Practical Rod Pumping Optimization Course Description:
This course covers artificial lift fundamental principles including advances and disadvantages of most commonly used artificial lift systems (Rod Pumping, Gas Lift, Hydraulic, ESP, and PCP). It primarily covers modern rod pumping system optimization and the knowledge you need to understand how rod pumping systems work, how to design and analyze them, and what affects their performance. Since a failure in any part of a rod pumping system will result in production loss and is expensive to repair, this course will cover all subjects related to proper equipment selection, system design, diagnostic analysis of existing systems, pumping unit balancing, and in general, all techniques that minimize failures and maximize system efficiency.
When attending this course, you need to have an iPad Air, iPad, iPad mini or an Apple laptop computer available and the “Practical Rod Pumping Optimization” ebook downloaded from the iTunes iBooks store. The iBooks app must be installed to be able to read this ebook.
If an iPad or Apple laptop is not available, you can order a physical hard bound book instead. However, please be advised that the physical printed version of the book is more expensive (because of the printing costs) and also not as complete as the interactive smart eBook that contains multi frame figures, animations, and other smart content not available of possible in the printed physical book. The eBook contains many multi frame interactive figures. For these figure, the physical hard bound book only shows the first figure. Also, when you purchase the eBook you will be getting free updates in the future that will keep the book current, fix errors, update the software descriptions and other sections in the book, etc. This is why E8 LLC recommends that you use the eBook and not the Physical printed manual for this course.
In addition to the course manual you will need a windows laptop (or an Apple laptop with a windows virtual machine) with Theta’s software installed before the class starts by an IT administrator if you are using a company computer, or by yourself if you are using a personal computer. The link to the software download will be provided by E8 LLC after you sign up for this course. The USB software sentinel (dongle) you will need to run the software will be provided to you in the class.
The course has 13 Chapters which are as follows:
Introduction:
It covers what is Natural Lift, what is Artificial Lift, the most commonly used artificial lift methods and how to select the appropriate artificial lift method based on advantages and disadvantages of each method. It also explains why rod pumping is the most popular method of artificial lift. It also discusses the main targets of rod pumping system optimization including equipment selection and maintenance, system efficiency, resource management, and oilfield automation, etc.
Chapter 1 – Fundamental principles:
Covers the definition of: stress, pressure, work, power, energy, machine, and torque. Definition of “Dynamometer” and what a dynamometer card represents. What are Group 1 and Group 2 rod pumping systems. Also covers fundamentals of wave principles including explanation of different wave types, how stress waves transmit energy in the rod string, wave interactions, and wave superposition.
Chapter 2 – The Rod Pumping System and It’s Surface Equipment:
What are the major components of rod pumping systems and the most commonalty used surface equipment. How rod pumping systems work and the functions of the main components of a rod pumping system including prime mover, rods, pump, etc. Common pumping unit types, advantages and disadvantages of different pumping unit and prime mover types, data needed to simulate pumping units, in modern optimization software, how rod and tubing rotators work, maximum and minimum pumping speeds, how a back pressure valve works, etc.
Chapter 3 – Downhole Equipment:
Covers downhole rod pumping equipment and their function, including the rod string, couplings, rod guides, tubing, downhole pump types and their advantages and disadvantages, and common pump components. The five main pump components and their function, pump material selection, pump and plunger selection for sandy and gassy wells, pump compression ratio, pump slippage, the Patterson Equation, Gas Anchor selection and design, production tubing, tubing anchors, how to set a TAC and how to calculate inches of tubing pull required to set the tubing anchor. How to use tubing centralizers, and paraffin scrapers. Plunger types available and how to select pumpplungers and maximum pump setting depth. How on-off tools work, advantages and disadvantages of common API and non-API pumps, explanation of API pump designation, advantages and disadvantages of Polyethylene tubing lining, how to calculate rod-tubing friction coefficient when using Polylined Tubing, Solutions for tubing leak problems, paraffin and asphaltene deposition problems, and more.
