from each pump intake pressure can be determined
using quadratic curve of dimensionless IPR
corrected with P3/PBHP (Figure 5). To create a
dimensionless IPR, one value of PBHP/SBHP and
qo/qomax is needed from well test data. Maximum
flow rate can be calculated using Vogel’s equation
when the well is in multiphase flow well. By having
these two values, constant values for a, b and c in
the pump intake pressure equation for sucker rod lift
wells can be acquired using mathematical
elimination method. This elimination process is a
linear approach which does not match the IPR
profile if the two values of pump intake pressure
have a great difference. A slight difference of two
pump intake pressures will match the IPR line in a
certain segment. After a, b and c are found, the
optimization study can be done to increase oil
production rate to the maximum incremental oil
production rate (Figure 6).
Well case study
There are 3 wells which were inspected and have
good potential to be optimized (namely Well X-024,
Well X-235, Well X-258). These 3 wells were
examined to calculate their potential incremental oil
production. Acoustic liquid level surveys have been
done for the inspected wells. This was done to
combine fluid depth and a wellhead casing pressure
value to calculate producing bottom hole pressure
(PBHP) using Gilbert’s method. PBHP
measurement is done during the production phase,
while the annulus is closed. The pressure value
provided by the fluid column in the annulus at
producing well is used. Static bottom hole pressure
can be achieved by shutting in the well until it
builds to a constant pressure value. Using the flow
rate at certain PBHP, the maximum flow rate can be
calculated using Vogel’s equation for a multiphase
flow well. From 3 points of flow rates and PBHPs, a
simplified dimensionless IPR can be constructed by
using quadratic extrapolation. The minimum
allowable PBHP is 50 psia which allows calculation
of the maximum allowable possible liquid flow rate.
From these results we know the potential oil
incremental of each well.
RESULTS : Evaluation of the proposed
approach and sucker rod producing efficiency
The purpose of sucker rod lift optimization is to
maximize flow rates and producing efficiency of the
well. The chief goal of sucker rod optimization is to
adjust the mechanical configurations to their most
efficient setting (primarily adjusting the pump speed
and stroke length). Up to date, pump surveys such
as dynamometer survey, standing valve-traveling
valve test, and motor power surveys are important
to understand the current conditions of the sucker
rod pump. Inadequate survey data is the most
common problem in mature fields especially if the
productivity of the field is low. It is a balance
between minimizing cost and optimizing
production. Because of financial constraints, this
new approach was proposed to complete production
optimization study of sucker rod lift wells with
existing data and minimal costs. There are many
factors which affect sucker rod lift well
performance such as fluid weight, rod weight, crank
to pitman ratio, friction term, acceleration term,
buoyancy term, service factor, peak polished rod
load, minimum polished rod load, stroke length and
pump speed. These factors mentioned above are
always changing with time during the well’s
producing life. Many of the changes are
undocumented and undefined because of lack of
survey reports and pump maintenance, making
optimization difficult. Sucker rod pump intake
pressure is not the same as producing bottom hole
pressure, and is dependant on the pump setting
depth distance to formation depth.
This approach is used to solve sucker rod lift
optimization without calculating all factors above
which have already changed from ideal conditions.
Acoustic liquid level survey reports become useful
information due to accurate information of static
bottom hole pressure, producing bottom hole
pressure, pump intake pressure, oil production rates
at certain producing phases with certain pump
setting depths, and configuration of stroke length
and pump speed. By using Vogel’s equation for
multiphase producing well, maximum oil
production can be calculated to form a
dimensionless Inflow Performance Relationship
(dimensionless IPR). To begin an optimization
study, a calculation is needed to know the value of
a, b and c from the equations below :
*P3 = a + bNq
*P3 = a + (c/S)q2
Where “P3” is pump intake pressure value (psia),
“a”, “b” and “c” are constant values, “N” is pump
speed value (Strokes Per Minute), “S” is stroke
length value (inches), and “q” is oil production rate
(STB/d). Two pump setting depth conditions with
the same configuration of stroke length and pump
speed are needed to conduct a mathematical
eliminating operation. That elimination allows
approximate calculation for a, b and c values. A
correction factor of pump intake pressure and
producing bottom hole pressure relationship is
needed for accurate values of pump intake pressure
at certain pump setting depths. The calculation
method involves basic knowledge of quadratic
curves and linear equations. The node point for
nodal analysis is being placed at the pump intake
depth to construct a suitable inflow curve for
analysis. As a result of this study, a sucker rod lift
well performance optimization can be simulated by
calculating configuration of stroke length and pump
speed for an expected producing bottom hole
pressure and oil production rate. This approach can
be helpful to solve sucker rod lift well performance
optimization problems due to lack of survey reports
data. Several studies have been done in ‘X’ wells in
‘Y’ field. The observed wells were using crank to
pitman ratio of 0.33. The production optimization
evaluation result can be seen attached below
(Table 1).
CONCLUSIONS
1. An approach has been developed for sucker rod
lift well optimization studies that can be applied
for sucker rod lift wells without adequate
periodic inspection such as dynamometer
surveys, standing-traveling valve tests, and
motor power surveys.
2. This approach can be used to solve sucker rod
optimization problems due to pump setting
depth distance to formation depth and give
nodal analysis of sucker rod lift well
performance when it is normally difficult to
construct.
3. The node point is placed in the pump intake
depth to create an appropriate inflow curve for
nodal analysis.
4. The numerical method approach is needed for
accurate value of a, b and c.
5. Correction factors for depth and pressure can
accurately determine the P3 value.
6. The Well X-024 production rates can be
increased from 36.3% to 53.1% of its maximum
production rate by using configuration of 6.2
SPM pump speed and 208.6 inches stroke
length.
7. The Well X-235 production rate can be
increased from 49.1% to 74.4% of its maximum
production rate by using configuration of 5.6
SPM pump speed and 161.9 inches stroke
length.
8. The Well X-258 production rate can be
increased from 31.7% to 41.8% of its maximum
production rate by using configuration of 7.1
SPM pump speed and 162.9 inches stroke
length.
 TABLE 1
PRODUCTION OPTIMIZATION EVALUATION OF
WELL X-024, WELL X-235 AND WELL X-258

