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www.gotheta.com or www.xspoc.com
Email Addresses:
John G. Svinos - President: jsvinos@gotheta.com
Terry Treiberg - XSPOC Dev. Manager: terry@xspoc.com
Software Support: Rudy Nesmith: rudy@gotheta.com
All Rights Reserved. This manual may not be reproduced in whole or in part without the written permission of Theta Oilfield Services, Inc.
RODSTAR, RODSTAR-D, RODSTAR-V, RODDIAG, XDIAG, CBALANCE, and XTOOLS are
trademarks of Theta Oilfield Services, Inc..
Printed in the United States of America
First Edition, October 2006
RODSTAR |
Contents
Technical Support . . . . . . . . . . . . . . . . v
System Requirements . . . . . . . . . . . . . . v
1
Introduction
Software Installation
Running RODSTAR
21
iii
iv | Table of Contents
51
59
Technical Support
Technical Support for RODSTAR is provided by
phone and e-mail to customers with a current Annual Technical Support Agreement.
The first year of technical support is provided free
with the initial purchase of a license.
Support for customers with an expired agreement
is billed at $100/hour with a one-hour minimum
per incident.
Please include the Serial Number from your Sentinel bitlock when contacting support.
Phone Support:
E-Mail Support:
support@gotheta.com
System Requirements
Processor:
Operating System:
Windows XP
Memory:
RODSTAR |
Display:
RODSTAR |
Introduction
RODSTAR for Windows is a powerful, easy-touse rod pumping system simulator and design tool.
With RODSTAR you can design new rod pumping installations or make changes to existing rod
pumping systems. It is a tool that you can use to
compare pumping units, pumping speeds, plunger
sizes, rods, motor types, etc. You can evaluate the
effect of pump fillage, fluid level, or an out-of-balance unit. Also, you can study the effect of prime
mover speed variation, stuffing box friction, etc.
RODSTAR also allows you to combine sophisticated rod pumping system modeling with inflow
performance data for even more powerful capabilities.
There are two versions of RODSTAR: RODSTAR-D and RODSTAR-V. This manual applies
to both for most items since the programs user
interface is practically identical except for an additional input window in RODSTAR-D for entering
the wellbore deviation survey. RODSTAR-D is
primarily for rod pumping systems with deviated
wellbores, while RODSTAR-V is for vertical wellbores (little to no deviation).
When the program discusses RODSTAR it
applies to both versions of the program. If there
are differences between RODSTAR-D and V, the
description in the manual will specify the program
version (RODSTAR-D, or RODSTAR-V).
RODSTAR is very easy to use, flexible, customizable, and fast. With a single click of the mouse you
can access any input screen at any time. You can
change an input by simply clicking on it, and when
you have a question, simply press ! for context
sensitive help for any input item. You can also take
advantage of standard Windows features such as
being able to copy the dynamometer, torque plots,
or IPR plots to the clipboard and then paste them
RODSTAR can read well files created with RODDIAG, XDIAG (Theta Oilfield Services,
Inc.s diagnostic computer programs) and CBALANCE (Theta Oilfield Services, Inc.s pumping
unit balancing program). RODSTAR can read all
the data contained in a RODDIAG or XDIAG
file, including the measured dynamometer card.
| Introduction
This allows you to redesign pumping systems without having to reenter system data. RODSTAR can
display and print the measured dynamometer card
overlaid on the same plot as the predicted surface
dynamometer card. This feature has many uses
that include finding the correct rod-tubing friction,
or determining whether the load cell used to record
the dynamometer card may be out of calibration.
By being able to read CBALANCE files, RODSTAR can get the existing maximum counterbalance moment based on the existing position of
the counterweights. This eliminates the need for a
field measurement of counterbalance effect. Also,
you can enter the calculated balanced maximum
counterbalance moment back into CBALANCE
to find out how to balance the pumping unit in one
step.
RODSTAR can simulate any pumping system and
can accurately predict its performance. For a system you specify, the program predicts the surface
and downhole dynamometer cards. Also, it calculates the peak gearbox torque and gearbox loading,
structure loading, rod loading, pump stroke, minimum required pump length, plunger length, pump
spacing, expected production rate, the counterbalance needed to balance the unit, the prime mover
size, overall system efficiency, daily energy consumption, monthly electricity bill, and other useful
information. Also, RODSTAR allows you to enter
inflow performance data so that you can easily design a pumping system for any pump intake pump
intake pressure, calculate the expected production
rate, pump intake pressure and pump condition for
any rod pumping system, find out the maximum
production rate you can get, and more.
