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Rodstar Manual
Rodstar Manual
Email Addresses:
John G. Svinos - President: jsvinos@gotheta.com
Terry Treiberg - XSPOC Dev. Manager: terry@xspoc.com
Software Support: Rudy Nesmith: rudy@gotheta.com
Orders: Sandy B. Rodriquez - Of. Manager: sandyb@gotheta.com
© heta Oilield Services, Inc., 2006.
All Rights Reserved. his manual may not be reproduced in whole or in part without the written per-
mission of heta Oilield Services, Inc.
Contents
Technical Support . . . . . . . . . . . . . . . v
System Requirements . . . . . . . . . . . . . v
1 Introduction 1
1.1 Program Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Advanced Capabilities and Program Limitations. . . . . . . . . . . . . . . 2
1.3 Help System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 RODSTAR CD and Software Sentinel . . . . . . . . . . . . . . . . . . . . 3
2 Software Installation 5
2.1 RODSTAR Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Questions About Installation . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Installing the Software Sentinel . . . . . . . . . . . . . . . . . . . . . . 5
4 Running RODSTAR 21
4.1 RODSTAR’s User Interface . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.1 RODSTAR’s Help System . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Entering Rod Pumping System Data . . . . . . . . . . . . . . . . . . . . 22
4.2.1 Entering Well Information Data . . . . . . . . . . . . . . . . . . . 23
4.2.2 Entering Production Information. . . . . . . . . . . . . . . . . . . 25
4.2.3 Entering Pump and Tubing Information Data . . . . . . . . . . . . . 26
4.2.4 Entering Rod String Data . . . . . . . . . . . . . . . . . . . . . . 29
4.2.5 Entering Wellbore Deviation Data (RODSTAR-D) . . . . . . . . . . . . 33
4.2.6 Entering Pumping Unit Data. . . . . . . . . . . . . . . . . . . . . 38
iv | Table of Contents
Phone Support:
Monday-Friday 8:00 AM - 4:00 PM PST.
(562) 694-3297
E-Mail Support:
support@gotheta.com
System Requirements
Processor:
1-GHz Pentium III-class processor recommended.
Operating System:
Windows XP
Windows 2000 (Service Pack 2 recommended)
Memory:
512 megabytes (MB) of RAM recommended.
1 Introduction
his allows you to redesign pumping systems with- RODSTAR comes with a large pumping unit
out having to reenter system data. RODSTAR can data base so that you can easily select and com-
display and print the measured dynamometer card pare pumping units without having to get the unit
overlaid on the same plot as the predicted surface dimensions yourself. RODSTAR can model any
dynamometer card. his feature has many uses pumping unit geometry including long stroke units
that include inding the correct rod-tubing friction, such as the Rotalex. Also, you can enter your own
or determining whether the load cell used to record pumping unit data in case your unit is not in the
the dynamometer card may be out of calibration. program’s database. Advanced error trapping and
warning messages help prevent errors and make
By being able to read CBALANCE iles, ROD-
you aware of special requirements necessary for
STAR can get the existing maximum counterbal-
proper system operation.
ance moment based on the existing position of
the counterweights. his eliminates the need for a RODSTAR-D also allows you to enter a deviation
ield measurement of counterbalance efect. Also, survey and calculates side load, dogleg severity, rod
you can enter the calculated balanced maximum guide spacing recommendations, etc.
counterbalance moment back into CBALANCE
to ind out how to balance the pumping unit in one
step.
RODSTAR can simulate any pumping system and
1.2 Advanced Capabilities and
can accurately predict its performance. For a sys-
tem you specify, the program predicts the surface
Program Limitations
and downhole dynamometer cards. Also, it calcu- RODSTAR has many advanced features that
lates the peak gearbox torque and gearbox loading, enable you to accurately predict system perfor-
structure loading, rod loading, pump stroke, mini- mance for any rod pumping system. It can simulate
mum required pump length, plunger length, pump wells of any depth including very deep or shal-
spacing, expected production rate, the counterbal- low wells. It is the only program of its kind that
ance needed to balance the unit, the prime mover models luid inertia efects that are present in wells
size, overall system eiciency, daily energy con- that pump incompressible luids with larger than
sumption, monthly electricity bill, and other useful 2.00” plungers from depths of less than 4000 feet.
information. Also, RODSTAR allows you to enter RODSTAR-D can simulate deviated wells, while
inlow performance data so that you can easily de- RODSTAR-V can only be used for wells that are
sign a pumping system for any pump intake pump vertical or have little deviation.
intake pressure, calculate the expected production By calculating the minimum stress at the bottom
rate, pump intake pressure and pump condition for of each rod section, RODSTAR shows whether
any rod pumping system, ind out the maximum the rods are in compression or not. his is vital for
production rate you can get, and more. iberglass rods which must never be in compression
Also, in contrast to the conventional trial and error to avoid premature failures. his is also important
system design, with RODSTAR you can enter a for steel rods since excessive compression can cause
target production and ask the program to simulta- buckling failures.
neously calculate the strokes per minute, plunger RODSTAR-V can model the efect of prime
size, and rod string design. It even recommends mover speed variation and pumping unit inertia
the pumping unit size you need. Or, you can enter and can accurately calculate electricity consump-
IPR data and have RODSTAR calculate the target tion and the monthly energy bill. Because ROD-
production and design the system for that target STAR uses actual motor eiciency curves, the
production based on any pump intake pressure or results are very accurate. You can use this capabil-
luid level you want. ity to compare the energy consumption of systems
RODSTAR | 3
with diferent rod designs, plunger sizes, or pump- RSWIND.Exe he program ile for
ing unit types. RODSTAR-D. It is
the ile that your Desk-
RODSTAR’s Inlow Performance Relationship top Icon runs when you
(IPR) capabilities allow you to select the IPR double-click it.
relationship you want RODSTAR to use (Vogel or RODSTAR.CDB Contains the costs for
Fetkovich), your can enter one to ten test points, both rods and pumping
and can integrate IPR and rod pumping system units. Once you create
models to predict the maximum production rate this ile by entering rod
possible, the luid level and pump condition for a and pumping unit cost
data, you can provide
given pumping speed, or the target production for copies to other users in
any luid level or pump intake pressure you want. your company.
Because of all these features, RODSTAR has vir- CUSTOM32.PUD his ile contains the
tually no limitations and is the most advanced and measured pumping
easiest to use program of its kind. unit information you
entered in Setup. Once
you create this ile, you
can distribute copies
to other users in your
1.3 Help System company.
RODSTAR takes full advantage of Microsoft Files ending in .PUD he program’s pumping
unit database. When
Windows to bring you state-of-the-art context- updates are announced
sensitive help for any input ield by simply press- on our Website for new
ing the ! key. Also, you can search help for any pumping units that
have been added, you
other item. can download a zipped
ile that contains addi-
tional PUD iles to add
to your folder.
1.4 RODSTAR CD and Software Files beginning with Several iles are in-
demo_ cluded that are example
Sentinel cases to demonstrate
the program functions.
he RODSTAR program installation CD con- During installation,
tains many compressed iles that the installation there are copies of these
program copies to the hard disk of your computer. iles placed in the folder
Some of these are useful to know about. hese are used when opening
case iles.
located in the same folder where you elected to
install RODSTAR. he default is “C:\Program Files ending in .RST Case iles saved by
RODSTAR release
Files\heta Enterprises\RODSTAR-V” or “C:\ prior to 3.0.
Program Files\heta Enterprises\RODSTAR-D”.
Files ending in .RSVX Case iles saved by
RODSTAR-V.
Files ending in .RSDX Case iles saved by
RSWINV.Exe he program ile for RODSTAR-D.
RODSTAR-V. It is the
ile that your Desktop Files ending in .RDG Case iles saved by
Icon runs when you RODDIAG.
double-click it. Files ending in .XDG Case iles saved by
XDIAG.
4 | Introduction
2 Software Installation
Before you install the program, make sure you Rodstar is in another directory, you can specify to
have the hardware and software you need to run install over it. It will not replace any of your case
RODSTAR for Windows. iles, just the old version of the program.
he installation defaults to setting “C:\THETA”
as the common folder for your case iles. Using a
2.1 RODSTAR Installation common folder is a good idea since several of the
heta Enterprise applications that you might have
RODSTAR is installed from the heta Software can all share the same case iles.
Suite installation CD that you received. Load the
CD onto your PC and the installation program Although a new version of RODSTAR can read
should load automatically. After the “Welcome” iles created with older versions, an older version of
screen you will have three options for whether RODSTAR cannot read iles created with a new
you are using a Network or Standalone license version of the software.
and whether you have a USB Sentinel bitlock or a What happens to iles I have created with older
Parallel Port Sentinel. After selecting the proper versions of RODSTAR?
choice, the next screen will prompt you for the
Nothing. When you install or reinstall ROD-
programs to install. hat screen also has a button
STAR for Windows, only program iles are re-
that lets you display and print the detailed Installa-
placed. he latest version of RODSTAR saves iles
tion Guide for your speciic installation.
in the XML ile format but can read iles created
After installing the program, put your original CD with older versions of RODSTAR as well.
away in a safe place. If the Software Installation
What happens to the Setup Settings from previ-
Suite CD becomes damaged or lost, please call
ous versions?
heta Oilield Services, Inc. at (714)526-8878 for a
If the previous version is not very old (before the
replacement.
new setup options were developed) then your set-
tings will be preserved.
3.1 Starting RODSTAR from the File Manager, simply double click on it.
windows, move and restore icons, select text, the name of the ile currently in memory. If more
choose commands from menus, and dialog boxes, than one window is open, the title bar for each
and complete almost any other task in RODSTAR active window (the one that you are working with)
aside from typing text. is a diferent color or intensity than the other title
Following is an explanation of the parts of the bars.
