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ARTIFICIAL LIFT SYSTEMS
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Introduction
Components
Applications &
Considerations
Troubleshooting
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IntroductionIntroduction
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General
Well Design
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ARTIFICIAL LIFT SYSTEMS
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Complete
ConventionalSucker Rod
Pump
System
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APIClassification
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ARTIFICIAL LIFT SYSTEMS
®
API Method of Pump
Assembly Description
Heavy-Wall
Barrel
Thin-Wall
Barrel
Heavy-Wall
Barrel
Thin-Wall
Barrel
Stationary Barrel,
Top Anchor RHA RWA - RSA
Stationary Barrel,
Bottom Anchor RHB RWB RXB RSB
Traveling Barrel,Bottom Anchor RHT RWT - RST
Tubing Pumps TH - TP -
ROD PUMP TYPE
SOFT-PACKED PLUNGER
PUMPSMETAL PLUNGER PUMPS
Letter Designations
Heavy-Wall
Barrel
Thin-Wall
Barrel
Heavy-Wall
Barrel
Thin-Wall
Barrel
Stationary Barrel,
Top Anchor RHA RWA - RSA
Stationary Barrel,
Bottom Anchor RHB RWB RXB RSB
Traveling Barrel,Bottom Anchor RHT RWT - RST
Tubing Pumps TH - TP -
ROD PUMP TYPE
SOFT-PACKED PLUNGER
PUMPSMETAL PLUNGER PUMPS
Letter Designations
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Tubing Pumps vs. Insert Pump
Barrel Assembly of this type pump is screwed onto,
and becomes part of the tubing.
Larger bore than a rod pump, thus it produces a
greater volume of fluid in any give diameter of tubing
The complete pump is attached to, and inserted into
the well tubing with the sucker rod string.
As a complete unit, this pump may be pulled out of
the well without pulling the tubing.
Tubing Pump
Insert Pump
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Basic Rod PumpConfigurations
RWTC
Rod-Type,
Thin Wall,
Traveling Barrel,
Bottom
Holddown (Cup)
RWAM
Rod-Type,
Thin Wall,
Top Holddown
(Mechanical)
RHBC
Rod-Type,Heavy Wall,
Bottom Holddown
(Cup)
THM
Tubing-Type,Heavy Wall,
Mechanical
Holddown
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Rod PumpOperation - Concept
Visualization of Rod Pump Working
(A) (B) (C)
Pump grabs a “bite” of fluid
on each downstroke of the
pump, as the “mouth” of the
traveling valve opens on the
downstroke, and grabs a
bite of whatever is within the
compression chamber.
(A)
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Rod PumpOperation - Concept
Upstroke closes thetraveling valve, traps the
fluids in the chamber and
physically lifts them up thewell a few feet. This bite is
simply stacked below the
previous bite until enough
bites start running out at
the surface of the well.
(B)
Visualization of Rod Pump Working
(A) (B) (C)
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Rod PumpOperation - Concept
Standing Valve opens at the
start of upstroke to admit
fluids into the compression
chamber from the reservoir,and closes on downstroke
of pump to prevent these
fluids from returning to theformation.
