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COMMON MISUNDERSTANDINGS OF SUCKER ROD PUMPING & MISDIAGNOSIS OF WELL
PROBLEMSMARK W. MAHONEY
SENIOR SALES APPLICATIONS ENGINEERHARBISON-FISCHER
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COMMON MISUNDERSTANDINGS OF SUCKER ROD PUMP
FUNCTIONS
• HOW THE PUMP FUNCTIONS• DOES IT PUMP ON THE UPSTROKE OR
THE DOWNSTROKE?• WHAT IS A DOWNSTROKE PUMP?• WHAT IS AN UPSTROKE PUMP?
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VISUALIZING PROBLEMS
• THINK IN PICTURES NOT WORDS• DRAW IT OUT JUST LIKE WELL BORE
DIAGRAMS
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ESTABLISH ROOT CAUSE
• START WITH THE SYMPTOMS NOT A DIAGNOSIS
• NOT, I HAVE GAS LOCK!• NOT, I HAVE A SAND PROBLEMS!BE SPECIFIC• I HAVE LOW PUMP EFFICIENCY• COARSE SAND IS CUTTING THE PLUNGER• I AM BREAKING PARTS ABOVE THE PLUNGER!• I HAVE DEFLECTION WEAR ON THE PLUNGER!
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PUMP FUNCTION
START OF UP
STROKE
START OF DOWNSTROKE
PLUNGER FALLS THROUGH
FLUID FLUID LIFTED TOWARD
SURFACE
Operation of Sucker Rod Pump
Copyright April 2002 Harbison-Fischer
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SURFACE PUMP DISCHARGE
PLUNGER
POLISHEDROD
PLUNGER SIZE VS POLISHED
ROD SIZE
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SOLID PLUNGER "DOWNSTROKE PUMP"
B o tto m D is c h a r g e V a lv e
F lu idE x it toT u b in g ,d o w n s tro k e
D is c h a rg eV a lv e
P ro d u c tio n F lu id
S ta n d in gV a lv e
P ro d u c tio nF lu id th ruP u m p , u p s tro k e
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SOLID PLUNGER VS HOLLOWFLUID ENTERS THROUGH STANDING VALVE
DISCHARGES THROUGH THE TRAVELING VALVE AND PLUNGER ID
FLUID ENTERS THROUGH STANDING VALVEDISCHARGERS THROUGH THE BOTTOM
DISCHARGE VALVE
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SOLID PLUNGER VS HOLLOW
BOTH PLUNGERS HAVE HYDROSTATICLOAD ON THE UPSTROKE
THE SOLID PLUNGER WILL HAVE HIGHER FORCESON THE BOTTOM OF THE PLUNGER ON THE DOWNSTROKE
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DESIGN RESTRAINTS OF BOTTOM DISCHARGE VALVES
F lu idE x it toT u b in g ,d o w n s tro k e
D is c h a rg eV a lv e
P ro d u c tio n F lu id
S ta n d in gV a lv e
P ro d u c tio nF lu id th ruP u m p , u p s tro k e
FOR EACH SIZE OF TUBING THERE IS A DESIGN TRADE-OFF
OF STANDING VALVE FLOW AND DISCHARGE VALVE
THE FLOW PASSAGES ALSO ADD TO THE
UNCOMPRESSIBLE VOLUME
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BUOYANCY FORCESFLUID
FORCES &PUMP FRICTION
• SUBSURFACE PUMPS HAVE MANY FORCES AT WORK DURING THE PUMP CYCLE
• UNDERSTANDING THE BASIC PHYSICS & FORCES HELPS UNDERSTAND WHAT IS PHYSICALLY POSSIBLE AND WHAT IS NOT
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BUOYANCY
FORCE ON BOTTOM =BUOYANCY
NO UPWARD FORCE=NO BUOYANCY
FLUID SURFACE
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BUOYANCY
SUCKER ROD COUPLINGS AND THE UPSET AREA =
BUOYANCY FORCES
EXAMPLE:¾" SUCKER RODS WEIGH 1630 LBSPER 1000' IN AIR
BUT ONLY1,410 LBS PER
1000'BUOYANT
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BUOYANCY & FLUID FORCES
FLUID FORCES ACT IN ALL
DIRECTIONS SO SOME UPWARD
FORCES CANCEL OUT DOWNWARD
FORCES
PUMP INTAKE PRESSURE
HYDROSTATIC LOAD
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FLUID FORCES
FLUID FORCES ACT IN ALL DIRECTIONS
PUMP INTAKE PRESSURE
HYDROSTATIC LOAD
NET FORCES
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Dow
nstr
oke Ups
trok
e
Production Fluid Flow
Production Fluid Flow
IN
Slippage
High Pressure Fluid
Slippage Past Plunger
Low Pressure
Copyright April 2002 Harbison-Fischer
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PUMP FRICTIONFRICTION FROM FLUID BETWEEN BARREL &
PLUNGER
BUOYANCY
FLUID FRICTION THROUGH VALVE &PLUNGER
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FLUID LOAD (Fo)=NET FORCE OF HYDROSTATIC LOAD MINUS PUMP CHAMBER PRESSURE
PUMP INTAKE PRESSURE MINUS
FRICTIONAL FORCES THROUGH THE STANDING
VALVE=PUMP CHAMBER
PRESSURE
UPSTROKE
HYDROSTATIC LOAD
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G as or V acuum
G asF luid
G as
FluidF luid
F luid Pound
G as P ound
G as L ocking
T ypical Pum ping Problem s
C op yright A p ril 2002 Harbison-Fisch er
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U n sw e p tV olu m e
S tro keL e n gth(S w e p tV olu m e )
C o m p ress io n R a tio
C R = S w ep t V o l. + U n sw ep t V o l.U n sw ep t V o l.