RODSTAR window as shown in Figure 3.2. he menu bar lists the available menus. A menu
he control-menu box is in the upper-left corner contains a list of commands, or actions, you can
of each window. he control menu is most useful carry out with RODSTAR. For example, click on
if you use the keyboard. You can use the control the Help menu to see a list of helpful choices.
menu commands to resize, move, maximize, mini- he Minimize button reduces RODSTAR to an
mize, and close windows. Also, you can use it to icon. After you minimize RODSTAR, you can
switch to other applications. (If you use a mouse, reopen it by double clicking on the RODSTAR
you can perform these tasks by clicking and drag- icon at the bottom of your screen.
ging.) Double-clicking on the control menu box
he Maximize button causes the RODSTAR win-
closes RODSTAR.
dow to ill the entire screen. After you maximize
he title bar shows the name of the application and the RODSTAR window, the maximize button
RODSTAR | 9
shows a double box and is called the restore but- and shows the standard open ile icon used by most
ton. Clicking on the restore button re-sizes the Windows programs. Click on this button to read
RODSTAR window to the size it was before you a RODSTAR, RODDIAG, or XDIAG ile that
maximized it. was previously stored on disk.
Using the mouse you can resize RODSTAR’s Save ile - his is the third item on the toolbar and
main windows. When you resize RODSTAR’s shows a picture of a diskette. Click here to save the
window to a size smaller than required to display data in memory to disk. If this is the irst time you
all information, it will display vertical or horizon- are saving this case, RODSTAR asks for a new
tal scroll bars as necessary. You can use these scroll ile name. After you save a ile, or after you load
bars with the mouse to view unseen portions of a ile from disk and make changes to it, click on
entry windows that do not it in the allotted space. this button to quick-save the data under the same
ile name. To save it under a diferent ile name
he Close button causes RODSTAR to exit. It’s
click on File on the menu bar and then select Save
easier to click the Close button once than to select
As....
Exit from the File menu.
Setup - his is the fourth item on the toolbar.
he Status bar shows useful messages during data
Click here to see RODSTAR’s Setup window.
entry, when you load a case from disk or when you
his allows you to specify inputs and preferences
point to a toolbar icon.
that normally do not change often such as: your
he toolbar gives you quick access to menu com- company name, electricity cost, units of measure,
mands using your mouse. When you irst load standard sucker rod length, custom sucker grades,
RODSTAR, only some of the buttons on the measured pumping unit data, pumping unit and
toolbar are active. When you enter data or read a sucker rod cost, batch run options, printed report
ile from disk, then the print button and all the options, and custom summary spreadsheet formats.
buttons that correspond to input windows become
Well information - his is the ifth item on the
active. If you load a ile that contains output then
toolbar and shows a picture of a ile cabinet. Click
the report icon also activates. Otherwise, if the
here to open the well information window. When
ile contains only input then the report icon re-
you irst load RODSTAR this icon (and the next
mains inactive until you run the case. For a quick
ive icons) is inactive until you enter well informa-
reminder of what each toolbar button does, simply
tion data or until you load a ile from disk. he ile
place the mouse pointer on it. A small message box
information window contains data such as pump
called a “tool tip” appears that tells you what the
depth, run time, pump condition, tubing and cas-
toolbar icon does (see Figure 3.2). Also, the status
ing pressures, luid gravity, etc.
bar shows more information about the same tool
bar item. Production information - his is the sixth item on
the toolbar and shows a picture of a barrel. Click
Following is a more detailed explanation of each
here to open the production information window
button on the toolbar from left to right:
that has data for items such as luid level, pump
New ile - his is the irst button on the toolbar intake pressure, target production, IPR data, etc.
and shows a picture of a blank page. Click on this
button to start entering data for a new case.
Pump and tubing information - his is the seventh
Open ile - his is the second button on the toolbar
item on the toolbar and shows a picture of a down-
hole pump . Click here to see data for tubing size, screen. If this button is inactive (dimmed) it means
pump type and size, tubing anchor depth, rod-tub- that there is no output report in memory. To make
ing friction, and luid inertia efects. it active, run the case, or load a case with saved
Rod string information - his is item eight on the output.
toolbar and shows a picture of a sucker rod. Click Email Icon - Click on this icon to email one or
here to open the rod string information window. more cases to heta Oilield Services, in case you
his is where you specify what kind of rod string have questions.
you want RODSTAR to design for you. Also, you
Print - his button follows the Report button on
can enter your own rod string design, specify the
the toolbar and shows a picture of a printer. Click
service factor you want to use, etc.
it to send the output to the printer.
Deviation Survey Input - his is the ninth item on
If you have entered data for a case, but haven’t run
the toolbar and shows a picture of a deviated well-
the calculations yet, you can get a printout of your
bore. It is only available in RODSTAR-D, since
input data by itself. You get the same one-page
this is the input window for the deviation survey
output, except that only the input data appears on
of the well. Click here see the deviation survey and
the page.
also to see the 3-D plot of the wellbore.
he Print… command on the File menu allows
Pumping unit information - Click here to open
you to select exactly which parts of the output you
the pumping unit information window that has
want printed. For more information, see section
data for pumping unit type, crank rotation, stroke
3.3.4, Output Options under Setup.
length, structural unbalance and counterbalance
data. Export CBM - his item is second from last on
the toolbar and shows a picture of a crank and
Motor information - his icon shows a picture of
counterweight. his button becomes active after
a motor. Click here to open the motor information
RODSTAR runs or after you load a ile with saved
window that has data for electricity cost, power
output. Click it to place the maximum counter-
meter type, motor type and size, moments of iner-
balance moment for balanced conditions on the
tia and whether to include motor speed variation.
clipboard for use in CBALANCE for Windows.
Previous window - his icon shows an arrow
Help - his is the last item on the toolbar and
pointing to the left. Click it to go back to the pre-
shows a picture of a question mark. Click this but-
vious input window.
ton at any time to get help.
Next window - his shows an arrow pointing to
the right. Click here to advance to the next win-
dow when entering data for the irst time or when
you are changing data. 3.3 Setting up RODSTAR
Run - his item follows the arrow icon on the Click on the Setup button on the toolbar to open
toolbar and shows a picture of surface and down- RODSTAR’s Setup window. Another way to
hole dynamometer plots. Click here to run ROD- access Setup is to open the Tools menu and then
STAR after entering all your data or after you select RODSTAR Setup. his window as shown
change an input. in Figure 3.5 allows you to enter items that do
not normally change from run to run. Also,
Report - his item follows the run icon on the
Setup allows you to customize RODSTAR by
toolbar and shows a picture of a printed page.
entering your company name, default electricity
Click here to view the output in memory. his
cost, custom rod grades, measured pumping units,
allows you to view the output saved in a ile you
rod and pumping unit cost data, and a lot more.
just loaded from disk, or to return to the output
RODSTAR | 11
• IPR correlation ing limits discussed above, you can also specify the
• Motor type type of rod guides you want to use and how much
side load each rod guide can take, according to the
• Oil gravity manufacturer of the rod guide.
• Plunger size
• Pump condition 3.3.4 Output Options
• Pump eiciency RODSTAR gives you full control over what is
• Pump illage shown on the printed output. Using the Output
Options tab in Setup, shown in Figure 3.7, you
• Pump load adjustment
can select the items you want included on the
• Run time output. he options you select here are the items
• Standard steel sucker rod length printed by default when you select Print… from
the File menu, or use the Print toolbar button.
• Steel rod service factor You can choose from among the following:
• Stuing box friction ♦ Input data and calculated results.
• Tubing pressure his option prints one page showing all the input
• User name data and the results of the calculations, as well
as miniature predicted dynamometer and torque
• Water cut
plots.
• Water speciic gravity
♦ Cost analysis.
he program uses the standard steel sucker rod
his option prints both the rod string and the
length (typically 25 or 30 ft.) to calculate steel
pumping unit costs. You must already have entered
rod string section lengths that are evenly divisible
the costs into RODSTAR’s cost database (see sec-
by it. his works whenever RODSTAR designs
tion 3.3.6, “Cost Database,” on page 23 for more
the rods string (when RODSTAR calculates a
steel rod string taper
design, whether for a
steel rod string, or a
tapered steel rod sec-
tion beneath a iber-
glass.) For Corod rod
strings, RODSTAR
ignores this number.
For iberglass rods,
the program uses the
standard length of
37.5 feet.
Figure 3.6d Shows the
Defaults input win-
dow for RODSTAR-
D. Here, in addition
to the default values
and rod stress load- Figure 3.6 - Setting up default quantities for RODSTAR-V
RODSTAR | 13
RODSTAR’s pumping unit list, do the following: additional information about the pumping unit
1. Click on the “+” symbol on the left of “Pump- as shown in Figure 3.10. his is especially use-
ful for manufacturers (for example, American
ing Unit Options.” hen, click on “Custom
conventional) who have more than one unit
pumping unit list”. his opens the window
with the same designation but diferent crank
shown in Figure 3.8.
types. In such a case, the Other: ield shows
2. Drop down the manufacturer list by clicking the crank type of the unit or other information
on the down arrow next to “Manufacturer:” that helps identify the pumping unit type. his
3. Select a manufacturer you want to add to your is not the only way to customize the pump-
custom pumping unit list as shown in Fig- ing unit database. As discussed in the section
ure 3.9. If this is a new manufacturer for the dealing with the pumping unit information
custom list, all available pumping units will screen, you can also select a unit you want to
appear in the window on the right side of the add to the customized unit list by irst selecting
screen. it from the full database and then selecting to
use the custom pumping unit list. At that point
4. You can select the units to include in the cus- RODSTAR will ask you if you want to add
tom pumping unit list using drag and drop. To this unit to the custom pumping unit database.
add a unit from the list of available units to the If you do, then select Yes.
custom database list, you simply drag (click on
it with the mouse and hold the left mouse but- 6. After you are done customizing the pumping
ton while moving it) the units you want from unit list, click on OK.
the list on the right to the custom list on the ♦ Measured Pumping Unit List
left. Or, you can click on a unit once to select
Here you can enter data for pumping units that are
it, and then click on the <<Add button (in the
not in RODSTAR’s main database. If you have the
middle of the screen). he program automati-
dimensions you need for these units you can enter
cally arranges the units in the proper order
them here to make them a permanent part of your
(largest stroke length and largest gearbox size
RODSTAR software. To enter dimensions for a
irst).
pumping unit, do the following:
5. To remove a unit from
the customized list,
simply drag it from
the list on the left, and
drop it in the list to
the right. Or, you can
click on a unit once
and then click the Re-
move>> button (in the
middle of the screen).