(C)
Visualization of Rod Pump Working
(A) (B) (C)
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Types of Insert Pumps
Rod Pump - Top Anchor
Rod Pump - Bottom Anchor
Rod Pump - Travel Barrel Bottom Anchor
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Rod PumpBarrel ApplicationTop Anchor
BottomHold-Down
Pump
TopHold-DownPump
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Rod PumpTop Anchor
Valve Rod
Plunger
Barrel
Ball Stop
Standing
Valve
Seat
Traveling
Valve
Valve Rod
Plunger
Barrel
Ball Stop
Standing
Valve
Seat
Traveling
Valve
PumpPump
MovementMovement
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Rod PumpTop Anchor
Good for sandy wells
Pump Barrel acts as Gas Anchor
Excellent for low fluid wells
Advantages
Disadvantages
Valve rod is weak leak of sucker rod
Not recommend for deep wells
Barrel Tube subject to sedimentation on
part-time pumping
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Rod PumpBarrel Application
Bottom Anchor
BottomHold-Down
Pump
TopHold-DownPump
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Rod PumpBottom Anchor
Valve Rod
Plunger
Barrel
Ball Stop
Standing
Valve
Seat
Traveling
Valve
Valve Rod
Plunger
Barrel
Ball Stop
Standing
Valve
Seat
Traveling
Valve
PumpPump
MovementMovement
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Rod PumpBottom Anchor
Run in deep wells
Good valve location
Better design where long pumps necessary
Advantages
V-rod weak link in S-rod chain
Barrel Tube subject to sedimentation
Barrel Tube subject to corrosion
Disadvantages
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Rod PumpTraveling BarrelBottom Anchor
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ARTIFICIAL LIFT SYSTEMS
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Rod PumpTraveling Barrel
Valve Rod
Plunger
Barrel
Ball Stop
Standing Valve
Seat
Traveling
Valve
Valve Rod
Plunger
Barrel
Ball Stop
Standing Valve
Seat
TravelingValve
PumpPump
MovementMovement
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Rod Pump- Traveling BarrelBottom Anchor
Agitation keep sand from settling Good discharge distribution
Both cages are open type
Advantages
Not recommend for gas wells
Not recommend for pumps in deep wells
Poor valve placement
Disadvantages
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Types of Tubing Pumps
Tubing Pump- Bottom Anchor
Large Bore Tubing Pump
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API Pump
Assembliesfor Tubing Pump
Bottom Anchor
THC
Pump
THM
Pump
TPC
Pump
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Tubing Pumps
Valve Rod
Plunger
Barrel
Ball Stop
Standing Valve
Seat
TravelingValve
Valve Rod
Plunger
Barrel
Ball Stop
Standing Valve
Seat
TravelingValve
PumpPump
MovementMovement
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Tubing Pump-Bottom Anchor
Higher volume Simple Rugged for severe service
Used to stroke in & out of barrel
Pulling cost factor
Prone to gas locking
Stuck SV leads to pulling wet string
Advantages
Disadvantages
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High VolumeFluid Pumps
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High Volume Fluid Pumps
Casing Pump - attached to the Packer
Advantages - Highest volume available;
insert style, therefore retrievable Disadvantages - Wear by the rods on the
casing; sanding in of the packer
‘Bottled-Up’ Pump Advantages - Greater Production Volumes
Disadvantages - Plunger larger than the tubing
Oversized Tubing Pump
ID threads on barrel allow larger plunger
than normal
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ComponentsComponents
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Rod PumpHolddowns
MechanicalBottom Lock
Holddown
MechanicalTop Lock
Holddown
Cup-TypeHolddown
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ARTIFICIAL LIFT SYSTEMS
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Rod PumpBarrels & Plungers
Barrels materials available -
Regular steel
Hardened steel Regular steel w/ chromed I.D.
Brass
Brass w/chromed I.D.
Stainless w/chromed I.D. Steel Nickel Carbide
Brass Nickel Carbide
Plungers available inall standard API
sizes and types
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Rod PumpBarrels
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ARTIFICIAL LIFT SYSTEMS
® Rod
Pump
Barrels
TubingPump
Barrels
Thin Wall Heavy Wall
