Sucker Rod Pumping Systems
أنظمة الضخ بالقضبان (Sucker Rod)
- Next date
- Available in-house
- Fees from
- —per delegate
- Formats
- In-house training0 sessions
- Duration
- 5 daysCertificate
Overview
Sucker rod pumping is the most widely used artificial lift method in the world, with hundreds of thousands of beam pumping units operating in onshore oil fields. Its simplicity, ruggedness and ease of maintenance make it the first choice for many low and medium rate wells, from shallow heavy oil to deeper light oil producers. However, poorly designed or badly operated rod pumping systems suffer from rod and tubing failures, pump wear, gas interference, fluid pound and high energy consumption. Each failure means a costly workover and lost production, so good design and surveillance pay back quickly.
This course provides a practical understanding of the design, operation, optimisation and troubleshooting of sucker rod pumping systems. Participants learn the components of beam pumping units, rod strings and downhole pumps, and how pumping unit geometry and rod string behaviour affect loads and production. The course covers system design using API RP 11L and wave equation methods, unit and rod selection, counterbalancing, and the use of dynamometer cards and fluid level surveys for diagnosis. It also explains pump-off control, variable speed drives, failure analysis, gas and sand handling, and practical methods to extend run life and cut lifting costs.
Objectives
- Describe beam pumping unit types, rod strings and downhole pump components
- Explain inflow performance and how it limits rod pumped well production
- Design rod pumping systems using API RP 11L and wave equation methods
- Select pumping units, rods and pumps and set correct counterbalance
- Interpret surface and downhole dynamometer cards and fluid level surveys
- Diagnose and prevent rod, tubing and pump failures in the field
- Optimise systems with pump-off control and variable speed drives
Who should attend
Production and petroleum engineers, artificial lift specialists, field supervisors, well service staff and technicians responsible for rod pumped wells.
Training methodology
The course combines explanation of rod pumping principles with design calculations and diagnosis of real field data. Participants calculate inflow performance, size pumping units and rod strings using API RP 11L methods, and review outputs from wave equation design software. A large set of dynamometer cards from field wells is interpreted in groups to identify fluid pound, gas interference, leaking valves and other problems. Photographs of failed rods, couplings and pumps support failure analysis exercises. Case studies of optimisation programmes show measurable gains in run life, production and energy use.
Programme outline
Day1Rod Pumping System Fundamentals
- The place of sucker rod pumping among artificial lift methods and its typical operating range
- Inflow performance relationships and how reservoir deliverability limits pump capacity
- Beam pumping unit types: conventional, Mark II, air balanced and long stroke units
- Gearboxes, prime movers, polished rods and stuffing boxes at the wellhead
- Sucker rod grades, couplings, sinker bars and fibreglass and continuous rod options
- Downhole pump types, plungers, barrels and standing and travelling valves
- Practical exercise: calculating inflow performance and target production for a rod pumped well
Day2System Design
- Rod string behaviour, stretch, dynamic loads and the effect of pumping speed on loads
- Design using API RP 11L: peak polished rod load, minimum load and torque
- Wave equation design methods and the use of modern rod pumping design software
- Selecting stroke length, pumping speed and plunger size for the required production rate
- Rod string taper design and checking stresses with the modified Goodman diagram
- Tubing anchors, tubing stretch and the selection of tubing size for rod pumped wells
- Practical exercise: designing a complete rod pumping system for a sample oil well
Day3Surface Equipment, Counterbalance and Energy
- Pumping unit geometry, torque factors and the rating of gearboxes in service
- Counterbalancing methods and the calculation of correct counterbalance for each well
- Measuring and adjusting counterbalance in the field using power and load data
- Motor selection, energy consumption and the efficiency of rod pumping systems
- Variable speed drives and their use to match pumping rate with well inflow
- Pumping unit installation, alignment, maintenance and safety around moving equipment
- Practical exercise: checking gearbox torque loading and recommending suitable counterbalance changes
Day4Diagnostics and Surveillance
- Surface dynamometer cards and how they are measured with load cells and position sensors
- Calculated downhole cards and the information they provide about pump condition
- Recognising full pump, fluid pound, gas interference and gas locking on dynamometer cards
- Identifying leaking valves, worn pumps, tubing leaks and parted rods from cards
- Acoustic fluid level surveys and the calculation of pump intake pressure
- Pump-off controllers and well automation systems for rod pumped fields
- Practical exercise: interpreting a set of field dynamometer cards and recommending actions
Day5Failure Analysis and Optimisation
- Common rod and coupling failures caused by fatigue, corrosion, overload and wear
- Rod and tubing wear in deviated wells and the use of rod guides and centralisers
- Gas and sand handling methods, gas separators and pumps designed for difficult fluids
- Failure tracking, mean time between failures and root cause analysis for rod pumped wells
- Field optimisation programmes and the improvements achieved in run life and production
- Group exercise: analysing a well with repeated failures and preparing an optimisation plan
- Final assessment and discussion of rod pumping problems in participants' own fields
Dates and fees
There are no scheduled dates for this course at the moment. Request it as in-house training, or ask us about the next date.
Certificate
Every delegate who attends the full programme receives a Harfard Technology certificate of completion stating the course title, duration, dates and venue.
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