Well Name X-024 X-235 X-258

Pump Type C-114-D-143-74 C-114-D-143-74 C-114-173-75
Pump Depth (ft) 1430 1430 1585 1585 1512 1512
Formation Depth (ft) 1494 1494 1587 1587 1579 1579
Pump Speed (SPM) 12 6.2 12 5.6 8 7.1
Stroke Length (ft) 74 208.6 54 161.9 74 162.9
Pump Intake Pressure (psia) 250.5 209.17 149.3 99.4 147.3 134.42
PBHP (psia) 279.6 233.47 250.5 166.78 177.78 162.23
SBHP (psia) 360.3 360.3 220.2 220.2 220.3 220.3
qo (bbl/d) 31 45.3 44 66.6 42 55.2
ql (bbl/d 342 500 342 518 84 110
qomax (bbl/d) 85.4 85.4 89.6 89.6 132.3 132.3
qlmax (bbl/d) 942.2 942.2 696.1 696.1 264.6 264.6

Figure 1 - Ideal Nodal Analysis.

Figure 2 - Real Condition of Nodal Analysis.

 Figure 3 - P3/PBHP to Formation Figure 4 - SD/FD and P3/PBHP Relationship.
Depth Relationship.

*P3 = a+bNq
P *P3 = a+bNq *P3 = a+(c/S)q2
P
R *P3 = a+(c/S)q2 R
E E
S S
S S
U U
R R
E E

FLOWRATE
FLOWRATE

Figure 5 - Pump Intake Pressures Figure 6 - Matched Linear Approach to IPR Line.
Elimination to Approach IPR
Line.