Heavy WallCommon Working
Barrel
SEAL
SEAL
RW, RS RH
TP TH
THREADED
SEAL
Difference
BetweenRod PumpandTubing PumpBarrels
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Thin Wall Barrel &Heavy Wall Barrel
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Metallurgy
Nobility Chart
Galvanic
Series of Metals
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M i l d
M o d e r a
t e
S e v e r e
M i l d
M o d e r a
t e
S e v e r e
Precision - 1026 Steel
90 HRB - 23
HRC X X
Precision - 443 Brass 85 HRB (Min) X X
Nitrided - Alloy Steel 58 - 63 HRC X X
Carburized - Carbon
Steel
58 - 63 HRC X X
Barrel MetallurgySurface
Hardness
AbrasionCorrosion
Service
Barrel Metallurgy Applications(Steel Barrel)
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M i l d
M o d e r
a t e
S e v e r e
M i l d
M o d e r
a t e
S e v e r e
Chrome Plated ID -
1026 Steel69 - 72 HRC X X
Chrome Plated ID - 443
Brass69 - 72 HRC X X
Chrome Plated ID -
Nickel Copper Alloy
69 - 73 HRC X X
Nickel Carbide Coated -
1026 Steel72 - 75 HRC X X
Nickel Carbide Coated -
443 Brass72 - 75 HRC X X
MetallurgySurface
Hardness
Service
Corrosion Abrasion
Barrel Metallurgy Applications
(Steel CID Barrel)
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Barrel Comparison for 2.75"
0
0.5
1
1.5
2
2.5
Steel ChromePlated ID Steel Nickel
Carbide Coated
Brass ChromePlated ID Brass Nickel
Carbide Coated
V a l u e
o f B a r r e l
Barrel Performance
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Chrome Plated Barrel(Loosing Chrome)
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Rod PumpPlungers
Plungers available in all
standard API sizes and
types
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ARTIFICIAL LIFT SYSTEMS
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WeatherfordManufactured Plungers
Pin End
Plunger Box End
Plunger
Grooved
Plunger
Monel Pin
End
Plunger
Pressure
Actuated
Plunger
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Plunger
MaterialMild Moderate Severe Mild Moderate Severe Mild Moderate Severe
Spray Metal
58 RC min. X X X
Chrome Plated
67 - 71 RCX X X
Spray Metal
Monel Pin 58
RC min
X X X
Pressure
Actuated with
Steel Pins
58 RC min
X X X
Pressure
Actuated with
Monel Pins 58
RC min
X X X
CO2Abrasion H2S
Plunger MaterialSelection
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Pressure ActuatedPlunger
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Rod PumpFluid Slippage
Depending upon well fluids and
conditions, 2-3% slippage of
produced fluid is expected to keep
barrel/plunger contact sufficiently
lubricated.
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High-Pressure Fluid Effectson Rod Pump Barrels
Fig. #1 Fig. #2 Fig. #3
A. Traveling Valve
B. Pump Barrel
C. Pump SuctionD. Pressure created by fluid
column in tubing
E. Plunger
F. Tubing
G. Bottom Holddown
H. Sucker or Pony Rod
I. Top Holddown
J. Fluid level in the well
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Shows the effect of
pressure caused by
the fluid column hydrostaticpressure against the part
of the barrel not supported
internally by the plunger.
As the plunger moves, it
contacts the convex wall
of the barrel causing it to
wear into a ‘cigar’ shape.
Fig. 3 - Bottom Holddown Rod Pump
High-Pressure Fluid Effectson Rod Pump Barrels
Figures 1 & 3
Fig. 1 -Traveling Barrel Rod Pump
Fig. 2Fig. 1 Fig. 3
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High-Pressure Fluid Effectson Rod Pump Barrels
Fig. 2Fig. 1 Fig. 3
Figure 2
Shows the effect of thepressure of the
fluid column hydrostatic
pressure on a stationary
barrel pump (top or bottomholddown)
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Standing Valves
Closed-Type
Cage
Open Cage,
Traveling BarrelOpen Cage,
Tubing
Open Cage, Tubing,
Drain-Type Closed Cage,Tubing, Permanent
Closed Type
Cage,
Insert Style
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Standing Valves
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Double Valve
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Four Ball Guides
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Double Traveling Valve &Standing Valves
Extra set of valves offer backup seal in
the event of trash or valve wear.
Extra set of valves reduces the unswept
area in the pump, which reduces the
compression ratio, thus limiting the
pumps ability to handle gas.