To make sure you se-
lect the correct pump-
ing unit, highlight it
(click on it once with
the mouse) and the
Name: and Other:
ields on the bottom of
the screen will show Figure 3.7 - Selecting output options
RODSTAR | 15
1. Click on “Measured
Pumping Unit List”.
2. Click on the “+”
symbol (on the left of
the pencil symbol).
his will open the
window shown in
Figure 3.11.
3. Enter the data in
this window starting
with the pumping
unit manufacturer
name.
4. Enter the pumping Figure 3.8 - Customizing the pumping unit database
unit data for your
pumping unit. that is not in the program’s database, do the fol-
5. When you are done entering data click on lowing:
“OK”. 1. From the setup window, click on “Custom
If you need help with one of the items you have to Rod Grades.”
enter, press ! to get context sensitive help on that 2. To add a new rod grade, click on the “+” button
(to the left of the pencil icon). his opens up a
item. For example, if you press ! when you are
new window where you can enter the name of
in one of the pumping unit dimension input ields,
the rod you want to add, the tensile strength,
the program will show you an outline drawing of
and the stress analysis method you want ROD-
the pumping unit with a visual explanation of the
STAR to use for this rod as shown in Figure
pumping unit dimensions (see Figure 3.12). To get
3.13.
more information on any of the dimensions you
see, simply click on it with the mouse. For exam- 3. You can also specify that this is a sinker bar
ple, you can click on the
“P” box to see detailed
help on the P dimen-
sion. Also, you can click
on the “See Also” hot
button to get help for
any other pumping unit
related item.
by clicking on the
“Sinker bar” option
at the lower left
hand corner of this
window.
4. Enter the rest of the
information for the
rod you want to add
and then click on
the “OK” button.
RODSTAR allows
you to select any of the
available stress analysis
methods. Once you
enter a special rod Figure 3.10 - Customizing the pumping unit database
grade to the program,
it becomes part of the unit manufacturer. As shown in Figure 3.15, after
program’s equipment database and it works exactly you select the manufacturer, RODSTAR dis-
the same way as RODSTAR’s built-in rod grades. plays a mini-spreadsheet that you can use to enter
pumping unit costs. To enter the cost for a pump-
For example, once you enter a special rod grade, ing unit, click on the cell to the right of the pump-
you can enter cost information for it, and you can ing unit and enter the cost.
select it from the same rod grade menu that ROD-
STAR uses for the built-in rod grades. When you are done entering pumping unit costs
for the pumping units you want, click on OK. Or,
he modify (Pencil Icon) and delete (“X” Icon) if you want to enter rod string cost data, Select
options allow you to change or erase custom rod “Rod string costs” and then select the rod type
grades you have already entered. and rod grade. RODSTAR will display a mini-
4 Running RODSTAR
To start RODSTAR, double click on its icon. programs have a menu bar with drop-down menus
After a few seconds you will see RODSTAR’s and a control menu box at the top left corner. You
introductory window and then the RODSTAR can access all menu items using either the mouse or
main window. When RODSTAR irst loads, only the keyboard. Using the mouse is by far the easiest
the new ile, open ile, setup, and help buttons are way.
active on the toolbar. If you have not set up ROD-
When selecting an item from a menu, visual clues
STAR then do so before entering a new case (see
tell you what will happen next.
Chapter 1 for information on setting up ROD-
STAR). ♦ An item followed by no markings starts an
action. (For example, click on File and then click
on New.
♦ An item followed by an ellipsis (...) needs
4.1 RODSTAR’s User Interface more information before taking action; normally,
RODSTAR has a user-friendly interface that the additional information is entered into a dia-
simpliies and speeds up data entry. he program log box. (For example, click on File and click on
uses standard Windows features along with other Open…)
unique features we designed to make entering and
changing data as easy as possible. Figure 4.1 shows
how to access the most recently saved iles and
select the ile you want to load into RODSTAR. An easy way to load iles you recently saved:
If you are not familiar with Microsoft Windows, RODSTAR has a most-recently-used ile list on
please take some time to study your Windows the File menu, as shown in Figure 4.1. Selecting
manual. Teaching you how
to use Windows is beyond
the scope of this manual
(although many Windows
procedures are explained).
By taking the time to un-
derstand and learn how to
use Windows, you will be
able to efectively use not
only RODSTAR, but any
other Windows program.
RODSTAR’s interface
has most of the elements
that are common to all
Windows programs. For
Figure 4.1 - he most recently saved d ile list
example, all Windows
22 | Running RODSTAR
the Recent Files sub-menu will show you up to diagram, press “P” and then click on Permissible
nine of the most recently accessed iles. A ile is load diagram.
placed at the top of the list whenever it is loaded, RODSTAR has context sensitive help for each
or saved with a new name. his list can also be ac-
cessed by clicking on the drop-down button on the input item. To access the help, simply press !
toolbar to the right of the open ile icon. while in the input ield in question.
with the calculated pump intake pressure. RODSTAR to simulate. For example, if you
want to simulate water in the casing-tub-
he Production Information window also gives
ing annulus instead of oil, then enter an API
you the option of having RODSTAR calculate the
gravity of 10 (which corresponds to a luid
required pumping speed based on a target produc-
speciic gravity of 1.0).
tion you enter. However, the option of calculat-
ing the SPM from your target production is
only available if you select a full pump. For luid
Percent water cut
pound or gas interference, you must enter a pump-
ing speed in the Production Information window. he percent water cut input along with oil API
gravity allows RODSTAR to calculate a default
speciic gravity for the produced luid. Also, it uses
this data to calculate $/bbl (or $/m3) electricity
Other input data in the Well Information window: costs.
Comment
You can enter a comment about the case. You can Oil API gravity
type up to 100 characters in the comment ield.
he comment string you enter is included on the RODSTAR uses the oil API gravity to calculate
screen and printed outputs. luid load on the plunger and the default speciic
gravity of the produced luid. Also, as discussed
above, RODSTAR uses this number to calculate
Pump Load Adjustment (RODSTAR-V Only) the speciic gravity of the luid in the casing-tubing
annulus which it assumes to be 100% oil.
he pump load adjustment allows you to increase
the luid load picked up by the plunger. Usually
this is unnecessary. However, this input allows you Fluid speciic gravity
to account for extra downhole loads due to exces-
sive downhole friction (for example due to wellbore RODSTAR uses the oil API gravity and per-
deviation), or due to the “plunger efect” of large cent water cut you entered to calculate the default
sinker bars. It is recommended that you use zero speciic gravity of the produced luid. he program
for this number unless you have more than 1000 will display this value when it prompts you to enter
feet of large sinker bars such as 15/8’’ or 1¾’’ bars the luid speciic gravity. RODSTAR calculates
in 2’’ tubing. he value of this number in pounds the default speciic gravity without considering free
is typically 5% to 10% of the pump depth in feet. gas. his is okay for designing new wells since we
For example, for a pump depth of 6000 feet, enter prefer to be more conservative. However, if you
a value of 300 to 600 pounds (but only if you use want to simulate an existing system that produces
more than 1000’ of large sinker bars). RODSTAR gas, you must enter a lower number than the one
will not allow you to enter a value that is larger calculated by RODSTAR. With some experience
than 15% of pump depth. Also, you can use this and with “history-matching” between predicted
input to add pump load for more conservative and actual dynamometer cards you can come up
predictions. with efective speciic gravities that will accurately
model your rod pumping systems. If you use a
Please note that RODSTAR assumes that the speciic gravity that only considers liquids, it will
tubing-casing annulus is full of oil. It calcu- result in higher predicted loads, power consump-
lates the speciic gravity of the oil from the API tion, etc.
gravity you enter. If you do not agree with this
assumption then change the oil API gravity If you are designing a new system and you are not
to correspond to the speciic gravity you want sure what the speciic gravity is, use the higher
RODSTAR | 25
value you expect to have to make sure that your and bubble point pressure. Also, you can enter
system will not be overloaded when in operation. from one to 10 test points. If you select to use the
However, when matching measured dynamometer Vogel method for the oil IPR calculations then
cards, use a speciic gravity that is as close as pos- you only need one point. If you use Vogel and enter
sible to the actual value. more than one point, then only the irst point is
After you inish entering data for the Well Infor- used. You can enter more than one test point if you
mation window click on the next screen button use the Fetkovich method. he pressure that cor-
(right arrow) on the toolbar to open the Production responds to each production test point can either
Information input window. To move back to the be pump intake pressure or lowing bottomhole
previous window, simply press the left arrow icon pressure (in the middle of the perfs). To add a new
on the toolbar. pair of Pi and Fluid production data, click on the
add button (top right) icon. To delete a set of data
Remember that pressing @ converts to the op- points, click on the remove icon (bottom right).
posite system of units. For example, if you selected
English units but want to enter the pump depth You can get help for any input item by pressing !
when in the input ield or by clicking on the ques-
in feet, press @ before entering the value. If the tion mark icon on the toolbar.
value for any ield with units has already been
If you do not know what the bubble point pres-
entered, pressing @ will show it in the opposite sure is, but you know the well is producing below
units. the bubble point pressure, then leave the bubble
point pressure ield blank and click on “Producing
below bubble point” or in the check box next to
4.2.2 Entering Production Information it. After you enter the last piece of IPR data, click
he Production Information input window allows to a diferent input ield, press T or click on the
you to enter a luid level or pump intake pres- “Update prod.” button to allow RODSTAR to
sure as shown in Figure 4.4. Also, you can select calculate the maximum oil, water, and luid pro-
to enter a pumping speed,
enter a target production
(the program will calculate
the pumping speed to get
the target production), or
you can select to calculate
the target production from
inlow performance data.
If you choose to enter IPR
data, the Production In-
formation window expands
to reveal the data you must
enter. his includes the cor-
relation you want to use for
the inlow performance re-
lationship (IPR), the depth
from surface to the middle
of the perforations, the
static bottom hole pressure, Figure 4.4 - he Production Information input window
26 | Running RODSTAR
for deviated wells when the deviation is close to the molded rod guides.
the bottom of the wellbore. Rod guide manufacturers need to provide you with
3. For deviated wells with the deviation close friction ratio values for the diferent rod guides
to the surface you may need to enter a larger they make.
number such as 4-6 times as high as the values
calculated by the program. Also, it may be
appropriate to use diferent values for upstroke Buoyancy efects
and downstroke frictions to better match your
downhole conditions. he option to include buoyancy efects should
be left unchecked in most cases. his is because
he above comments refer to RODSTAR-V. buoyancy does not cause buckling of the rod string.
