Section I

Sucker Rod Pumping

1.1 Introduction
Advantages
• provides mechanical energy to lift oil
• efficient, simple and easy to operate
• pumps a well down to very low pressure
• applicable to slim holes, multiple completions,
and high-temperature and viscous oils
• easy to change to other wells with minimum cost

Disadvantages
• excessive friction in crooked/deviated holes
• solid-sensitive problems
• low efficiency in gassy wells
• limited depth due to rod capacity
• bulky in offshore operations.
1.2 Pumping
System
 Walking Beam

Fulcrum

an Force
Pitm

Well
Load

Counter
Balance

(a) Conventional Unit

 Walking Beam

Fulcrum

an
Force

Pitm
Well
Load

Counter
Balance

(b) Lufkin Mark II Unit

 Walking Beam

Fulcrum

Counter Balance
Force

an
Pitm
Well
Load

(c) Air-Balanced Unit

 Figure 1-3: The pumping cycle: (a) plunger moving down, near bottom of stroke;
(b) plunger moving up, near bottom of stroke; (c) plunger moving up, near top of stroke; (d)
plunger moving down, near top of stroke (From Nind, 1964)
Figure 1-4: Two types of plunger pumps (From Nind, 1964)
1.3 Polished
Rod Motion

Figure 1-5
 A
C

R H
G

Figure 1-6: Definitions of conventional pumping unit API geometry dimensions

 Table 1-1: Conventional pumping unit API geometry dimensions

A C I P H G R1, R2, R3 Cs
API Unit Torque
Designation (in.) (in.) (in.) (in.) (in.) (in.) (in.) (lb) Factor

C-912D-365-168 210 120.03 120 148.5 237.88 86.88 47, 41, 35 -1500 80.32
C-912D-305-168 210 120.03 120 148.5 237.88 86.88 47, 41, 35 -1500 80.32
C-640D-365-168 210 120.03 120 148.5 237.88 86.88 47, 41, 35 -1500 80.32
C-640D-305-168 210 120.03 120 148.5 237.88 86.88 47, 41, 35 -1500 80.32
C-456D-305-168 210 120.03 120 148.5 237.88 86.88 47, 41, 35 -1500 80.32
C-912D-427-144 180 120.03 120 148.5 237.88 86.88 47, 41, 35 -650 68.82
C-912D-365-144 180 120.03 120 148.5 237.88 86.88 47, 41, 35 -650 68.82
C-640D-365-144 180 120.03 120 148.5 238.88 89.88 47, 41, 35 -650 68.82
C-640D-305-144 180 120.08 120 144.5 238.88 89.88 47, 41, 35 -520 68.45
C-456D-305-144 180 120.08 120 144.5 238.88 89.88 47, 41, 35 -520 68.45
C-640D-256-144 180 120.08 120 144.5 238.88 89.88 47, 41, 35 -400 68.45
C-456D-256-144 180 120.08 120 144.5 238.88 89.88 47, 41, 35 -400 68.45
C-320D-256-144 180 120.08 120 144.5 238.88 89.88 47, 41, 35 -400 68.45
C-456D-365-120 152 120.03 120 148.5 238.88 89.88 47, 41, 35 570 58.12
C-640D-305-120 155 111.09 111 133.5 213 75 42, 36, 30 -120 57.02
C-456D-305-120 155 111.09 111 133.5 213 75 42, 36, 30 -120 57.02
C-320D-256-120 155 111.07 111 132 211 75 42, 36, 30 55 57.05
C-456D-256-120 155 111.07 111 132 211 75 42, 36, 30 55 57.05
C-456D-213-120 155 111.07 111 132 211 75 42, 36, 30 0 57.05
C-320D-213-120 155 111.07 111 132 211 75 42, 36, 30 0 57.05
C-228D-213-120 155 111.07 111 132 211 75 42, 36, 30 0 57.05
C-456D-265-100 129 111.07 111 132 211 75 42, 36, 30 550 47.48
C-320D-265-100 129 111.07 111 132 211 75 42, 36, 30 550 47.48
C-320D-305-100 129 111.07 111 132 211 75 42, 36, 30 550 47.48
C-228D-213-100 129 96.08 96 113 180 63 37, 32, 27 0 48.37
C-228D-173-100 129 96.05 96 114 180 63 37, 32, 27 0 48.37
C-160D-173-100 129 96.05 96 114 180 63 37, 32, 27 0 48.37
C-320D-246-86 111 111.04 111 133 211 75 42, 36, 30 800 40.96
C-228D-246-86 111 111.04 111 133 211 75 42, 36, 30 800 40.96
C-320D-213-86 111 96.05 96 114 180 63 37, 32, 27 450 41.61
C-228D-213-86 111 96.05 96 114 180 63 37, 32, 27 450 41.61
C-160D-173-86 111 96.05 96 114 180 63 37, 32, 27 450 41.61
C-114D-119-86 111 84.05 84 93.75 150.13 53.38 32, 27, 22 115 40.98
C-320D-245-74 96 96.05 96 114 180 63 37, 32, 27 800 35.99
C-228D-200-74 96 96.05 96 114 180 63 37, 32, 27 800 35.99
C-160D-200-74 96 96.05 96 114 180 63 37, 32, 27 800 35.99
C-228D-173-74 96 84.05 84 96 152.38 53.38 32, 27, 22 450 35.49
C-160D-173-74 96 84.05 84 96 152.38 53.38 32, 27, 22 450 35.49
C-160D-143-74 96 84.05 84 93.75 150.13 53.38 32, 27, 22 300 35.49
C-114D-143-74 96 84.05 84 93.75 150.13 53.38 32, 27, 22 300 35.49
C-160D-173-64 84 84.05 84 93.75 150.13 53.38 32, 27, 22 550 31.02
C-114D-173-64 84 84.05 84 93.75 150.13 53.38 32, 27, 22 550 31.02
C-160D-143-64 84 72.06 72 84 132 45 27, 22, 17 360 30.59
C-114D-143-64 84 72.06 72 84 132 45 27, 22, 17 360 30.59
C-80D-119-64 84 64 64 74.5 116 41 24, 20, 16 0 30.85
C-160D-173-54 72 72.06 72 84 132 45 27, 22, 17 500 26.22
C-114D-133-54 72 64 64 74.5 116 41 24, 20, 16 330 26.45
C-80D-133-54 72 64 64 74.5 116 41 24, 20, 16 330 26.45
C-80D-119-54 72 64 64 74.5 116 41 24, 20, 16 330 26.45
C-P57D-76-54 64 51 51 64 103 39 21, 16, 11 105 25.8
C-P57D-89-54 64 51 51 64 103 39 21, 16, 11 105 25.8
C-80D-133-48 64 64 64 74.5 116 41 24, 20, 16 440 23.51
C-80D-109-48 64 56.05 56 65.63 105 37 21, 16, 11 320 23.3
C-57D-109-48 64 56.05 56 65.63 105 37 21, 16, 11 320 23.3
C-57D-95-48 64 56.05 56 65.63 105 37 21, 16, 11 320 23.3
C-P57D-109-48 57 51 51 64 103 39 21, 16, 11 180 22.98
C-P57D-95-48 57 51 51 64 103 39 21, 16, 11 180 22.98
C-40D-76-48 64 48.17 48 57.5 98.5 37 18, 14, 10 0 23.1
C-P40D-76-48 61 47 47 56 95 39 18, 14, 10 190 22.92
C-P57D-89-42 51 51 51 64 103 39 21, 16, 11 280 20.56
C-P57D-76-42 51 51 51 64 103 39 21, 16, 11 280 20.56
C-P40D-89-42 53 47 47 56 95 39 18, 14, 10 280 19.92
C-P40D-76-42 53 47 47 56 95 39 18, 14, 10 280 19.92
C-57D-89-42 56 48.17 48 57.5 98.5 37 18, 14, 10 150 20.27
C-57D-76-42 56 48.17 48 57.5 98.5 37 18, 14, 10 150 20.27
C-40D-89-42 56 48.17 48 57.5 98.5 37 18, 14, 10 150 20.27
C-40D-76-42 56 48.17 48 57.5 98.5 37 18, 14, 10 150 20.27
C-40D-89-36 48 48.17 48 57.5 98.5 37 18, 14, 10 275 17.37
C-P40D-89-36 47 47 47 56 95 39 18, 14, 10 375 17.66
C-25D-67-36 48 48.17 48 57.5 98.5 37 18, 14, 10 275 17.37
C-25D-56-36 48 48.17 48 57.5 98.5 37 18, 14, 10 275 17.37
C-25D-67-30 45 36.22 36 49.5 84.5 31 12, 8 150 14.53
C-25D-53-30 45 36.22 36 49.5 84.5 31 12, 9 150 14.53
API Designation

