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Email Addresses:
Product Manager: Kevin Lo, kevin@gotheta.com
Software Support: support@gotheta.com
Sales: Christy Kukula, christy@gotheta.com
Theta Oilfield Services, Inc., 2014.
All Rights Reserved. This manual may not be reproduced in whole or in part without the written per-
mission of Theta Oilfield Services, Inc.
Contents
Technical Support . . . . . . . . . . . . . . . . . . . v
System Requirements . . . . . . . . . . . . . . . . . v
1 Introduction 1
1.1 Program Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Advanced Capabilities and Program Limitations . . . . . . . . . . . . . . . 2
1.3 Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Software Installation 5
2.1 RODSTAR Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Questions About Installation . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Installing the Software Sentinel. . . . . . . . . . . . . . . . . . . . . . 5
4 Running RODSTAR 23
4.1 RODSTARs User Interface. . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.1 RODSTARs Help System. . . . . . . . . . . . . . . . . . . . . . 24
4.2 Entering Rod Pumping System Data. . . . . . . . . . . . . . . . . . . . 24
4.2.1 Entering Well Information Data. . . . . . . . . . . . . . . . . . . 25
4.2.2 Entering Production Information. . . . . . . . . . . . . . . . . . 27
4.2.3 Entering Pump and Tubing Information Data. . . . . . . . . . . . . 29
4.2.4 Entering Rod String Data . . . . . . . . . . . . . . . . . . . . . 31
4.2.5 Entering Wellbore Deviation Data (Deviated Mode) . . . . . . . . . . 36
4.2.6 Entering Pumping Unit Data. . . . . . . . . . . . . . . . . . . . 40
4.2.7 Entering Motor Information and Energy Cost . . . . . . . . . . . . . 50
iv | Table of Contents
Technical Support
Technical Support for RODSTAR is provided by
phone and e-mail to customers with a current An-
nual Technical Support Agreement.
The first year of technical support is provided free
with the initial purchase of a license.
Support for customers with an expired agreement
is billed at $100/hour with a one-hour minimum
per incident.
Please include the Serial Number from your Senti-
nel bitlock when contacting support.
Phone Support:
Monday-Friday 8:00 AM - 4:00 PM PST.
(562) 694-3297
E-Mail Support:
support@gotheta.com
System Requirements
Processor: 1.6 GHz or higher
Operating System: Windows XP/Vista/7/8
Memory: 1 GB of RAM or higher
Hard Disk Space: 125 MB available disk space
Display: 1024 x 768 or higher
RODSTAR| 1
1 Introduction
allows you to redesign pumping systems without RODSTAR comes with a large pumping unit
having to reenter system data. RODSTAR can database so that you can easily select and compare
display and print the measured dynamometer card pumping units without having to get the unit
overlaid on the same plot as the predicted surface dimensions yourself. RODSTAR can model any
dynamometer card. This feature has many uses pumping unit geometry including long stroke units
that include finding the correct rod-tubing friction, such as the Rotaflex. Also, you can enter your own
or determining whether the load cell used to record pumping unit data in case your unit is not in the
the dynamometer card may be out of calibration. programs database. Advanced error trapping and
warning messages help prevent errors and make
By being able to read XBAL files, RODSTAR can
you aware of special requirements necessary for
get the existing maximum counterbalance moment
proper system operation.
based on the existing position of the counter-
weights. This eliminates the need for a field mea- RODSTAR deviaed version also allows you to
surement of counterbalance effect. Also, you can enter a deviation survey and calculates side load,
enter the calculated balanced maximum counter- dogleg severity, rod guide spacing recommenda-
balance moment back into XBAL to find out how tions, etc.
to balance the pumping unit in one step. After you run your case, RODSTAR will score
RODSTAR can simulate any pumping system and your design. Based on surface loading, rod string
can accurately predict its performance. For a sys- loading, and pump performance, RODSTAR will
tem you specify, the program predicts the surface score the design so that you will know what sec-
and downhole dynamometer cards. Also, it calcu- tions may need improvement.
lates the peak gearbox torque and gearbox loading,
structure loading, rod loading, pump stroke, mini-
mum required pump length, plunger length, pump
spacing, expected production rate, the counterbal- 1.2 Advanced Capabilities and
ance needed to balance the unit, the prime mover
size, overall system efficiency, daily energy con- Program Limitations
sumption, monthly electricity bill, and other useful RODSTAR has many advanced features that en-
information. Also, RODSTAR allows you to enter able you to accurately predict system performance
inflow performance data so that you can easily de- for any rod pumping system. It can simulate wells
sign a pumping system for any pump intake pump of any depth including very deep or shallow wells.
intake pressure, calculate the expected production It is the only program of its kind that models fluid
rate, pump intake pressure and pump condition for inertia effects that are present in wells that pump
any rod pumping system, find out the maximum incompressible fluids with larger than 2.00 plung-
production rate you can get, and more. ers from depths of less than 4000 feet. The devi-
Also, in contrast to the conventional trial and error ated mode can simulate deviated wells, while the
system design, with RODSTAR you can enter a vertical mode can only be used for wells that are
target production and ask the program to simulta- vertical or have little deviation.
neously calculate the strokes per minute, plunger By calculating the minimum stress at the bottom
size, and rod string design. It even recommends of each rod section, RODSTAR shows whether
the pumping unit size you need. Or, you can enter the rods are in compression or not. This is vital for
IPR data and have RODSTAR calculate the target fiberglass rods which must never be in compression
production and design the system for that target to avoid premature failures. This is also important
production based on any pump intake pressure or for steel rods since excessive compression can cause
fluid level you want. buckling failures.