RODSTAR-D can calculate the efect of deviation However, for iberglass-steel rod strings, after the
(such as side load) from the deviation survey. design is inalized, It is recommended that an ad-
ditional run be made including buoyancy efects to
ensure that the iberglass portion of the rod string
RODSTAR-D Friction Coeicients is not in compression. If it is in compression, then
more sinker bars must be used, the pumping speed
In RODSTAR-D, the upstroke and downstroke
need to be reduced, or both.
rod-luid damping coeicients on the pump and
tubing information window are only for luid When buoyancy is not included, the bottom of
damping on rods. RODSTAR-D also allows you each rod section except the last section should have
to enter rod-tubing friction (drag) coeicients for a positive stress. Otherwise the rods may be going
each rod string section in the rod string input win- into buckling. It is normal for the very bottom of
dow. he default bare rod rod-tubing drag friction the rod string to be in compression if you enter a
coeicient is 0.2. he range for this value is from pump friction that is not zero (a minimum pump
0.1 (for oil lubrication between smooth rods and friction of 200 lbs is recommended).
tubing) to 0.3 (for high water cut wells and rough For more information on the theory behind these
rod and tubing surfaces). Again, the best way to recommendations, please read SPE paper number
determine what to use is by plotting a measured 25416 “Interpretation of Calculated Forces on
dynamometer card on the same plot as the pre- Sucker Rods” by J. F. Lea and P. D. Pattillo. Pre-
dicted dynamometer card and changing the values sented at the Production Operations Symposium
of the rod-tubing friction coeicients for each sec- in Oklahoma City, March 1993.
tion of the rod string. You can do this by loading a
RODDIAG or XDIAG ile into RODSTAR.
To simulate the efect of rod guides, you need to Fluid inertia efects
adjust the friction coeicients for each section
of the rod string. You can use the ratio of guide If the well depth is less than 4250 feet and the
friction to bare rod friction to adjust the default pump plunger size is larger than 2.00 inches,
friction coeicient. For example, the friction ratio RODSTAR allows you to consider luid inertia
default value for molded rod guides is 1.5. his efects. hese dynamic efects become important
means that if you use molded rod guides, you need in wells with plungers larger than 2.0” and pump
to increase the rod-tubing friction coeicient by depths of 4000 feet or less. However, there is no
50% to accurately simulate the additional rod- exact “magic” depth for which luid inertia be-
tubing drag. So, if you use molded rod guides, comes important. herefore, RODSTAR allows
you need to enter a friction coeicient of 0.3 you to include these efects for wells up to 4250
(0.2*1.5=0.3) for the section of the rod string with feet deep and with a plunger size equal to or larger
than 2.0”. Another important factor is luid com-
RODSTAR | 29
rod grade or type. For example, you can have iberglass section (for two or more rod sections) so
RODSTAR design a Corod rod string for semi that there is equal stress loading at the top of each
elliptical “Ultra” Corods using a maximum diam- section as shown in Figure 4.11.
eter of 17/16”, a minimum diameter of 13/16”, and his Figure shows a iberglass-steel rod string
a 375’ section of 1 5/8’’ sinker bars on the bot- designed with RODSTAR-V. RODSTAR-V can
tom. RODSTAR uses only the rod sizes it needs. design tapered steel rod strings under the iber-
For example, if the loads are not high enough to glass section for any type of steel rod, including
require the use of the 17/16” rod diameter then non-API high strength rods, and Corods. If you
RODSTAR will go to the next size (16/16”). If want to ine-tune a RODSTAR design, select to
this is still too big, it will use the 15/16”. enter your own rod string design by clicking on
he maximum rod loading used by RODSTAR the manual rod string entry icon. RODSTAR will
to decide when the next larger diameter rods show you the current rod string design in memory
are needed is 95% by default. However, you can as if you entered it yourself. hen, you can make
change this number if you like by going to the any changes you want to the rod string without
Setup “Defaults” window. having to reenter everything.
Also, you can have RODSTAR design the rod
string while calculating the pumping speed and
Fiberglass/steel RODSTAR design plunger size, to get the target production. How-
If you select the option to have RODSTAR-V de- ever, because of the complexity of the calculations,
sign a iberglass-and-steel rod string, you will see simultaneous use of all or most of RODSTAR’s
the data input screen in Figure 4.10. For example, “smart” options will result in longer run times.
let us say you want to use a design with iberglass his is especially true if you also select to include
rods on top followed by a tapered steel section with the efect of prime mover speed variation. Also,
1” and 7/8” rods, and then 375 feet of 1” sinker depending on the case, RODSTAR’s run time may
bars. RODSTAR is able to design this rod string be longer if you enter a target production that is
for you. Also, it balances the steel design under the too large for the pumping system.
If you select only sinker bars on the bottom (with- tapered steel section under the iberglass, and a
out regular steel rods between the iberglass and 500 foot 1.5 inch sinker bar section on the bottom.
sinker bar) then RODSTAR will calculate the RODSTAR will determine the iberglass diameter
length of the sinker bar section for you. If you and length you need, and the steel rod section and
select both sinker bars and a tapered steel design tapers you need. If RODSTAR cannot balance the
between the sinker bars and the iberglass rods, steel rod string design because the 3/4’’ section is
then you must enter the length of the sinker bar (or not needed, it will not use any 3/4” rods.
sinker rod) section. RODSTAR will determine the Another interesting capability of RODSTAR is
length and diameters of the tapered steel portion that if you use continuous rods (Corod or Prorod)
Entering Your Own (Manual) Rod String can be up to 50 feet shorter than the pump depth.
However, it cannot be longer than the pump
his option is primarily used for entering rod
depth. For example, if the pump depth is 5000
string data for an existing system you want to
feet, you can enter a rod string that is between
simulate, or to modify a design that RODSTAR
4950 and 5000 feet. When entering rod string
itself came up with (when you select to have the
data for the irst time, RODSTAR shows a default
program design the rod string for you). his is
length for the last rod section equal to the difer-
not a good option to use when you irst design a
ence between the pump depth and the rod string
new system because it requires the most work and
length you entered so far.
experience.
Selecting the option to enter your own rod string
When you select this option, you can enter data for
gives you maximum lexibility. However, it re-
either steel or iberglass rods as Figure 4.12 shows.
quires the most expertise to come up with a good
You can enter the number of rod sections, the ser-
rod string design. You can use this option to select
vice factor you want to use, and rod string data for
diferent rod grade or manufacturer for each rod
up to eight rod sections. For each section, you can
section. In general, this option allows you to enter
select the rod type or grade, diameter, and length.
any rod string design, no matter how unusual. he
For Fiberlex iberglass rods you can also specify
minimum length you can enter for any rod section
the sucker rod length.
is 25’ (length of a single sucker rod).
If you select one of the iberglass manufacturers
When entering the rod string data manually,
listed on the drop down list next to the rod grade
RODSTAR allows you to add and remove rod sec-
input ield, the program knows the weight per
tions from anywhere in the rod string, instead of
foot and modulus of elasticity and will not prompt
only at the bottom. he window has icons on the
you for them. he program warns you about rods
left side for inserting a rod section, for removing
that do not it in the tubing. Also, it warns you if
a rod section, or for moving a section up or down.
the rod string length is shorter or longer than the
For example, if you want to remove a rod section,
pump depth. he total length of the rod string
irst click on it and then click on the Delete Rod
RODSTAR | 33
Step 1 prompts you to select the ile to be imported Selecting a pumping unit manufacturer
as shown in Figure 4.18.
RODSTAR allows you to easily select a pumping
Step 2 allows you to select the Workbook and unit manufacturer and unit size with drop-down
Spreadsheet to use in cases where there are more list boxes. To display the menu with all pumping
than one in the Excel ile as shown in Figure 4.19. unit types available, click on the drop arrow next
Step 3 automatically locates the columns in the to the “Manufacturer” ield (see Figure 4.24).
spreadsheet where the values are stored for the his is a scrollable list of all units in the program’s
Measured Depth, Inclination, and Azimuth as database in alphabetical order. You can go to the
shown in Figure 4.20.
he next step loads the data and then inishes as
top of the list by pressing}. You can jump to
shown in Figure 4.21. the bottom of the list by pressing ~. You can
Click “Done” and view the imported deviation also move up or down by pressing O (Page up)
survey data as shown in Figure 4.22.
or N (Page Down). A convenient way to move
Please keep in mind that for program to be able to through the list is to press the irst letter of the
load the deviation data from an Excel spreadsheet, unit name you want to use. For example, to locate
it must see three columns with the deviation data. the National “E” Series pumping unit entry, you
hese columns need to be labeled as follows:
can press n and the highlight bar will jump to
“Measured Depth (ft)” or “MD (ft)”, or “MD (m)”
the irst name in the list that starts with N. hen
“Inclination” simply click on the National “E” Series entry. At
“Azimuth” the top of the list of pumping unit manufactur-
ers is the item (Measured pumping units). his
Clicking the “Plot Survey” tab on the right side
of the window will display the Deviation Plot as option allows you to select a unit for which you
shown in Figure 4.23. From this screen, you can entered geometric data in Setup.
rotate the plot to better understand and visualize
the wellbore deviation, you can zoom in, etc. When you select the (Measured pumping units)
option, RODSTAR will display a list that only
shows the measured pumping units, as Figure 4.25
shows.