C – 228D – 200 – 74.

The first field is the code for type of pumping unit.

C = Conventional units
A = Air-Balanced units
B = Beam Counterbalance units
M = Mark II units.

The second field is the code for peak torque rating in 1000 in.-lb.
D stands for Double Reduction Gear Reducer.

The third field is the code for polished rod load rating in 100 lb.

The last field is the code for stroke length in inches.

Approximate Motion

Figure 1-7
If x denotes the distance of B below its top
position C and is measured from the instant at
which the crank arm and pitman arm are in the
vertical position with the crank arm vertically
upward, the law of cosine gives

( AB )2 = (OA)2 + (OB )2 − 2(OA)(OB ) cos AOB

i.e.,

h = c + (h + c − x ) − 2c(h + c − x ) cos ωt
2 2 2
where ω is the angular velocity of the crank.
The equation reduces to
x 2 − 2 x[h + c(1 − cos ωt )] + 2c(h + c )(1 − cos ωt ) = 0

so that

x = h + c(1 − cos ωt ) ± c cos ωt + h − c

2 2
( 2 2
)
When ωt is zero, x is also zero, which means that
the negative root sign must be taken.
Therefore,

x = h + c(1 − cos ωt ) − c cos ωt + h + c

2 2
( 2 2
)
 2
d x
Acceleration is a= 2
dt
Carrying out the differentiation for acceleration,
it is found that the maximum acceleration
occurs when ωt is equal to zero (or an even
multiple of π radians) and that this maximum
value is

a max = ω c (1 +
2 c
h
) (1-1)
It also appears that the minimum value of
acceleration is

a min = ω c (1 −
2 c
h
) (1-2)

If N is the number of pumping strokes per

minute then

2πN
ω= (rad/sec) (1-3)
60
The maximum downward acceleration of point B
(which occurs when the crank arm is vertically
upward) is

cN 2 ⎛ c⎞
a max = ⎜1 + ⎟ (ft/sec2) (1-4)
91.2 ⎝ h⎠

or

cN g ⎛
2
c ⎞ (ft/sec2)
a max = ⎜1 + ⎟ (1-5)
2936.3 ⎝ h⎠
Likewise the minimum upward (amin) acceleration of point
B (which occurs when the crank arm is vertically
downward) is

cN g ⎛
2
c⎞
a min = ⎜1 − ⎟ (ft/sec2) (1-6)
2936.3 ⎝ h⎠

It follows that in a conventional pumping unit the

maximum upward acceleration of the horse’s head
occurs at the bottom of the stroke (polished rod)
and is equal to

d 1 cN 2 g ⎛ c⎞
a max = ⎜1 + ⎟ (ft/sec2) (1-7)
d 2 2936.3 ⎝ h⎠
where d1 and d2 are shown in Figure 1-5. But

2cd 2
=S
d1

where S is the polished rod stroke length.