RODSTAR| 3
RODSTAR can model the effect of prime mover RSWIND.exe The program file for
speed variation and pumping unit inertia and can RODSTAR deviated
accurately calculate electricity consumption and cases. It is the file that
the monthly energy bill. Because RODSTAR uses your Desktop Icon runs
actual motor efficiency curves, the results are very when you double-click
it.
accurate. You can use this capability to compare
the energy consumption of systems with different RODSTAR.CDB Contains the costs for
both rods and pumping
rod designs, plunger sizes, or pumping unit types. units. Once you create
RODSTARs Inflow Performance Relationship this file by entering rod
and pumping unit cost
(IPR) capabilities allow you to select the IPR data, you can provide
relationship you want RODSTAR to use (Vogel or copies to other users in
Fetkovich), your can enter one to ten test points, your company.
and can integrate IPR and rod pumping system CUSTOM32.PUD This file contains the
models to predict the maximum production rate measured pumping
possible, the fluid level and pump condition for a unit information you
given pumping speed, or the target production for entered in Setup. Once
you create this file, you
any fluid level or pump intake pressure you want. can distribute copies
Because of all these features, RODSTAR has vir- to other users in your
tually no limitations and is the most advanced and company.
easiest to use program of its kind. Files ending in .PUD The programs pumping
unit database. When
updates are announced
on our Website for new
pumping units that
1.3 Help System have been added, you
can download a zipped
RODSTAR takes full advantage of Microsoft file that contains addi-
Windows to bring you state-of-the-art context- tional PUD files to add
sensitive help for any input field by simply press- to your folder.
ing the ! key. Also, you can search help for any Files beginning with Several files are in-
other item. demo_ cluded that are example
cases to demonstrate
the program functions.
During installation,
there are copies of these
files placed in the folder
used when opening
case files.
Files ending in .RST Case files saved by
RODSTAR release
prior to 3.0.
Files ending in .RSVX Case files saved by
RODSTAR in vertical
mode.
Files ending in .RSDX Case files saved by
RODSTAR in deviated
mode.
4 |Introduction
2 Software Installation
Before you install the program, make sure you RODSTAR cannot read files created with a new
have the hardware and software you need to run version of the software.
RODSTAR.
What happens to files I have created with older
versions of RODSTAR?
Nothing. When you install or reinstall ROD-
2.1 RODSTAR Installation STAR, only program files are replaced. The latest
RODSTAR can be downloaded and installed from version of RODSTAR saves files in the XML file
our website, gotheta.com. It is recommended that format but can read files created with older ver-
you install the software into the default directory; sions of RODSTAR as well.
however, you can still select a custom directory. What happens to the Setup Settings from previ-
If you require assistance downloadng or installing ous versions?
your software, please contact support@gotheta. If the previous version is not very old (before the
com. new setup options were developed) then your set-
tings will be preserved.
3.1 Starting RODSTAR Figure 3.2 shows the RODSTAR window that
appears when you start the program. RODSTAR
The RODSTAR installation program will put an behaves like any other standard Windows pro-
Icon on your Desktop and an entry in your Start gram. You can use the mouse to move and size
Programs for access to RODSTAR. To start the windows, move and restore icons, select text,
program, simply double-click on its icon. choose commands from menus, and dialog boxes,
and complete almost any other task in RODSTAR
aside from typing text.
RODSTAR has a getting-started window,
shown in Figure 3.1, that appears whenever you Following is an explanation of the parts of the
start the program. The window shows the most RODSTAR window as shown in Figure 3.2.
common toolbar icons you need to know to begin The control-menu box is in the upper-left corner
using RODSTAR. of each window. The control menu is most useful
if you use the keyboard. You can use the control
menu commands to resize, move, maximize, mini-
mize, and close windows. Also, you can use it to
3.2 Exiting RODSTAR switch to other applications. (If you use a mouse,
To exit RODSTAR,
double click on its
Control-menu box (up-
per left hand corner)
or select File and then
Exit. Another way to
exit RODSTAR is to
press A+ $. Before
exiting RODSTAR
make sure you have
stored your data to disk
(RODSTAR asks you
if you want to save the
data when you exit, if
you have changed your
data since the last time
you saved it). Otherwise
it will be lost.