4.2.6 Entering Pumping Unit Data
As Figures 4.24 and 4.25 show, there is a check
he pumping unit input screen allows you to select
box that allows you to use the custom pumping
a pumping unit from the database that comes with
unit list instead of the main pumping unit list. If
RODSTAR, or from your measured pumping unit
you check this option, before you select a unit,
database (if you entered your own pumping unit
the Manufacturer list will show a shorter list that
dimensions in Setup).
contains only the manufacturers you selected in
Another option is to enter a pumping unit ID. Setup in your custom unit list as shown in Figure
he pumping unit ID is a unique string of letters 4.26. When the “Use custom pumping unit list”
and numbers. RODSTAR displays the pumping option is checked, when you select a pumping unit,
unit ID along with other unit information after you will see a short list containing only the unit
you select a unit. If you make a note of this unit sizes you selected for your customized list for this
ID (in the well ile for example), you can use it manufacturer.
to specify the pumping unit instead of having to After you select a manufacturer you can use the
select it from the list. his is a unique ID for each same procedure to select the unit size you want
pumping unit in the program’s database. from the pumping unit drop-down list box . You
RODSTAR | 39
can move through this list the same way as with How to add units to the custom pumping unit list
the pumping unit manufacturer selection menu.
You can use the “Use custom pumping unit list”
he pumping units on this menu are ordered from
check box to add units from the main list to your
largest to smallest stroke length, gearbox size, and
custom list. For example, if you run across a pump-
structure size. However, if the window shows the
ing unit that is not in your custom list yet, clear
pumping unit name (for old units) the units are
the “Use custom pumping unit list” check box so
listed alphabetically.
that you can use the general pumping unit list.
When you enter a unit, the Unit ID, the program
After you select the pumping unit then click on
automatically displays the unit that the ID cor-
the “Use custom pumping unit list” check box.
responds to. RODSTAR displays the information
RODSTAR asks if you want to add this pumping
necessary for you to correctly identify your unit.
unit to the custom pumping unit database. Select
For example, for American conventional units you
Yes to add this unit to your custom list. he pro-
will see that certain unit sizes appear more than
gram will add this unit to the custom list and also
once on the selection list. However, they have dif-
switches to the custom list.
ferent cranks.
his option only allows you to add units to your
custom list without having to do it from Setup. To
remove units from your custom list or to add more
40 | Running RODSTAR
than one unit, go to the setup window and cus- TIP: If your unit is not listed in RODSTAR
tomize the list of units as described earlier in this and you do not have the unit dimensions, then
manual. use a unit that is closest to it. As long as you use
the same unit geometry and a unit with the same
stroke length and gearbox rating, the results should
Selecting to enter a pumping unit ID be close to actual as long as the pumping unit is
he unit ID option is the fastest way to enter the same unit type as the one you selected.
pumping unit information if you already know If after you enter a pumping unit ID RODSTAR
the pumping unit ID for your unit. You can see displays “he pumping ID you entered is not valid”
the pumping unit ID on the pumping unit entry this means that ID you entered is not recognized
window after you select a unit. Once you locate by RODSTAR. his can happen for two reasons:
your unit, you can make a note of its ID in the well
1) You entered the wrong ID such as R0 (which
ile. hen, the next time you want to use this unit,
does not exist), or CL901 instead of CL91.
you can select to enter its ID. For example, for a
Lufkin Mark II M-456-305-144, the unit ID is 2) You have erased the pumping unit ile by acci-
ML32. dent, or the pumping unit iles are not in the same
directory as the program.
To identify some units correctly, it is necessary
to know the crank number since they may have RODSTAR Recommended unit size
the same API designation but diferent geometric If you enter a target production instead of pump-
dimensions depending on crank number (primarily ing speed, RODSTAR will display a recommended
units made by American International Manufac- pumping unit size to help you select a pumping unit.
turing Company). his recommendation can be very helpful if you are
RODSTAR | 41
designing a new pumping system and must decide another one. he recommended unit size is a push
what size unit you need. RODSTAR recom- button, as shown in Figure 4.27. So, whenever you
mends sizes that are closest to conventional units want to return to the pumping unit size recom-
as Figure 4.27 shows. herefore, if you plan to use mended by RODSTAR, just click the button and
uncommon unit geometries such as the Rotalex, RODSTAR will automatically select the unit size
then this recommendation may not be as useful. that is closest to the recommended size.
RODSTAR makes this recommendation with- In general, the size recommended by RODSTAR
out running through the predictive calculations. will be close to the minimum required conventional
herefore, it may not necessarily recommend the unit. RODSTAR recommends only the API unit
best pumping unit size for your application. How- size. You must decide what manufacturer and
ever, in most cases it should be pretty close to the unit type to use. If you select a conventional unit
size you need. and RODSTAR predicts that the gearbox will
here are other important factors that you must be overloaded, then try using the same size Mark
consider when deciding what unit size you need. II or enhanced geometry unit. In some cases you
hese include: available used pumping units, ex- may be able to use a smaller unit by selecting a
pected changes in well conditions, desired pump- geometry that is better suited for your application.
ing speed, etc. When you enter data for a case here are several factors that determine what unit
for the irst time and you are at the pumping unit is best. hey include, cost, gearbox loading, system
selection screen, RODSTAR will not only display eiciency, rod compression, minimum polished rod
the recommended unit size, but will automatically load (indicates separation of the polished rod from
select the unit closest to the recommended size the carrier bar if close to zero), etc.
from the available list. If you do not want to use
the unit recommended by RODSTAR then select
42 | Running RODSTAR
Selecting crank hole number and crank rotation Entering your own pumping unit data
After you select a pumping unit you must select If the pumping unit you want to simulate is not
the crank hole number, and the direction of rota- in RODSTAR’s database, you can enter your own
tion with the well to the right (if you are using a pumping unit dimensions. To enter the data in the
unit that can rotate either way). For units with a program you have to irst access the setup screen
required direction of rotation, like the Mark II , of RODSTAR (click on fourth button on toolbar).
Torqmaster, Lufkin Reverse Mark, or American hen, double-click on “Pumping Unit Options”
Producer II, the program will not allow you to tab and select “Measured Pumping Unit List” as
change crank rotation. For units that can rotate explained in section 3.3.5 in this manual. hen,
either clockwise or counterclockwise, RODSTAR select to add a new unit to enter data for a new
defaults to the direction of rotation that will usu- pumping unit.
ally give the lowest torque. However, this default he data you must enter consists of geometric
direction of rotation may not always be ideal for dimensions as deined in the API 11E publication.
your system design. To ind out for sure which You can get these dimensions from the pumping
rotation is best for your system you must make unit manufacturer or measure them yourself. Or,
two runs: one with clockwise crank rotation and you may be able to ind most of the dimensions
one counterclockwise. hen look at the efect of you need from catalogs or blue prints. For old units
rotation on gearbox torque, system eiciency, rod without an API designation on their nameplate,
loading, etc. you may be able to put together an equivalent API
designation. Look at the gearbox nameplate for the
gearbox rating in thousands of in-lbs. Measure the
RODSTAR | 43
stroke length, and try to decipher additional infor- 11E deines the above dimensions as follows:
mation from the unit’s nameplate for the structure
rating, stroke length, and structural unbalance.
If the nameplate is legible then write down the Dimension: Description:
unit’s serial number or order number. If the unit’s R Radius of the crank (inches)
manufacturer is still in business, you may be able A Distance from the centerline of the
to get the data you need from the serial number saddle bearing to the centerline of
or order number. For help in locating dimensional the polished rod (inches)
data for pumping units not in the manual call C Distance from the centerline of the
heta Oilield Services, Inc.. saddle bearing to the centerline of
the polished rod (inches)
RODSTAR allows you to enter data for Conven-
tional, Mark II, Air Balanced, Enhanced Geom- I Horizontal distance from the
centerline of the saddle bearing to
etry, or Long Stroke units. When you enter your the centerline of the crankshaft
own pumping unit dimensions, RODSTAR cal- (inches)
culates and displays the stroke length based on the P Efective length of the pitman
dimensions you enter. For all pumping unit types arm, in inches (from the center of
you must irst enter the name of the manufacturer, the equalizer bearing to the center
the unit name or model number, the gearbox rating of the crank-pin bearing)
in thousands of inch pounds, the structure rating K Distance from the center of the
in hundreds of pounds, and the maximum stroke crankshaft to the center of the
length in inches. From these numbers RODSTAR saddle bearing (inches). Some-
times, instead of the K dimen-
puts together the API pumping unit designation. sion, pumping unit manufacturers
he API pumping unit designation is a standard supply data for dimensions H and
way of describing the size and capacity of pumping G instead (described below). From
units as the following example explains: these dimensions and dimension I
(deined above) you can calculate
he irst number is the gearbox rating in thousand
inch-pounds. In this example the gearbox rating is )2 2
Air Balanced Pumping Unit Data Long Stroke Pumping Unit Data
For these units you must also enter pumping unit For these units you must enter the sprocket diam-
dimensions R, A, C, I, P, and K in inches. In ad- eter (D), the centerline distance between the top
dition, you need data for M, S and V0. and bottom sprockets (distance C), the pitman arm
length (P) if one exists (usually this is zero), and
he API spec. 11E deines the above dimensions the top drum diameter ratio (usually equal to 1).
as follows: You can see a diagram of the dimensional data you
Dimension: Description: need by pressing F1 in any input ield, or you can
R Radius of the crank (inches) take a look at Figure 4.28.
A Distance from the center of the You can also use this pumping unit model to sim-
Sampson Post bearing to the cen- ulate any non-beam pumping unit with a long,
terline of the polished rod (inches) slow stroke. You can do this by entering data that
C Distance from the centerline of will produce the same stroke length as the unit you
the Sampson Post bearing to the want to model. he stroke length of a long stroke
center of the equalizer bearing unit is given by:
(inches)
Stroke = C + D
For example, to simulate a hydraulic pumping unit
RODSTAR | 45
from the walking beam to balance a beam bal- motor performance and eiciency data for NEMA
anced unit. D, Sargent Ultra High Slip, Reliance Ultra High
Slip motors, and Rotalex Multi-HP NEMA
C motors. If you select a NEMA D motor you
4.2.7 Entering Motor Information and Energy Cost can enter a motor size, or you can choose to have
RODSTAR recommend a NEMA D motor for
RODSTAR can simulate NEMA D or ultra high you. If you select an ultra high slip motor then you
slip motors and calculates power consumption must select the motor size and torque mode. If you
from actual motor eiciency curves. he program select a motor size or mode that is too small for
uses the electricity cost you enter to predict the the well conditions then RODSTAR will display
monthly electricity bill, $/bbl luid, and $/bbl oil a warning message and will give you the option to
(based on water cut). RODSTAR defaults to the change your data.
cost number you specify in Setup. he $ symbol
here is meant to represent currency (not just US RODSTAR warns you if you select an ultra-high-
dollars). As Figure 4.31 shows, under the electric- slip motor when you have selected an air-balanced
ity cost input box there are option buttons that you or long stroke pumping unit. hese units have little
can use to select the power meter type. You have or no rotating moment of inertia, so using an ultra-
two options: Detent, or Non-detent. A Detent high-slip motor does not result in any signiicant
KWH meter can rotate only in one direction. A diferences in the calculations. herefore, for these
ratchet prevents it from turning the other way. units, do not select an ultra high slip motor or to
herefore, if your unit is generating electricity, you include speed variation efects.
do not get credit for it. he non-detent meter can If you select a NEMA D motor type for a new
rotate either way and so it credits you for electricity case, or switch from an ultra-high-slip motor to
the pumping unit generates. a NEMA D motor, RODSTAR automatically
selects the option to recommend the motor size.
