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Table of Contents Polished Rod Dynamometer Examples of Dynamometer Cards Sign up to vote on this title Mechanical Dynamometer & Hydraulic Dynamometer Useful Not useful Hydraulic Dynamometer Drawing Electronic Dynamometer
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POLISHED ROD DYNAMOMETERS
Rod-pumped Rod-pumped wells must be monitored to ensure the continued efficient and econ operations operations of a field. After a pumping unit has been installed in the field, dynamome of pumping wells are conducted to determine the system efficiency, and whether adjustments need to be made in stroke length, pump speed or other operating param These tests are designed to answer such well performance questions as: Is the well pumped off? What is the pump intake presssure? Sign up to vote on this title What is the pump fillage? Useful Not useful What is the pump displacement? Is the standing valve or traveling valve leaking? • • •
• •
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(Figure 1: Example of surface (top) and pump (bottom) dynamometer ca
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MECHANICAL DYNAMOMETER
A mechanical dynamometer measures rod loads by measuring the deflectio steel ring placed between the carrier bar and the polished-rod clamp. A rec this ring deflection is made on a paper dynamometer card, attached to a ro drum driven by the vertical movement of the polished rod. The card traces rod loads against rod vertical displacement. Its major disadvantage Sign up to vote on this title is that t pumping unit must be stopped before it can be installed onNot the polished ro Useful useful
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Figure 2
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ELECTRONIC DYNAMOMETER The electronic dynamometer uses electronic transducers to measure wel and rod displacements (Figure 3: Polished rod dynamometer transducer). Figure 3 Sign up to vote on this title
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DYNAMOMETER CARD INTERPRETATION (Figure 4) shows a dynamometer card shortly after it is recorded at the surface.
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With a dynamometer card for a given rod pump and the definitions above, w make the diagnostic calculations listed in Table 1:
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Table 1: Diagnostic Calculations for Beam Pumping System
Peak polished rod load Minimum polished rod load Polished rod load range Counterbalance effect Approximate CBE
PPRL =D 1C MPRL = D Sign 2C up to vote on this title C(D 1 - D 2) Useful Not useful Actual CBE = CD 3 (C/L) ((A 1+(A 2/2))
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Using this equation, we can look loo k at the dynamometer card, insert the crank angle on it for a numbe values of W and TF, TF, and make net torque calculations using the above equation. Note that W is a fu crank angle and is measured from the dynamometer card. The torque factor, TF, TF, is supplied s upplied by the m for a given unit in 150 angles of the crankshaft. This net torque calculation should provide a plo t similar to that shown sho wn in the dashed curve of (Figu be the peak torque at the maximum point on the curve. It suggests that the counterweights should Sign up to vote on thisfor titleexample, a se order to even out the net torque curve. cur ve. After an adjustment of the counterweights, .Useful Not useful obtained (solid curve), showing that the unit i s now more balanced
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The downhole condition of the pump and its pumping action can be analyzed with a dy With the dynamometer, those terms that affect the surface operating condition can be and necessary adjustments to the unit can be made. If the operation of the subsurface the surface unit are satisfactory, is it possible to improve production by changing the pu length, its speed or its surface control control system? Generally, Generally, a unit that runs intermitt i ntermittentl entl controlled either by a timer or with a pump-off controller. Careful adjustments in the fi required to maximize production, without damaging the pumping unit. The informat Sign up to vote on this title dynamometer tests taken both before before and after changes are made in the pumping equ Useful Not useful the help determine whether the adjustments have improved operating conditions.
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UNANCHORED TUBING (Figure 1) represents the rod load as a function of displacement for unanchored tubing. No load scale goes as high as 10,000 pounds, and that the pump displacement (in feet) has system that runs from a point above the top of the subsurface pump down to the standing When the plunger is at its lowest point, it carries no load; its displacement is 9 feet from th coordinate coordinate to the ground coordinate system, but it is stationary with respect to the stretch Sign up to vote on this title
Figure 1
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In (Figure 2), as the traveling valve reaches point “C”, the entire fluid load is supported b rods, until it begins to transfer to the tubing at point “D.”
Figure 2 Sign up to vote on this title
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In (Figure 3), as the traveling valve reaches point “E”, the transfer of the load from the ro tubing is almost complete, but the tubing continues to stretch somewhat. At point “F”, th fluid load is now supported by the tubing, causing the tubing to stretch to its greatest len plunger now descends with respect to both the ground and tubing coordinate systems. A there is no load on the traveling valve and it continues to descend until it reaches a displ position, indicated by point “A”. The cycle then repeats. Sign up to vote on this title
Figure 3
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ANCHORED TUBING
If the tubing is anchored, it will not stretch or contract in response to the movement of and the “ideal” load-displacement diagram will have the appearance shown in (Figure 4 load-displacement diagram for a pump with anchored tubing).
Figure 4 Sign up to vote on this title
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PUMP VALVE VALVE DYNAMOMETERS DYNAMOME TERS
Efficient Efficient operation of a sucker-rod pump depends on the integrity of the standing and trave valves. If these valves lose their ability to hold a seal, the lifting capacity of the pump is affe Therefore, the valves should be tested periodically with a dynamometer.