Chapter 4 – Sucker Rod String:
Covers API and Non-API sucker rod grades, advantages and disadvantages of steel (conventional and coiled rods) versus Fiberglass and Steel rod strings, API and Non-API steel rod stress analysis, rod make up, sinker bar design, polished rod material selection and sizing, and main causes of sucker rod failures. Shows how the Modified Goodman Diagram works and how to use it. How sinker bars work and how to design them with modern design software, etc.
Chapter 5 – Field Measurements:
What are polished rod dynamometer cards and how they are measured. Dynamometer system evolution, what data is needed for a good dynamometer card measurement, etc. Other field measurements including counterbalance effect, valve checks, horseshoevs clamp-on load cells, understanding the shape of surface dynamometer cards, and calculation of pump leakage from a traveling valve leakage rate. How many dynamometer cards should you measure and analyze per well? Using Amp plots to check unit balancing, identifying pumping unit crank type, and acoustic fluid level measurements.
Chapter 6 – Gearbox Torque Analysis:
What is the main function of the gearbox and why it is important to avoid overriding it. Understanding Gearbox Torque and how to do a gearbox torque analysis. How to select the proper gearbox size, how to determine if a pumping unit is balanced, how to use torque factor tables, how to calculate balanced counterbalance moment, and how to balance beam balanced units. The effect of pumping unit and crank and counterweight inertia on gearbox torque, gear backlash and regenerated power. How the measured counterbalance effect is used, The permissible load diagram and its meaning and how to understand the Permissible Load Diagram in RODSTAR, XROD, and XDIAG.
Chapter 7 – Pumping Unit Balancing:
Field pumping unit balancing and balancing software. What is the exact definition of a “ balanced pumping unit”,. balancing pumping units with an Amp Meter versus the XBAL balancing software, how to balance units for minimum gearbox torque or minimum energy consumption, and how balancing affects system performance. What is the Cyclic Load Factor, how is its used in RODSTAR and XDIAG, and how to use the XBAL software.
Chapter 8 – Rod Pumping System Design:
What is rod pumping system design and what data is needed to design a vertical or deviated rod pumping system. Evolution of rod pumping system design methods, API RP 11 L and Wave Equation methods, System design considerations, system design problem solution checklists for reducing gearbox torque, reducing rod loading, increasing system efficiency, and maximizing production. When to use Fiberglass-Steel rod strings, how to calculate target production using inflow performance data, Vogel and Fetkovich IPR methods, and using IPR software. Lessons from the API RP 11L method, Fo/Skr versus N/No’, rod pump system design for vertical and deviated wells with RODSTAR. Using Artificial Intelligence design software (XROD), step-by-step use of RODSTAR to design vertical and deviated rod pumping systems, understanding the software inputs and outputs, how to enter custom rod grades and measured pumping units, etc. Hands-on use of RODSTAR and XROD to design rod pumping systems faster and better. Detailed explanation of the latest RODSTAR features for deviated well designs, rod guide placement recommendations, program setup options including batch, entering custom rod grade and pumping unit data, rod and pumping unit costs. Polished rod sizing, motor sheave and belt length calculations, how to calculate the number of V-belts needed, and how to determine maximum and minimum pumping speeds.
Chapter 9 – Rod Pumping System Diagnostic Analysis:
What is the meaning of “Diagnostic Analysis” of rod pumping systems, surface versus calculateddownhole dynamometer cards, the secret to understand the shapes of downhole dynamometer cards, downhole dynamometer card shapes for common pump problems, Group 1 versus Group 2 rod pumping systems, understanding fluid inertia effects and its effect on surface and downhole dynamometer card shapes, how to set vertical and horizontal lines on the downhole pump card to calculate pump intake pressure and fluid level, and modern wave equation diagnostic software and how to use them.