So if S is measured in inches, then
2cd 2 S
=
d1 12
or
cd 2 S
= (1-8)
d1 24
So substituting Eq (1-8) into Eq (1-7) yields

SN 2 g ⎛ c⎞
a max = ⎜1 + ⎟ (ft/sec2) (1-9)
70471.2 ⎝ h⎠

or we can write Eq (1-9) as

2
SN g
a max = M (ft/sec2) (1-10)
70471.2
where M is the machinery factor and is defined as

M =1+ c
h (1-11)

Similarly,

SN 2 g ⎛ c⎞
a min = ⎜1 − ⎟ (ft/sec2) (1-12)
70471.2 ⎝ h⎠
1.4.1 Maximum PRL

(A − Ar ) γ s DAr γ s DAr ⎛ SN 2 M ⎞
PRL max = S f (62.4)D + + ⎜⎜ ⎟⎟
p

144 144 144 ⎝ 70471.2 ⎠

(1-13)

Equation (1-13) can be rewritten as

DAp DAr γ s DAr γ s DAr ⎛ SN 2 M ⎞

PRL max = S f (62.4) − S f (62.4 ) + + ⎜⎜ ⎟⎟
144 144 144 144 ⎝ 70471.2 ⎠

(1-14)
If the weight of the rod string in air is

γ s DAr
Wr = (1-15)
144
which can be solved for Ar which is
144Wr
Ar = (1-16)
γ sD
Substituting Eq (1-16) into Eq (1-14) yields

DAp Wr ⎛ SN 2 M ⎞
PRL max = S f (62.4) − S f (62.4) + Wr + Wr ⎜⎜ ⎟⎟ (1-17)
144 γs ⎝ 70471.2 ⎠
The above equation is often further reduced by
taking the fluid in the second term (the subtractive
term) as an API 50° with Sf = 0.78. Thus, Eq (1-
17) becomes (where γs= 490)
DAp ⎛ SN 2 M ⎞
PRL max = S f (62.4) − 0.1Wr + Wr + Wr ⎜⎜ ⎟⎟
144 ⎝ 70471.2 ⎠
or
⎛ SN 2 M ⎞
PRL max = W f + 0.9Wr + Wr ⎜⎜ ⎟⎟ (1-18)
⎝ 70471.2 ⎠
DA p
where W f = S f (62.4 )
144
and is called the fluid load (not to be confused
with the actual fluid weight on the rod string).
Thus, Eq (1-18) can be rewritten as

PRL max = W f + (0.9 + F1 )Wr (1-19)

where for conventional units

SN (1 +
2 c
)
F1 = h
(1-20)
70471.2

and for air-balanced units

SN 2 (1 − c
)
F1 = h (1-21)
70471.2
1.4.2 Minimum PRL

Wr
PRL min = − S f (62.4) + Wr − Wr F2
γs

which, for API 50° oil, reduces to

PRL min = 0.9Wr − F2Wr = (0.9 − F2 )Wr (1-22)

where for the conventional units

SN (1 − )
2 c
F2 = h
(1-23)
70471.2

and for air-balanced units

SN (1 + )2 c
F2 = h (1-24)
70471.2
1.4.3 Counterweights

The idea counter-balance load C is the

average PRL. Therefore,

C= 1
2
(PRL max + PRL min )

Using Eqs (1-19) and (1-22) in the above we get

C = 12 W f + 0.9Wr + 1
2
(F1 − F2 )Wr (1-25)
or for conventional units

⎛ SN 2
c⎞
C = 2 W f + Wr ⎜⎜ 0.9 +
1
⎟⎟ (1-26)
⎝ 70471.2 h ⎠

and for air-balanced units

⎛ SN c⎞
2
C = W f + Wr ⎜⎜ 0.9 −
1
2
⎟⎟ (1-27)
⎝ 70471.2 h ⎠
 r d1
C = C s + Wc
c d2
where

Cs = structure unbalance, lbs

Wc = total weight of counterweights, lbs
r = distance between the mass center of
counterweights and the crank shaft
center, in.
1.4.4 Peak Torque and Speed Limit

Peak torque T is (see Figure 1.5)

T = c[C − (0.9 − F2 )Wr ]

d2 (1-28)
d1

Substituting Eq. (1-25) into Eq. (1-28) gives

T = 12 S [C − (0.9 − F2 )Wr ] (1-29)

or
 [
T = 12 S 12 W f + 1
2
(F1 + F2 )Wr ]
or
⎛ 2 SN 2
Wr ⎞
T = 4 S ⎜⎜W f +
1 ⎟⎟ (in-lbs) (1-30)
⎝ 70471.2 ⎠

Torque factors and efficiency are used in practice:

1
[PRLmax (TF1 ) + PRLmin (TF2 )] (1-31)
T= 2

0.93
Torque factor is defined:

Torque Exerted to the Crankshaft

TF =
Polished Rod Load

TF1 = Maximum upstroke torque factor

occurred when the crank is in the
horizontal position

TF2 = Maximum downstroke torque factor

occurred when the crank is in the
horizontal position
Approximate Maximum Torque Factor
Conventional and Air Balance Units

Stroke (in.) TF1 (in.) TF2 (in.)

16 8.5 8.5
24 13 13
30 16 16
36 19 19
42 22 22
48 26 26
54 29 29
64 34 34
74 39 39
86 45 45
100 52 52
120 63 63
144 75 75
168 87 87
Approximate Maximum Torque Factor
Mark II Units

Stroke (in.) TF1 (in.) TF2 (in.)