TESTING THE STANDING VALVE
Dynamometer testing of the standing valve requires that pumping unit to be stopped near Sign up to vote ondynamometer this title bottom of the downstroke. The initial polished-rod load is recorded on the ch Useful Notload usefulrecorded at the fluid load is completely completely carried by the standing valve, thepolished-rod of the test will measure only the buoyant weight of the rod string. When the standing valve holds a good seal, the polished-rod load will remain steady, resul
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TESTING THE T HE TRAVELING VALVE VALVE
Testing the traveling valve will help to distinguish whether the traveling valve or the barrel-plunger fit test, the pumping unit is stopped near the top of the upstroke and the initial polished-rod load on the recorded. The initial recorded polished-rod load measures the buoyant weight of the rod string and the fluid load plunger. plunger. The standing valve is open so s o it carries no load. If the seal s eal in the traveling valve is good, and a barrel and plunger fit is good, then no change in polished-rod load should be observed over the test pe A leak either in the t raveling valve or between between the pump barrel and plunger will allow fluid to pass t valve. This leak will slowly force the standing valve to close. Once closed, the fl uid load transfers to the the tubing, and this load transfer will be observed on the dynamometer card. Theoninitial polished-rod l Sign up to vote this title weight plus fluid load) recorded on the card will be greater than theloads measured later in the test. T Useful Not useful decrease is proportional to the leak rate. This test cannot distinguish between a leaking traveling valve and leaking caused by a worn barrel or p
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SYSTEM MONITORING: DYNAGRAPHS
Surface dynamometer cards cards cannot be used to directly measure the operations of a downhole pump, surface measurements record all the static and dynamic forces acting on the rod string. We can make accurate evaluation evaluation of the pump by placing a dynamometer just above it. Meas urements of rod loads immediately above the pump are called dynagraph cards, to distinguish disti nguish them from surface-recorded cards. To illustrate the use of dynagraph cards, consider the idealized typical profiles shown in i n the following In (Figure 1) , a small, gradual curvature on the dynagraph during the u pstroke indicates indicates that a small sm all a perhaps coming out of solution, solutio n, is being compressed during the upstroke. As the pump begins its dow the load is not entirely transmitted to the tubing due to a period of gas compression on the downstro Sign up to vote on this title traveling valve opens.
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In (Figure 2) , the fall-off in load is sharper during the downstroke downstroke than for the gas comp dynagraph of Figure 1. This type of response generally means that the well is pumped-o almost pumped-off. off. In this condition, the pump chamber doesn’t completely fill with flu plunger moves down and compresses the gas, the pressure below the traveling traveling valve is enough to prevent the plunger from striking the liquid interface in the lower part of the The shock that results when the plunger hits the fluid interface and Sign up to votereleases on this titlethe load, Useful that Not useful fluid pound. Often, fluid pound can be felt at the surface,indicating the well is pum Dynagraph cards recorded recorded on wells with gas compression look similar to wells that expe fluid pound, and it can be difficult to distinguish between between the two.
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(Figure 3) is a dynagraph profile indicating low pump efficiency. The pump is “gas locked” a fluid in its chamber. chamber. The pump is simply causing gas to compress and then expand.
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(Figure 4) indicates a leaking traveling valve. Movement during the upstroke is requir full load is taken on and, because the traveling traveling valve is leaking, the rods begin to lose before the pump has reached the top of the upstroke. Sign up to vote on this title
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(Figure 5) indicates a leaking standing valve. The leak causes premature premature loading of the ro the beginning of the upstroke, and also delays the unloading of the rods during the down thus the traveling valve closes during the downstroke, downstroke, causing it to bear some of the loa
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If (Figure 4) and (Figure 5) were combined, the results would look like (Figure (Figure 6). This indicates a worn-out pump that is leaking at the traveling valve, at the standing valve, a has excessive plunger slippage, too. This pump should be replaced.
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SYNTHETIC DYNAGRAPHS
The dynagraph is a valuable diagnostic tool too l for analyzing pump performance. Unfortunately, Unfortunately, because the pump depth, this analysis may be difficult to obtain. Alternative procedures include: Using dynamometer cards of load displacements measured at the su rface to interpret interpret what is happe subsurface, and Using surface measurements and procedures (Gibbs, 1963 and Gibbs and Neely, 1966), to develop m derived dynagraphs called synthetic dynagraphs (often referred referred to as pump cards). •
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In the latter case, Gibbs and Neely made it pos sible to measure loads and displacements at the surfac Sign up to vote on this title calculate the required synthetic dynagraph by solving the appropriate non-linear partial differential differential e Useful Not useful Obtaining a synthetic dynagraph is fairly straightforward. The polished rod load versus time (Figure 7) polished rod displacement versus time (Figure 8) during a pumping cycle are measured.
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These two graphs are then combined to give a polish ed rod load versus polished rod displacement Using the data collected at the surface and so lving the appropriate partial differential equations, th
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In (Figure 10), the scale of the dynagraph has been expanded to show that the fluid load i pounds. The buoyant force force on the rods is given gi ven by the magnitude of the negative load on dynagraph. Here, it is 1,400 pounds .
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With the dynamometer cards calculated at the top of each tapered rod section the load rod of each section can be measured; dividing that load by the rod cross-sectional area g estimate of the respective respective rod stress. Doing this yields a peak rod stress of about 30,000 that is below rod limitations. The dynamometer card is used for the balance of the analy When synthetic dynagraphs are not used, an alternative is to use the dynamometer card both the surface and subsurface operation of the pumpingSign system. Ason a this guide up to vote title to this typ interpretation interpretation API Bulletin 11L2 (1969; reaffirmed Sept. 1999) provides extensive set Useful Notanuseful dynamometer cards, categorized categorized according to the dimensionless variables used in the pu procedures.
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