Prime mover type selection
Using drop-down list boxes you can select the Motor speed variation
motor type you want to simulate. RODSTAR has he option to include the efect of motor speed
variation is only available for conventional, en- of a body is a measure of its resistance to accelera-
hanced geometry, and Mark II units. Inertia ef- tion. In other words, the higher the moment of
fects are negligible for long stroke and air balanced inertia of a body, the more diicult it is to quickly
units. speed it up or slow it down.
If you select not to include speed variation efects he rotating and articulating moments of inertia
then RODSTAR assumes constant prime mover are important in accurately simulating the behavior
speed and will not model the efect of pumping or the pumping unit and in calculating net gearbox
unit inertia. If you choose to include speed varia- torque when you use a high speed variation prime
tion then RODSTAR gives you the option to enter mover. he rotating moment of inertia that ROD-
a percent speed variation or have the program STAR needs is the total rotating moment of iner-
calculate the speed variation for your prime mover. tia. his includes the individual rotating moments
of inertia of the cranks and counterweights about
the slow speed shaft of the pumping unit, the total
Pumping unit moments of inertia gear reducer inertia, and the motor rotor inertia.
If you select to include the efect of motor speed he articulating moment of inertia of the pumping
variation then you can enter a rotating moment unit around the saddle bearing includes the inertia
of inertia in lbs-ft2, or have the program estimate of the walking beam, horsehead, and pitman arms.
this number for you. For the articulating moment As mentioned above, you can either enter a rotat-
of inertia RODSTAR defaults to a number that ing moment of inertia, or you can have ROD-
is either the actual articulating moment of inertia STAR estimate it for you. To calculate accurately
supplied by the pumping unit manufacturer, or the rotating moment of inertia you must have
an estimate based on unit size. herefore, unless moment of inertia data for the cranks and coun-
you have an even more accurate number for the terweights, gearbox, motor rotor, etc. Also, the
articulating moment of inertia, it is recommended rotating moment of inertia depends on the position
that you use the default number displayed by the of the counterweights on the cranks. Since this
program. data may not be known, it is recommended that
For more accurate results, have RODSTAR cal- you let RODSTAR estimate the rotating moment
culate the prime mover speed variation. However, of inertia for you.
you can also enter a speed variation value if de- Since the articulating moment of inertia depends
sired. If you select to enter speed variation, ROD- on the walking beam size, horsehead and pitman
STAR shows a default value of 8% which corre- arms, it is a ixed number for any given pumping
sponds to a recommended average speed variation unit. herefore, it is easier to calculate than the
for NEMA D motors. You can get more conser- rotating moment of inertia. RODSTAR’s pump-
vative results by entering a speed variation that is ing unit data base contains accurate articulating
less than the maximum expected speed variation moment of inertia values that were either obtained
for your prime mover. Selecting to include prime from unit manufacturers, or were estimated based
mover speed variation will approximately double on unit size. he articulating moment of inertia
RODSTAR’s run time. from the pumping unit database appears as the
default number when the program prompts you for
the articulating moment of inertia.
What is moment of inertia?
Including speed variation and moments of inertia
Although this manual is not intended to teach will usually result in lower predicted peak gearbox
engineering or physics, it is important to briely torque, lower peak polished rod load, and higher
explain moment of inertia and how it can afect minimum polished rod load. his is because a
RODSTAR’s results. he mass moment of inertia
RODSTAR | 49
5.1 Visual Input then choosing Save As... his brings up a stan-
dard Windows dialog box that allows you to save
Figure 5.1 shows RODSTAR’s “visual” input facil- your ile with the ile name you want. RODSTAR
ity that makes it easy to locate a system parameter shows the default ile name it creates from the well
you want to change. As you are entering the data name and by adding an “.RSVX” ile name exten-
for a new case, or after you have loaded a case from sion for RODSTAR-V or “.RSDX” for ROD-
disk, the visual input window can be displayed by STAR-D. If you enter data for a case in ROD-
clicking on the Visual Input button on the toolbar.
his shows an interactive picture of the pumping
system.
As you move your mouse over the picture of the
system, tool tips appear naming various parts of
the system. Whenever a tool tip is showing, you
can right-click with the mouse to get a pop-up
menu listing input variables associated with that
part of the system. his visual way of changing
data is more useful when you are changing data
in existing iles or when you are making “what
if...” runs. If you are entering a case from scratch,
menu items that correspond to data you haven’t yet
entered will be disabled.
Left-clicking when a tool tip is displayed opens the
data entry window associated with the part of the
system you clicked on. Another way to change data
is to click on the “Alphabetical list…” button at
the bottom of the visual input window. his brings
ups an alphabetical listing of all variables you can
change. You can locate the variable you want to
change by scrolling down using the mouse.
STAR-D but do not enter deviation survey data, output then you can view and print the output
the program will save the ile with an extension of without having to rerun the case.
“.RSVX” instead of “.RSDX”. You can change the
ile name by typing over it, but you cannot change
the ile name extension. When you type your own
ile name, you do not have to type the ile name 5.3 Running and Viewing the
extension. RODSTAR automatically adds this
extension for you. Output
You do not have to store your data every time After you enter all your data and you press the
you make a change. It is recommended that you Next Screen button from the motor information
save the original data and then wait until you get window, the Run button on the toolbar becomes
a good design before storing data to disk. After active. To run the program simply click on the
saving data once, RODSTAR makes it very easy Run button on the toolbar (the dynamometer card
to update the ile with the data in memory with a icon to the right of the right arrow icon). Another
single mouse click on the Quick Save button on way to run the program is to click on Run on the
the toolbar. menu bar. After RODSTAR runs, it displays the
output report, as Figure 5.2 shows. At the bottom
If you save your data after running RODSTAR of this screen there are buttons that allow you to
and the output is displayed on screen, then ROD- view the dynamometer, torque, or IPR plots and
STAR saves both the input and output in the ile. the report. When you select to see the dynamom-
his is advantageous because once you save the
To look at diferent parts of the output you can RODSTAR can calculate two possible ways to
click the appropriate buttons at the bottom of the balance a unit: for minimum torque, or for mini-
screen (Dynamometer, Torque, IPR Plot, Dev. mum energy consumption.
Plots when using RODSTAR-D, or Report). he most common way to balance a unit is for
When you click on Report, you can scroll up or minimum torque. However, if the gearbox is not
down with the mouse, or you can click and drag on overloaded, you may want to balance the unit for
the report itself. Figure 5.3 shows the bottom sec- minimum energy consumption instead.
tion of the summary report. he summary report
After viewing the output you can decide which
looks exactly the same as the printed report.
value of balanced counterbalance moment you
If you have CBALANCE for Windows on your want to export to CBALANCE (so that CBAL-
computer, you can have RODSTAR export the ANCE can calculate the counterweight positions
balanced maximum counterbalance moment it required to balance the unit). When you click on
calculates to CBALANCE. You can do this any the Export CBM... button RODSTAR displays
time the calculations have been run (whether or the window shown in Figure 5.4 (if there are two
not you are actually viewing them) by clicking on possible ways to balance the unit). Click on the op-
tion you want and click on the OK button. ROD-
54 | Changing, Loading and Saving Data
You can use RODSTAR to quickly design any rod ful features help you design rod pumping systems
pumping system, compare pumping units, sucker faster than ever before. Also, because RODSTAR
rod designs, insert versus tubing pumps, clockwise uses state-of-the-art design algorithms, it is very
versus counterclockwise crank rotation, include accurate and reliable.
IPR modeling in your predictions, etc. ROD-
Because RODSTAR can predict energy consump-
STAR can calculate the pumping speed, pump
tion very accurately, you can use it to select the
plunger size, and rod string design for you. Also,
most economic system designs. he following
it can recommend motor size and pumping unit
sections explain how to apply RODSTAR to solve
size based on your target production. hese power-
common design problems. As you become more
eter card from a RODDIAG or XDIAG ile (if and gearbox loading, look at the torque analy-
you selected that option), and the permissible load sis section of the printout. he permissible load
diagram. RODSTAR uses a permissible load diagram corresponds to existing conditions if you
diagram that shows if the gearbox or structure entered a counterbalance moment. If you did not
of the pumping unit are overloaded or if the enter an existing max. CB moment then the pro-
minimum polished rod load is negative. his gram shows a permissible load diagram for bal-
is diferent than the traditional permissible load anced condition (for minimizing gearbox torque).
diagram that only shows whether the gearbox is Note!: he above discussion about ROD-
overloaded. his extended permissible load dia- STAR’s permissible load diagram refers to
gram can be made up of curved lines only, combi- beam pumping units. he permissible load dia-
nation of curved and straight lines, or straight lines gram for long stroke units such as the Rotalex
only. If the upstroke part of the predicted surface will have straight line segments that corre-
dynamometer card exceeds the curved line of the spond to gearbox loading or structure loading.
permissible load diagram this indicates that the Please look at the structure loading number
gearbox is overloaded at that point. If the dyna- on the irst page of the output and the percent
mometer card cuts into the straight line section of gearbox loading under torque analysis for the
the permissible load diagram on the upstroke, this exact percent unit loading.
indicates that the structure of the pumping unit is
overloaded because the polished rod load is larger In addition to showing whether the gearbox is
than the structure rating of the unit. overloaded, the permissible load diagram also
shows how well the pumping unit matches the
For the exact numbers of peak net gearbox torque load requirements of your system. If the predicted
polished rod dynamometer card its nicely in the match between the dynamometer card and permis-
permissible load envelope, this indicates a good sible load diagram.
agreement between the pumping unit and the rest Including prime mover speed variation and inertia
of the system. efects will alter the shape of the permissible load
However, if the predicted surface dynamometer diagram. he lines will be smoother if you do not
card shows a trend that is opposite that of the include prime mover speed variation. If you in-
permissible load diagram, this shows that design clude speed variation the permissible load diagram
changes are necessary to avoid overloading the will tend to relect changes in polished rod load.
pumping unit and to better match it to the rest of his is because the permissible load diagram in
the system. If the permissible load has a trend that RODSTAR includes the efect of rotating and ar-
is opposite than the predicted dynamometer card, ticulating moments of inertia. As the prime mover
it may indicate that the pumping unit you selected speed changes, this causes changes in polished rod
is not the best geometry for this application. Or, velocity and acceleration which in turn changes the
that you may have to change the spm, plunger size, polished rod load and the distance between the dy-
rod string design, or stroke length to get a better namometer card and the permissible load diagram.
he output window has new buttons that allow 6.1.3 IPR Plot
you to animate the calculated dynamometer cards.