RODSTAR |
RSWIND.Exe
RODSTAR.CDB
CUSTOM32.PUD
ing the ! key. Also, you can search help for any
other item.
| Introduction
RODSTAR |
Software Installation
Nothing. When you install or reinstall RODSTAR for Windows, only program files are replaced. The latest version of RODSTAR saves files
in the XML file format but can read files created
with older versions of RODSTAR as well.
What happens to the Setup Settings from previous versions?
If the previous version is not very old (before the
new setup options were developed) then your settings will be preserved.
| Program Installation
If the sentinel is not installed correctly, the program will warn you that the sentinel does not appear to be connected. If this occurs, make sure the
sentinel in properly installed and the connection is
not loose. If the sentinel is properly installed but is
not working, it may have been damaged. Frequent
plugging and unplugging, and static electricity can
damage the sentinel. If this occurs, contact Theta
Oilfield Services Inc. to determine if you need a
replacement. Do not discard the damaged sentinel.
Even if it is damaged, you must return it to Theta
Oilfield Services, Inc. before a replacement can be
sent out. When RODSTAR first starts, it reads
and displays the serial number of your sentinel on
the opening screen.
Theta Oilfield Services, Inc. uses Sentinel SuperPro for software protection. If you use software
sentinels from other vendors, you may be able to
cascade Sentinels as long as the LPT1 port has
only one Sentinel C on it. The rest of the Sentinels must be a different type. If you have one or
more Sentinel PRO and one Sentinel C, then
plug the Sentinel C at the end of the Sentinel
PROs or SuperPros. USB type Sentinels can be
plugged into any available USB port or hub on the
PC.
RODSTAR |
2. If the file is not already associated with RODSTAR-D, windows will let you know and ask
you to select the program from a list. Make
sure this option is selected and click on the OK
button.
3. Click on Browse, go to the directory where
RSWIND.EXE resides (typically, it will be in
C:\Program Files\
Theta Enterprises\
RODSTAR-D, and
double click on it.
The Maximize button causes the RODSTAR window to fill the entire screen. After you maximize
the RODSTAR window, the maximize button
RODSTAR |
shows a double box and is called the restore button. Clicking on the restore button re-sizes the
RODSTAR window to the size it was before you
maximized it.
The toolbar gives you quick access to menu commands using your mouse. When you first load
RODSTAR, only some of the buttons on the
toolbar are active. When you enter data or read a
file from disk, then the print button and all the
buttons that correspond to input windows become
active. If you load a file that contains output then
the report icon also activates. Otherwise, if the
file contains only input then the report icon remains inactive until you run the case. For a quick
reminder of what each toolbar button does, simply
place the mouse pointer on it. A small message box
called a tool tip appears that tells you what the
toolbar icon does (see Figure 3.2). Also, the status
bar shows more information about the same tool
bar item.
RODSTAR | 11
Casing pressure
Electricity cost
Company name
IPR correlation
Oil gravity
Pump condition
Motor type
Plunger size
Pump efficiency
Pump fillage
Tubing pressure
Water cut
User name
Cost analysis.
RODSTAR | 13
information).
Deviation
Charts
1. Click on the + symbol on the left of Pumping Unit Options. Then, click on Custom
pumping unit list. This opens the window
shown in Figure 3.8.
2. Drop down the manufacturer list by clicking
on the down arrow next to Manufacturer:
4. You can select the units to include in the custom pumping unit list using drag and drop. To
add a unit from the list of available units to the
custom database list, you simply drag (click on
it with the mouse and hold the left mouse button while moving it) the units you want from
the list on the right to the custom list on the
left. Or, you can click on a unit once to select
it, and then click on the <<Add button (in the
middle of the screen). The program automatically arranges the units in the proper order
(largest stroke length and largest gearbox size
first).
5. To remove a unit from
the customized list,
simply drag it from
the list on the left, and
drop it in the list to
the right. Or, you can
click on a unit once
and then click the Remove>> button (in the
middle of the screen).