Detailed downhole pump dynamometer card shape interpretation and explanation of common pump conditions including full pump, gas interference, fluid pound, leaking traveling and standing valves, effect of unanchored tubing, malfunctioning tubing anchor, pump hitting down (tagging), bent or sticking barrel, and worn or split pump barrel. Combination pump problems and how they affect the calculated downhole pump dynamometer card shape, tubing leak detection, and updated downhole pump card shape library.
How XDIAG works and how to use it. The effect of input data errors on diagnostic analysis results and how you can tell if the load cell is out of calibration, if the pumping speed is wrong, etc.
Chapter 10 – The Seven Step Optimization Process:
How the Seven Step Optimization (SSO) process works and how to use it. What each step of the SSO process does, what software to use for each step, and why it is necessary to follow the seven steps as recommended. How to apply the SSO to your existing wells to optimize their performance, how to design rod pumping systems for “worst case” conditions, and how to document the benefits of the SSO process.
Step by step explanation and demonstration of the SSO process and hands-onapplication of the SSO on several real examples by the students on their computers.
Chapter 11 – Modern Rod Pump Controllers:
What problems are caused by uncontrolled fluid pound, how timers and Rod Pump Controllers (RPCs) can be used to minimize the damaging effects of fluid pound. What equipment make up a modern RPC and how they work. How RPCs detect fluid pound and the advantages and disadvantages of the different methods. What sensors are used in RPC systems to measure load and position and their advantages and disadvantages. How Variable Speed Drives (VSDs) work with RPCs to control fluid pound. VSD advantages and disadvantages, and how modern RPCs use a calculated downhole pump dynamometer card to detect fluid pound. Understanding RPC data errors and XDIAG auto-corrections.
Chapter 12 – Rod Pumping System Automation:
When use of automation is justified and what it can do for you. The building blocks of a successful automation system, the basic benefits of RPCs alone vs the combination of RPCs and automation. Documented benefits of artificial lift system automation. The XSPOC automation software and its advantages. How to perform the SSO process in XSPOC.
Instructional Objectives:
After completing this course, students will learn the following:
1. Understand the advantages and disadvantages of the main artificial lift systems and how to select the best system for their wells.
2. How rod-pumping systems work and how to design, analyze, and maintain them, how system efficiency affects lifting costs and what to do to improve it.
3. What types of pumping units, motors, gas engines, rods, pumps, gas anchors, tubing anchors, rod and tubing rotators and other equipment are available and how they work.
4. How to select the pump, rod, and tubing size, type and material for different wellbores and produced fluid, presence of free gas, etc.
5. Understand the API RP11L and wave equation rod pumping system design methods and their capabilities.
6. How to perform belt length and motor sheave size calculations, rod makeup procedures, polished rod selection, and how to diagnose sucker rod failures.
7. How to measure dynamometer cards with modern dynamometer equipment, and also how to measure counterbalance effect, valve checks and fluid level measurements.
8. How to determine if a pumping unit gearbox or structure is overloaded and how to balance the pumping unit to minimize torque or energy consumption using modern balancing software.
9. What is the permissible diagram and how to use it when designing a rod-pumping system.
10. How to use modern rod pumping system design software to design a complete rod pumping system for vertical or deviated wells for optimum performance and how to properly place rod guides.
11. How to calculate downhole pump dynamometer cards using modern wave equation software and how to interpret their shape.
12. How to diagnose problems from downhole dynamometer cards and the differences between “Group 1” and “Group 2” rod pumping systems.
13. What is the “secret” of downhole pump dynamometer card shapes.
14. How to use Theta’s RODSTAR, XDIAG, XBAL, and XTOOLs software to design, analyze, balance, and in general optimize your rod pumping systems.
15. How to perform the Seven Step Optimization process to optimize rod-pumping systems.
16. Understand how modern rod pump controllers work and the advantages of modern automation software (XSPOC).
Course Prerequisites:
Some familiarly with some basics of oilfield production, and being able to use personal computers and the Apple iPad.
E8 LLC offers in-house rod pumping optimization and Theta software training to interested companies.
