10 th Annual Sucker Rod Pumping Workshop Renaissance Hotel Oklahoma City, Oklahoma September 16-19, 2014 Rod String Design Software Simulation of Sandia Downhole Load Cell Wells by Norman W. Hein, Jr., P.E. Norris/AOT & DAL Lynn Rowlan Echometer Scott Malone Norris DAL
Content Background & prior software simulation comparison Sandia well & operating information Rod string software & results Comparison with actual loads Summary & Conclusions Sucker Rod Pumping Workshop; DAL/NWH 2
Background A Current Comparison of Sucker Rod String Design Programs By Norman W. Hein, Jr., P.E. Oil & Gas Optimization Specialists, Ltd. & Russell Stevens, Norris Paper #7 - Presented at Southwestern Petroleum Short Course (SWPSC), April 21/22, 2004 Sucker Rod Pumping Workshop; DAL/NWH 3
Purpose Compared predictive steel, vertical rod string design results to actual dynamometer cards using: Q Rod Rod Star S Rod Lufkin LoadCalB (API) Conoco Modified API (no sinker bars) Sucker Rod Pumping Workshop; DAL/NWH 4
Accuracy Fig. 5. Well #1 Accuracy Comparison 120.00% 110.00% 100.00% 90.00% 80.00% Wrf =SVL (lb) TVL (lb) PPRL (lb) MPRL (lb) Max Rod Stress... Diff. A Diff. B Diff. C Diff D Diff. E Sucker Rod Pumping Workshop; DAL/NWH 5
Accuracy Fig. 8. Well #3b Accuracy Comparison 250.00% 200.00% 150.00% 100.00% 50.00% 0.00% Diff. A Diff. B Diff. C Diff. D Diff. E Wrf =SVL (lb) TVL (lb) PPRL (lb) MPRL (lb) Max Rod Stress (psi) Sucker Rod Pumping Workshop; DAL/NWH 6
Results Comparison showed not all the required loads and nondimensional operating parameters that are required for optimization and troubleshooting were provided by all the programs Inaccuracies may be within 10 to 15% for simple string When sinker bars installed and comparison made, inaccuracies may be from -40% to +25% of actual measurements Maintained belief that programs cannot accurately predict dynamic effects of sinker bars Some programs were changed over time plus new capabilities of designing effect of well bore deviations included Sucker Rod Pumping Workshop; DAL/NWH 7
Sandia well & operating data Sucker Rod Pumping Workshop; DAL/NWH 8
Well No. Depth Casing Tubing Seat Nipple TAC Depth Rod No. Coupling Guides PBD (ft) (in) (in) Depth (ft) (ft) & grade Size Installed 1 2780 5.5 2.875 2710 2647 66/C FS 2/rod 2 7799 7 2.875 7655 6168 1.25" FRP to 4362'; 1.0" D to 7564' 3 9270 5.5 2.875 9220 8968 87/D w 408' 1.0" D SB 4 3090 5.5 2.875 3061 3058 76/D w 300' 1.25" SB 5a 5278 5.5 2.875 5060 4970 86/D w 250' 1.5" SB 5b 5278 5.5 2.875 5060 4970 86/D w 250' 1.5" SB 6 2975 5.5 2.875 2909 2603 77/N-97 w 500' 1.5" SB SHSM - FRP; FSSM - D SHSM - 1"; FSSM 7/8" Sucker Rod Pumping Workshop; DAL/NWH 9 0 0 FS 0 SH - 1"; FS - rest SH - 1"; FS - rest 2/rod on 3/4" 2/rod on 3/4" FSSM 0
Well No. 1 Pump Dia Pump Length Unit Size Motor Tubing Casing Produced Fluid (in) (Ft) (HP) Pressure (psi) Press (psi) G 1.5 12 228-213-86 20 60 0 0.995 2 1.5 30 M640-305-144 75 45 76 1.027 3 2.25 35 Rotoflex 1100-500-306 100 40 40 1.019 4 1.5 26 M640-305-168 40 20 0 1 5a 2 24 M640-305-168 60 205 180 0.982 5b 2 24 M640-305-168 60 205 180 0.982 6 2.25 24 456-305-144 72 43 vacuum 1.015 Sucker Rod Pumping Workshop; DAL/NWH 10
Well No. 1 2 3 4 5a 5b 6 N S Fluid Level Tool (spm) (in) FAP (ft) Depths (ft) 11 86 2710 #1- below pump - Not Work (NW); #2 - above pump @2689'; #3-2462' (in 3/4"); #4-1010' (in 3/4"); #5 - Below PR @2' 8.2 144 428' #1 - below pump; #2 - above pump @7566'; #3-7489' (75' above pump) - NW; #4-4362' (FG to Stl x); #5-4285' (75' above x) 3.9 306 86 #1 - above pump 9229'; #2-9087' (in 1" SB); #3-8785' (in 1" SB); #4-7658' (SB to 7 x); #5-7506' (in 7/8") 4.58 168 243 #1 - below pump; #2 - above pump @3010'; #3-2708' (SB to 6 x); #4-1006' (6 to 7 x); #5 - below PR @2' 9.1 168 4767 #1 - below pump; #2 - above pump @4993'; #3-4741' (SB to 7 x); #4-4714' (25' above x); #5 - below PR @2' 6.5 168 4767 #1 - below pump; #2 - above pump @4993'; #3-4741' (SB to 6 x); #4-3114' (6 to 7 x); #5-1512 (7 to 8 x) 7.1 143.5 1054 #1 - below pump; #2 - above pump @2860'; #3-2783' (in SB); Sucker Rod Pumping Workshop; #4-2356' DAL/NWH (SB to 7 x); 11 #5 - below PR @2'