64 29 37
74 34 43
86 39 51
100 47 57
120 55 71
144 66 88
168 79 102
Maximum Permissible Pumping Speed

As given earlier the maximum value of the

downward acceleration is equal to

SN 2 g (1 ± c
)
a max/ min = h
(1-32)
70471.2

SN (1 ±
2 c
)
h
≤L (1-33)
70471.2
or

70471.2 L
N limit =
S (1 m hc )
(1-34)

For L = 0.5

187.7
N limit = (1-35)
S (1 m c
h
)
The minus sign is for conventional units
and the plus sign for air-balanced units.
1.4.5 Tapered Rod Strings
Tapered rod strings can be identified by their numbers such
as:

a. No. 88 is a non-tapered 8/8” or 1” diameter rod string

b. No. 76 is a tapered string with 7/8” diameter rod at the top,
then a 6/8” diameter rod at the bottom.
c. No. 75 is a 3 way tapered string consisting of
7/8” diameter rod at top
6/8” diameter rod at middle
5/8” diameter rod at bottom
d. No. 107 is a 4 way tapered string consisting of
10/8” (or 1 1/4”) diameter rod at top
9/8” (or 1 1/8”) diameter rod below 10/8” diameter rod
8/8” (or 1”) diameter rod below 9/8” diameter rod
7/8” diameter rod below 8/8” diameter rod
There are two criteria used in the
design of tapered rod strings:

1. Stress at the top rod of each rod size is the

same throughout the string

2. Stress in the top rod of the smallest

(deepest) set of rods should be the highest
(~30,000 psi) and the stress progressively
decreases in the top rods of the higher
sets of rods.
Example Problem 1-1:

The following geometry dimensions are for

the pumping unit C – 320D – 213 – 86:

d1 = 96.05 in.
d2 = 111 in.
c = 37 in.
c/h = 0.33
If this unit is used with a 2 1/2” plunger and 7/8 in.
rods to lift 25 °API gravity crude (formation volume
factor 1.2 rb/stb) at depth of 3,000 ft, answer the
following questions:

a) What is the maximum allowable pumping speed if L =

0.4 is used?
b) What is the expected maximum polished rod load?
c) What is the expected peak torque?
d) What is the desired counter-balance weight to be
placed at the maximum position on the crank?
Solution:

The pumping unit C – 320D – 213 – 86 has a

peak torque of gearbox rating of 320,000 in-lbs, a
polished rod rating of 21,300 lbs, and a maximum
polished rod stroke of 86 in.

(a)Based on the configuration for conventional

unit shown in Figure 1-5(a) and Table 1-1,
thepolished rod stroke length can be estimated
as:
 d2 111
S = 2c = (2)(37) = 85.52 in.
d1 96.05

The maximum allowable pumping speed is:

70471.2 L (70471.2)(0.4)
N= =
S (1 − h )
c
(85.52)(1 − 0.33)

= 22 SPM
(b) The maximum PRL can be calculated with Eq
(12-17). The 25° API gravity has an Sf =
0.9042. The area of the 2 ½” plunger is Ap =
4.91 in.2 The area of the 7/8” rod is Ar = 0.60
in.2 Then

DA p
W f = S f (62.4 ) = (0.9042)(62.4 )
(3,000)(4.91)
= 5,770 lbs
144 144

γ s DAr (490)(3,000)(0.60)
Wr = = = 6,138 lbs
144 144
 SN (1 + hc ) (85.52)(22) 2 (1 + 0.33)
2
F1 = = = 0.7940
70471.2 70471.2

Then the expected maximum PRL is:

Wr
PRL max = W f − S f (62.4) + Wr + Wr F1
γs
= 5,770 − (0.9042)(62.4)(6,138) /(490) + 6,138 + (6,138)(0.794)

= 16,076 lbs

< 21,300 lbs, OK

(c) The peak torque is calculated by Eq (1-30):

⎛ 2 SN 2
W ⎞ ⎛ 2(85.52)( 22) 2
(6,138) ⎞
T = 14 S ⎜⎜W f + r
⎟⎟ = 14 (85.52) ⎜⎜ 5,770 + ⎟⎟
⎝ 70471.2 ⎠ ⎝ 70471.2 ⎠

= 280,056 lb-in. < 320,000 lb-in. OK

 Accurate calculation of counter-balance load
requires the minimum PRL:

SN (1 − hc ) (85.52)(22) 2 (1 − 0.33)
2
F2 = = = 0.4
70471.2 70471.2

Wr
PRL min = − S f (62.4) + Wr − Wr F2
γs
= −(0.9042)(62.4 )
6,138
+ 6,138 − (6,138)(0.4)
490
= 2,976 lbs
C= 1
2
(PRL max + PRL min ) = 12 (16,076 + 2,976) = 9,526 lbs

A product catalog of LUFKIN Industries indicates

that the structure unbalance is 450 lbs and 4 No.
5ARO Counterweights placed at the maximum
position (c in this case) on the crank will produce
an effective counter-balance load of 10,160 lbs.
That is,

(37) (96.05)
Wc + 450 = 10,160
(37) (111)
which gives Wc = 11,221 lbs. In order to generate
the ideal counter-balance load of C = 9,526 lbs,
the counterweights should be place on the
crank at

(9,526)(111)
r= (37) = 36.30 in.
(11,221)(96.05)

The computer program SuckerRodPumpingLoad.xls

can be used for quickly seeking solutions to similar
problems. It is available from the publisher with this
book. Solution is shown in Table 1-2.
SuckerRodPumpingLoad.xls
Description: This spreadsheet calculates the maximum allowable pumping
speed, the maximum PRL, the minimum PRL, peak torque, and counterbalance
load.
Instruction: 1) Update parameter values in the Input section; and 2) view result
in the Solution section.
Input Data:
Pump setting depth (D): 3,000 ft
Plunger diameter (dp): 2.5 in.
Rod section 1, diameter (dr1): 1 in.
length (L1): 0 ft
Rod section 2, diameter (dr2): 0.875 in.
length (L2): 3,000 ft
Rod section 3, diameter (dr3): 0.75 in.
length (L3): 0 ft
Rod section 4, diameter (dr4): 0.5 in.
length (L4): 0 ft
Type of pumping unit (1 = conventional; -1 = Mark II or
Air-balanced): 1
Beam dimension 1 (d1) 96.05 in.
Beam dimension 2 (d2) 111 in.
 Crank length (c): 37 in.
Crank to pitman ratio (c/h): 0.33
Oil gravity (API): 25 oAPI
Maximum allowable acceleration factor (L): 0.4

