SPE-189231-MS

Performance Evaluations of the Different Sucker Rod Artificial Lift Systems

M. Kennedy Dave and M. Ghareeb Mustafa, SSI Lift

Copyright 2017, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Symposium: Production Enhancement and Cost Optimisation held in Kuala Lumpur, Malaysia, 7-8 November 2017.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
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Abstract
The majority of oil wells operated throughout the world requires some form of artificial lift during their life
cycle. Wells lifted by reciprocating sucker rod pumping systems represent almost more than 70 % of the
total artificially lifted oil wells worldwide.
As consequence of previous and current global crisis, the pressure on the operators is to maximizing
production and net profit out in a very safe and environmentally controlled manner. The primary challenge
is to select the suitable system capable to achieve these goals over the life cycle of the well. For years,
operators have been looking for reliable, flexible and intelligent lifting systems to improve their operating
costs, reservoir recovery factor by maximizing well production and filed safety.
There are several sucker rod-pumping systems applied all over the world. Each has its different
advantages and disadvantage. Selecting the right system technology requires detailed analysis, including
well, fluids, reservoir and location.
This study will present detailed comparisons between the different systems in the area of production,
depth, downhole failures, power saving, safety related to system operations. The comparison will be between
the conventional beam, enhanced geometry beam, linear vertical mechanical Long Stroke pumping units
and long stroke Wellhead Mounted Hydraulic pumping units systems. This study was undertaken using
advanced predictive methods. The results compared with actual field applications from Canada, USA, Latin
America and Middle East. The latest technology in sucker rod pumping systems regarding the system’s
capabilities as production, depth, optimization, power consumption and control considered in this study.

Introduction
Artificial lift is need in wells when there is insufficient energy (depleted and/or naturally flowing wells)
in the reservoir to lift the desired production rate of the well fluids to the surface with wellhead pressure
capable to displace the produced fluid to the production facilities.
Generally, this is achieve by the use of a device inside the wellbore and/or by decreasing the weight of
the hydrostatic fluid column by injecting gas into the liquid some distance down the wellbore.
There are several types of artificial Lift systems using to move the production fluids to the surface.
○ Reciprocating Sucker Rod Pumping (SRP)
2 SPE-189231-MS

○ Electric Submersible Pumps (ESP)

○ Progressive Cavity Pumps (PCP)
○ Gas Lift (GL)
○ Plunger Lift (PL)
○ Hydraulic jet pumps (JP)
The earliest documented reciprocating walking beam artificial lift system described in the Egyptian
historical writing dated 476 AD2 and called Shadof as shown in Figure 1. It was limited to lift low volume
of water from shallow depth.

Figure 1—First beam unit system (Shadof)

With the time, the new discover oil reservoirs (oil fields) became harder in production as fluid type,
production rate, reservoir pressures, well depth, hole characterizations …etc. This push the manufactures
to present and develop different forms of surface and subsurface equipment in order to produce these
reservoirs.
The mechanism introduced to oil industries was not different in principle than Shadof. It is name Beam
Pumping units (pump jacks or surface pumping units). Different geometries and configurations introduced
as shown by Figures (2a) and (2b). The beam unit is used to stroke the bottom hole pump up and down. This
is accomplished by converting rotary motion to reciprocating vertical motion. Rotary power is supplied to
a gear reduce by a prime mover. The gear reducer uses a series of gears to convert the high-speed power
supplied by the prime mover to low speed power. (Usually a ratio of approximately 30 to 1 on a double
reduction unit). The gear reducer turns the cranks and the cranks lift the pitman arms up and down (rotary
to reciprocating). The pitman arms move the walking beam up and down consequently the horses head on
the opposite end of the walking beam has to go up and down. This action causes the bridle cable to move
the carrier bar up and down which in turn moves the sucker rod string up and down and consequently the
traveling valve that connect to plunger.
SPE-189231-MS 3

Figure 2a—Conventional Beam Pumping Units

Figure 2b—Enhanced Geometry Beam Pumping Units

These traditional beam pumps has not seen much evolution or change in over 100 years. These type of
pumping units are limited in the capabilities to produce high fluid volume and improve the well performance
in difficult wells (wellbore and/or fluids). Some of these challenges are:

• The mechanical wear between rod and tubing especially in deviated and/or crooked holes which
present a friction problem
• Inefficient pumping in gassy wells

• Depth limited, primarily because of rods and surface unit capabilities.