To make sure you select the correct pumping unit, highlight it
(click on it once with
the mouse) and the
Name: and Other:
fields on the bottom of
the screen will show
Here you can enter data for pumping units that are
not in RODSTARs main database. If you have the
dimensions you need for these units you can enter
them here to make them a permanent part of your
RODSTAR software. To enter dimensions for a
pumping unit, do the following:
RODSTAR | 15
1. Click on Measured
Pumping Unit List.
2. Click on the +
symbol (on the left of
the pencil symbol).
This will open the
window shown in
Figure 3.11.
3. Enter the data in
this window starting
with the pumping
unit manufacturer
name.
4. Enter the pumping
unit data for your
pumping unit.
by clicking on the
Sinker bar option
at the lower left
hand corner of this
window.
RODSTAR allows
you to select any of the
available stress analysis
methods. Once you
Figure 3.10 - Customizing the pumping unit database
enter a special rod
grade to the program,
unit manufacturer. As shown in Figure 3.15, after
it becomes part of the
programs equipment database and it works exactly you select the manufacturer, RODSTAR displays a mini-spreadsheet that you can use to enter
the same way as RODSTARs built-in rod grades.
pumping unit costs. To enter the cost for a pumpFor example, once you enter a special rod grade,
ing unit, click on the cell to the right of the pumpyou can enter cost information for it, and you can
ing unit and enter the cost.
select it from the same rod grade menu that RODWhen you are done entering pumping unit costs
STAR uses for the built-in rod grades.
for the pumping units you want, click on OK. Or,
The modify (Pencil Icon) and delete (X Icon)
if you want to enter rod string cost data, Select
options allow you to change or erase custom rod
Rod string costs and then select the rod type
grades you have already entered.
and rod grade. RODSTAR will display a mini-
RODSTAR | 17
RODSTAR | 19
the only format that appears is the (Default) format that RODSTAR will
use when you run it in the
batch mode and choose to
create a summary spreadsheet file. To create a new
spreadsheet format click on
the + button. This opens
the spreadsheet setup window that you see in Figure
3.18.
RODSTAR | 21
Running RODSTAR
22 | Running RODSTAR
When entering data in RODSTARs input windows, it helps to know the following:
Contents..
Index..
Search..
About RODSTAR..
Click on Contents to see a list of items RODSTAR can provide help for. As you can see, RODSTAR shows text and pictures in its help screen.
For example, RODSTAR displays a picture of the
toolbar and instructs you to click on the button you
want help for. Using the mouse, you can resize or
move the Help window.
Next, click on Help and then click on Glossary to
see an alphabetical listing of artificial lift terms. To
see the definition of any of the terms in the glossary, click on it. For example, click on API gravity to see a definition. Also, you can click in the
list of items in the Glossary and then type a letter
to go to the terms that start with that letter. For,
example, to find the definition for Permissible load
RODSTAR | 23
press S+ T to move backwards. After entering data in fields with yellow background color,
sumptions or limitations.
field by pressing !.
Please use the context
sensitive help as often as
possible because it contains important information that will allow you to
make better use of RODSTAR. Also, the context
sensitive help makes you
aware of program as-
24 | Running RODSTAR
RODSTAR uses the oil API gravity and percent water cut you entered to calculate the default
specific gravity of the produced fluid. The program
will display this value when it prompts you to enter
the fluid specific gravity. RODSTAR calculates
the default specific gravity without considering free
gas. This is okay for designing new wells since we
prefer to be more conservative. However, if you
want to simulate an existing system that produces
gas, you must enter a lower number than the one
calculated by RODSTAR. With some experience
and with history-matching between predicted
and actual dynamometer cards you can come up
with effective specific gravities that will accurately
model your rod pumping systems. If you use a
specific gravity that only considers liquids, it will
result in higher predicted loads, power consumption, etc.
If you are designing a new system and you are not
sure what the specific gravity is, use the higher
RODSTAR | 25
After you finish entering data for the Well Information window click on the next screen button
(right arrow) on the toolbar to open the Production
Information input window. To move back to the
previous window, simply press the left arrow icon
on the toolbar.