More parts = more expensive pump
Advantages
Disadvantages
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Traveling Valves
Closed-Type
Cage for Pin-
End Plunger
Closed-Type
Cage for Box-
End Plunger
Open-Type Cage for
Traveling Barrel
Pump Barrel
Closed-Type
Cage,
Insert Style
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Piston Steel Chrome Molly Stainless Steel N50Spray Metal
Coating
C1045 Carbon A4140 431 N50Nickel Base
Alloy
Chemical Analysis
Carbon C 0.41 - 0.49 0.38 - 0.43 0.20 max 0.06 max 0.50 - 1.00
Manganese Mn 0.60 - 0.87 0.75 - 1.00 1.00 max 4.00 - 6.00
Phosphorus P 0.04 max 0.035 max 0.04 max 0.00 - 0.02
Sulfur S 0.05 max 0.04 max 0.03 max 0.00 - 0.02
Chromium Cr 0.80 - 1.10 15.00 - 17.00 20.50 - 23.50 12.00 - 18.00Silicon Si 0.15 - 0.35 1.00 max 1.00 max 3.50 - 5.50
Iron Fe Balance Balance 3.00 - 5.50
Boron B 2.50 - 4.50
Cobalt Co 0.00 - 0.10
Nickel Ni 1.25 - 2.50 11.5 - 13.50 66.00 - 79.00
Copper Cu
Nitrogen N 0.20 - 0.40
Molybdenum Mo 0.15 - 0.25 1.50 - 3.00
Properties
Tensile 90K - 120K 120K - 150K 120K min 135K min N/A
Yield 85K - 110K 90K - 120K 100K min 105K min N/AElongation 9% - 12% 10% - 20% 20% 20% N/A
Hardness Rc 19 - 28 Rc 25 - 33 Rc 24 - 55 Rc 35 max Rc 55 - 62
Raw Material
General Terminology for
Polished RodPiston Steel Chrome Molly Stainless Steel N50
Spray Metal
Coating
C1045 Carbon A4140 431 N50Nickel Base
Alloy
Chemical Analysis
Carbon C 0.41 - 0.49 0.38 - 0.43 0.20 max 0.06 max 0.50 - 1.00
Manganese Mn 0.60 - 0.87 0.75 - 1.00 1.00 max 4.00 - 6.00
Phosphorus P 0.04 max 0.035 max 0.04 max 0.00 - 0.02
Sulfur S 0.05 max 0.04 max 0.03 max 0.00 - 0.02
Chromium Cr 0.80 - 1.10 15.00 - 17.00 20.50 - 23.50 12.00 - 18.00Silicon Si 0.15 - 0.35 1.00 max 1.00 max 3.50 - 5.50
Iron Fe Balance Balance 3.00 - 5.50
Boron B 2.50 - 4.50
Cobalt Co 0.00 - 0.10
Nickel Ni 1.25 - 2.50 11.5 - 13.50 66.00 - 79.00
Copper CuNitrogen N 0.20 - 0.40
Molybdenum Mo 0.15 - 0.25 1.50 - 3.00
Properties
Tensile 90K - 120K 120K - 150K 120K min 135K min N/A
Yield 85K - 110K 90K - 120K 100K min 105K min N/A
Elongation 9% - 12% 10% - 20% 20% 20% N/A
Hardness Rc 19 - 28 Rc 25 - 33 Rc 24 - 55 Rc 35 max Rc 55 - 62
Raw Material
General Terminology for
Polished Rod
Polished Rod Specifications
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Special Applications
& Considerations
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Pump Failure Types
Operational
Well Condition
Mechanical
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Operational Problems
Bottomhole Assembly design
Bad spacing of pump
Bad seating nipple
Deviated wells
Loose Tubing Anchor
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Well Condition Problems
Fluid Pound
Gas Locking
Sand
Scale
Corrosion
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Mechanical Problems
Seized Pumps
Parted V-Rods
Split Cages
Split Barrels
Scored Plungers
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Solutions to“Well” Known Problems
Gas Locking
Sand Problems
Heavy Oil
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®
What is Gas Locking?
Gas Lock Occurs when a barrel iscompletely filled with Gas.
Gas can not be compressed enough to
overcome the Hydrostatic head acting
on the traveling valve.
Consequently both valves remainclosed and the pump is gas locked.
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Required Compression Ratiosas Reservoir Pressure Depletes
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Gas Locking vs Gas Interferencevs a Pumped Off Condition
Gas Locking
No valves open during pumping cycle.
No fluid lifted to surface.
Gas Interference
Valves function properly, but reduced efficiencyas gas takes place of some fluid.
Pumped Off ConditionPumping rate exceeds ability of fluid to flow
into pump. Well does produce some fluid.
G L ki G I t f
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Gas Locking, Gas Interference& a Pumped Off Condition
R d P
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ARTIFICIAL LIFT SYSTEMS
®
Rod PumpGas Locking
Not enough pressure generated in
compression chamber on down stroke
to open traveling valve.
Produced fluid in tubing rides up anddown with traveling valve, which is not
opening.
Causes
R d P
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®
Rod PumpGas Lock
Effects
No fluid produced to the surface.Fluid level on backside continues
to rise as no fluids are removed
from well.