Figure 3.1 - The Getting Started Window
you can perform these tasks by clicking and drag- dow to fill the entire screen. After you maximize
ging.) Double-clicking on the control menu box the RODSTAR window, the maximize button
closes RODSTAR. shows a double box and is called the restore but-
The title bar shows the name of the application and ton. Clicking on the restore button re-sizes the
RODSTAR window to the size it was before you
the name of the file currently in memory. If more
maximized it.
than one window is open, the title bar for each
active window (the one that you are working with) Using the mouse you can resize RODSTARs
is a different color or intensity than the other title main windows. When you resize RODSTARs
bars. window to a size smaller than required to display
all information, it will display vertical or horizon-
The menu bar lists the available menus. A menu
tal scroll bars as necessary. You can use these scroll
contains a list of commands, or actions, you can
bars with the mouse to view unseen portions of
carry out with RODSTAR. For example, click on
entry windows that do not fit in the allotted space.
the Help menu to see a list of helpful choices.
The Close button causes RODSTAR to exit. Its
The Minimize button reduces RODSTAR to an
easier to click the Close button once than to select
icon. After you minimize RODSTAR, you can
Exit from the File menu.
reopen it by double clicking on the RODSTAR
icon at the bottom of your screen. The Status bar shows useful messages during data
entry, when you load a case from disk or when you
The Maximize button causes the RODSTAR win-
RODSTAR| 9
length, structural unbalance and counterbalance 3.3.4, Output Options under Setup.
data. Export CBM - This item is second from last on
Motor information - This icon shows a picture of the toolbar and shows a picture of a crank and
a motor. Click here to open the motor information counterweight. This button becomes active after
window that has data for electricity cost, power RODSTAR runs or after you load a file with saved
meter type, motor type and size, moments of iner- output. Click it to place the maximum counter-
tia and whether to include motor speed variation. balance moment for balanced conditions on the
clipboard for use in XBAL.
Previous window - This icon shows an arrow
pointing to the left. Click it to go back to the pre- Help - This is the last item on the toolbar and
vious input window. shows a picture of a question mark. Click this but-
ton at any time to get help.
Next window - This shows an arrow pointing to
the right. Click here to advance to the next win-
dow when entering data for the first time or when
you are changing data.
3.3 Setting up RODSTAR
Run - This item follows the arrow icon on the
Click on the Setup button on the toolbar to open
toolbar and shows a picture of surface and down-
RODSTARs Setup window. Another way to
hole dynamometer plots. Click here to run ROD-
access Setup is to open the Tools menu and then
STAR after entering all your data or after you
select RODSTAR Setup. This window as shown
change an input.
in Figure 3.5 allows you to enter items that do
Report - This item follows the run icon on the not normally change from run to run. Also, Setup
toolbar and shows a picture of a printed page. allows you to customize RODSTAR by entering
Click here to view the output in memory. This your company name, default electricity cost,
allows you to view the output saved in a file you custom rod grades, measured pumping units, rod
just loaded from disk, or to return to the output and pumping unit cost data, and a lot more. The
screen. If this button is inactive (dimmed) it means measured pumping unit data you enter is saved
that there is no output report in memory. To make in the CUSTOM32.PUD file in the program
it active, run the case, or load a case with saved directory; the cost data you enter for rods and
output. pumping units is saved the RODSTAR.CDB
Email Icon - Click on this icon to email one or file in the program directory. RODSTAR stores
more cases to Theta Oilfield Services, in case you all other information you enter in Setup in the
have questions. registry.
another user to use. This avoids the problem where Pump efficiency
the license may be locked onto that computer Pump fillage
because the user left the software running but left
there computer for an extended amount of time. Pump load adjustment
There is also a checkbox to save your work before Run time
the program exits in this fashion. This will allow
you to retain what you have worked on before the Standard steel sucker rod length
program exits. Steel rod service factor
Stuffing box friction
a rod string it begins with a single taper using the be selected from the option on the setup window.
smallest diameter set by the user. Once the tapers Once you select a guide for RODSTAR to use,
are set, the program balances the rod string then you can specify the amount of side loading each
the program checks the rod loading against these rod guide is designed to inhibit, and the amount
values. If the rod loading is more than what is of friction that the rod guides have against the
entered in these fields, it will redesign the string tubing. A friction coefficient value of 0.2 models
with stronger rods, rebalance the string, and check the friction between bare steel rods against steel
the loading against these values again. This routine tubing. To determine the friction value to use for
will continue until either the rod loading is equal your selected rod guides, consult the manufacturer.
to or less than the values entered here, or until the The manufacturer should be able to tell you, in
strongest rods are used. reference to the steel rod friction value, what the
rod guide friction value is for your rod guides. The
Here you will also see a checkbox which is labeled
manufacturer may tell you the rod guides have 2
Use all diameters when designing Rod String.
times the amount of friction as bare steel on steel
RODSTAR will use a single taper in designing the
tubing, then you would enter 2 * 0.2 which is 0.4.
rod string if it will satisfy the lifting requirement.
