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2018 Sucker Rod Pumping
WorkshopCox Convention Center, Oklahoma City, OK
September 11 - 13, 2018
Horizontal Well Downhole
Dynamometer Data Acquisition:
Prototype is ready!Project sponsored by ALRDC
Chair: Victoria Pons Ph.D.
Lynn Rowlan Cleon Dunham
Ronda Brewer Tony Podio Ph.D.
Ryan Gernentz Gabriel Guillen
Walter Phillips Gregg Hurst
Michael Romer Rajan Chokshi, Ph.D.
Sept. 29 - 30, 20162016 Sucker Rod Pumping Workshop
The Project – Overview
• Design & build downhole dynamometer tools• Generate dynamometer tool specifications
• Design and Test prototype
• Manufacture tools in sets of 6
• Deploy tools in deviated & horizontal wells• Generate test procedures for field data capture
• Design includes six tools strategically placed in each rod string
• Record data during pumping operation according to test schedule
• Retrieve and Download downhole data sets
• Validate & maintain data• Developing visualization tools and user interface
• Accessible to all ALRDC members for model validation and creation
▪ Gather true measured data on both deviated & horizontal rod-pumped wells
▪ Actual downhole load & position: dynagraph cards
▪ Provide that measured downhole data to industry
▪ Improve our understanding of side loads, bending, friction, damping, and other factors resulting from well deviation
Project Goal & Overview
3Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
“Our industry needs downhole measurements in deviated wells that serve
the same purposes that the 1990s measurements served for vertical or
near vertical wells”, Dr. Sam Gibbs
Historical Perspective - Sandia
▪ Gathered and published data
from multiple test wells
▪ Project took place during a
period of low oil prices
▪ Proved wave equation methods
are sound and accurate
▪ But… This only holds for vertical
wells
▪ Number of well drilled since
Sandia?
▪ How many of those wells are
straight holes?
4Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Rod Pump Diagnostics: Introduction
• Historically, the pump condition has
been determined by dynamometer
analysis
• A surface dynamometer measures
position and load to generate a
surface card
• The downhole card is calculated by
solving the 1D wave equation (the
surface card is projected downhole)
• The solution removes all dynamics
in the surface card to show you the
resulting work at the pump
• Since the rod string acts as a
transmission line for the pump, any
distortion in load signals result in
poor downhole resolution
5Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Example 1: Vertical Wellbore
▪ Calculations:
• Pump Intake Pressure
• Pump Efficiency
• Pump Displacement
• Rod Loading
▪ Additional observations:
• Well is pumped off
• Tubing movement is
apparent
• Confidence in original
design: Pumping
conditions can be
duplicated by predictive
software
6Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Example 2: Deep Deviation▪ Calculations:
• Possibly Pump Intake Pressure
• Possibly Pump Efficiency
• Possibly Pump Displacement
• Possibly Rod Loading
▪ Additional observations:• Well is close to
pumped off
• Confidence in original design: Pumping conditions can be (relatively) duplicated by predictive software
7Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Example 3: Shallow Deviation▪ Calculations:
• No reliable downhole
calculation available
• Both the Net Stroke and
Fluid Load are distorted
▪ Additional observations:
• Production is the only
proxy for the condition of
the pump
• Incomplete fillage
calculations will not be
reliable
8Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Rod Pump Diagnostics: Current Pitfalls
▪ The diagnostic solution to the 1D wave equation assumes all elastic deformation originates at the pumpa) Shallow friction distorts both Gross
Stroke and Fluid Load
b) Deep deviation will tend to mostly affect Fluid Load
▪ The damping term of the wave equation is only meant to account for viscous forces, not mechanical friction
▪ Furthermore “…incorrect dynamometer data can give false indication of buckling anywhere in the string” - Gibbs
9Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
HWDDDA Members at 2018 ALCE
102018 Sucker Rod Pumping Workshop Oklahoma City, OKSept. 11 - 13, 2018
Walter Phillips
Gregg Hurst
Dr. Tony Podio
Bill Lane
Cleon Dunham
Lynn Rowlan
Dr. Victoria Pons
Rob Shoup
HWDDDA Project Structure
General Committee:
• Manage overall project
• Develop and Present to Industry
• Report progress to ALRDC R&D Committee
Business Sub-Committee:
• Define/manage budget and document project
Tool Design/Manufacturing/Testing Sub-Committee:
• Define tool specifications and tool testing requirements
• Select tool manufacturer
Tool Deployment/Retrieval/Data Gathering Sub-Committee:
• Outline testing procedures and well selection criteria
• Gather data
Data Validation/Maintenance Sub-Committee:
• Validate data, build and maintain database
General Committee
BusinessTool
Design
Tool
Deployment
Data Validation
11Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Test Wells▪ All distinct categories of deviated wells
• Vertical (for control test)
• Deviated
• Slant
• Horizontal
▪ Testing Criteria• Test at different SPM
• Anchored vs. unanchored tubing
• Rod guides vs. no rod guides (varying rod guides placement)
• Rod string configuration (steel, fiberglass, sinker bars)
• Depth of kick off point
• Fluid properties i.e. viscosity, gas, etc.
12Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Project Overview: Test Scenarios
▪ Pump Considerations:• Fluid Pound
• Gas Compression
▪ Operational Considerations:• Vary SPM
• Vary Stoke Length
• Vary Inter-stroke Speed (proxy for pumping unit geometry testing)
• Valve Checks (PIP calculations)
▪ Design Considerations:• Point of Initial Deviation
• Sinker Bar Length/OD
• Taper % (87, 86, etc.)