E x a m p le : 1 -1 /4 ” p lu n g er1 3 4 ” d o w n h o le s tro k e len g th9 .5 cu b ic in ch es u n sw ep t vo lu m e(1 6 4 .4 + 9 .5 ) / 9 .5 = 1 8 .3
C op yrig h t A p ril 2 0 0 2 H a rb is on -F is ch er
D isch a rg e P ressu re = ( In tak e P ress) tim es (C R )E x a m p le : 4 0 0 p s i In tak e P ressu re1 8 .3 co m p ress io n ra tio , C R4 0 0 tim es 1 8 .3 = 7 ,3 2 0 p s i
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PLUNGER PUMP HYDROSTATICPOSITION VOLUME PRESSURE
134.75 173.9 15.62
116.8 152 31.25
54.5 76 62.5
23.36 38 125
7.78" 19 250
0 9.5 500UnsweptVolume
StrokeLength(SweptVolume)
Copyright April 2002 Harbison-Fischer
DECOMPRESSIONIdeal gas law
V1 P2V2 P1
VOLUME AND PRESSURE ARE INVERSELY PROPORTIONAL
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WHAT IS GAS LOCK?
• USUAL ANSWER IS GAS FILLED PUMP CHAMBER AND PRESSURE DOES NOT BUILD HIGH ENOUGH TO OPEN TRAVELING VALVE AND THE PUMP CHAMBER PRESSURE DOES NOT DROP ENOUGH TO OPEN THE STANDING VALVE
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WHAT IS GAS LOCK?
• BETTER ANSWER IS PUMP HAS PUMPED DOWN TO PUMP CHAMBER DECOMPRESSION LIMIT
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PLUNGER PUMP HYDROSTATICPOSITION VOLUME PRESSURE
134.75 173.9 15.62
116.8 152 31.25
54.5 76 62.5
23.36 38 125
7.78" 19 250
0 9.5 500UnsweptVolume
StrokeLength(SweptVolume)
Copyright April 2002 Harbison-Fischer
DECOMPRESSIONIdeal gas law
V1 P2V2 P1
VOLUME AND PRESSURE ARE INVERSELY PROPORTIONAL
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Dow
nstr
oke
T w o S ta g e “ G a s C h a s e r ” P u m p
Ups
trok
e
P ro d u c tio n F lu id F lo w
IN
F u llP o s it iv eS e a l
C o p y rig h t A p ril 2 0 0 2 H a rb is o n -F is ch e r
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Sliding Top Valve
Sliding Sleeve
Fluid Ports
Copyright April 2002 Harbison-Fischer
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WHAT IS GAS LOCK?
• GAS LOCK IS NOT JUST A PUMP MECHANICAL PROBLEM BUT ALSO A STROKE LENGTH PROBLEM.
• PUMP MECHANICS CAN BE CHANGED BUT FOR THE CHANGES TO BE THE MOST EFFECTIVE THE LONGEST POSSIBLE STROKE ALSO NEEDS TO BE USED
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PUMP EFFICIENCY• SLIPPAGE NEED AT LEAST 2-3% FOR
LUBRICATION AND COOLING• TO MINIMIZE ROD STRETCH LOSS. USE A
STIFF STRING SLOW TO MINIMIZE OR ELASTIC STRING FAST TO GAIN OVERTRAVEL
• DO NOT POUND FLUID: SIZED TO FIT, TIME CLOCK, OR USE PUMP CONTROLLER OR VSP PUMP
• GOR THROUGH THE PUMP OR STOCK TANK SHRINKAGE WILL REDUCE PRODUCTION
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PUMP EFFICIENCY
• WHAT IS MORE IMPORTANT; ELECTRICITY COST OR CYCLES BEFORE FAILURE?
• GAS POUND, IF WE CANNOT SEPARATE THE GAS USE A LARGER PUMP TO GET PRODUCTION & DESIGN TO HANDLE THE GAS COMPRESSION EFFECTS
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PUMP EFFICIENCY
• DO NOT ALLOW PUMP EFFICIENCY TO AFFECT NEW DESIGN TO HANDLE STICKING PROBLEMS, PUMP FRICTION PROBLEMS AND IMPROVE CYCLE LIFE.