• Obtrusive in urban locations.

• Safety hazards. Pumping units have large and heavy rotating parts.

To overcome some of these challenges the manufactured introduced in the late 1980s a mechanical long-
stroke pumping unit (Figure 3). It offered many advantages over traditional beam pumping units. This
vertical mechanical system is lacking of the flexibility of changing stroke lengths where it is limited to three
of four choices.
4 SPE-189231-MS

Figure 3—mechanical long-stroke pumping unit

Today’s due to the level of the oil prices, well operators require more control on well operation and
economics than the beams and mechanical long stroke units can do. To address this, industry has introduced
intelligent hydraulic skid mounted long stroke pumping units Figure 4. They offer fully flexible longer
stroke lengths which allowing operators to make the same or more fluid with less number of strokes. This
result in less wear and tear on the sucker rods, tubing and the bottom-hole pump. Reduced wear will reduced
the frequent well interventions, and increase mean time between failures (MTBF). This will lead to increase
well production and reducing lifting cost and safety hazard. In addition, this new type of hydraulics units
are able to overcome the rod fall (carrier bar separation) issues.

Figure 4—Long Stroke Hydraulic skid mounted unit

Systems Evaluation for Well Depth and Production Capabilities

Many factors must be consider when evaluate the performance of the applied lift system for a particular
well. One of the main evaluation criteria is the range of depth and production rate where particular lift types
can function.
The ability of a sucker rod pumping system to produce a fluid is constrained by (1) the stroke length,
(2) the plunger diameter of the bottom-hole pump, (3) the strength of the sucker rods, (4) unit capacity and
SPE-189231-MS 5

geometry and (5) the rod free fall from a given well. For any given pumping unit the critical pump speed
is controlled by two main variables, (1) stroke length, and (2) the well forces, such as friction, buoyancy,
etc., that retard rod fall (Byrd, 1968).
Several field studies and simulations done to predict the behavior of the rod lift system to produce a
practicality high volumes production. The majority of these studies ignored rod buckling tendency and
almost most of them when studied the system capabilities as production and depth not considered the effect
of wells and fluids problems. It will be cover in this study.
A simulation study made by using one of program using for sucker rod pumping system design (SROD)
to compare the performance of four of common using long stroke surface pumping units (conventional
beam enhanced geometry beam, mechanical long stroke and hydraulic skid mounted long). This study done
by consider three different cases for well depths and productions. Table 1 presented the criteria used in the
designs.

Table 1—Criteria used in the design.

Depth 5000 8000 11000

Production 1000 700 300

Pump intake Pressure psi 100

Surface wellhead Pressure psi 200

Tubing Size inch, 3.5

Water Cut % 50

Oil Gravity API 30

Water Gravity 1.05

A number of general assumptions were applied in making these simulations. In all cases the wells
considered vertical and tubing was anchored, thus no tubing stretch. The output results of the simulation for
the three cases are shown in Tables 2, 3 and 4 for three depths 5000 ft, 8000 ft and 11,000 ft respectively.
Analyses of the three tables indicates that as stroke length increases, the required pumping speed SPM
(stroke per minutes) to produce the same volume of fluid decreased. This lead to decrease PPRL (peak
polished rod load) while MPRL (minimum polished rod load) increases due to dynamic effects. This
will increase the well performance and reduces well intervention due to decreasing buckling tendencies,
decreasing side & drag loads, decreasing rod loading and decreasing the load range (PPRL – MPRL). Fewer
cycles mean less rods, tubing, and pump wear will be seen Lower losses of stroke as a percentage of the
total stroke, making the system more efficient.