When you click on the “IPR Plot” button, ROD-
Figure 6.2 shows a “play” button (the one with the
STAR displays separate oil, water, and luid pro-
double arrow) which causes small dots to move
duction versus lowing bottomhole pressure plots
around the surface and downhole dynamometer
as Figure 6.4 shows. Also, it shows a line with the
cards; a “stop” button which makes the movement
current bottom hole pressure and the test points
stop; and a “step” button (the one with the single
you entered. he line below the title of the plot
arrow) which lets you move the dots one time-step
shows the correlation you selected to use for the
at a time, while holding the button down moves
oil IPR and if you selected the Fetkovich method,
the dots in slow motion. his facility can be used
it shows the value of n. If you only enter one test
to get a better understanding of rod stretch efects
point, n is set to one. If you enter two or more test
and other phenomena such as the position and
points then RODSTAR calculates the value of n
speed of the pump plunger and how this relates to
by doing a log-log plot. For water, RODSTAR
the surface dynamometer card.
uses a straight line IPR.
From this screen you can look at any other part of
the output by clicking the appropriate option at
the bottom of the screen. For example, to view the 6.1.4 Report
torque plots click on Torque. Also, you can select
to view the report on screen, or you can send the To see the report, click on the “Report” button.
output to the printer. After you are done viewing You can scroll this window using the mouse by
the output, close the screen by clicking on Close. clicking or the up or down arrows at the top or
bottom of the range bar on the right edge of the
window.
6.1.2 Torque Plot Or, you can click and drag the range bar or the
report itself with the mouse.
When you click on the “Torque Plot” button
RODSTAR displays the net gearbox torque plots
for existing and balanced conditions. If you entered Input and Output Summary
an existing maximum counterbalance moment,
then you may see a plot with up to three curves: he summary report that appears when you irst
one for existing conditions, one for balanced con- run RODSTAR shows input data on the left side
ditions for minimum torque, and one for minimum of the page and calculated numbers on the right
energy consumption. If there is no diference be- size. he top part of the printout shows the com-
tween the curve for minimum torque and the one pany name, well name, user name, date of the run,
for minimum energy, then the program shows only and comment. Following is a detailed explanation
two curves (existing and balanced). If you selected of each item on the output.
“unknown” max. CB moment then RODSTAR
will only show one curve if there is little diference
between balanced for min. torque vs balanced for Polished Rod Loads and Horsepower
minimum energy consumption (see Figure 6.3). he peak and minimum polished rod loads show
Otherwise, it will show two balanced curves: one the polished rod load luctuation predicted by
for minimizing torque and one for minimizing RODSTAR. he polished rod horsepower shows
energy consumption. how much work the pumping system is putting
into the rod string to lift the predicted production
from the present luid level to the surface.
If you entered a target production or used IPR data
64 | Rod Pump System Design
For low Fo/Skr numbers (below 0.25) iberglass- Pumping Unit Data
steel rod strings will have very low system eicien- his section (see Figure 6.5) shows the pumping
cies and should be avoided. For iberglass rods try unit you selected, the pumping unit ID, the calcu-
to keep Fo/Skr above 0.3 and below .8 for best lated stroke length, the structural unbalance, the
results. Also for iberglass rod strings, you should crank ofset angle, crank rotation with the well
keep N/No’ below 1.0 and above .4 for best results. to the right, and the crank hole number. If you
entered your own pumping unit dimensions for a
unit not in the program’s database, if the calculated
Prime Mover Speed Variation
stroke length is diferent from what you think it
If you select to have RODSTAR calculate the mo- should be, check the pumping unit data to make
tor speed variation for you then this section shows sure you entered the right dimensions. If you se-
what this number is. For NEMA D motors this lected to include speed variation and inertia efects
number will vary from 2% to 14% depending on in the calculations, RODSTAR will also print the
motor size. For correctly sized ultra high slip mo- rotating and articulating moments of inertia.
tors it can be as high as 50%. If motor speed varia-
tion is not considered then this will be indicated
on the output report. Torque Analysis and Electricity Consumption
In this section, the program prints the predicted
peak gearbox torque, percent gearbox loading,
cyclic load factor, maximum counterbalance mo- To maximize gearbox life you must keep gearbox
ment, and counterbalance efect. Also, it calculates loading less than 100%. he cyclic load factor
electricity consumption. RODSTAR predicts the indicates how smooth the gearbox torque is. he
KWH consumed per day, the estimated monthly smaller this number is, the more uniform the net
bill, and cost per barrel of luid and per barrel of gearbox torque is. Also, a smaller cyclic load factor
oil per day. Use the cost per barrel numbers when will result in higher system eiciency because of
comparing system performance to ensure a valid less thermal losses in the motor.
comparison. his is because a system that shows
a lower monthly bill may also be producing less
luid. Tubing, and Pump Information
If you enter a non-zero maximum counterbalance Here you see the tubing inside and outside di-
moment the program calculates the above num- ameters, the anchor depth, the calculated tubing
bers for both existing and balanced conditions. If stretch, the upstroke and downstroke rod-tubing
the existing max. CB is unknown, it will calculate friction factors you entered or that were calculated
the above numbers for balanced conditions only. by RODSTAR, pump load adjustment., etc. Also,
RODSTAR has the capability to balance pumping this section shows the pump depth, the pump
units for minimum torque and minimum energy. If type, and plunger size.
the maximum counterbalance moment for mini- RODSTAR uses the pump volumetric eiciency
mum energy equals the one for minimum torque you enter to calculate the expected production rate.
then the program shows only one recommendation When you ask the program to calculate the spm
for balanced conditions. However, if the two values by entering a target production, it will calculate a
are more than 2% diferent then it shows two bal- larger spm if you enter 80% pump eiciency than
anced columns: One for minimum torque, and one when you enter 90% pump eiciency.
for minimum energy. he torque plots show how
net gearbox torque changes throughout the pump-
ing cycle for existing and balanced conditions.
Tubing, Pump and Plunger Calculations any other rod section other than the sinker bar sec-
tion on the bottom of the rod string.
his section shows tubing stretch and production
loss due to tubing stretch, gross pump stroke, the If you are using iberglass rods you would not want
pump spacing recommendation, minimum re- to use a design with a negative bottom minimum
quired pump length, and recommended plunger stress on the iberglass section even with buoyancy
length. he pump spacing recommendation should efects included. Compressive loading will cause
be used as follows: iberglass rods to part. Also, to maximize rod
life, stress loading must be less than 100% in all
After working on the well and before you
cases. For sinker bars, RODSTAR calculates stress
are ready to restart the pumping unit, make
loading, top maximum and top minimum stresses
sure the tubing is full of luid. hen lower the
based on the elevator neck or pin undercut diam-
rod string slowly until it tags bottom. hen
eter of the sinker bars. However, RODSTAR still
raise the rod string a distance equal to the one
uses the full body diameter in the calculation of
recommended by RODSTAR next to: “Pump
stress at the bottom of the sinker bar section.
spacing (in. from bottom): ” hen, attach the
polished rod to the bridle with the unit stopped
at the very bottom of the downstroke. Rod String and Pumping Unit Cost Analysis
Please note that the working luid level makes a his section shows the cost of each rod section as
big diference in pump spacing and pump length. well as the total rod string cost (see Figure 6.6).
his is especially true for iberglass rods since the Also, below the rod string cost is the pumping
plunger travel is strongly dependent on luid load unit cost. RODSTAR shows the cost information
on the plunger. only if you select this option in Setup. You must
irst enter rod string and pumping unit cost data in
Setup before RODSTAR can show you accurate
Rod String Design and Stress Analysis
cost information here.
his section shows the rod string design and ser-
vice factor you selected, the calculated percent rod
loading for each rod section, the maximum and Inlow Performance Relationship Information
minimum stresses at the top, and the bottom min- his section shows the correlation used for oil
imum stress for each rod section. To ensure your IPR, mid-perf depth, the static bottomhole pres-
rods are in tension, do not include buoyancy efects sure, and the bubble point pressure (if entered) or
(this should always be the case for steel rods). whether the well is producing below the bubble
hen, make sure there are no negative stresses on
68 | Rod Pump System Design
point pressure. Also, it shows a table of input test 6.2.1 Deviation Plots
point data of lowing bottomhole pressure versus
measured production, and a table of pressure vs. After RODSTAR-D runs, it will display the
production table. As Figure 6.7 shows, this table summary output page as shown in Figure 6.8.
shows separate oil, water, and luid production When you click on the “Dev. Plot” button on
rates for diferent pump intake pressures. the bottom. It will display the irst deviation
related plot as shown in Figure 6.9. his plot
shows side load as a function of measured depth.