Remember that pressing @ converts to the opposite system of units. For example, if you selected
English units but want to enter the pump depth
in feet, press @ before entering the value. If the
value for any field with units has already been
entered, pressing @ will show it in the opposite
units.
26 | Running RODSTAR
RODSTAR | 27
28 | Running RODSTAR
Buoyancy effects
The option to include buoyancy effects should
be left unchecked in most cases. This is because
buoyancy does not cause buckling of the rod string.
However, for fiberglass-steel rod strings, after the
design is finalized, It is recommended that an additional run be made including buoyancy effects to
ensure that the fiberglass portion of the rod string
is not in compression. If it is in compression, then
more sinker bars must be used, the pumping speed
need to be reduced, or both.
When buoyancy is not included, the bottom of
each rod section except the last section should have
a positive stress. Otherwise the rods may be going
into buckling. It is normal for the very bottom of
the rod string to be in compression if you enter a
pump friction that is not zero (a minimum pump
friction of 200 lbs is recommended).
For more information on the theory behind these
recommendations, please read SPE paper number
25416 Interpretation of Calculated Forces on
Sucker Rods by J. F. Lea and P. D. Pattillo. Presented at the Production Operations Symposium
in Oklahoma City, March 1993.
RODSTAR | 29
4.8.
30 | Running RODSTAR
RODSTAR | 31
If you select only sinker bars on the bottom (without regular steel rods between the fiberglass and
sinker bar) then RODSTAR will calculate the
length of the sinker bar section for you. If you
select both sinker bars and a tapered steel design
between the sinker bars and the fiberglass rods,
then you must enter the length of the sinker bar (or
sinker rod) section. RODSTAR will determine the
length and diameters of the tapered steel portion
32 | Running RODSTAR
When you select this option, you can enter data for
either steel or fiberglass rods as Figure 4.12 shows.
You can enter the number of rod sections, the service factor you want to use, and rod string data for
up to eight rod sections. For each section, you can
select the rod type or grade, diameter, and length.
For Fiberflex fiberglass rods you can also specify
the sucker rod length.
If you select one of the fiberglass manufacturers
listed on the drop down list next to the rod grade
input field, the program knows the weight per
foot and modulus of elasticity and will not prompt
you for them. The program warns you about rods
that do not fit in the tubing. Also, it warns you if
the rod string length is shorter or longer than the
pump depth. The total length of the rod string
RODSTAR | 33
34 | Running RODSTAR
RODSTAR | 35
If RODSTAR is being used to analyze an existing well, the Deviation Survey Direction Toolbar
should be disabled. To disable this toolbar, click
the Setup icon, click the Defaults option, and uncheck the box labeled
Show Deviation
Direction Toolbar.
The Deviation Survey
Direction Toolbar
is used to design a
deviated well. While
the toolbar is active,
the Azimuth is input
in degrees and the
toolbar is utilized to
designate a direction.
Select a direction first,
then input the degree
value. The field will be
automatically updated
with the direction once
the field is left.
NOTE: The NE
direction is the default
tion data.
36 | Running RODSTAR
RODSTAR | 37
38 | Running RODSTAR
Azimuth
Clicking the Plot Survey tab on the right side
of the window will display the Deviation Plot as
shown in Figure 4.23. From this screen, you can
rotate the plot to better understand and visualize
the wellbore deviation, you can zoom in, etc.
RODSTAR | 39
40 | Running RODSTAR
2) You have erased the pumping unit file by accident, or the pumping unit files are not in the same
directory as the program.
RODSTAR Recommended unit size
If you enter a target production instead of pumping speed, RODSTAR will display a recommended
pumping unit size to help you select a pumping unit.
This recommendation can be very helpful if you are
RODSTAR | 41
42 | Running RODSTAR
RODSTAR | 43
stroke length, and try to decipher additional information from the units nameplate for the structure
rating, stroke length, and structural unbalance.
If the nameplate is legible then write down the
units serial number or order number. If the units
manufacturer is still in business, you may be able
to get the data you need from the serial number
or order number. For help in locating dimensional
data for pumping units not in the manual call
Theta Oilfield Services, Inc..