Table 2—simulation results for well producing 1000 BFPD form 5000 ft.

C 1280 D-365-192 M 912 D-365-192 RF 1150 - 500 - 366 SSI 350-372

Power Required (hp) 73.47 72.61 54.82 55.87

Surface Max Load (lbs) 29454 29680 27422 27308

Surface Min Load (lbs) 4826 2668 7627 7801

Average Pumping Speed (SPM) 7.65 7.73 3.41 3.4

Polished Rod Horse Power (hp) 44.85 45.78 42.41 43.22

Computed Surface Stroke (in) 193.3 192.3 366.1 372

In-balance Max Torque (m in-lbs) 1204.3 966.9 161.6 NA

Pump Diameter (in) 2.75

6 SPE-189231-MS

C 1280 D-365-192 M 912 D-365-192 RF 1150 - 500 - 366 SSI 350-372

Net Pump Stroke, inches 147.6 146.7 332.7 339.3

Net bpd at 100% pump eff 1000

Rod Loading % 76 80 65 64

Service Factor 0.9

Rod Type UHS

Rod String 86

Table 3—simulation results for well producing 700 BFPD form 8000 ft.

C 1280 D-365-192 M 912 D-365-192 RF 1150 - 500 - 366 SSI 350-0372

Power Required (hp) 95.77 91.13 62.11 63.50

Surface Max Load (lbs) 37831 37533 35762 34644

Surface Min Load (lbs) 8165 7304 12766 10326

Average Pumping Speed (SPM) 8.5 8.71 3.63 3.57

Polished Rod Horse Power (hp) 53.04 53.06 48.26 49.34

Computed Surface Stroke (in) 193.3 192.3 366.1 372

In-balance Max Torque (m in-lbs) 1313 1116.1 183.9

Pump Diameter (in) 2.25

Net Pump Stroke, inches 139.6 135.9 327.8 329.4

Net bpd at 100% pump eff 700

Rod Loading % 99 99 85 85

Service Factor 0.9

Rod Type UHS

Rod String 86

Table 4—simulation results for well producing 300 BFPD form 11000 ft.

C 1280 D-365-192 M 912 D-365-192 RF 1150 - 500 - 366 SSI 350-0372

Power Required (hp) 72.44 64.06 45.15 45.58

Surface Max Load (lbs) 35772 37273 35848 34806

Surface Min Load (lbs) 14388 14613 17047 16121

Average Pumping Speed (SPM) 7.29 7.45 3.42 3.34

Polished Rod Horse Power (hp) 34.95 35.92 32.61 32.92

Computed Surface Stroke (in) 193.3 192.3 366.1 372

In-balance Max Torque (m in-lbs) 1010.9 789.4 147.3

Pump Diameter (in) 1.5

Net Pump Stroke, inches 157.4 154 334.8 340.3

Net bpd at 100% pump eff 300

Rod Loading % 82 88 78 75

Service Factor 0.9

Rod Type UHS

Rod String 86
SPE-189231-MS 7

Systems Evaluation by Operation Modes and Related Downhole Failures

Sucker rod operation modes are usually designed based on well production and well & fluids conditions.
Three main parameters are mainly controlled well production rate and well performance. These parameters
are subsurface pump, stroke length and pumping speed. The stroke length and pumping speed are generated
by the surface pumping unit. Therefore selecting the right surface pumping unit can have great impact in
the system performance and controlling the equipment failures frequency. For a particular production rate
and set of well conditions there are many combinations of stroke lengths, strokes per minute and plunger
diameter.
Most failures associated with the reciprocating sucker rod pumped wells can be attributed to one
of downhole components (subsurface pump, sucker rod string, tubing string…etc.). Failure of these
components will required servicing rig to pull and change out one or more of these parts. The rate of
the failure frequency (Numbers of component failures/ well, per year) will have direct impact in the well
performance and economics. Effectively manage the failures rate to generate the highest revenue possible
will required carefully select the most efficient running parameters in order to reduce well failure frequency
rate.
Using the simulation data presented by tables 2, 3 and 4, the type of the surface unit and its operational
modes are cleared in its effect in the equipment running lives and system performance for the following
common problems:

• Rod buckling: It is one of the main problem in rod-pumped wells especially deviated well. It
happens during the downstroke. The rod buckles and contact against tubing. It cause tubing ware
and leaks. It can also cause rod parts. The main reasons for rod buckling are:

◦ Downhole friction, especially in a deviated well due to larger drag friction.

◦ Pumping speed. Increasing pumping speed especially in the downstroke can cause rod
compression due to the rod dynamic. Tension force becomes a compression at free end of
pump. It happens both in vertical and deviated wells. Pump-off condition and /or under-balance
condition may also aggravate buckling. Some unit geometry may also aggravate buckling
tendency at fluid pound condition.
◦ Most cases of rod buckling happens at any combination of above.

Comparing the performance of Beam, Hydraulic Skid mounted long stroke and mechanical long
stroke units along with their features and controller capabilities in running wells with rod buckling
problems, indicated that the longer the stroke the better the performance in handling this type of
wells. This is mainly due to several reasons. The longer stroke especially ultra-long stroke length
units allow to use a smaller subsurface pump size to handle the same production. Use smaller pump
will reduce the fluid loads consequently reduce the side/drag loads between rods and tubing. Long
stroke with smaller pump size and slow speed will reduce the dynamic caused rod buckling and
peak polished rod load. The buckling tendency overcome to high degree when using hydraulic units
with the integrated intelligent control system. Adjustable accelerations and decelerations at the top
and the bottom of the stroke combined with variable speed control on the up and down stroke.
• Fluid Pound: As experienced in a pumping oil well, fluid pound is one of the most common
operational problems. It is caused when the subsurface pump not completely filled with liquid on
the upstroke. As the downstroke begins, the entire fluid and rod string load moves down through a
void until the plunger hits the fluid level in the pump barrel which transmits a shock wave through
the pumping system (Figure 5). This shock wave causes damages entire parts of the pumping
system. This problem occurs when the downhole pump operated at a rate exceeds the production
rate of the formation. It is usually the main cause of fatigue failures of the surface pumping unit
8 SPE-189231-MS