Solution:
d2
S = 2c = 85.52 in.
d1
70471.2 L
N=
S (1 − hc ) = 22 SPM

πd p2
Ap = = 4.91 in.2
4
πd r2
Ar = = 0.60 in.
4
DA p
W f = S f (62.4 ) = 5,770 lbs
144
γ s DAr
Wr = = 6,138 lbs
144
 SN 2 (1 ± hc )
F1 = = 0.7940
70471.2

Wr
PRL max = W f − S f (62.4) + Wr + Wr F1 = 16,076 lbs
γs

⎛ 2 SN 2
Wr ⎞
T = 14 S ⎜⎜W f + ⎟⎟
= 280,056 lbs
⎝ 70471.2 ⎠

SN 2 (1 m hc )
F2 = = 0.40
70471.2

Wr
PRL min = − S f (62.4) + Wr − Wr F2
γs = 2,976 lbs

C= 1
2
(PRL max + PRL min ) = 9,526 lbs
1.5 Pump Deliverability and
Power Requirements
Liquid flow rate delivered by the plunger pump
can be expressed as

Ap S p E v (24)(60)
q= N (bbl/day)
144 12 Bo 5.615

or

A p NS p E v
q = 0.1484 (stb/day)
Bo
1.5.1 Effective Plunger Stroke Length

The magnitude of the rod stretch is

W f Dr
δl r = (1-36)
Ar E

Tubing stretch can be expressed by a

similar equation. That is

W f Dt
δl t = (1-37)
At E
The magnitude of the rod stretch due to acceleration
is called plunger over travel:

Wr Dr
δl o = n (ft) (1-38)
Ar E

But the maximum acceleration term n can be

written as

SN 2 (1 ± c
)
n= h
70471.2
so that Eq (1-38) becomes

Wr Dr SN 2
(1 ± c
)
δl o = h
(ft) (1-39)
Ar E 70471.2

Let us restrict our discussion to conventional

units. Then Eq (1-39) becomes

2
W r D r SN M
δl o = (ft) (1-40)
Ar E 70471.2
Eq (1-40) can be rewritten to yield δlo in
inches. Wr is

W r = γ s Ar D r

and γS = 490 lb/ft3 with E = 30 x 106 lb/m2

Eq (1-40) becomes

δl o = 1.93 × 10 −11 Dr2 SN(in)

2
M (1-41)
Plunger stroke is approximated using the above
expressions as

S p = S − δl r − δl t + δl o

or

12 D ⎡ ⎛ 1 1 ⎞ SN 2 M Wr ⎤
Sp = S − ⎢W f ⎜⎜ + ⎟⎟ − ⎥ (in)
E ⎣ ⎝ Ar At ⎠ 70471.2 Ar ⎦

(1-42)
If pumping is carried out at the maximum permissible
speed limited by Eq (1-34), the plunger stroke
becomes

12 D ⎡ ⎛ 1 1 ⎞ 1+ c
LW r ⎤
Sp = S − ⎢W f ⎜⎜ + ⎟⎟ − h
⎥ (in) (1-43)
E ⎢⎣ ⎝ Ar At ⎠ 1 − c
h
Ar ⎥⎦

For the air-balanced unit the term

1+ c
h
is replaced by its reciprocal.
1− c
h
1.5.2 Volumetric Efficiency

Guidelines are

a. Low viscosity oils (1 to 20 cps) can be pumped

with a plunger to barrel fit of -0.001”.

b. High viscosity oils (7400 cps) will probably

carry sand in suspension so a plunger to barrel
fit or ~0.005” can be used.
An empirical formula has been developed that
can be used to calculate the slippage rate, qs
(bbl/day), through the annulus between the
plunger and the barrel.

k p (d b − d p ) (d + d p ) Δp
2.9

qs =
b
(1-44)
μ d 0.1
b Lp
1.5.3 Power Requirements

The power required for lifting fluid is called

hydraulic power. It is usually expressed in
terms of net lift:

Ph = 7.36 × 10 qγ l LN
−6 (1-45)

and

ptf
LN = H +
0.433γ l (1-46)
The power required to overcome friction losses
can be empirically estimated as

−7
Pf = 6.31×10 Wr SN (1-47)

Thus the required prime mover power can

be expressed as

Ppm = Fs ( Ph + Pf ) (1-48)
Example Problem 1-2:

A well is pumped off (fluid level is the pump

depth) with a rod pump described in Example
Problem 1-1. A 3” tubing string (3.5” OD, 2.995
ID) in the well is not anchored. Calculate (a)
expected liquid production rate (use pump
volumetric efficiency 0.8), and (b) required prime
mover power (use safety factor 1.35).
Solution:

This problem can be quickly solved using the

computer program
SuckerRodPumpingFlowrate&Power.xls. Solution is
shown in Table 1-3.

Table 1-3: Solution given by SuckerRodPumpingFlowrate&Power.xls

SuckerRodPumpingFlowRate&Power.xls

Description: This spreadsheet calculates expected

deliverability and required prime mover power for a given
sucker rod pumping system.
Instruction: 1) Update parameter values in the Input section;
and 2) view result in the Solution section.
Input Data:

Pump setting depth (D): 4,000 ft

Depth to the liquid level in annulus (H): 4,000 ft
Flowing tubing head pressure (ptf): 100 ft
Tubing outer diameter (dto): 3.5 in.

Tubing inner diameter (dti): 2.995 in.