RODSTAR allows you to enter data for Conventional, Mark II, Air Balanced, Enhanced Geometry, or Long Stroke units. When you enter your
own pumping unit dimensions, RODSTAR calculates and displays the stroke length based on the
dimensions you enter. For all pumping unit types
you must first enter the name of the manufacturer,
the unit name or model number, the gearbox rating
in thousands of inch pounds, the structure rating
in hundreds of pounds, and the maximum stroke
length in inches. From these numbers RODSTAR
puts together the API pumping unit designation.
The API pumping unit designation is a standard
way of describing the size and capacity of pumping
units as the following example explains:
The first number is the gearbox rating in thousand
inch-pounds. In this example the gearbox rating is
320,000 inch-lbs. The second number is the structure rating in hundreds of pounds. In this case the
structural rating is 256. This means that to avoid
overloading the structure of the unit, polished rod
load must not exceed 25,600 lbs. The last number
shows the maximum stroke length of the unit in
inches (100 inches in this case). Following is an
explanation of the rest of the data needed for each
unit type:
Conventional and Enhanced Geometry
Pumping Unit Data
For these units you must enter pumping unit dimensions R, A, C, I, P, and K in inches, the structural unbalance in pounds, and the crank offset
angle in degrees. For enhanced geometry units the
crank offset angle must be negative. The API spec.
H
G
2
)
K as follows: K= ( H-G + I
Height from the center of the
saddle bearing to the bottom of
the base beams (inches)
Height from the center of the
crank shaft to the bottom of the
base beams (inches)
44 | Running RODSTAR
Dimension:
R
A
C
K
H
G
Description:
Radius of the crank (inches)
Distance from the center of the
Sampson Post bearing to the centerline of the polished rod (inches)
Distance from the centerline of the
Sampson Post bearing to the center of the equalizer (or cross yoke)
bearing (inches)
Horizontal distance between the
centerline of the Sampson Post
bearing and the centerline of the
crankshaft (inches)
Effective length of the pitman
arm, in inches (from the center of
the equalizer (or cross yoke) bearing to the center of the crank-pin
bearing)
Distance from the center of the
crankshaft to the center of the
Sampson Post bearing (inches)
Height from the center of the
saddle bearing to the bottom of
the base beams (inches)
Height from the center of the
crank shaft to the bottom of the
base beams (inches)
Description:
Radius of the crank (inches)
Distance from the center of the
Sampson Post bearing to the centerline of the polished rod (inches)
Distance from the centerline of
the Sampson Post bearing to the
center of the equalizer bearing
(inches)
K
M
V0
For these units you must enter the sprocket diameter (D), the centerline distance between the top
and bottom sprockets (distance C), the pitman arm
length (P) if one exists (usually this is zero), and
the top drum diameter ratio (usually equal to 1).
You can see a diagram of the dimensional data you
need by pressing F1 in any input field, or you can
take a look at Figure 4.28.
You can also use this pumping unit model to simulate any non-beam pumping unit with a long,
slow stroke. You can do this by entering data that
will produce the same stroke length as the unit you
want to model. The stroke length of a long stroke
unit is given by:
Stroke = C + D
RODSTAR | 45
46 | Running RODSTAR
The range of allowable counterweight is different for different Rotaflex units. RODSTAR takes
this into account when validating your entry for
counterbalance weight. For example, the minimum counterweight possible for the 1200 model
is 13,500 lbs. Therefore, if you try to enter a counterweight that is less than 13.5 M lbs, (M =thousands) RODSTAR will warn you that the counterweight for this unit must be between 13.5 and 32.5
M lbs.
RODSTAR | 47
RODSTAR warns you if you select an ultra-highslip motor when you have selected an air-balanced
or long stroke pumping unit. These units have little
or no rotating moment of inertia, so using an ultrahigh-slip motor does not result in any significant
differences in the calculations. Therefore, for these
units, do not select an ultra high slip motor or to
include speed variation effects.
If you select a NEMA D motor type for a new
case, or switch from an ultra-high-slip motor to
a NEMA D motor, RODSTAR automatically
selects the option to recommend the motor size.
Motor speed variation
48 | Running RODSTAR
variation is only available for conventional, enhanced geometry, and Mark II units. Inertia effects are negligible for long stroke and air balanced
units.
For more accurate results, have RODSTAR calculate the prime mover speed variation. However,
you can also enter a speed variation value if desired. If you select to enter speed variation, RODSTAR shows a default value of 8% which corresponds to a recommended average speed variation
for NEMA D motors. You can get more conservative results by entering a speed variation that is
less than the maximum expected speed variation
for your prime mover. Selecting to include prime
mover speed variation will approximately double
RODSTARs run time.
What is moment of inertia?
of a body is a measure of its resistance to acceleration. In other words, the higher the moment of
inertia of a body, the more difficult it is to quickly
speed it up or slow it down.
RODSTAR | 49
RODSTAR | 51
then choosing Save As... This brings up a standard Windows dialog box that allows you to save
your file with the file name you want. RODSTAR
shows the default file name it creates from the well
name and by adding an .RSVX file name extension for RODSTAR-V or .RSDX for RODSTAR-D. If you enter data for a case in ROD-
RODSTAR | 53
).
RODSTAR | 55
The spreadsheets that RODSTAR create summarize the results of all the runs and loads it directly
into Excel. Under the Setup window you can design and save an unlimited number of spreadsheet
formats. If you do not specify a spreadsheet format
before running many cases in batch mode, RODSTAR uses the default spreadsheet format that
comes with RODSTAR and contains the most
RODSTAR | 57
RODSTAR has a
powerful and easy-touse file management
system. When you select
to load data from disk,
RODSTAR displays the
current path and a list
of files in the current
directory in alphabetical
Figure 5.10 - Selecting a file to open
order. Also, RODSTAR
allows you to read
5.4.1 Viewing Previously Saved Output
RODDIAG files, XDIAG files, and even older
RODSTAR files. RODSTAR displays a list of the When you load a file that contains output you
file type you selected in the current directory as the can display the output without having to rerun
the case. When you load a case that contains
Figure 5.10 shows.
input data only (no output results were saved),
To load one of these files, double click on it, or
RODSTAR displays the first input window (well
click on it once and then click on OK. If the file
information). Also, the report and print icons on
you want is not in the current directory, you can
the toolbar are not available. However, when you
easily move to any directory on any drive in your
load a file that contains both input and output,
system since this window also lists sub directories,
RODSTAR does not open any input windows.
and system drives.
The status bar at the bottom of the screen shows a
If your current directory contains many RODmessage like the following:
STAR files, it may be faster to press the first charSuccessfully loaded file: C:\Theta\RODSTAR-V
acter of the file you are looking for. For example,
cases\special cases\abc#1.rsvx (output results are
if you are looking for well name PR101.RSVX,
available).
click in the list once, and then press p and the
Also, the report and print icons on the tool bar are
program will jump to the first file in the list that
active. To see the output without having to re-run
starts with P.
the case, click on the report icon on the tool bar.
To print the output, click on the printer icon (next
to the email icon).
After entering data for a case or after loading a file from disk, click on each windows icon on
the toolbar. This loads all input windows.
RODSTAR | 59
Because RODSTAR can predict energy consumption very accurately, you can use it to select the
most economic system designs. The following
sections explain how to apply RODSTAR to solve
common design problems. As you become more
RODSTAR | 61
and gearbox loading, look at the torque analysis section of the printout. The permissible load
diagram corresponds to existing conditions if you
entered a counterbalance moment. If you did not
enter an existing max. CB moment then the program shows a permissible load diagram for balanced condition (for minimizing gearbox torque).
Note!: The above discussion about RODSTARs permissible load diagram refers to
beam pumping units. The permissible load diagram for long stroke units such as the Rotaflex
will have straight line segments that correspond to gearbox loading or structure loading.
Please look at the structure loading number
on the first page of the output and the percent
gearbox loading under torque analysis for the
exact percent unit loading.
RODSTAR | 63
6.1.4 Report
To see the report, click on the Report button.
You can scroll this window using the mouse by
clicking or the up or down arrows at the top or
bottom of the range bar on the right edge of the
window.
Or, you can click and drag the range bar or the
report itself with the mouse.
Input and Output Summary
Pumping unit Structural Loading indicates whether or not the pumping unit structure is overloaded.
This is a function of the peak polished rod load
and the structural capacity of the pumping unit
(the middle number in the API pumping unit
designation).
Buoyant Rod Weight
RODSTAR | 65
For low Fo/Skr numbers (below 0.25) fiberglasssteel rod strings will have very low system efficiencies and should be avoided. For fiberglass rods try
to keep Fo/Skr above 0.3 and below .8 for best
results. Also for fiberglass rod strings, you should
keep N/No below 1.0 and above .4 for best results.
Prime Mover Speed Variation
If you select to have RODSTAR calculate the motor speed variation for you then this section shows
what this number is. For NEMA D motors this
number will vary from 2% to 14% depending on
motor size. For correctly sized ultra high slip motors it can be as high as 50%. If motor speed variation is not considered then this will be indicated
on the output report.
cyclic load factor, maximum counterbalance moment, and counterbalance effect. Also, it calculates
electricity consumption. RODSTAR predicts the
KWH consumed per day, the estimated monthly
bill, and cost per barrel of fluid and per barrel of
oil per day. Use the cost per barrel numbers when
comparing system performance to ensure a valid
comparison. This is because a system that shows
a lower monthly bill may also be producing less
fluid.
Here you see the tubing inside and outside diameters, the anchor depth, the calculated tubing
stretch, the upstroke and downstroke rod-tubing
friction factors you entered or that were calculated
by RODSTAR, pump load adjustment., etc. Also,
this section shows the pump depth, the pump
type, and plunger size.
RODSTAR | 67
This section shows the rod string design and service factor you selected, the calculated percent rod
loading for each rod section, the maximum and
minimum stresses at the top, and the bottom minimum stress for each rod section. To ensure your
rods are in tension, do not include buoyancy effects
(this should always be the case for steel rods).
Then, make sure there are no negative stresses on
any other rod section other than the sinker bar section on the bottom of the rod string.
If you are using fiberglass rods you would not want
to use a design with a negative bottom minimum
stress on the fiberglass section even with buoyancy
effects included. Compressive loading will cause
fiberglass rods to part. Also, to maximize rod
life, stress loading must be less than 100% in all
cases. For sinker bars, RODSTAR calculates stress
loading, top maximum and top minimum stresses
based on the elevator neck or pin undercut diameter of the sinker bars. However, RODSTAR still
uses the full body diameter in the calculation of
stress at the bottom of the sinker bar section.
Rod String and Pumping Unit Cost Analysis
RODSTAR | 69
The buckling tendency shows the buckling tendency load as a function of measured depth. It is
generally accepted that buoyancy does not cause
buckling. The bottom of the rod string is subjected to negative loads because of pump friction
and other frictional effects due to wellbore deviation. According to a paper titled Interpretation of
Calculated Forces on Sucker Rods by J.F. Lea and
P.D. Pattillo, published in SPE production and Facilities, February 1995, the critical load necessary
to buckle a rod string is calculated as follows:
Where:
w = rod weight in fluid
I = moment of inertia of cross section (in4)
E= elastic modulus of rod = 30.5x10 psi for steel
The Moment of inertia of the rod section (I
above) can be calculated as follows:
them in tension.
RODSTAR | 71
following parameters:
Production Rate
Capital costs
Rod loading
Gearbox loading
72 | Well Information
stroke length, using a smaller pump, or by installing a percentage timer or pump off controller.
Because RODSTAR can simulate fluid pound,
you can use it to see what will happen if the well
pumps off.
To minimize energy consumption and stress loading, use the largest plunger diameter and slowest pumping speed combination possible without
overloading the rod string and pumping unit. If
you have to make a choice between stress loading
and power consumption, opt for lower stress loading especially if you are close to 100% since rod
breaks are more costly than a slightly lower system
efficiency.
Note that these are only general guidelines. Economics and local field conditions may require a
different design philosophy than the one described
above. Regardless of your objectives and design
philosophy, with RODSTAR you can design rod
pumping systems faster and more accurately than
with any other computer program.
RODSTAR | 73
74 | Well Information
RODSTAR-D allows you to change the rod-tubing damping coefficients for upstroke and downstroke and also the friction coefficient between
rods and tubing for each section in the rod string.
This allows you to better simulate use of different
rod guides, or more exactly match the correct friction between rods and tubing for a better match
with the measured dynamometer card.
Theta Oilfield Services, INC., 1901 E. Lambert Rd. Suite 108 La Habra, CA 90631 USA
Telephone #: (562) 694-3297, Fax #: (562) 694-8641 www.gotheta.com