(structure, gear teeth, bearings and unit base), rod string. It accelerate subsurface pump components
(valves, valve rod and barrel) failures. Also fluid pound accelerates wear of the tubing due to rod
buckling.
Performance evaluation of the different surface pumping units in running wells suffered from
pounding fluids done based on the units concept of operation and its flexibility in adapting the
unit’s running parameters (speeds and stroke length). Followings are the main observations:
• Conventional and enhanced geometry beam units which have fixed speed for up and downstrokes,
the performance were found to be very low and the reported failure rates were very high. Initially
the operators improve the situation by used well timers and pump off controllers. The use of timers
or pump off controllers lead in some wells to reduce the well production. This is because in the
period of down time, the well production will decrease with increasing the fluid level (well will
be under build-up condition). Also, since it is primarily used as an on/off type control, the system
will transfer from static to dynamic several time per hours. This will accelerate the motor, surface
unit, rods failures. The situations was notices worst in the cases when using the enhanced geometry
units. This is because this units featured with faster downstroke speed compared with the upstroke.
The fasted down stroke increase the shock wave what the plunger hit the fluid inside the pump
barrel. Also, on and off is not preferred for well produce with certain amount of sand. San can fall
back on top of the plunger if the off periods.
• Linear vertical mechanical Long Stroke pumping units’. This unit proved to be much better than
Beam type units. Manly due to the feature of the long stroke and slow pumping speed. This allow
for more time for (Fill Time) the fluid to inflow to the pump during the upstroke. When unit is
equipment with variable frequency drive, pumping speed can be slow down. The drawdown of such
type of unit is the availability of the stroke lengths. It is limited to 3 to 4 lengths. This will reduce
the chance to reduce the unit running parameters in order to match well productivity. Therefore
chance of fluid pound problems is exist.
• Hydraulic skid mounted Long Stroke Pumping Units. This type of units shows the best performance
in running wells with fluid pounding problem. This is mainly found to be due to the different
features these units have. Where with very simple adjustments while the unit is running, an operator
can optimize the system to match pumping conditions to well productivity. The stroke length can be
made from one inch to the maximum allowable stroke with one inch increments. For example, a unit
equipped with 360 inches, the available stroke lengths are 1, 2, 3, 4………….358, 359,360 inches.
This wide range of stroke lengths with the availability to speed up or down the units, operator can
adjust very closely the unit running parameters to match well productivity and fluid pound can
almost eliminated.
It also featured with independent Up and down stroke speed. Speed can be control by slowing
down the up stroke period in order to allow for more time for (Fill Time) the fluid to inflow
to the pump during the upstroke. The longer the time interval of the upstroke, the longer the
fill time to charge the barrel, and the greater the amount of fluid permitted to inflow during the
productive cycle; hence, increased production. Moreover to avoid the shock force resulting from
fluid pounding condition, this type of system is featured with a very smart automation system which
can lead to almost eliminate the bad effect of the fluid pound in the entire system. It provides Eight
Independent Speeds for Up and Down Stroke plus Independent Acceleration and deceleration for
Up and Down Stroke. The unit can be adjusted to slow down almost near to zero speed in the
downstroke before it hits the fluid level inside the pump. This will allow the plunger to pass the
fluid without any shock load and by that, the fluid pound will eliminated.
SPE-189231-MS 9

Figure 5—Fluid Pound

Safety related to system operations

Sucker rod pumped well are running with large equipment running 24/7. Therefore when we compare the
different surface unit’s safety hazards, we need to consider all the type of operations where the times of
particular danger can happen. This can occur mainly during:

• The erection,

• Stroke change,

• Counterbalance change,

• General unit maintenance,

• Well servicing and

• While taking dynamometer card reading.

A review of recent and historic incidents show that Beam type units related worker fatalities is the worst
among the other type of units. This is because Pumping units have large and heavy rotating parts. Even a
temporarily stationary pumping units has components which can start moving from the effect of gravity.
Comparing with the long stroke vertical units where almost all moving parts enclosed within the tower and
away from personnel, very few incidents reported. The Hydraulic skid mounted computerized units recorded
the safest units. Where No crane required for work-over activities a tracking system for sliding pumping unit
back and forward for well workover without dismantle the unit is using. Therefore less injuries exposure
observed. Also all the required operations for changing stroke length, pumping speed and balancing the
units found to be more safer where all can be done without stopping or access the units. All these operations
done from the power skid.

Case Histories
Case Study 1: San Ardo, California oil producer had a need to increase production beyond that which
was possible with a beam pump, but wanted to avoid the additional costs of operating an ESP, while also
reducing maintenance costs resulting from frequent rod separations.
10 SPE-189231-MS