In cases where the loading is low enough to war- You can also specify the maximum and minimum
rant a single taper design, checking this checkbox number of rod guides per rod. When RODSTAR
will force RODSTAR to use a tapered design with recommends the rod guide placement, it will use
all the diameters between and including the max the minimum number of rods per guide if the cal-
and min diameters set by the user. This feature was culated number is less than the minimum number.
designed for users that use only tapered rod string The same is true for the maximum rod guides per
designs. rod. If the calculated number of guides per rod is
Figure 3.6d shows
the Defaults input
window for the de-
viated mode. Here,
in addition to the
default values and
rod stress loading
limits discussed
above, you can also
specify the type
of rod guides you
want to use. There
are two main op-
tions to the rod
guide selection, you
may enter the rod
guide information
manually or have
RODSTAR design
the rod guides for Figure 3.6d - Setting up default quantities for the deviated mode
you. To have the
program design the
more than the maximum value, then the recom-
rod guides for you, the preferred rod guide must
mendation will use the maximum number.
14 | Starting and Setting Up RODSTAR
This option will generate a cover page for the The maximum gearbox loading when the unit is
output report which contains all your company balanced. It is important to note that this score
information and the recipients information. You is based on a balanced unit. If your unit is not
can edit what information is on this page in the balanced, the actual loading will not correspond to
setup window under defaults. The user information the loading percentage displayed in this section. Be
that is set in defaults (such as user name and sure to observe the actual loading of the gearbox if
company name) is your information. The items the unit has not been balanced.
that are labeled as Second Company before the Maximum Rod Loading
item in defaults are for the recipients information.
This score is based on the maximum rod loading
For example, Second Company Name is the
of all tapers of the rod string. For example, if the
name of the recipients company. To add additional
rod string has three tapers, and each taper has a
information to the cover page, you may go to the
rod loading of 90%, 99%, 47% respectively, then
well information window and click the + button
the score will be based on the 99% loading of
next to the comment entry field. You can also edit
taper two. If the loading is low, the score will be
the cover page after the case is ran by clicking
lowered slightly because the rod string is over-sized
the + button on the bottom of the output report
or over-designed. If the rod loading is overloaded
window. After clicking the + button, you will
then the score is lowered severely as that will lead
see the main cover page editing window. You can
to premature failure in the rod string.
insert items such as the well information comment
RODSTAR| 15
Structure Loading unit, the rod string doesnt follow carrier bar and
separates from the pumping unit. This causes a
The structure loading score is based on the peak
severe problem where the system will suffer a
loading at the surface on the polished rod (peak
shock at the bottom of the stroke as the pumping
polished rod loading). This load is compared to the
unit begins the upstroke and the rod string comes
structural rating of the pumping unit to calculate
down on the carrier bar. The effect is like a very
the structural loading. Similar to the rod loading
large hammer, with the weight of the rod strong
score, the structure loading score is lowered
and fluid over the plunger, hitting the top of the
slightly if the unit is oversized and lowered severely
carrier bar on each stroke.
if the unit is overloaded.
Input data and calculated results
System Efficiency
This option prints one page showing all the input
This score is dependent on pump depth and
data and the results of the calculations, as well
production rate. This is because the maximum
as miniature predicted dynamometer and torque
efficiency fluctuates depending on the depth
plots.
and production. To further explain, a very deep
well requires a lot of energy to lift the rod string. Cost analysis
Comparing the energy required to lift the rod This option prints both the rod string and the
string to the energy required to lift the fluid (at pumping unit costs. You must already have entered
the given production rate) the maximum efficiency the costs into RODSTARs cost database (see sec-
drops. Based on this principle, the scoring of the tion 3.3.6, Cost Database, on page 23 for more
efficiency is adjusted so that the grade is calculated information).
on the appropriate scale.
Inflow performance (IPR) chart
Bottom Minimum Stress
Selecting this option gives you an additional page
This refers to the bottom minimum stress of with the IPR plots, the IPR data including the test
the sucker rods. This score is not affected by points, and a table of pressure versus production.
the bottom minimum stress of sinker rods or
sinker bars. If the bottom minimum stress on Dynamometer cards and Torque Plots
the sucker rods is negative, the score is lowered Selecting this option prints a separate single page
because compression in the sucker rods may cause containing the predicted surface and downhole
buckling. Buckling rods can cause tubing leaks dynamometer cards with the predicted permissible
and premature failures. If the stress on the bottom load diagram. It also prints the net gearbox torque
minimum stress of the sucker rods is high, the plots for existing and balanced conditions on the
score is lowered slightly. This is because the sinker bottom half of the page. The dynamometer card
bars are too long, which cause the high tension plot may also show the actual (measured) surface
on the bottom of the sucker rods, and the well dynamometer card (if you loaded a RODDIAG or
requires more energy to lift throughout the cycle XDIAG case into RODSTAR).
than necessary.
Additional items on Output Options:.
Minimum Polished Rod Loading
Deviation Charts
The minimum polished rod load is used to
determine this score. If the minimum load on If selected, it will add a page with deviation related
the polished rod is negative, the score is lowered charts such as side load as a function of measured
because the rod string will float. A floating rod depth, axial loading, buckling tendency, dogleg
string is where the pumping unit begins the down- severity, and the wellbore trajectory views from
stroke and, due to friction or speed of the pumping North to Looking down.
16 | Starting and Setting Up RODSTAR
first).
5. To remove a
unit from the custom-
ized list, simply drag
it from the list on the
left, and drop it in
the list to the right.
Or, you can click on
a unit once and then
click the Remove>>
button (in the middle
of the screen). To
make sure you select
the correct pump-
ing unit, highlight it
Figure 3.9 - Selecting a manufacturer (click on it once with
the mouse) and the
4. You can select the units to include in the cus- Name: and Other:
tom pumping unit list using drag and drop. To fields on the bottom of the screen will show
add a unit from the list of available units to the additional information about the pumping unit
custom database list, you simply drag (click on as shown in Figure 3.10. This is especially use-
it with the mouse and hold the left mouse but- ful for manufacturers (for example, American
ton while moving it) the units you want from conventional) who have more than one unit
the list on the right to the custom list on the with the same designation but different crank
left. Or, you can click on a unit once to select types. In such a case, the Other: field shows
it, and then click on the <<Add button (in the the crank type of the unit or other information
middle of the screen). The program automati- that helps identify the pumping unit type. This
cally arranges the units in the proper order is not the only way to customize the pumping
(largest stroke length and largest gearbox size unit database. As
discussed in the sec-
tion dealing with the
pumping unit infor-
mation screen, you
can also select a unit
you want to add to
the customized unit
list by first select-
ing it from the full
database and then
selecting to use the
custom pumping unit
list. At that point
RODSTAR will ask
you if you want to
Figure 3.10 - Customizing the pumping unit database add this unit to the
custom pumping unit
18 | Starting and Setting Up RODSTAR
database. If you do, then select Yes. of the pumping unit dimensions (see Figure 3.12).
To get more information on any of the dimensions
6. After you are done customizing the pumping
you see, simply click on it with the mouse. For ex-
unit list, click on OK.
ample, you can click on the P box to see detailed
help on the P dimen-
sion. Also, you can click
on the See Also hot
button to get help for
any other pumping unit
related item.
4. Enter the pumping unit data for your pumping 4. Enter the rest of the information for the rod
unit. you want to add and then click on the OK
button.
5. When you are done entering data click on
OK. RODSTAR allows you to select any of the avail-
able stress analysis methods. Once you enter a
If you need help with one of the items you have special rod grade to the program, it becomes part
to enter, press ! to get context sensitive help on of the programs equipment database and it works
that item. For example, if you press ! when you exactly the same way as RODSTARs built-in rod
are in one of the pumping unit dimension input grades.
fields, the program will show you an outline draw- For example, once you enter a special rod grade,
ing of the pumping unit with a visual explanation you can enter cost information for it, and you can
RODSTAR| 19
4 Running RODSTAR
To start RODSTAR, double click on its icon. example, all Windows programs have a menu bar
After a few seconds you will see RODSTARs with drop-down menus and a control menu box at
introductory window and then the RODSTAR the top left corner. You can access all menu items
main window. When RODSTAR first loads, only using either the mouse or the keyboard. Using the
the new file, open file, setup, and help buttons are mouse is by far the easiest way.
active on the toolbar. If you have not set up ROD-
When selecting an item from a menu, visual clues
STAR then do so before entering a new case (see
tell you what will happen next.
Chapter 1 for information on setting up ROD-
STAR). An item followed by no markings starts an
action. (For example, click on File and then click
on New.
the Recent Files sub-menu will show you up to diagram, press P and then click on Permissible
nine of the most recently accessed files. A file is load diagram.
placed at the top of the list whenever it is loaded, RODSTAR has context sensitive help for each
or saved with a new name. This list can also be ac-
cessed by clicking on the drop-down button on the input item. To access the help, simply press !
toolbar to the right of the open file icon. while in the input field in question.
double click it before typing in it. ing data in fields with yellow background color,
their color changes to white when you move to the
If an input window contains a name that is
next field.
made up of more than one word, double click any
word to select it. Then, to replace it, simply type a You can get context sensitive help for any input
new word. field by pressing !. Please use the context sensi-
To enter rod system data in RODSTAR for the tive help as often as possible because it contains
first time, click on the first icon on the toolbar or important information that will allow you to make
open the File menu and select New. This opens better use of RODSTAR. Also, the context sensi-
the Well Information input window, shown in tive help makes you aware of program assumptions
Figure 4.3. You can move this window with the or limitations.
mouse by dragging it to the desired location. Also,
you can use the mouse to resize this input window.