R d P
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Rod Pump -Gas Locking
Increase compression ratio in pump
through better design/assembly.
Increase compression ratio in pump
through longer stroke or smaller plunger.
Install II stager valve to removehydrostatic pressure from traveling valve.
Reduce gas intake into pump through
better downhole separation.
Increase pump intake pressure by
allowing higher fluid level on backside.
Solutions
R d P
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Rod PumpGas Interference
Poor gas separation, prior to fluidentering the pump, allows gas to
take the place of fluid in thecompression chamber.
Causes
R d P
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Effects
Pump shows poor efficiency becauseonly fluid is being measured.
Pump is actually operating properly,
but fluid production is limited bygas in pump.
Rod PumpGas Interference
R d P
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Solutions
Separate gas from fluid before it gets
to pump intake through better downhole separation.
Increase rate of well by lengtheningstroke, changing strokes per minute
or changing bore size.
This increases both gas and fluidwhich are produced through
the pump.
Rod PumpGas Interference
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API RWB Pump
API RHB Pump
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API RWB Pump
API RHB Pump
Pumps with
Extensions have
greater chancefor gas locking
then Pumps without Extensions
WHY?
More space
Decreases
compression ratios
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ARTIFICIAL LIFT SYSTEMS
® Gas Compression Ratios
Spacing vs. Fluid Over Pump
2438 meters - 2" pump - 100" Net Plunger Travel
0
1000
2000
3000
4000
5000
6000
7000
8000
.5" 2.5" 4.5" 6.5" 8.5" 10.5" 12.5" 14.5" 16.5" 18.5"
Spacing Off Bottom
M a x i m u m P r e s s u r e i n
C o m p r e s s i o
n C h a m b e r
0
50
100
150200
250
300
350
400
M e t e r s o f
F l u i d a b o v e
P u m p
Pressure in Barrel Pressure on Traveling Valve
Fluid Required Over Pump
API Subsurface Pump
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0
10
20
30
40
50
60
70
54 64 74 86 100 120 144 168 192
Stroke Length
C o m p
r e s s i o n R a t i o
1-1/4" Plunger )Rod) 1-1/2" Plunger(Rod) 1-3/4" Plunger (Rod)
2" Plunger (Rod) 2-1/4" Plunger(Tubing)
API Subsurface PumpCompression Ratios
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Combating Gas Locking
High Compression Valves
Gas Breakers
Gas Anchors
Combating
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CombatingGas Locking
Gas Breakers
Two Stager
Gas Compression Valves
Gas Compression Plugs
Sliding Top Valve
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COMPRESSION RATIOS
A B C D
Well Depth (mts.) 2,286.0 2,286.0 2,286.0 2,286.0
Plunger Travel 90" 90" 90" 90"
Pump Bore 1.25 1.25 1.25 1.25
Oil Cut 80% 80% 80% 80%
Seat Plug Type Standard Standard Hex Plug Hex Plug
Intake Pressure 80 PSI 80 PSI 80 PSI 80 PSIS.V. Cage Type Standard Standard Inverted Inverted
Unswept Barrel Area 1.287 5.582 5.037 0.74
Unswept S.V. Area 2.244 2.244 1.264 1.264
Total Unswept Area 3.531 7.826 6.301 2.004Distance Spaced Off Bottom 1/2" 4" 4" 1/2"
Load on Traveling Valve 3200 3200 3200 3200
Pressure in Barrel 2582 1209 1483 4488
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Conventional
(Poor Boy)
Gas Anchor
Gas Separation
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Gas Separation(Concept 1 of 4 )
Casing
Tubing
Rods
Pump
Spillover Tube
Crossover Packer
Pump IntakePerforations
Producing Zone
Packer-Type Anchor
Casing
Tubing
Rods
Producing Zone
Pump
Seating Nipple
Tubing Intake
Perforations
Natural-Gas Anchor
Gas Separation
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Poor-Boy Gas Anchor
Tubing
Rods
Pump
Tubing IntakePerforations
Producing Zone
Casing
Seating Nipple
Suction Tube
Mud Anchor
Modified Poor-Boy
Gas Anchor
Tubing
Rods
Pump
Tubing IntakePerforations
Producing Zone
CasingSeating Nipple
Suction TubeMud Anchor
Gas Separation(Concept 2 of 4 )
Gas Separation
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1.9-in. Casing
Rods
2 7/8-in. O.D. Casing
Pump
Seating Nipple
1.316-in. OD Tubing
Producing Zone
TubingPerforations
Modified Natural-Gas Anchor
(For Small-Diameter Casing)
Rods
2 7/8-in. OD Casing
Pump
Seating Nipple
30 in. x 1.0-in.O.D. Tubing
Producing Zone
Packoff
Modified Packer-Type Gas Anchor
(For Small-Diameter Casing)
Gas Separation(Concept 3 of 4 )
Gas Separation
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Fluid Level
Liquid
Gas5 1/2-in. Casing
Decentralizer
DiametricallyOpposed to Lower Port (not to scale)
Casing
Perforations
2 7/8-in. Tubing
Seating Nipple
Upper Port
3 5/8-in.Thin WallPipe (1/8-in.)