Tubing anchor (1 = yes; 0 = no): 0
Plunger diameter (dp): 2.5 in.
Rod section 1, diameter (dr1): 1 in.
length (L1): 0 ft
Rod section 2, diameter (dr2): 0.875 in.
length (L2): 0 ft
Rod section 3, diameter (dr3): 0.75 in.
length (L3): 4,000 ft
Rod section 4, diameter (dr4): 0.5 in.
length (L4): 0 ft
 Type of pumping unit (1 = conventional; -1 = Mark
II or Air-balanced): 1
Polished rod stroke length (S) 86 in.
Pumping speed (N) 22 spm
Crank to pitman ratio (c/h): 0.33
Oil gravity (API): 25 oAPI
Fluid formation volume factor (Bo): 1.2 rb/stb
Pump volumetric efficiency (Ev): 0.8
Safety factor to prime mover power (Fs): 1.35

Solution:
π d t2
At =
4 = 2.58 in.2

πd p2
Ap = = 4.91 in.2
4
πd r2 = 0.44 in.
Ar =
4
 DA p
W f = S f (62.4 ) = 7,693 lbs
144
γ s DAr
Wr =
144 = 6,013 lbs

M = 1± c
h = 1.33

12 D ⎡ ⎛ 1 1 ⎞ SN 2 M Wr ⎤
Sp = S − ⎢W f ⎜ + ⎟− ⎥
E ⎣ ⎜⎝ Ar At ⎟⎠ 70471.2 Ar ⎦
= 70 in.

A p NS p E v = 753 sbt/day
q = 0.1484
Bo
ptf
LN = H + = 4,255 ft
0.433γ l

Ph = 7.36 × 10 −6 qγ l LN = 25.58 hp

Pf = 6.31×10 −7 Wr SN = 7.2 hp

Ppm = Fs ( Ph + Pf ) = 44.2 hp
1.6 Procedure for Pumping
Unit Selection
The following procedure can be used for selecting
a pumping unit:
1) From the maximum anticipated fluid production (based on
IPR) and estimated volumetric efficiency, calculate required
pump displacement.
2) Based on well depth and pump displacement, determine
API rating and stroke length of the pumping unit to be used.
This can be done using either Figure 1-8 or Table 1-4.
3) Select tubing size, plunger size, rod sizes, and pumping
speed from Table 1-4.
4) Calculate the fractional length of each section of the rod
string.
5) Calculate the length of each section of the rod string to the
nearest 25 ft.
6) Calculate the acceleration factor.
7) Determine the effective plunger stroke length.
8) Using the estimated volumetric efficiency, determine the
probable production rate and check it against the desired
production rate.
9) Calculate the dead weight of the rod string.
10) Calculate the fluid load.
11) Determine peak polished rod load and check it
against the maximum beam load for the unit
selected.
12) Calculate the maximum stress at the top of each rod
size and check it against the maximum permissible
working stress for the rods to be used.

13) Calculate the ideal counterbalance effect and check

it against the counterbalance available for the unit
selected.

14) From the manufacturer's literature, determine the

position of the counterweight to obtain the ideal
counterbalance effect.
15) On the assumption that the unit will be no more than
five per cent out of counterbalance, calculate the
peak torque on the gear reducer and check it against
the API rating of the unit selected.

16) Calculate hydraulic horsepower, friction horsepower,

and brake horsepower of the prime mover. Select
the prime mover.

17) From the manufacturer's literature obtain the gear

reduction ratio and unit sheave size for the unit
selected, and the speed of the prime mover. From
this determine the engine sheave size to obtain the
desired pumping speed.
Example Problem 1-3:

A well is to be put on a sucker rod pump. The

proposed pump setting depth is 3,500 ft. The
anticipated production rate is 600 bbl/day oil of
0.8 specific gravity against wellhead pressure
100 psig. It is assumed that working liquid level
is low, and a sucker rod string having a
working stress of 30,000 psi is to be used.
Select surface and subsurface equipment for
the installation. Use safety factor of 1.35 for
prime mover power.
Solution:

(1) Assuming volumetric efficiency of 0.8, the required

pump displacement is
(600)/(0.8) = 750 bbl/day.

(2) Based on well depth 3,500 ft and pump displacement

750 bbl/day, Figure 1-8 suggests API pump size 320 unit
with 84 in. stroke, i.e., a pump is selected with the following
designation:
C - 320D – 213 - 86
(3) Table 1-4 (g) suggests:
Tubing size: 3 in. O.D., 2.992 in. I.D.
Plunger size: 2 ½ in.
Rod size: 7/8 in.
Pumping speed: 18 spm

(4) Table 1-1 gives d1 = 96.05 in., d2 = 111 in.,

c = 37 in. and h = 114 in., thus c/h = 0.3246.
Spreadsheet program
SuckerRodPumpingFlowRate&Power.xls gives
qo = 687 bbl/day > 600 bbl/day, OK
Ppm = 30.2 hp
(5) Spreadsheet program SuckerRodPumpingLoad.xls
gives

PRLmax = 16,121 lbs

PRLmin = 4,533 lbs
T = 247,755 lbs < 320,000 in.-lbs, OK
C = 10,327 lbs

The cross-sectional area of the 7/8 in. rod is 0.60 in.2

Thus the maximum possible stress in the sucker rod is

σmax = (16,121)/(0.60) = 26,809 psi < 30,000 psi, OK

Therefore, the selected pumping unit and rod meet well

load and volume requirements.
(6) If a LUFKIN Industries C - 320D – 213 – 86 unit is
chosen, the structure unbalance is 450 lbs and 4 No.
5ARO Counterweights placed at the maximum position
(c in this case) on the crank will produce an effective
counter-balance load of 12,630 lbs. That is,

(37) (96.05)
Wc + 450 = 12,630 lbs
(37) (111)
which gives

Wc = 14,075 lbs. In order to generate the ideal counter-

balance load of C = 10,327 lbs, the counterweights
should be place on the crank at

(10,327)(111)
r= (37) = 31.4 in.
(14,076)(96.05)
(7) The LUFKIN Industries C - 320D – 213 – 86
unit has a gear ratio of 30.12 and unit sheave
sizes of 24 in., 30 in. and 44 in. are available. If a
24 in. unit sheave and a 750 rpm electric motor
are chosen, the diameter of the motor sheave is