RODSTARs input windows use the following 4.2.1 Entering Well Information Data
unique color scheme: If you entered a company name in Setup, it appears
Required data input fields appear with a in the Company name field. This saves you from
yellow background. You must enter data in these having to enter the same company name every
fields before closing the window, continuing to the time you enter data. The date defaults to the date
next window, or running the calculations. in your computers memory. If the date in your
computer is not correct, you can type over it. The
The active input field or list box appears in well name is required because RODSTAR uses it
cyan. to create the default file name when you save data
This color scheme helps you to easily see what data to disk.
you need and where you are in the input window. The pump condition panel allows you to select
There are two ways of moving around in an input pump condition and pump efficiency or pump
window. You can click the input field you want, fillage. To select one of these input fields click on
or you can enter data in order by pressing T to the input field or its label. Press ! while in one of
move forward from field to field. Also, you can these fields for some useful information.
press S+ T to move backwards. After enter- The option to have the pump condition and fillage
26 | Running RODSTAR
calculated works along with the Production Infor- will not allow you to enter a value that is larger
mation window. When you select this option you than 15% of pump depth. Also, you can use this
must enter a pumping speed and IPR data in the input to add pump load for more conservative
second input window. Based on the SPM you en- predictions.
ter, RODSTAR calculates the pump displacement Please note that RODSTAR assumes that the
versus maximum available production from the tubing-casing annulus is full of oil. It calcu-
IPR data as well as the final pump intake pressure. lates the specific gravity of the oil from the API
RODSTAR uses an iteration scheme to converge gravity you enter. If you do not agree with this
to the correct pump condition and pump fillage assumption then change the oil API gravity
that will result from the SPM you enter, along to correspond to the specific gravity you want
with the calculated pump intake pressure. RODSTAR to simulate. For example, if you
The Production Information window also gives want to simulate water in the casing-tubing
you the option of having RODSTAR calculate the annulus instead of oil, then enter an API
required pumping speed based on a target produc- gravity of 10 (which corresponds to a fluid
tion you enter. However, the option of calculat- specific gravity of 1.0).
ing the SPM from your target production is
only available if you select a full pump. For fluid
pound or gas interference, you must enter a pump- Percent water cut
ing speed in the Production Information window. The percent water cut input along with oil API
gravity allows RODSTAR to calculate a default
specific gravity for the produced fluid. Also, it uses
Other input data in the Well Information window: this data to calculate $/bbl (or $/m3) electricity
costs.
Comment
You can enter a comment about the case. You can
type up to 100 characters in the comment field. Oil API gravity
The comment string you enter is included on the RODSTAR uses the oil API gravity to calculate
screen and printed outputs. fluid load on the plunger and the default specific
gravity of the produced fluid. Also, as discussed
above, RODSTAR uses this number to calculate
Pump Load Adjustment (Vertical Mode Only) the specific gravity of the fluid in the casing-tubing
The pump load adjustment allows you to increase annulus which it assumes to be 100% oil.
the fluid load picked up by the plunger. Usually
this is unnecessary. However, this input allows you
to account for extra downhole loads due to exces- Fluid specific gravity
sive downhole friction (for example due to wellbore RODSTAR uses the oil API gravity and per-
deviation), or due to the plunger effect of large cent water cut you entered to calculate the default
sinker bars. It is recommended that you use zero specific gravity of the produced fluid. The program
for this number unless you have more than 1000 will display this value when it prompts you to enter
feet of large sinker bars such as 15/8 or 1 bars the fluid specific gravity. RODSTAR calculates
in 2 tubing. The value of this number in pounds the default specific gravity without considering free
is typically 5% to 10% of the pump depth in feet. gas. This is okay for designing new wells since we
For example, for a pump depth of 6000 feet, enter prefer to be more conservative. However, if you
a value of 300 to 600 pounds (but only if you use want to simulate an existing system that produces
more than 1000 of large sinker bars). RODSTAR gas, you must enter a lower number than the one
RODSTAR| 27
calculated by RODSTAR. With some experience or you can select to calculate the target production
and with history-matching between predicted from inflow performance data.
and actual dynamometer cards you can come up If you choose to enter IPR data, the Production
with effective specific gravities that will accurately Information window expands to reveal the data
model your rod pumping systems. If you use a you must enter. This includes the correlation you
specific gravity that only considers liquids, it will want to use for the inflow performance relationship
result in higher predicted loads, power consump- (IPR), the depth from surface to the middle of the
tion, etc. perforations, the static bottom hole pressure, and
If you are designing a new system and you are not bubble point pressure. Also, you can enter from
sure what the specific gravity is, use the higher one to 10 test points. If you select to use the Vogel
value you expect to have to make sure that your method for the oil IPR calculations then you only
system will not be overloaded when in operation. need one point. If you use Vogel and enter more
However, when matching measured dynamometer than one point, then only the first point is used.
cards, use a specific gravity that is as close as pos- You can enter more than one test point if you use
sible to the actual value. the Fetkovich method. The pressure that cor-
responds to each production test point can either
After you finish entering data for the Well Infor-
be pump intake pressure or flowing bottomhole
mation window click on the next screen button
pressure (in the middle of the perfs). To add a new
(right arrow) on the toolbar to open the Production
pair of Pi and Fluid production data, click on the
Information input window. To move back to the
add button (top right) icon. To delete a set of data
previous window, simply press the left arrow icon
points, click on the remove icon (bottom right).
on the toolbar.