• Specialty Pumps
• Guiding
13Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Tool Specifications
Tools• Placed along the rod string for
collecting and storing data on-board
• Location of tools to be determined by deviation survey
Sensors:
• 3 axis accelerometer – position & relative gravity vector
• Multiple load cells – linear loading, plus bending and compression
• Pressure, temperature, vibration, etc.
• Synchronized clocks – for correlating data across multiple tools
14Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Downhole Dynamometer Tool
152018 Sucker Rod Pumping Workshop
Oklahoma City, OKSept. 11 - 13, 2018
Technical Details
• The ALRDC dynamometer tool is a battery powered
electromechanical system used for data acquisition during artificial lift
operations and can record
• acceleration – X, Y, Z
• pressure - external
• temperature - external
• axial strains
• Footprint – matching existing API 11B specifications and can easily be
placed within the string – 1.75” dia. and 30 inches long
• Has a pin/pin connection – 7/8” API thread
• Constructed out of steel – meets or exceeds artificial lift operating
conditions
• Passed “temperature and vibration” downhole
162018 Sucker Rod Pumping Workshop Oklahoma City, OKSept. 11 - 13, 2018
Technical Specifications
Software interface functions:
• Communicate with the tool
• Program data acquisition sequence, frequency, scheduling
• Record data in the memory, battery usage, memory
allocation
• Validate tool status, display data, calibrate channels
• Calculate remaining battery life and memory space
available
• Save data in ASCII format
172018 Sucker Rod Pumping Workshop Oklahoma City, OKSept. 11 - 13, 2018
Software Interface
182018 Sucker Rod Pumping Workshop Oklahoma City, OKSept. 11 - 13, 2018
Technical Specifications
Firmware distinctive features• Record high/low frequency data
• 9 data acquisition channels
• Selectable accelerometer range
• Power consumption (power management) optimization
• Memory allocation (writing to memory) optimization
• On-demand data acquisition
• Record high resolution data
• Recordkeeping capability for tool setup and running parameters
192018 Sucker Rod Pumping Workshop Oklahoma City, OKSept. 11 - 13, 2018
Current State of Software Tools
Predictive Modeling Software• Srod, RodStar, Qrod, LOWIS
• All of the current software are based on data from Sandia (vertical)
Diagnostic Modeling Software for deviated wells does not exist
20
“It is unwise and economically risky to apply the results of such
extended models without having adequate validation of their
accuracy” , Dr. A.L. (Tony) Podio
“The software used by the industry to design sucker rod strings is
based on data collected in vertical wells. Therefore, it isn’t
sufficiently accurate for design and analysis of rod strings in our
newer wells”, Cleon Dunham, President of ALRDC
Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Future State of Software Tools
• Improve Predictive modeling
• Replace guess work with scientific design
• Precise placement of rod guides
• Optimal Sinker bar size and placement
• Etc…
• Development of Deviated Diagnostic Models
• Remove mechanical friction from downhole card
• Enhanced well control based on deviation
• Extended life of artificial lift system
21Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Benefits to Industry
• Improved understanding of effects of mechanical friction
• Data for new development of models for both predictive
and diagnostic designs
• Improved optimization of Rod Lift Systems
• Provide basis for comparison of measurements i.e.
deviation survey, surface data, etc…
• Ability to isolate effects of other issues i.e. paraffin, scaling
• Ability to quantify effects of poor drilling practices that
directly impact operations efficiency throughout the life of
each well
22Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Benefits for Participants
Operational Benefits
▪ Testing various rod string designs
▪ Determine effects of deviation, pumping speed, and incomplete fillage
▪ Understand if inadequate tubing tension is a potential root cause of failures
▪ Develop more reliable intake pressure calculations
▪ Provide feedback to drilling on optimal back build profiles
▪ Reduction in CAPEX and OPEX through improved rod lift system design
23Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Benefits for Participants
• Use information for making improvements to well designs and
workflow tools during project period that will reduce or defer
failures
• No more waiting until a significant number of failures have
occurred before determining design success and understanding
the root causes of failure: accelerate learnings from project
testing to solve previously unknown failures on high visibility
wells
• Early access to data (5 years)
• Customize testing procedure to address current failure issues on
your wells
• Ownership of tools for use after project completion (if
purchased)
24Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Conclusions
▪ Improved downhole models can result in substantial
reductions in operational expenses• Better decisions and well designs
• We can’t eliminate downhole friction, but we should be able to design
around it, once better understood
▪ Gathering real-world data is a first & significant step
25Sept. 11 - 13, 2018 2018 Sucker Rod Pumping Workshop
Oklahoma City, OK
Copyright
Rights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Sucker Rod Pumping Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), rights to:
▪ Display the presentation at the Workshop.
▪ Place it on the www.alrdc.com web site, with access to the site to be as directed by the Workshop Steering Committee.
▪ Place it on a CD for distribution and/or sale as directed by the Workshop Steering Committee.
Other use of this presentation is prohibited without the expressed written permission of the author(s). The owner company(ies) and/or author(s) may publish this material in other journals or magazines if they refer to the Sucker Rod Pumping Workshop where it was first presented.
262018 Sucker Rod Pumping Workshop
Oklahoma City, OKSept. 11 - 13, 2018
Disclaimer
272018 Sucker Rod Pumping Workshop
Oklahoma City, OKSept. 11 - 13, 2018
The following disclaimer shall be included as the last page of a Technical Presentation or Continuing Education Course. A similar disclaimer is included on the front page of the Sucker Rod Pumping Web Site.
The Artificial Lift Research and Development Council and its officers and trustees, and the Sucker Rod Pumping Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Sucker Rod Pumping Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained.
The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials.
The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose.