SPE 68864
Modern Total Well Management - Sucker Rod Lift Case Study
J. N. McCoy, Echometer Company, A.L. Podio, University of Texas at Austin; Bill Drake, Echometer Company, Lynn
Rowlan, Echometer Company
Copyright 2001, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at the SPE Western Regional Meeting held in
Bakersfield, California, 2630 March 2001.
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presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
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Abstract
Oilfield operators continually need to verify that their wells
are being produced at the optimum capacity and in a cost
effective manner. An integrated analysis of the pumping
system is required to reduce operating costs, increase oil
production and increase net income. The integrated analysis
of the pumping system must include the performance and
interaction of all the elements: the prime mover, surface
equipment, well bore equipment, down hole pump, down hole
gas separator and the reservoir. This integrated analysis
methodology is called Total Well Management, TWM. The
TWM analysis is made based on data obtained at the surface
without entering the well bore and yields an accurate
representation of the conditions existing on the surface, within
the well bore and within the reservoir. A field case study of a
sucker rod lifted well illustrates the procedure and benefits of
the Total Well Management methodology.
Introduction
The need to increase oil production and reduce operating costs
from wells requires an integrated analysis of the pumping
system including the performance and interaction of all the
elements: the surface equipment, the down hole equipment,
the well bore and the reservoir. The analysis is to be based on
data obtained at the surface without entering the well bore and
must yield an accurate representation of conditions that exist
at the surface, within the well bore, at the sand face and within
the reservoir.
Such system analysis can now be undertaken efficiently
using portable notebook computer data acquisition systems in
conjunction with appropriate sensors and a suite of analysis
software. The analysis can be undertaken on sucker rod lifted,
electrical submersible pumped, progressive cavity pumped,
plunger lift, gas lift, flowing and other types of wells to
determine the wells performance so the production rate can
be maximized and the operating expenses minimized.
Field experience undertaking such analysis in numerous
wells has resulted in the development of a methodology: Total
Well Management (or TWM) insures good results are
obtained with the minimum of effort. Operation of artificial
lift wells using the concept of TWM results in a more
complete understanding of the performance of a given well.
Implementation of this concept can result in significant
reductions in operating costs and increased oil production as
shown by results of numerous operators in a variety of
operating conditions. TWM production optimization
methodology is a broad analysis and optimization concept, and
is applicable to sucker rod lifted wells, electrical submersible
pumped wells, progressive cavity pumped wells, plunger lift
wells, gas lift wells and other types of artificial lift. An
example of a sucker rod lifted field case study illustrates the
procedure and benefits of the Total Well Management
methodology.
Such procedure is greatly facilitated by the use of a fully
integrated portable instrument that includes all the necessary
sensors, precision analog to digital electronics, computer
hardware and software components. The integrated system
allows immediate analysis of the well performance at the well
site. The alternative is to use separate conventional fluid
level, dynamometer and power instruments for data
acquisition and then combine the results of each test using
various application programs. One of the cost-effective
advantages of an integrated analysis system is that the well
data is entered only once into a data file and the integrated
system uses the data to determine well performance.
Well Productivity and Inflow Performance
Most operators desire that wells be produced at or near their
maximum production rate. The maximum production rate
(potential) of a well is obtained when the producing bottom
hole pressure (PBHP) is low compared to the static bottom
hole pressure (SBHP). A well may be producing at 20%, 50%
or 80% of the maximum flow rate depending on the ratio
between the PBHP and the SBHP. If sufficient size equipment
exists on the well, the PBHP should be less than 10% of the
SBHP to insure maximum production. Most producing and
2 J.N. MCCOY, A. L. PODIO, BILL DRAKE, LYNN ROWLAN
static bottom hole pressures and analyses are obtained from
surface measurements by acoustically measuring the distance
to the liquid level in the well, measuring the casing pressure
and calculating the bottom hole pressure1, 2, 3.
Accurate knowledge of well productivity is lacking in
most oil fields. Very few operators have determined inflow
performance of their wells because static BHP surveys are
seldom undertaken, since few operating companies are willing
to shut-in wells for extended periods of time. Also, liquid
level measurements taken with strip chart acoustic instruments
are seldom converted to a calculated producing BHP. Every
effort should be made to obtain representative values of
producing and static bottom hole pressures that can be used in
determining Productivity Index or Inflow Performance
Relations (IPR). One way to obtain SBHP data is to institute a
policy to routinely make static fluid level measurements any
time that any well in a field is shut-in for any reason (work
over, repair, equipment failure) and to interpret these static
fluid level measurements in terms of static bottom hole
pressures. What is required is at least an estimate within 10-
15% of the actual stabilized SBHP. Operators should attempt
to periodically determine the static bottom hole pressures
when the wells are down for any reason, and then maintain the
producing bottom hole pressure at less than 10% of the SBHP,
when maximum inflow is desired.
Thus, it should be clear that in order to be able to make a
judgment about how efficiently we are producing a well we
must know BOTH the Static and the Producing bottom hole
pressures and have an accurate and up to date well production
test. If any one parameter is missing or is inaccurate (or
guessed) we may reach the wrong conclusion regarding the
potential of the well. Fig. 1 illustrates that the example well is
producing 99% of the maximum potential based on the 2000-
psi SBHP and the computed 58-psi PBHP. The PBHP is
obtained from an acoustic fluid level and casing pressure
measurement and then computed taking into account the effect
of annular gaseous liquid column if present. This test
indicates that the well is being produced at the formations
maximum producing efficiency. The operator is doing an
excellent job at maximizing the production from the well.
A well with a fluid level 1000 feet over the pump will
indicate the importance of determining both the producing and
static bottom hole pressures. Many operators may attempt to
correct the problem of an assumed 1000 feet of liquid column
over the pump, which would exert backpressure and restrict
production, by installing a larger pump. What if the 1000 feet
of liquid column over the pump is actually a mixture of
liquid aerated by gas flowing up the casing annulus and
discharging at the surface? The actual producing bottom hole
pressure may be only 150 PSI due to the liquid column being
aerated with gas bubbles flowing upward through the liquid
column. If the static bottom hole pressure is 2000 PSI, the
PBHP of 150 PSI is less than 10% of the SBHP and the
maximum production rate is being obtained. Installing a
larger pump would be a waste of time and money. In other
cases, a well may be produced with considerable liquid over
SPE 68864
the formation or a high casing pressure that does restricts fluid
flow from the reservoir.
Sucker Rod Lifted Wells
The TWM procedure for sucker rod lifted wells involves the
following steps:
1. Analyze the wells inflow performance to determine
if additional production is available.
2. Determine the overall efficiency to identify wells
that are candidates for improvement.
3. Analyze the performance of the pump.
4. Analyze the performance of the down hole gas
separator.
5. Analyze mechanical loading of rods and
pumping unit.
6. Analyze performance of prime mover.
7. Design modifications to existing system.
8. Implement changes and verify improvement.
Well Screening by Inflow Performance. All wells should be
tested to insure that the producing bottom hole pressure is low
compared to the static bottom hole pressure. This is the first
and most important step in optimizing a wells performance.
See Fig. 1 for an example of a well that is being operated at its
maximum potential to produce oil.
Well Screening by Energy Efficiency. Many different
parameters can be used to identify those wells that are the
most likely candidates for improvement. Experience has
shown that one method of identifying wells that need
improvement is to determine the overall efficiency of the
wells pumping system. This requires only the measurement
of input power to the prime mover, determination of the
producing bottom hole pressure (PBHP) and accurate
production test data.
Fig. 2 shows the results of a power survey on the case
study well illustrated in Fig. 1 obtained with power probes.
Both instantaneous motor power and motor current are plotted
for one complete pump stroke. The balanced RotaFlex
pumping unit in Fig. 2, shows the motor generates very little
power during the entire stroke and the overall efficiency is a
high 57.9%. For comparision purposes data from a
counterweight-heavy conventional pumping unit, Fig. 3,
shows the motor generating power over a large portion of the
stroke, plus the overall efficiency is a low 30.4%. The
software, using the well data (partially shown in Fig. 4) and
acquired field data, performs a complete motor power and
current analysis. The overall efficiency4 of a sucker rod lifted
system should approximate 50%. In Fig. 3 the wells
performance could be improved, while in Fig. 2 the system is
being operated near peak efficiency.
The operating cost is calculated on the basis of a barrel of
fluid pumped and a stock tank barrel of oil produced. These
values are calculated from the production rates that were
SPE 68864 MODERN TOTAL WELL MANAGEMENT - SUCKER ROD LIFT CASE STUDY
entered in the well data file and based on the most recent well
test.
Pump Performance. Using an integrated data acquisition
system, motor power and dynamometer data can be obtained
simultaneously. The dynamometer measurement can be made
with a polished rod transducer (PRT) that is installed by a
single technician in a matter of minutes. Or the dynamometer
measurement can be made with a horseshoe loadcell
transducer (HT) installed between the pumping unit carrier bar
and the permanent polished rod clamp. Analysis of the down
hole pump operation is undertaken by calculation of the pump
dynamometer card from surface acquired load and position
data. Surface dynamometer and pump cards are immediately
available in the field so that a diagnosis can be made to
determine whether a pulling job needs to be scheduled. Fig. 5
shows that incomplete pump fillage is the main cause of this
wells inefficiency. The shape of the pump dynamometer card
gives a strong indication that gas interference due to an
inefficient down hole gas separator is the primary reason for
the problem. A down hole dynamometer card indicating
incomplete pump fillage coupled with an acoustic liquid level
test, Fig. 6, showing the presence of a gaseous liquid column
above the pump is conclusive evidence that an inefficient
separation of gas is occuring at the pump intake. Reference 5
gives detailed information on efficient down hole gas
separators.
Correct operation of the pump valves is mandatory to
achieve high efficiency. Although standing and traveling
valve tests are routinely made, proper interpretation depends
on the requirement that the tests are performed correctly. For
this reason, a series of valve measurements should be
performed in order to insure their reproducibility and validity.
Fig. 7 shows a series of three traveling valve tests followed by
two standing valve tests. These tests show that they are
reproducible (thus valid and well executed) and that the
measured values agree with the theoretical values (thus the rod
and pump data is correct and there is little rod-tubing friction)
and therefore we can conclude that the valves are operating
properly.
Mechanical Loading of Rods, Gear Reducer and Pumping
Unit. It is important to maintain the loading of the rods within
the recommended guidelines for the well's service factors and
the corresponding rod's characteristics. The consistent overlay
of several dynamometer cards, Fig. 8, indicates the well is
pumping under steady state conditions and the measured loads
are within the allowable loads for the surface unit. In Fig. 8
the rod string loading is displayed in relation to the allowable
loads determined from the modified Goodman diagram and
the stresses at each rod diameter change. Proper loading of
the pumping unit and the gear reducer is equally important.
An under-loaded unit operates at low mechanical efficiency.
An overloaded unit requires excessive maintenance. Gearbox
torque loading is established more efficiently from an
instantaneous motor power survey rather than from
dynamometer measurements and does not require knowledge
3
of the pumping units geometry, counterbalance effect or
counterbalance moment.
Performance of the prime mover. The primary objective of
acquiring power data is to determine the efficiency with which
the pumping unit is being operated from both standpoints of
energy utilization and of mechanical loading. In particular the
following can be studied:
How does the measured power usage compare to the
power billed?
Is the pumping unit operating at an acceptable electrical
efficiency (50% or more)?
Does changing the direction of rotation reduce power
cost or improve pumping unit balance?
Does excessive pumping off (pump pounding fluid)
cause inefficiency?
Is the motor the correct size for the unit? Or, is the
motor over or undersized?
What techniques are available for minimizing the
overall power consumption of a lease?
Experience has shown that the general tendency is to oversize
electrical motors installed on sucker rod lifted systems. The
reasoning varies but in general it can be said that most
operators are more concerned with providing abundant starting
torque than with the efficiency of the prime mover. In general,
if a motor is twice or more oversized for a given pumping
system it should be replaced with an appropriate size motor.
This will reduce the operating cost by reducing the
consumption, the electrical demand charge and the line losses.
See Reference 4 for additional information on power analysis.
Gearbox Balancing. An additional objective of power
measurement is the determination of the torque at the gearbox6
from direct conversion of the motor power to torque as shown
in Fig. 9. The downstroke torque peak exceeds the upstroke
peak indicating that the unit is overbalanced. This is partly
due to the fact that the pump is not full, Fig. 5. If the unit
operates continuously and this is the normal steady state mode
of operation, a significant reduction of peak torque could be
gained balancing the unit by moving the 5000-pound
counterweights inwards for a distance of 16 inches as shown
in Fig. 9. One advantage of this method of balancing based on
power measurement is that it does not require knowledge of
the geometry of the pumping unit nor the measurement of the
counterbalance effect at the polished rod nor calculation of the
counterweight moment.
Design Modifications to Existing System. The objective of
the TWM study is either to modify the pumping system to
reduce overloading of some production equipment (such as
torque or rod stress) or to modify the system to better match
its pumping capacity to the productivity of the well. In most
cases, the final criterion for selecting among various operating
modes will be the overall system efficiency.
Predictive programs for design of sucker rod lifted systems
based on wave equation modeling vary in complexity and
4 J.N. MCCOY, A. L. PODIO, BILL DRAKE, LYNN ROWLAN
flexibility. The best software should interface seamlessly with
the data acquisition software and should provide the necessary
design and analysis capability. Regardless of the model that is
used, the first step is to replicate with the predictive program,
the surface dynamometer that was measured on the well. A
reasonable match will indicate that the predictive model is
sufficiently complex and accurate to include the majority of
the parameters that influence the mechanical performance of
the system. The criteria for a match should include the
polished rod loads, power, plunger travel, and pump
displacement. Since the predictive software generates a
surface dynamometer card and the software is capable of
importing the measured dynamometer data, then the shape of
the predicted card should be matched to the measured card as
close as possible, in addition to matching the load levels. Fig.
10 shows a good match of the measured and computed
dynamometer cards. The matching procedure is generally by
trial and error. A good match gives confidence that the
predictive software can be used to investigate changes in the
operation and equipment that will result in improved
performance.
Generally the type of problem indicated by the measured
performance will give an indication of which parameters
should be varied. The starting point should always be those
parameters that can be changed with a minimum of
expenditure. For example if rod loads are excessive, then
direction of rotation, pumping speed and stroke length should
be varied in this order. If this does not produce the desired
reduction, then the rod string configuration and pump plunger
should be varied, and so on.
The cost effectiveness of the changes that would be
required in order to improve the efficiency of the system needs
to be evaluated. In this analysis, both increase in income and
reduction in expenses must be included. It has been observed
that reduction in power consumption on a lease-wide basis is
often accompanied by reduced overall power demand. This
may be translated into lower demand costs as well as possible
basis for rate negotiation with the Utility Company.
Implementation and Verification of Optimized Design. Is
perhaps the most important step in the process and is often
neglected. Adequate internal communications helps insure
and verify that the optimized design is implemented without
arbitrary modification. Poor communication between
operating and design personnel is a problem that must be
resolved. Similarly feedback on the result of the changes must
be obtained, recorded in the appropriate database, and
analyzed by the operating and design personnel.
Pressure Transient Measurements in Pumping Wells.
Frequently the well's productivity is impaired by formation
damage in the vicinity of the well bore. A pressure transient
test gives the skin (or well bore damage) and the static
reservoir pressure along with other formation parameters.
The presence of the rods in a pumping well precludes using
SPE 68864
wire line-conveyed pressure recorders and thus pressure
transient tests are seldom undertaken.
This deficiency has been eliminated with the development
of systems for automatic measurement of casing head pressure
and annular fluid level that yields the data necessary to
analyze pressure buildup or draw down tests in pumping
wells7. This is done with a minimum of expenditure since it
does not require pulling the rods or tubing to install a down
hole pressure sensor or run a wire line pressure recorder.
The automatic pressure buildup system is programmed to
generate an acoustic pulse at periodic intervals (such as 30
shots per log cycle), record the casing pressure, determine the
fluid level and calculate the bottom hole pressure for as long
as it is necessary to obtain a representative pressure response.
Fig. 11 shows a plot of the Horner plot obtained in this
manner. The ability to analyze the data during the test gives
the user confidence that the test has run a sufficient length of
time to yield the desired data and thus limit the shut-in period
to a minimum. The data can be exported for analysis in other
programs if desired.
Technician Time Requirement. A production technician can
undertake the complete TWM survey including acquisition
and field processing of the acoustic, dynamometer and motor
power data in about 45 minutes per well. The same
measurements are then used to define the wells productivity,
the down hole pump performance, the down hole gas separator
performance, the rod and pumping unit loading and the motor
performance. The wells production rate can be maximized
and the operating costs minimized with this 45-minute well
analysis.
While at the well as the collected data is analyzed, the goal
for the production technician should be to answer the WELL
PERFORMANCE QUESTIONS listed in Table 1.
Recommendations to fix any problems discovered in the
analysis of the collected data should be typed as notes in the
comments text box. These notes recording the work necessary
to fix a problem are called the production technicians work
plan and the notes are called recommendations. When the
recommended changes to the well are completed, new data
should be collected in a few weeks once the well is operating
under stabilized conditions. The production technician should
re-read the recommendations from the previous analysis of the
wells data and notice if the well performance has changes as
planned. The analysis step to evaluate the recommended
changes is called the follow-up step of the analysis.
Following-up on recommendations is how production
technicians learn from their successes and failures; and their
role changes from a data collector to a knowledgeable well
analyst and problem solver.
Sucker Rod Lift Case Study
The Mallet Land & Cattle Co. well No. 50 is the RotaFlex-
equipped well tested. Chevron USA Inc operates the well.
Following is a description of the configuration of the
equipment installed on the well: The RotaFlex pumping unit,
Fig. 12, is a model 1100 with a 306-inch stroke. The API
SPE 68864 MODERN TOTAL WELL MANAGEMENT - SUCKER ROD LIFT CASE STUDY
designation is R-320-500-306. A 75 horsepower Nema D
motor, Corods and a long stroke pump are utilized. The 2 inch
pump is set below the formation, and the gas/liquid separation
capacity5 of the 2-7/8 tubing on the inside of 5-1/2 casing
exceeds the pump capacity of this high volume pump so that
gas interference in the pump is not a problem.
A complete well analysis was performed to fully evaluate
the wells performance8. An acoustic liquid level test is
shown in Fig. 13. The upward kicks occurring at 16 to 16.5
seconds on the acoustic trace identifies the depth of the casing
perforations (7669-8049 Feet). A downward kick on the
acoustic chart at 16.514 seconds indicates that the fluid level is
below the casing perforations. Liquid is flowing from the
casing perforations into the wellbore and falling to the pump
intake. The low (36.8 PSI) casing pressure and the low (57.7
PSI) PBHP cause negligible resistance to the fluid flow from
the high pressure (2000 PSI) formation into the wellbore. The
maximum liquid inflow into the wellbore is obtained. The
casing annulus gas flow rate is approximately 13 MCF per
day. Two vibration anomalies are shown on the acoustic
trace. One vibration anomaly is at 5.309 seconds, and the
second vibration anomaly is at 14.394 seconds. The
anomalies (or vibrations) occur when the pumping unit
reverses direction at the top and bottom of each stroke. These
reversals vibrate the gas gun microphone and were noted when
viewing the acoustic trace before the gas gun generated the
acoustic pulse to determine liquid level depth. The pumping
unit is running at 3.3 SPM, so these vibrations are about 9.09
seconds apart (60 SEC / 3.3 SPM / 2).
The dynamometer surface cards, pump card, traveling
valve test and rod loadings are shown in Fig. 8. Since the
velocity of the polished rod on the upstroke and downstroke
are relatively constant, the surface card tends to exhibit a
rectangular shape. The pump card shows that the pump is
being filled with liquid.
The 2 pump and 2-7/8 seating nipple are set 52 feet
below the bottom of the casing perforations. The
configuration forms a natural gas separator; allowing the free
gas from the formation to separate from the liquid and flow up
the casing annulus, while the liquid that flows downward and
enters the pump. The gas/liquid separation capacity8 of the 2-
7/8 tubing on the inside of 5-1/2 casing is approximately
635 B/D which exceeds the pump capacity of 423 B/D. Gas
interference is not a problem even in this relatively high-
volume, rod-pumped well. This gas separation technique of
setting the seating nipple below the producing interval results
in efficient separation of free gas from liquid and improves
pump efficiency when the gas/liquid separation capacity8 of
the tubing/casing combination exceeds the pump capacity.
A traveling valve test indicated that the pump leakage was
approximately 4 BPD. The standing valve did not leak and
the pump is operating properly.
Corods were installed in the well after problems occurred
with the use of conventional rods. The Corods have not failed
and are operating efficiently. The top Corod is 86% loaded at
a service factor of 0.85.
5
The power measurements shown in Fig. 14 were obtained
at the same time the dynamometer data was acquired. A 75
horsepower NEMA D motor is utilized as the prime mover. A
50 horsepower motor would operate this system, but the
additional horsepower may be desired during certain well
conditions. The overall system efficiency is 56.6%. That is,
the amount of power required to raise the liquid produced by
the well from the net liquid level depth is 56.6% of the power
supplied to the motor9. This is an efficient pumping system.
The torque analysis appears in the lower portion on the
same Fig. 15. The power or torque required on the upstroke is
less than the power or torque required on the downstroke.
Power can be converted to torque, Fig. 14 and Fig. 15, as
calculated from the instantaneous motor power measured
during one complete pump stroke using the following
equation:
Torque = 84.5 x Power x EFF / (SPM x CR x SV) ...(1)
The measured upstroke peak torque was 119,100 inch-
pounds, and the measured downstroke peak torque was
202,800 inch-pounds. Approximately 2,500 lbs. of the
auxiliary weights in the counterweight box should be removed
to reduce the counterbalance torque by 41,900 inch-pounds.
The software calculates all these numbers from the measured
power data and well file database.
The process of balancing the torque was undertaken in
stages over a one-hour period as shown in Table 2. Initially,
the unit was counterweight box heavy and more power and
torque were required raising the weight box than the rods.
The torque was more closely balanced after 782 lbs. of
weights were removed from the weight box. After another
1,058 lbs. of weights were removed from the weight box, the
pumping system was even more closely balanced. The second
and third dynamometer and power tests are not shown due to
space limitations, but are available upon request. Finally,
approximately 2760 lbs. of auxiliary weights were removed.
The resulting power and torque data is shown in Fig. 14. The
units upstroke and downstroke torques are balanced after
removal of the excess auxiliary weights and peak gearbox
torque is reduced from 202,800 inch-lbs. to 150,000 inch-lbs.
Fig. 14 also shows the power and torque usage after the
system was balanced. The average power consumption was
decreased from 27.5 KW to 27 KW. The overall system
efficiency increased from 56.6 to 57.5%, which is relatively
efficient.
This technique of balancing the unit is based on making
the peak torque on the upstroke equal the peak torque on the
downstroke. The motor will be more efficient if the average
power on the upstroke is balanced against the average power
on the downstroke so that the motor will be operating overall
at a higher efficiency. Motors operate more efficiently near
rated output. The operator has the option of balancing the
peak torques on the upstroke and downstroke, or balancing the
average power usage on the upstroke and the downstroke.
More efficient electrical operations will be obtained if average
power is balanced rather than peak torques. However, the
6 J.N. MCCOY, A. L. PODIO, BILL DRAKE, LYNN ROWLAN
peak torques on the upstroke and downstroke should be
balanced if the gearbox torque rating would be exceeded if
balancing by power usage.
The RotaFlex pumping system can also be balanced by
using the mechanical loadings of the system rather than the
electrical loadings on the motor. To balance the gearbox peak
torque loadings by mechanical means, the polished rod loads,
the polished rod positions, and the counterbalance weight of
the weight box and auxiliary weights must be known. In order
to determine the weight of the weight box plus auxiliary
weights, the counterbalance effect can be measured. On a
RotaFlex, the geometry of the polished rod load and the
counterweight box is symmetrical, and the load measured by
the horseshoe transducer is equal to the load in the belt that is
attached to the counterweight box. If the pumping unit is
stopped near the middle of the upstroke, the weight of the rods
plus the fluid load will exceed the weight of the counterweight
box plus auxiliary weights if the system is approximately
balanced during normal operation. If the brake is held until
some of the fluid load bleeds from the polished rod, the load
on the polished rod will decrease. The brake can be
momentarily released and reset, until a balanced condition
occurs when the load on the polished rod is equal to the
weight of the counterweight box. At this balanced condition,
the belt will not move because the loads are equal. This
weight can be measured accurately using the horseshoe load
cell transducer. If the brake is held longer, the load on the
polished rod will continue to bleed off and the counterweight
box and auxiliary weights will weigh more than the polished
rod. Fig. 16 shows the polished rod load while the system
was pumping and then stopped on the upstroke with the brake
set. Periodically releasing then resetting the brake showed that
at 46 seconds after data acquisition began, the belt did not
move when the brake was released. The load at 46 seconds
was 25,132 lbs. This polished rod load is equal to the weight
of the counterweight box plus auxiliary weights. After the
balanced condition was noted, the brake was reset, and the
dynamometer test shows a further decline in the polished rod
load.
The surface dynamometer cards and the pump cards after
the unit is balanced are shown in Fig. 17. The polished
rod/motor efficiency increased slightly since the motor is
operating in a more efficient range during the upstroke. The
polished rod horsepower, the polished rod peak loadings, and
the polished rod minimum loadings remained similar as
expected. Notice that 90% of the polished rod power of 29.4
HP is transferred to the pump power of 26.4 HP. The high
efficiency is probably due to the Corods having less metal-to-
metal sliding friction and the Corods having less resistance to
fluid flow from the pump to the surface up the tubing. A
summary of measured values is presented in Table 3.
Analysis
After balancing, the RotaFlex system is producing all of the
liquid available efficiently from the well. The RotaFlex unit is
operated using a P-O-C that pumps the well approximately
19.7 hours per day, which is all of the time required to remove
SPE 68864
all the liquids from the well bore. Removing approximately
2760 lbs. from the counterweight heavy box reduced excessive
power usage and gearbox load. After the unit was balanced,
the maximum gearbox load was reduced from 202,800 inch-
pounds to 150,000 inch-pounds, and the average power
requirement was reduced from 27.5 KW to 27 KW. The
relatively good system efficiency, when balanced, was 57.5%.
The cost of electricity was reduced approximately $14 per
month.
Summary and Conclusions
Table 1 lists a series of WELL PERFORMANCE
QUESTIONS that an operator must be able to answer to
efficiently produce a well. Oftentimes, an operator does not
know the answers to some of these questions, and hence, must
guess at the answer. An operator should know that the PBHP
is low compared to the SBHP so that the maximum production
is being obtained. An operator should know that the pump
traveling and standing valves are OK. An operator should
know whether the down hole gas separator is efficient or not,
and how to correct an inefficient gas separator problem. An
operator should know whether a pumping unit is out of
balance or not. An operator should know whether the rods are
overloaded or not. Analyzing a wells performance so that the
WELL PERFORMANCE QUESTIONS are answered allows
an operator to maximize oil production and minimize
operating costs.
Successful application of the TWM concept generally
includes some training of the operating personnel. Training is
especially necessary if effective application of modern data
acquisition hardware and software is to be introduced in an
operation that has been relying on limited computer resources.
Acknowledgments
The authors thank David Jennings from Chevron USA Inc for
the help provided in making the field measurements and
compiling all of the necessary data on the number 50 well on
the Mallet Land & Cattle Company lease.
Nomenclature
CR = pumping speed to gearbox sprocket rotational
speed ratio (chain ratio)
EFF = Motor to gearbox output shaft efficiency
Power = Instantaneous Input Motor Power (KW)
SPM = pumping speed, strokes per minute
SV = Speed Variation, minimum speed / average speed
References
1. McCoy, J.N., Podio, A.L. and Huddleston, K.L.: Analyzing
Well Performance XV, presented at the 1987 Artificial Lift
Workshop, Houston, TX, Apr. 22-24.
2. McCoy, J.N., Podio, A.L. and Huddleston, K.L.: Acoustic
Determination of Producing Bottomhole Pressure, paper SPE
SPE 68864 MODERN TOTAL WELL MANAGEMENT - SUCKER ROD LIFT CASE STUDY 7

14254 presented at the 1985 SPE Annual Technical Conference
and Exhibition, Las Vegas, NV, Sept. 22-25.
3. McCoy, J.N., Podio, A.L., Huddleston, K.L. and Drake, B.:
Acoustic Static Bottomhole Pressure, paper SPE 13810
presented at the SPE 1985 Production Operations Symposium,
Oklahoma City, OK, Mar. 10-12.
4. McCoy, J.N., Podio, A.L., Ott, R. and Woods, M.: Electrical
Motor Power Measurement as the Key for Optimized Rod
Pumping, paper SPE 36080 presented at the Fourth Latin
American and Caribbean Petroleum Engineering Conference,
Port-of-Spain, Trinidad & Tobago, Apr. 23-26, 1996.
5. McCoy, J.N. and Podio, A.L.: Improved Downhole Gas
Separators, presented at the Southwestern Petroleum Short
Course, Lubbock, TX, Apr. 7-8, 1998.
6. McCoy, J.N., Ott, R.E., Podio, A.L., Collier, F. and Becker, D.:
Beam Pump Balancing Based on Motor Power Utilization,
paper SPE 29533 presented at the SPE 1995 Production
Operations Symposium, Oklahoma City, OK, Apr. 2-4.
7. McCoy, J.N., Podio, A.L. and Becker, D.: Pressure Transient
Digital Data Acquisition and Analysis From Acoustic
Echometer Surveys in Pumping Wells, paper SPE 23980
presented at the 1992 SPE Permian Basin Oil and Gas Recovery
Conference, Midland, TX, Mar. 18-20.
8. Podio, A.L., J.N. McCoy, B. Drake and D. Becker: "Total Well
Management-A Methodology for Minimizing Production Cost
of Beam Pumped Wells", The Petroleum Society of CIM, Paper
95-26, May, 1995.
9. Lea, J.F., Lynn Rowlan and Jim McCoy: "Artificial Lift Power
Efficiency," Southwestern Petroleum Short Course, Texas
Tech University, Lubbock, Texas, April 1999.

Table 1 - WELL PERFORMANCE QUESTIONS

From Acoustic Surveys:

Does liquid exist above the pump? At what depth is the top of the liquid column?
Does the liquid in the casing annulus restrict production from the well?
What is the maximum production rate available from the well?
What is the casing-head pressure? Does it restrict production?
What is the percentage of liquid in the annular fluid column?
Is gas flowing up the annulus? At what rate? What is the gas gravity?
Are there any restrictions or anomalies in the annulus above the liquid level?
From Dynamometer Surveys:
Is the well pumped off? What is the pump intake pressure? What is the pump fillage?
Is the traveling valve or standing valve leaking? What is the pump displacement?
What is the effective pump plunger travel? What is the current pumping speed?
Are the maximum and minimum rod loads within allowable limits?
What is the polished rod horsepower?
Is the gearbox overloaded?
Is the unit properly balanced? What movement of the counterweights is required to balance the unit?
Is the downhole gas separator operating effectively?

From Motor Power Surveys:

What is the overall electrical efficiency of the pumping system?
Is the overall electrical efficiency above 50%?
What is the power consumption, $/month, $/BBL, and power demand, KW?
What is the motor current? Does the motor overheat?
Does the motor generate electricity sometimes during the stroke? Is credit allowed for generation?
Is the gearbox overloaded?
Is the unit balanced? What movement of the counterweights is required to balance the unit?
From Transient Pressure Surveys:
What is the reservoir pressure? What is the producing bottom hole pressure?
What is the liquid/gas annular afterflow when the well is shut in?
Is there any wellbore damage? Does the formation need treatment? Is the well fractured?
From Predictive Dynamometer Design Programs:
Is the predicted dynamometer in agreement with accurately measured horseshoe dynamometer data?
Can the performance be improved by a change in pump size, polished rod stroke length, SPM, rod string configuration or other
factors?
8 J. N. MCCOY, A. L. PODIO, BILL DRAKE, LYNN ROWLAN SPE 68864

Table 2. Balancing of Rotaflex Pumping Unit Staged Over a One-Hour Period.

Peak Peak Calculated Weights Cumulative Cumulative Counter-
Upstroke Downstroke Balanced To be Weight Weight No. of balance
Torque, Torque, Torque, Removed, removed, removed, weights Effect Test,
Time Kin-lbs Kin-lb Kin-Lb Lbs Lbs Lbs removed Lbs

12:30 119.1 202.8 161 2500 0 0 0

13:02 135.9 180.5 158.2 1300 782 782 17

25132
13:19 134.5 162.2 148.4 800 1058 1847 40

13:29 147.2 150 148.6 100 923 2760 60

Table 3. Summary of Measured Values.

Motor Polished Polished Pump/ Overall
Input Rod Pump Rod/Motor Motor System
PPRL, MPRL, Power, Power, Power, Efficiency, Efficiency, Efficiency,
Time Lbs Lbs HP HP HP % % %

12:30 32,200 13,700 36.8 29.7 26.7 80.8 72.5 56.6

13:02 32,100 13,900 36.9 29.7 26.6 80.5 72.2 56.6

13:19 32,000 14,200 36.5 29.5 26.5 80.7 72.4 57.1

13:29 32,000 14,200 36.2 29.4 26.4 81.1 72.8 57.5

Fig. 1 Analysis Showing Well Inflow Performance

SPE 68864 MODERN TOTAL WELL MANAGEMENT - SUCKER ROD LIFT CASE STUDY 9

Fig. 2 - Results of Power Survey (Operated Near Peak Efficiency)

Fig. 3 - Results of Power Survey (Efficiency Could be Improved)

10 J. N. MCCOY, A. L. PODIO, BILL DRAKE, LYNN ROWLAN SPE 68864

Fig. 4 Well Data Fig. 5 Incomplete Pump Fillage

Fig. 6 Gaseous Liquid Column Fig. 7 Standing and Traveling Valve Tests
SPE 68864 MODERN TOTAL WELL MANAGEMENT - SUCKER ROD LIFT CASE STUDY 11

Fig. 8 Dynamometer Analysis

Fig. 9 Out of Balance Conventional Pumping Unit with Large Negative Torque
12 J. N. MCCOY, A. L. PODIO, BILL DRAKE, LYNN ROWLAN SPE 68864

Fig. 10 Match of Measured and Computed Dynamometer Cards

Fig. 11 Pressure Transient Analysis Horner Plot Fig. 12 Rotaflex Pumping Unit
SPE 68864 MODERN TOTAL WELL MANAGEMENT - SUCKER ROD LIFT CASE STUDY 13

Fig. 13 Complete Acoustic Liquid Level Test

Fig. 14 Power and Torque with System Balanced Fig. 15 Power and Torque when Counterweight Box Heavy
14 J. N. MCCOY, A. L. PODIO, BILL DRAKE, LYNN ROWLAN SPE 68864

Fig. 16 Counter Balance Effect Load Test

Fig. 17 Dynamometer Cards After Unit Balanced