Rod Design Software Evaluated Programs considered: QRod RodStar Srod Program defaults used Assumption for pump/plunger friction = -200 pounds While some wells reported with guides, deviation surveys not available so assumption all wells vertical Assumed friction coefficient = 0.2 no guides; 0.3 w/guides One program did not have the Rotoflex geometry in analysis capabilities; so CW Conventional unit used Sucker Rod Pumping Workshop; DAL/NWH 12
Sandia load translation using DHLC Sucker Rod Pumping Workshop; DAL/NWH 13
SANDIA Test AHC SSAU 4115 08/04/96 10:00 AM Sept. 17-20, 2014 14
From L. Rowlan: Update on Sandia Downhole Dynamometer Testing, SRL WS, OKC, 09/18/2014 Sucker Rod Pumping Workshop; DAL/NWH 15
Well 1 Sept. 17-20, 2014 2014 Sucker Rod Pumping Workshop 16
Well 2 Sept. 17-20, 2014 2014 Sucker Rod Pumping Workshop 17
Well 3 Sept. 17-20, 2014 2014 Sucker Rod Pumping Workshop 18
Well 4 Sept. 17-20, 2014 2014 Sucker Rod Pumping Workshop 19
Well 5A Sept. 17-20, 2014 2014 Sucker Rod Pumping Workshop 20
Well 6 Sept. 17-20, 2014 2014 Sucker Rod Pumping Workshop 21
Summary Programs versus actual load Sucker Rod Pumping Workshop; DAL/NWH 22
Tabular Comparison Well 1 Load Sandia Prog 1 % Prog 2 % Prog 3 % PPRL 8815 8661-1.7 8746-0.7 8736-0.9 MPRL 1979 1600-19.1 1797-9.2 2167-0.9 MPL -58-744 +138 0 1-200 +245 Sucker Rod Pumping Workshop; DAL/NWH 23
Tabular Comparison Well 2 Load Sandia Prog 1 % Prog 2 % Prog 3 % PPRL 18.613 21,221 +14 20,484 +10.0 20,669 -+11.0 MPRL 5932 6074 +2.4 6224 +4.9 5547-6.5 MPL +217-2838 -1208 0 1-200 -7.8 Sucker Rod Pumping Workshop; DAL/NWH 24
Tabular Comparison Well 3 Load Sandia Prog 1 % Prog 2 % Prog 3 % PPRL 39,972 52,459 +31.2 42,639 +10.6 40,799 +2.1 MPRL 16.148 21,457 +32.9 14,134-11.5 14298-11.5 MPL +230-3367 -2710 0 1-200 -13.2 Sucker Rod Pumping Workshop; DAL/NWH 25
Tabular Comparison Well 4 Load Sandia Prog 1 % Prog 2 % Prog 3 % PPRL 8,656 8.946 +3.3 10,280 +18.7 8,462-2.2 MPRL 1,977 3,673 +85.8 2,201 +11.3 2,470 +24.9 MPL -93-2,613-2710 0 1-200 +115 Sucker Rod Pumping Workshop; DAL/NWH 26
Tabular Comparison Well 5A Load Sandia Prog 1 % Prog 2 % Prog 3 % PPRL 15,507 16,389 +5.68 15,701 +1.25 16.926 +9.1 MPRL 6651 7161 +7.7 7054 +6.1 6980 +4.9 MPL -34-4403 -4502 0 1-254 -647 Sucker Rod Pumping Workshop; DAL/NWH 27
Tabular Comparison Well 6 Load Sandia Prog 1 % Prog 2 % Prog 3 % PPRL 13,344 15,276 14.5 12,743-4.5 10,582-20.7 MPRL 7040 4485-36.3 4295-39.9 2793-60.3 MPL +804-2788 -2467 0 1-200 -75.1 Sucker Rod Pumping Workshop; DAL/NWH 28
Conclusions & Recommendations Currently program 2 &3 are very close to the same accuracy Program 3 had a consistent -200 pound minimum pump load (MPL) which was related to the 200 pound of assumed pump friction If this friction was removed, then MPL would be very close Sucker Rod Pumping Workshop; DAL/NWH 29
Conclusions & Recommendations - cont Prog 1 had consistently the worse accuracy and dramatically over-estimated MPL Prog 1 & 3 have provided all the load and nondimensional pumping parameters while prog 2 still is missing N/No While there were instances where there was a negative MPL, these loads did not increase nor stay applied over the plunger stroke length Sucker Rod Pumping Workshop; DAL/NWH 30
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