The in-house course covers all of the same material as the standard Practical Rod Pumping Optimization course but it can be modifed to meet specific needs.
Standard Costs:
For Open Courses:
Tuition fee per student: $1795.00. Also, each student must purchase a copy of “Practical Rod Pumping Optimization” course eBook from Apple’s iBooks store. If an iPad or Apple Laptop is not available, a physical hard bound book can be purchased from E8LLC for $195.00. Please select this option on the registration page. This book is 504 pages long but does not have the interactive content found in the eBook such as animations multi-frame figures, etc. Completion certificates and refreshment breaks will be included at no additional charge.
For In-House courses:
Tuition and travel fee per day: Contact E8 LLC for a quotation. Maximum number of students recommended per course is 30.
Each student must purchase a copy of “Practical Rod Pumping Optimization” course eBook from Apple’s iBooks store at: Click Here.
For in-house courses you will also be charged for all travel expenses including air fare, transportation to and from the airport, car rental, airport exit tax, all meals and hotel lodging.
Optional course completion certificates: ($10.00 each).
If you want us to customize the course for your wells and develop class example cases using RODDIAG, XDIAG, XBAL and RODSTAR files from your wells, an additional charge of $350.00 per hour will apply for the time it takes to prepare these examples.
For more information please call John G. Svinos for details at: 702-529-3716
or email him at: john.svinos@gmail.com
What students have said about this course:
- N.P., Talisman Energy, Inc.“I am a new graduate and have just started my new job as an optimization engineer. This was a great mix of general info and technical details. What a great course – it definitely exceeded my expectations! I learned a lot and the atmosphere made it comfortable. Doing all the examples myself really engrained the process. Thanks so much!”
- S.S., Gaffney Cline and Associates
“John, I didn’t get a chance to thank you for the course, but it was one of the most interesting and immediately applicable courses that I have attended. We continue to raise production levels, partly through your course and software and partly through other methods. So far this has created increases of about 250,000 bbls in the 2002. Not bad from about 250 wells.” - D.H., Santa Fe Energy
“The skills I learned can have a immediate impact on the bottom line through better designs, and increased efficiency.” - R.L.
“The best course I have ever attended. It had the perfect mix of theory and practice.” - D.W., Chevron
“Great class. First time I’ve been to one of John’s classes. It was one of the best classes I’ve been in.” - K.B., Crestar Energy, Calgary, AB
“A most excellent course! Well organized, presented and documented (great manual). You answered questions and gave explanations very clearly. Great job!” - N/A
“The content of the course is very complete and the experience of the instructor helps a lot.” - R.G., Hunt Oil Company
“I learned a lot about rod pumping in general as well as how computer software can help optimize rod pumping. Excellent class. Useful software. Taught very well. I enjoyed learning the theory behind the software calculations.” - C.D., Midland, TX
“One of the best organized industry courses I’ve attended.” - D.M. Chevron/Texaco Canada
“This was a very comprehensive presentation of rod pumping systems, how they work, what can happen to them, troubleshooting, etc. Having John’s expert background and vast experience in this field was excellent. Thank you for a very informative and enjoyable course.” - J.B., Schlumberger Baku, Azerbaijan
“Very practical, excellent examples and animations. This is by far the best organized course I have attended. I will recommend it to my colleagues.”
For the Online Course:
An online version of the Practical Rod Pumping Optimization course is now available. This course contains the same material as the live course and it is based on the “Practical Rod Pumping Optimization” eBook used in the live course. It uses the same presentations with recordings of my voice. It includes step by step software tutorials for RODSTAR, XROD, XBAL and XDIAG.
The cost of this course is about one fourth of the cost of the live course ($475.00 per person). Once you purchase this online course you have 60 days to complete it. The online course assumes you already have the Theta Software. E8 does not provide the Theta software for use during the online course. This option is only available for the live courses.
This online course is administered by a third party, please click here for more information.