Lower Port
Dip Tube
3 5/8-in. O.D. Thin-Wall Gas Separator
(For Small-Diameter Casing)
Gas Separation(Concept 4 of 4 )
Rod Pump
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®
Rod PumpHorizontal Wells
AdvantagesReduce reservoir pressure by lowering fluid level and recovering
more fluid. Better gas separation when pump is set below the
kickoff point.
Rod Pump
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Rod PumpHorizontal Wells
Limitations<15%/100’ (Some installations allow up to 25%).
Pump can be set at 90°.
Rod Pump
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Rod PumpHorizontal Wells
DisadvantagesIncrease tubing/rod wear decreases run times.
Friction results in increased loads on sucker rods, polish rod and
pumping unit. Typically shorter run life on rod pump.
Use of Rod Rotator advised to
increase life of rods and tubing.
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What causes Sand Problems?
Sand can come from the reservoir or a sand-Frac.
If sand is present from a sand-Frac, it is usually a
temporary problem that will clear itself as the well is
pumped.
If the sand is from the reservoir the problem will be
ongoing and special attention must be given to the
design of the pump and its material selection.
How do you Minimize
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How do you MinimizeSand Problems?
Pressure-Actuated Plunger
Combo Plunger Actuated Plunger
Chrome Plated Grooved Plunger
Sand Hogg
3-Tube Pump
Type of plungers
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Type of plungersfor Sand Problems?
Pin End
Plunger
Box End
Plunger
Grooved
Plunger
Monel Pin
EndPlunger
Pressure
ActuatedPlunger
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ARTIFICIAL LIFT SYSTEMS
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Best Particulate Producers
Traveling Barrel Pump , Top Holddown Pump,
& Tubing Pump
Stroke Through Pump
Short Barrel, Long Plunger
Special Pumps
3 Tube Pump
Others
Bottom Discharge Valve, Top Seal Assembly,
& Plunger Wipers
Designs to Handle Solids
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Special 3-Tube Pump
Efficient operation in extremely abrasive or
dirty production
Utilizes produced fluid as packing medium for
effective seal surface
Telescoping tubes give longer seal surfaceallowing for looser fit
Turbulence of fluid miniumizes the danger
of sanding in
Sandy Fluid/
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®
Sandy Fluid/Pampa Pump
Traveling barrel pump designed for use in wells
where abrasive or dirty fluids are produced.
Pump has a smooth plunger which extends througha relatively short hardened-liner section
Due to length of Plunger, the ends do not enter theliner section at either the top or bottom of the stroke
Plunger is wiped clean on each stroke, and foreign
material (sand, etc) is not carried into the liner.
When Pump is shut down, the Traveling valve on
top of the pump serves as check valve.
Rod Pump
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®
od u pTop Seals
Clutched
Top Seal
Fin
Top Seal
Rod Pump
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®
pBottom Discharge Valve
Coupling
Ball and Seat
Body
Cage
Plug
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®
Viscosity Problems
Viscosity problems are caused by wells which
produce heavy API oil.
If steam injection is not practiced, lifting fluidsto the surface would be difficult for the surface
and subsurface equipment to function properly.