To achieve the goal the producer installed late in 2008 four Skid mounted long stroke pumping units
with 100 hp power units. Immediately upon startup, the long stroke units have resulted in a more than 25%
increase in production over the beam pump's production of less than 2,000 BFPD to over 2500 BFPD on
each well. This production increase has been achieved while decreasing strokes per minute by 60%, from 10
SPM to 4 SPM. This has resulted in substantially lower failures frequency for downhole parts (rod, tubing
and downhole pump.
Installation & Purchase Payback in 6 Weeks; Over $1 Million Increase in Annual Cash Flow per Well
due to the this increased in production and reducing in well interventions costs
Case Study 2: Major International Producer Wyoming, USA have wells had severe side loading and
high frequent well services. Being June 2013 they installed four ultra-long stroke hydraulic SSI units. This
in order to evaluate the performance of using the fully control long stroke hydraulic units with the target of
reducing rod cycles (failures) while l maximizing liquid production. No tubing or rod failures up to date.
Case Study 3:
A Wasson Clearfork Team evaluated the performance of Hydraulic ling stroke skid mounted units on
deviated wells. The results was concluded as follows:
Increased Production - In one case, a Conventional 912 pumping at 7.9 SPM with a 2.25" BHP
producing 420 BFPD was changed to DynaPump Model 9 pumping at 4.3 SPM with a 2.25" BHP and ending
up producing 505 BFPD. This was a 20% increase without changing the size of the BHP. In most cases,
the BHP was increased to the next larger API pump size and production increased at least proportionally,
although in a few cases the well was subsequently pumped off with the larger pump. In at least one case,
the change to the DynaPump (SSI Lift)resulted in an increase in the production of oil by 25 BPD.
Less Down Time and Rig Cost – Certain wells have relatively high well maintenance cost related to
rod parts, tubing wear out, and BHP failures. Operator has even experienced some wells using submersible
pumps that have a high rate of replacement. Of course any time a well must be pulled to complete repairs
there are two negative operating factors that come into play: one is the cost of the rig crew plus the cost of
the replacement parts, and the other factor is the lost production revenue while the pump is out of service.
One common characteristic of the wells that have very high well maintenance costs is that they have a
severe deviation profile. In these cases, beam pumps running very fast experience a high rate of parted
rods even when steps are taken to use rod guides in the deviated section(s). Submersible pumps sometimes
experience electrical harness damage when being inserted on deviated wells which then leads to premature
pump failure. Use of a DynaPump (SSI Lift)on such wells allows production to be maintained, or in most
cases increased as noted above, but with the pump stroking at approximately ½ the speed of a normal beam
pump.

Conclusions and Recommendation

• When rod buckling, rod on tubing wear, rod parts and fluid pound are a problem, then a longer and
slower stroke per minute with a smaller plunger size will decrease the failures frequency, improve
the performance and increase run life consequently reduces Well Intervention by:

◦ Lowering peak polish rod load

◦ Reducing the loading by creating higher minimum polish rod load

◦ Decreasing buckling tendencies

◦ Decreasing side loads and drag loads

• The effects of rod string compression are expensive and unnecessary, and it can be greatly reduced
when long stroke units are utilized.
SPE-189231-MS 11

• Adjustable upstroke and downstroke speeds allow for more pump fillage.

• Long-stroke sucker-rod pumping units have definite advantages as compared to conventional beam
units. They produce greater liquid rates with less downhole pump problems and can also increase
the life of the rod string due to the reduced number of stress reversals
• Ultra-long stroke configuration provides efficient pumping in deep, troublesome, and high-volume
wells
• For high safety and less hazard related to well operation for persons and equipment, the Skid
Mounted units are proved to be the best choice. Where all well operation can be done from the
power skid

Acknowledgements
The authors wishes to express their thanks to Tundra Process Solutions and SSi Lift Company for permission
to publish this paper. Especially thanks for all SSi Team for their constructive advice and support.

Nomenclature
API Rod Tapered rod string stared with 1" rod at the top , 7/8" rod at the middle and ¾" rod at the
string 86 bottom
BPD Barrel per day
BFPD Barrel fluid per day
BS&W Basic sediment and water
BWPD Barrel water per day
ESP Electrical submersible pump
ft Feet
GOR Gas oil ratio
HMI Human Machine Interface
HP Horse power
Ibs Pounds
in Inch
MMSTBO Million stock tank barrel oil
MPRL Minimum polished rod load
OPEX Operating Expenses
PLC Programmable Logic Controller
PPRL Peak polished rod load
PSI pound per square inch
VFD Variable frequency drive
SAGD steam-assisted gravity drainage
SR Sucker rod
STB Stock tank barrel
UHS Ultra high strength

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