(18)(30.12)(24)
de = = 17.3 in.
(750)
 2,500
Curve API Size Stroke
Pump Displacement (bbl/day)

2,000 A 40 34
B 57 42
C 80 48
1,500 D 114 54
E 160 64
F 228 74
1,000
G 320 84
H 640 144

500

0
0 2,000 4,000 6,000 8,000 10,000 12,000
Pump Setting Depth (ft)

Figure 1-8: Sucker rod pumping unit selection chart

(After Kelley and Willis, 1954)
 Table 1-4: Design data for API sucker rod pumping units

(a) Size 40 Unit with 34-inch Stroke

Plunger Size Rod Sizes Pumping Speed
Pump Depth (ft) (in) Tubing Size (in) (in) (stroke/min)
1000-1100 2 3/4 3 7/8 24-19
1100-1250 2 1/2 3 7/8 24-19
1250-1650 2 1/4 2 1/2 3/4 24-19
1650-1900 2 2 1/2 3/4 24-19
1900-2150 1 3/4 2 1/2 3/4 24-19
2150-3000 1 1/2 2 5/8-3/4 24-19
3000-3700 1 1/4 2 5/8-3/5 22-18
3700-4000 1 2 5/8-3/6 21-18

(b) Size 57 Unit with 42-inch Stroke

Tubing Pumping Speed
Pump Depth (ft) Plunger Size (in) Size (in) Rod Sizes (in) (stroke/min)
1150-1300 2 3/4 3 7/8 24-19
1300-1450 2 1/2 3 7/8 24-19
1450-1850 2 1/4 2 1/2 3/4 24-19
1850-2200 2 2 1/2 3/4 24-19
2200-2500 1 3/4 2 1/2 3/4 24-19
2500-3400 1 1/2 2 5/8-3/4 23-18
3400-4200 1 1/4 2 5/8-3/5 22-17
4200-5000 1 2 5/8-3/6 21-17
 (c) Size 80 Unit with 48-inch Stroke
Plunger Size Rod Sizes Pumping Speed
Pump Depth (ft) (in) Tubing Size (in) (in) (stroke/min)
1400-1500 2 3/4 3 7/8 24-19
1550-1700 2 1/2 3 7/8 24-19
1700-2200 2 1/4 2 1/2 3/4 24-19
2200-2600 2 2 1/2 3/4 24-19
2600-3000 1 3/4 2 1/2 3/4 23-18
3000-4100 1 1/2 2 5/8-3/4 23-19
4100-5000 1 1/4 2 5/8-3/5 21-17
5000-6000 1 2 5/8-3/6 19-17

(d) Size 114 Unit with 54-inch Stroke

Plunger Pumping Speed
Pump Depth (ft) Size (in) Tubing Size (in) Rod Sizes (in) (stroke/min)
1700-1900 2 3/4 3 7/8 24-19
1900-2100 2 1/2 3 7/8 24-19
2100-2700 2 1/4 2 1/2 3/4 24-19
2700-3300 2 2 1/2 3/4 23-18
3300-3900 1 3/4 2 1/2 3/4 22-17
3900-5100 1 1/2 2 5/8-3/4 21-17
5100-6300 1 1/4 2 5/8-3/5 19-16
6300-7000 1 2 5/8-3/6 17-16
 (e) Size 160 Unit with 64-inch Stroke
Rod Sizes Pumping Speed
Pump Depth (ft) Plunger Size (in) Tubing Size (in) (in) (stroke/min)
2000-2200 2 3/4 3 7/8 24-19
2200-2400 2 1/2 3 7/8 24-19
2400-3000 2 1/4 2 1/2 3/4-7/8 24-19
3000-3600 2 2 1/2 3/4-7/8 23-18
3600-4200 1 3/4 2 1/2 3/4-7/8 22-17
4200-5400 1 1/2 2 5/8-3/4-7/8 21-17
5400-6700 1 1/4 2 5/8-3/4-7/8 19-15
6700-7700 1 2 5/8-3/4-7/8 17-15

(f) Size 228 Unit with 74-inch Stroke

Rod Sizes Pumping Speed
Pump Depth (ft) Plunger Size (in) Tubing Size (in) (in) (stroke/min)
2400-2600 2 3/4 3 7/8 24-20
2600-3000 2 1/2 3 7/8 23-18
3000-3700 2 1/4 2 1/2 3/4-7/8 22-17
3700-4500 2 2 1/2 3/4-7/8 21-16
4500-5200 1 3/4 2 1/2 3/4-7/8 19-15
5200-6800 1 1/2 2 5/8-3/4-7/8 18-14
6800-8000 1 1/4 2 5/8-3/4-7/8 16-13
8000-8500 1 1/16 2 5/8-3/4-7/8 14-13
 (g) Size 320 Unit with 84-inch Stroke
Rod Sizes Pumping Speed
Pump Depth (ft) Plunger Size (in) Tubing Size (in) (in) (stroke/min)
2800-3200 2 3/4 3 7/8 23-18
3200-3600 2 1/2 3 7/8 21-17
3600-4100 2 1/4 2 1/2 3/4-7/8-1 21-17
4100-4800 2 2 1/2 3/4-7/8-1 20-16
4800-5600 1 3/4 2 1/2 3/4-7/8-1 19-16
5600-6700 1 1/2 2 1/2 3/4-7/8-1 18-15
6700-8000 1 1/4 2 1/2 3/4-7/8-1 17-13
8000-9500 1 1/16 2 1/2 3/4-7/8-1 14-11

(h) Size 640 Unit with 144-inch Stroke

Pumping Speed
Pump Depth (ft) Plunger Size (in) Tubing Size (in) Rod Sizes (in) (stroke/min)
3200-3500 2 3/4 3 7/8-1 18-14
3500-4000 2 1/2 3 7/8-1 17-13
4000-4700 2 1/4 2 1/2 3/4-7/8-1 16-13
4700-5700 2 2 1/2 3/4-7/8-1 15-12
5700-6600 1 3/4 2 1/2 3/4-7/8-1 14-12
6600-8000 1 1/2 2 1/2 3/4-7/8-1 14-11
8000-9600 1 1/4 2 1/2 3/4-7/8-1 13-10
9600-11000 1 1/16 2 1/2 3/4-7/8-1 12-10
1.7 Principles of Pump
Performance Analysis

Figure 1-9: A sketch of pump dynagraph (From Nind, 1964)

Figure 1-10: Pump dynagraph cards: (a) ideal card,
(b) gas compression on down stroke, (c) gas expansion on upstroke,
(d) fluid pound, (e) vibration due to fluid pound, (f) gas lock (From Nind, 1964)
The surface dynamometer cards record the history
of the variations in loading on the polished rod
during a cycle. The cards have three principal
uses:

a. To obtain information that can be used to determine

load, torque and horsepower changes required of the
pump equipment.

b. To improve pump operating conditions such as pump

speed and stroke length.

c. To check well conditions after installation of equipment to

prevent or diagnose various operating problems (like
pounding etc).
Correct interpretation of surface dynamometer
card leads to estimate of various parameter
values.

• Maximum and minimum PRLs can be read directly from

the surface card (with the use of instrument calibration).
This data then allows for the determination of the torque,
counter balance, and horsepower requirements for the
surface unit.

• Rod stretch and contraction is shown on the surface

dynamometer card. This phenomena is reflected in the
surface unit dynamometer card and is shown in Figure
1-11 (a) for an ideal case.
Figure 1-11: Surface Dynamometer Card: (a) ideal card (stretch and contraction),
(b) ideal card (acceleration), (c) 3 typical cards (From Nind, 1964)
• Acceleration forces cause the ideal card to rotate
clockwise. The PRL is higher at the bottom of the
stroke and lower at the top of the stroke. Thus, in
Figure 1-11 (b), point A is at the bottom of the stroke.

• Rod vibration causes a serious complication in the

interpretation of the surface card. This is result of the
closing of the TV and the “pickup” of the fluid load by
the rod string. This is of course the fluid pounding.
Figure 1-12: Strain-gage-type dynamometer chart
Figure 1-13: Surface to down hole cards derived
from surface dynamometer card
Problems
1-1. If the dimensions d1, d2 and c take the same values for
both conventional unit (Class I lever system) and air-
balanced unit (Class III lever system), how different will their
polished rod strokes length be?

1-2. What are the advantages of the Lufkin Mark II and air-
balanced units in comparison with conventional units?

1-3. Use your knowledge of kinematics to proof that for

Class I lever systems,
(a) the polished rod will travel faster in down stroke than
in upstroke if the distance between crankshaft and the
center of Sampson post is less than dimension d1.
(b) the polished rod will travel faster in up stroke than in
down stroke if the distance between crankshaft and the
center of Sampson post is greater than dimension d1.
1-4. Derive a formula for calculating the effective
diameter of a tapered rod string.

1-5. Derive formulae for calculating length fractions of

equal-top-rod-stress tapered rod strings for (a) two-size
rod strings, (b) three-sized rod strings, and (c) four-sized
rod strings. Plot size fractions for each case as a function
of plunger area.

1-6. A tapered rod string consists of sections of 5/8” and

½” rods and a 2” plunger. Use the formulae from problem
1-5 to calculate length fraction of each size of rod.

1-7. A tapered rod string consists of sections of ¾”, 5/8”

and ½” rods and a 1 ¾” plunger. Use the formulae from
problem 1-5 to calculate length fraction of each size of
rod.
1-8. The following geometry dimensions are for the
pumping unit C – 80D – 133 – 48:

d1 = 64 in.
d2 = 64 in.
c = 24 in.
h = 74.5 in.

Can this unit be used with a 2” plunger and ¾”

rods to lift 30 °API gravity crude (formation volume factor
1.25 rb/stb) at depth of 2,000 ft? If yes, what is the
required counter balance load?
1-9. The following geometry dimensions are for the
pumping unit C – 320D – 256 – 120:
d1 = 111.07 in.
d2 = 155 in.
c = 42 in.
h = 132 in.

Can this unit be used with a 2 1/2” plunger and

¾”-7/8”-1”taperd rod string to lift 22 °API gravity
crude (formation volume factor 1.22 rb/stb) at depth
of 3,000 ft? If yes, what is the required counter
balance load?
1-10. A well is pumped off with a rod pump described in
Problem 12-8. A 2 ½” tubing string (2.875” OD, 2.441 ID)
in the well is not anchored. Calculate (a) expected liquid
production rate (use pump volumetric efficiency 0.80),
and (b) required prime mover power (use safety factor
1.3).

1-11. A well is pumped with a rod pump described in

Problem 1-9 to a liquid level of 2,800 ft. A 3” tubing string
(3.5” OD, 2.995” ID) in the well is anchored. Calculate (a)
expected liquid production rate (use pump volumetric
efficiency 0.85), and (b) required prime mover power
(use safety factor 1.4).
1-12. A well is to be put on a sucker rod pump. The proposed
pump setting depth is 4,500 ft. The anticipated production
rate is 500 bbl/day oil of 40 oAPI gravity against wellhead
pressure 150 psig. It is assumed that working liquid level is
low, and a sucker rod string having a working stress of
30,000 psi is to be used. Select surface and subsurface
equipment for the installation. Use safety factor of 1.40 for
prime mover power.

1-13. A well is to be put on a sucker rod pump. The proposed

pump setting depth is 4,000 ft. The anticipated production
rate is 550 bbl/day oil of 35 oAPI gravity against wellhead
pressure 120 psig. It is assumed that working liquid level will
be about 3,000 ft, and a sucker rod string having a working
stress of 30,000 psi is to be used. Select surface and
subsurface equipment for the installation. Use safety factor of
1.30 for prime mover power.