All deviation plots show colored lines that
6.2 RODSTAR-D Output correspond to diferent sections of the rod string.
he calculated side load afects is used by the
In addition to the output quantities discussed
program to determine the number of rod guides
above, RODSTAR-D calculates and prints num-
and their spacing, using rod guide manufacturer
bers and plots that are related to wellbore devia-
recommendations. Click on the “Next” button
tion. Following is an explanation of these outputs
on the bottom of this plot to see the rest of the
that are unique to RODSTAR-D.
deviation-related plots.
he next plot is the maximum and minimum axial
28.9 feet long. As these examples show, the only them in tension.
way to be sure the rods will not buckle is to keep he Dogleg severity in degrees per 100 feet, rep-
stroke length, using a smaller pump, or by install- To minimize energy consumption and stress load-
ing a percentage timer or pump of controller. ing, use the largest plunger diameter and slow-
Because RODSTAR can simulate luid pound, est pumping speed combination possible without
you can use it to see what will happen if the well overloading the rod string and pumping unit. If
pumps of. you have to make a choice between stress loading
and power consumption, opt for lower stress load-
6.3.1 Shallow, High Rate Well Simulation ing especially if you are close to 100% since rod
RODSTAR can simulate any pumping unit geom- breaks are more costly than a slightly lower system
etry and gives accurate results for any pump depth eiciency.
or production rate. his is especially signiicant Note that these are only general guidelines. Eco-
for shallow well applications because conventional nomics and local ield conditions may require a
design computer programs such as the API RP diferent design philosophy than the one described
11L and other wave equation programs give poor above. Regardless of your objectives and design
results. his is because at shallow depths, polished philosophy, with RODSTAR you can design rod
rod load is increasingly dependent on the dynamic pumping systems faster and more accurately than
efects of luid in the tubing. his is especially with any other computer program.
true for high production rate shallow wells (pump
depth less than 4000 feet with larger than 2.00”
plunger). 6.3.3 Avoiding Rod Compression
To accurately simulate these wells, RODSTAR uses RODSTAR calculates rod stresses at the top and
two wave equation models simultaneously, one for the bottom of each rod section. It calculates the maxi-
rod string and one for the luid in the tubing. his mum and minimum stress at the top of each rod
unique capability allows very accurate predictions. section in order to calculate the percent stress load-
RODSTAR can predict the expected surface and ing. It also calculates the minimum stress at the
downhole dynamometer card shapes common to bottom of each rod section. he bottom minimum
shallow, high rate wells. When designing shal- stress shows if the rods are in compression.
low high rate wells it is recommended that you
use pump eiciencies of 90%-95% to avoid un- Steel rods can tolerate some compressive force but
der-predicting peak polished rod load, torque, etc. iberglass rods cannot tolerate any compression
his higher pump eiciency will result in higher at all. his is why iberglass rods must have steel
luid velocity in the tubing and higher luid iner- rods or sinker bars at the bottom. he weight of
tia forces on the plunger. However, when you are the sinker bars overcomes the opposing hydrostatic
trying to “history match” an existing system, you force and pump friction. If correctly designed, the
may need to use a pump eiciency of less than 90% sinker bars or steel rods ensure that the iberglass
to better match the actual pump slippage of your rods are always in tension.
system. Although steel rods can be subjected to some com-
pression without adverse efects, excessive negative
stresses can cause buckling problems. he recom-
6.3.2 Selecting the Target Production mended way to use RODSTAR to determine if
To avoid severely over-sizing the displacement your rods may be subjected to compression is to
capacity of your pumping system, design it with a run the program without including buoyancy
pump eiciency of 80%-85% or even 75% if you efects. hen, add sinker bars or sinker rods to
expect the downhole pump to wear out quickly. overcome the negative stresses at the bottom
his ensures that you will get your production section of the rod string (above the sinker bar
without grossly over-designing the system. section) . Other ways of minimizing buckling
RODSTAR | 73
problems include using smaller pumping speeds 6.3.6 Using RODSTAR for Correct Equipment Sizing
and avoiding use of small diameter rods such as
When designing a new rod pump system you must
5/8” or even ¾”.
ensure that the system you select has suicient ca-
6.3.4 Minimizing Power Consumption pacity to produce the well under the heaviest loads
possible during its operating life. For most systems
In general, the slower the pumping speed and the this will occur when the luid level is at the pump.
larger the pump plunger size, the less energy the herefore, even if you do not expect the luid level
pumping system will use. However, minimizing to be at the pump, it is a good idea to design the
energy consumption must not be the sole purpose pumping system (especially when using steel rods)
of system design because a large pump plunger for luid level at the pump. his ensures that the
diameter will result in large polished rod load and equipment you plan to use will not be overloaded if
gearbox torque. his will require the purchase of a the luid level drops in the future.
larger unit, larger rods and bigger prime mover. To
come up with the best pumping system design you For systems with iberglass-steel rod strings, you
must consider the economics of the whole system may get higher gearbox torque loads and higher
and whether you plan to use existing equipment or polished rod horsepower when the luid level is
buy new ones. above the pump. his occurs because iberglass rods
are very sensitive to luid load. When the luid
RODSTAR’s power and ease of use allows you level is above the pump, the luid load on the pump
to get the most economic pumping system based is reduced. his causes a longer pump stroke which
on your economic criteria. Because RODSTAR in turn afects the shape of the surface dynamome-
calculates the predicted energy consumption, rod ter card making it fatter. his in many cases brings
sizes, rod loading, and recommends a pumping the predicted surface dynamometer card closer to
unit size, it provides you with the data you need for the permissible load diagram causing the gearbox
sound economic decisions. load to increase. Also, when the area of the surface
dynamometer card increases, the system requires
a larger motor size. his means that when you use
6.3.5 Reducing Gearbox Torque iberglass rods you should run system simulations
Sometimes, using the largest unit stroke may not using diferent luid levels (within the expected
be the best way to maximize production since it luid level range) to see which luid level results in
can result in severe gearbox overload. If this oc- the highest loads and largest required motor size.
curs you may be able to use the next smaller unit Using diferent luid levels also afects the calculat-
stroke and speed up the unit to get your produc- ed pump stroke length and therefore the required
tion without overloading the gearbox. Another way pump length and pump spacing . RODSTAR can
of reducing gearbox loading is by using a smaller recommend a NEMA D motor size based on the
pump plunger. Another way is to use a lighter rod luid level or pump intake pressure you enter.
string by using either high strength steel or iber-
TIP: You can speed up your system design consid-
glass rods.
erably by asking RODSTAR to design a rod string
Also, you can reduce gearbox torque with an ultra for you. Even if you do not plan to use the design
high slip motor. RODSTAR-V can predict the RODSTAR recommends, it is easy to “grab”
gearbox torque depending on the pumping unit RODSTAR’s recommended design and modify
size and ultra high slip motor size. Also, ROD- it. To do this, after the program runs, go to the
STAR-V can calculate the motor speed variation rod string entry screen and select the “Manual rod
and power consumption very accurately. string entry” option. he program will default to
the rod string it calculated, and it will display this
74 | Well Information
data as if you had entered it yourself. So, you can ain, scale, etc.), the measured dynamometer card
simply change only the data you want to modify. will be fatter than normal. he theoretical polished
Please keep in mind that RODSTAR expects the rod dynamometer card predicted by RODSTAR
length of the rod string you enter to be within 50 (for average friction calculated by the program)
feet of the pump depth. However, it cannot be will be smaller than the measured dynamometer
longer than the pump depth. card. By entering a larger rod-tubing friction coef-
icient you can get a better match between actual
and predicted dynamometer cards. his technique
6.3.7 Using RODSTAR for Diagnostic Analysis helps you igure out what rod-tubing friction factor
to use for better simulation of your rod pumping
Although RODSTAR is primarily a design tool it wells.
can be a very powerful diagnostic aid, when used
in conjunction with RODDIAG or XDIAG. his Rod-tubing friction is especially important
is due to the powerful overlay feature that allows for iberglass rods. Higher friction than
direct comparison of predicted versus measured normal may actually reduce the area of the
dynamometer cards. predicted surface dynamometer card because
it causes the rods to stretch which results in a
Using RODSTAR’s Dynamometer Overlay Feature small stroke at the pump.
his feature has many diferent uses. For example, RODSTAR-D allows you to change the rod-tub-
it can help you igure out if your load cell is out ing damping coeicients for upstroke and down-
of calibration, if the luid level you measured was stroke and also the friction coeicient between
incorrect, etc. RODSTAR can help you ind these rods and tubing for each section in the rod string.
problems by comparing the shape and load range his allows you to better simulate use of diferent
of the measured dynamometer card versus the one rod guides, or more exactly match the correct fric-
predicted by the program. Also, it can help verify tion between rods and tubing for a better match
downhole problems such as a worn pump, leaking with the measured dynamometer card.
traveling or standing valves, deep rod parts, stuck
pump etc. You can simulate a worn out pump or a
deep rod part by entering a luid level of zero feet 6.3.8 Using RODSTAR-D for better Wellbore Designs
from surface. his will result in zero luid load on
the pump plunger. RODSTAR-D can be a very useful tool in helping
you optimize the wellbore trajectory of your
RODSTAR cannot simulate a traveling valve leak, deviated wells to minimize side loads, rod-tubing
a hole in the pump barrel, or a sticking pump. wear and buckling, and to reduce lifting costs by
But, it can predict what the dynamometer card improving system eiciency.
should look like if there were no problems. hen,
by comparing the actual dynamometer card shape he optimum wellbore path will be diferent for
with the theoretical shape, you can have more each well, but by using RODSTAR-D you can
conidence in your diagnosis of the problem. For determine which is the best wellbore trajectory
example, if you have a traveling or standing valve by trial and error. Normally, wellbores that avoid
leak or a worn out pump, then the pump will be sharp turns and abrupt builds to the deviated sec-
doing less work and the surface dynamometer card tion will produce better results.
will have less area than the theoretical polished rod With careful planning and wellbore path control,
dynamometer card. deviated well design can be improved with ROD-
If the pump is sticking, or if there is more friction STAR-D.
than normal between rods and tubing (due to par-
heta Oilield Services, INC., 1901 E. Lambert Rd. Suite 108 La Habra, CA 90631 USA
Telephone #: (562) 694-3297, Fax #: (562) 694-8641 www.gotheta.com