You can get help for any input item by pressing !
Remember that pressing @ converts to the op-
when in the input field or by clicking on the ques-
posite system of units. For example, if you selected
tion mark icon on the toolbar.
English units but want to enter the pump depth
in feet, press @ before entering the value. If the If you do not know what the bubble point pres-
value for any field with units
has already been entered,
pressing @ will show it in
the opposite units.
can use these calculated values as guidelines to friction coefficient. For example, the friction ratio
decide what values to enter yourself to better default value for molded rod guides is 1.5. This
simulate your rod pumping system. means that if you use molded rod guides, you need
2. For heavy oil or for wells with paraffin or scale to increase the rod-tubing friction coefficient by
50% to accurately simulate the additional rod-
buildup, use 2-3 times the value calculated by
tubing drag. So, if you use molded rod guides,
RODSTAR. You can use the same guideline
for deviated wells when the deviation is close to you need to enter a friction coefficient of 0.3
(0.2*1.5=0.3) for the section of the rod string with
the bottom of the wellbore.
the molded rod guides.
3. For deviated wells with the deviation close
Rod guide manufacturers need to provide you with
to the surface you may need to enter a larger
number such as 4-6 times as high as the values friction ratio values for the different rod guides
they make.
calculated by the program. Also, it may be
appropriate to use different values for upstroke
and downstroke frictions to better match your
downhole conditions. Buoyancy effects
The above comments refer to the vertical mode. The option to include buoyancy effects should
The deviated mode can calculate the effect of be left unchecked in most cases. This is because
deviation (such as side load) from the deviation buoyancy does not cause buckling of the rod string.
survey. However, for fiberglass-steel rod strings, after the
design is finalized, It is recommended that an ad-
ditional run be made including buoyancy effects to
ensure that the fiberglass portion of the rod string
RODSTAR Friction Coefficients
is not in compression. If it is in compression, then
In the deviated mode, the upstroke and down- more sinker bars must be used, the pumping speed
stroke rod-fluid damping coefficients on the pump need to be reduced, or both.
and tubing information window are only for fluid
damping on rods. Also, the deviated mode allows When buoyancy is not included, the bottom of
each rod section except the last section should have
you to enter rod-tubing friction (drag) coefficients
a positive stress. Otherwise the rods may be going
for each rod string section in the rod string input
into buckling. It is normal for the very bottom of
window. The default bare rod rod-tubing drag
the rod string to be in compression if you enter a
friction coefficient is 0.2. The range for this value
pump friction that is not zero (a minimum pump
is from 0.1 (for oil lubrication between smooth
friction of 200 lbs is recommended).
rods and tubing) to 0.3 (for high water cut wells
and rough rod and tubing surfaces). Again, the For more information on the theory behind these
best way to determine what to use is by plotting a recommendations, please read SPE paper num-
measured dynamometer card on the same plot as ber 25416 Interpretation of Calculated Forces on
the predicted dynamometer card and changing the Sucker Rods by J. F. Lea and P. D. Pattillo. Pre-
values of the rod-tubing friction coefficients for sented at the Production Operations Symposium
each section of the rod string. You can do this by in Oklahoma City, March 1993.
loading a RODDIAG or XDIAG file into ROD-
STAR.
To simulate the effect of rod guides, you need to Fluid inertia effects
adjust the friction coefficients for each section If the well depth is less than 4250 feet and the
of the rod string. You can use the ratio of guide pump plunger size is larger than 2.00 inches,
friction to bare rod friction to adjust the default RODSTAR allows you to consider fluid inertia
RODSTAR| 31
effects. These dynamic effects become important 4.2.4 Entering Rod String Data
in wells with plungers larger than 2.0 and pump
The fourth input window deals with the rod string
depths of 4000 feet or less. However, there is no
design. As Figure 4.8 shows, you can select one of
exact magic depth for which fluid inertia be-
the three available rod string entry options:
comes important. Therefore, RODSTAR allows
you to include these effects for wells up to 4250 RODSTAR Steel design, RODSTAR Fiberglass-
feet deep and with a plunger size equal to or larger Steel design, or Manual rod string entry. The
than 2.0. Another important factor is fluid com- symbols for these options are explained in Figure
pressibility. The more compressible the fluid is, the 4.8.
less prominent the fluid inertia effects are.
If you include fluid inertia effects, RODSTAR will
prompt you for the fluid compressibility index. The
default is 3 but you can vary this number between
1 and 7 (x10-6 psi-1). The compressibility index
tells RODSTAR how compressible the fluid in the
tubing is. The value of the compressibility index
affects the shape of the predicted dynamometer
cards (surface and downhole). If you are not sure
what number to use, experiment with different
values until you can match measured dynamometer
cards for the well you are simulating. When you
include fluid inertia effects, pump efficiency becomes Figure 4.8 - Rod string entry options
a variable that affects the dynamic fluid load on the
plunger. Therefore, using 90% pump efficiency gives
higher peak polished rod load than using 80%.