Viscosity problems are best handled:
Heavy Oil Pump
Insert Anchors
Barrel Stabilizers
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®
Insert Anchor
A production tool which provides a
trouble free method of anchoring
and packing-off a pump in wells
where a pump seating nipple has not
been provided.
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®
Barrel Stabilizer
Used on long 1-1/4” Bore Pumps that are
operating inside 2-7/8 Tubing
Pumps have a tendency to lean to one side
of the tubing leading to uneven wear of
plunger and barrel.
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Ball and Seat
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ARTIFICIAL LIFT SYSTEMS
®
-
1.0
2.0
3.0
4.0
5.0
6.0
Stainless Steel Alloy (Dumore) Tungsten Carbide Nickel Carbide
V a l u
e
-
1.0
2.0
3.0
4.0
5.0
6.0
Stainless Steel Alloy (Dumore) Tungsten Carbide Nickel Carbide
V a l u
e
Seat Values Comparison
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ARTIFICIAL LIFT SYSTEMS
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Ball Values Comparison
-
10.0
20.0
30.0
40.0
50.0
60.0
Stainless
Steel
Alloy Ceramic Gold
Z Ball
Titanium
Carbide
Tungsten
Carbide
Nickel
Carbide
Ceramic Silicon
Nitride
V a l u e
-
10.0
20.0
30.0
40.0
50.0
60.0
Stainless
Steel
Alloy Ceramic Gold
Z Ball
Titanium
Carbide
Tungsten
Carbide
Nickel
Carbide
Ceramic Silicon
Nitride
V a l u
e
Relative Costs for Various
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ARTIFICIAL LIFT SYSTEMS
®
SRP Components
ABC Oil Company
0
1000
2000
3000
4000
5000
6000
7000
8000
Barrel Plunger Valve Rod SV Cage TV Cage SV Ball TV Ball SV Seat TV Seat Hold-down TV Seat
Plug
$ S p e
n t o n P u m p
P a r t s - 1 9 9 7
ABC Oil Company
0
1000
2000
3000
4000
5000
6000
7000
8000
Barrel Plunger Valve Rod SV Cage TV Cage SV Ball TV Ball SV Seat TV Seat Hold-down TV Seat
Plug
$ S p e
n t o n P u m p P a r t s - 1 9 9
7
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®
Stretch in the Rod String
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ARTIFICIAL LIFT SYSTEMS
®
Troubleshooting
& Failure Analysis
TYPES OF PUMP FAILURE
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ARTIFICIAL LIFT SYSTEMS
®
FOR XYZ COMPANY
Tubing Failure
12%
Rod Failure
19%
Work Over
5%
Pump Failure
42%
Foreign
Material
Green
Pumps
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ARTIFICIAL LIFT SYSTEMS
®
FAILED PARTS IN XYZ FIELD
Barrels
35%
Plungers
17%
Balls
13%
Seats
11%
Valve Rod
4%
Cage
13%
Hold-down7%
®
TYPES OF BARRELSFAILED IN XYZ FIELD
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ARTIFICIAL LIFT SYSTEMS
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FAILED IN XYZ FIELD
Brass Tri-Carb
0%
Steel Chrome75%
Tri-Carb
19%
Brass Chrome
6%
®
R f B l F il
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ARTIFICIAL LIFT SYSTEMS
®
Reasons for Barrel Failure
Corrosion64%
Bent9%
Hole
18%
Plunger Stuck
9%
®
S lit C
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ARTIFICIAL LIFT SYSTEMS
®
Split Cage
®
Standing Valve Cage
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ARTIFICIAL LIFT SYSTEMS
®
with Severe Corrosion
®
Pl D
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ARTIFICIAL LIFT SYSTEMS
®
Plunger illustrates
severe grooves causedfrom passage of sand
or iron sulfide
Plunger Damage
®
P t d T li V l C
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ARTIFICIAL LIFT SYSTEMS
Parted Traveling Valve Cage
®
Parted Standing Valve Cage
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ARTIFICIAL LIFT SYSTEMS
THREAD
PART
Parted Standing Valve Cage
Standing valve cage
parted at the pin endthat screws to barrel
®
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ARTIFICIAL LIFT SYSTEMS
TOP CAGESHOWSCORROSIONATTACK
®
Pitted Silicon Nitride Ball
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ARTIFICIAL LIFT SYSTEMS
Pitted Silicon Nitride Ball
®
Severely Pitted Ball
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ARTIFICIAL LIFT SYSTEMS
Severely Pitted Ball
®
Pitted and Non Pitted Ball
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ARTIFICIAL LIFT SYSTEMS
Pitted and Non-Pitted Ball
®
C k d S t
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ARTIFICIAL LIFT SYSTEMS
Cracked Seat
®
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ARTIFICIAL LIFT SYSTEMS
No-Go on SV
Mandrel
severely pitted
®
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ARTIFICIAL LIFT SYSTEMS
V-Rod Guide
PoundedSeverely
®
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ARTIFICIAL LIFT SYSTEMS
V-Rod Guide worn.
Showing signs of side loading
®
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ARTIFICIAL LIFT SYSTEMS
V-rod guide worn ( bottom view).Showing signs of side-loading
®
Worn & Parted Valve Rod
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ARTIFICIAL LIFT SYSTEMS
Wear Part
Worn & Parted Valve Rod
®
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ARTIFICIAL LIFT SYSTEMS
Pounded
Pull Tube Guide
®
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ARTIFICIAL LIFT SYSTEMS
Pounded
V-Rod
Guide
®
Elements thatInfluence Corrosion
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ARTIFICIAL LIFT SYSTEMS
Influence Corrosion
Hydrogen Sulfide - Sour (H2S)
Carbon Dioxide - Sweet (CO2)
Oxygen
Chlorides
Water Content
pH
Abrasion
®
Elements thatInfluence Corrosion
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ARTIFICIAL LIFT SYSTEMS
H2S Service
Sour conditions exist when H2S is equal to
or greater than 0.35 Kpa (0.05 psi)
OxygenSevere corrosion can be expected if
conditions include 50 ppb dissolved oxygen
ChloridesPitting corrosion will occur if total dissolved
solids exceed 10,000 mg/L and/or if totalchlorides exceed 6,000 mg/L.
Influence Corrosion
®
Elements thatInfluence Corrosion
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ARTIFICIAL LIFT SYSTEMS
Water Content
If water content is greater than 20%, fluid is in
water phase with oil droplets.
If water content is less than 20%, fluid is in oil
phase with water droplets. Use of an inhibitor isrecommended if the water content is greater
han 20%.
Influence Corrosion
®
Elements thatInfluence Corrosion
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ARTIFICIAL LIFT SYSTEMS
pH
pH content at bottom hole level is frequently
lower (more acidic) than that measuredat surface.
After acidizing, the pH should be monitored toensure the fluid does not attack any chromeplate
that may be used in pump.
Influence Corrosion
®
Elements thatInfluence Corrosion
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ARTIFICIAL LIFT SYSTEMS
Abrasion
Conditions are considered abrasive if solids
are greater than 100 ppm.
Abrasion refers not only to solid content but
also to corrosive by-products, e.g., iron sulfide
Influence Corrosion
®
Corrosion Identification - H2S
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ARTIFICIAL LIFT SYSTEMS
Corrosion Identification H2S
Pitting is random & scattered
Pits are steep walled
Edges flare out at surface
Black iron sulfide on surface
Hydrogen embrittlement causes breakfaces to appear brittle.
®
Corrosion Types - CO2
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ARTIFICIAL LIFT SYSTEMS
Corrosion Types CO2
Pitting is round based
Pits are steep walled
Edges appear sharp
Pits are filled with iron carbonate
Pits are interconnected in lines
CO2 gas in water forms carbonic acid,
which lowers pH of water
®
Mild Metal Loss Corrosion
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ARTIFICIAL LIFT SYSTEMS
Mild Metal Loss Corrosion
Water
- Water cut less than 25%
H2S
- Less than 10ppm
CO2
- Less than 250ppm
®
Moderate Metal Loss Corrosion
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ARTIFICIAL LIFT SYSTEMS
Moderate Metal Loss Corrosion
Water
- Water cut 25% to 75%
and/or H2S
- between 10 and 100 ppm
and/or CO2
- between 250 and 1500 ppm
®
Severe Metal Loss Corrosion
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Severe Metal Loss Corrosion
Water
- Water cut more than 75%
and/or H2S
- greater than 100 ppm
and/or CO2
- Greater than 1500 ppm