RODSTAR Steel Design
The option to include fluid inertia effects is only
available if you are modeling a full pump. Please If you select this option, RODSTAR displays
do not confuse fluid inertia effects with the mo- a window such as the one shown in Figure 4.9.
ments of inertia of the pumping unit that have to Here, you can select the maximum and minimum
do with gearbox torque due to prime mover speed rod diameters to consider, whether to include
variation. Fluid inertia effects refer to additional sinker bars, the service factor, and additional rod
dynamic forces on the plunger caused by the costs.
pickup and rapid acceleration of the fluid load. If you want to include sinker bars then you must
RODSTAR simulates fluid inertia effects with enter the diameter and length of the bar (or sinker
a second wave equation that models the pressure rod). RODSTAR does not calculate the length of
waves in the fluid in the tubing. This increases the sinker bar section because there is no industry
simulation accuracy by accounting for pressure consensus on how to design sinker bars. However,
pulses traveling up and down in the tubing fluid. RODSTAR will design the rod string above the
These pressure waves have a direct affect on the sinker bar section you specify.
pump plunger. Since the program has to do many RODSTAR attempts to design an optimum rod
additional calculations when you include fluid string based on the rod grade and the maximum
inertia effects, RODSTAR may take 60%-80% and minimum rod diameters you enter. First,
longer to run. RODSTAR figures out how many rod tapers are
needed. Then, it automatically adjusts the length
of each section until the stress loading is the same
32 | Running RODSTAR
rod string entry icon. RODSTAR will show you the effect of prime mover speed variation. Also,
the current rod string design in memory as if depending on the case, RODSTARs run time
you entered it yourself. Then, you can make any may be longer if you enter a target production that
changes you want to the rod string without having is too large for the pumping system.
to reenter everything. If you select only sinker bars on the bottom (with-
Also, you can have RODSTAR design the rod out regular steel rods between the fiberglass and
string while calculating the pumping speed and sinker bar) then RODSTAR will calculate the
plunger size, to get the target production. How- length of the sinker bar section for you. If you
ever, because of the complexity of the calculations, select both sinker bars and a tapered steel design
simultaneous use of all or most of RODSTARs between the sinker bars and the fiberglass rods,
smart options will result in longer run times. then you must enter the length of the sinker bar (or
This is especially true if you also select to include sinker rod) section. RODSTAR will determine the
length and diameters of the tapered steel portion program design the rod string for you). This is
based on the maximum and minimum diameter not a good option to use when you first design a
limits you enter. new system because it requires the most work and
experience.
RODSTAR may reject a steel rod diameter if it is
not needed. For example, if you asked RODSTAR When you select this option, you can enter data for
to design a rod string with fiberglass on top, a either steel or fiberglass rods as Figure 4.12 shows.
tapered steel section under the fiberglass, and a You can enter the number of rod sections, the ser-
500 foot 1.5 inch sinker bar section on the bottom. vice factor you want to use, and rod string data for
RODSTAR will determine the fiberglass diameter up to ten rod sections. For each section, you can
and length you need, and the steel rod section and select the rod type or grade, diameter, and length.
tapers you need. If RODSTAR cannot balance the For Fiberflex fiberglass rods you can also specify
steel rod string design because the 3/4 section is the sucker rod length. In the deviated mode, for
not needed, it will not use any 3/4 rods. each rod section, you may also enter the rod-tubing
friction coefficient, the type of rod guide, and
Another interesting capability of RODSTAR is
number of rod guides per rod. The rod-tubing fric-
that if you use continuous rods (Corod or Prorod)
tion is used to calculate the friction between the
instead of regular rods under the fiberglass, it may
rods and the tubing. This is different from the fluid
skip a rod diameter, if it has to, in order to bal-
friction coefficient which is used to calculate the
ance the rod string stress loading. This is not a bug.
friction between the rods and the fluid. In order
Sometimes the program has to do this to success-
to enter the number of rod guides for each section,
fully balance the steel portion of the rod string.
you must activate this feature in Setup. There is
more information about this in section 3.3.3.
Entering Your Own (Manual) Rod String If you select one of the fiberglass manufacturers
listed on the drop down list next to the rod grade
This option is primarily used for entering rod input field, the program knows the weight per foot
string data for an existing system you want to and modulus of elasticity and will not prompt you
simulate, or to modify a design that RODSTAR for them. The program warns you about rods that
itself came up with (when you select to have the
RODSTAR| 35
Figure 4.15 - Enter the number of entries The deviated mode has an additional
input window for entering wellbore
deviation shown in Figure 4.13. Figure
You can use the deviation import wizard option to as shown in Figure 4.18.
import an Excel spreadsheet or CSV file with de- Step 2 allows you to select the Workbook and
viation data, or to import a deviation survey from a Spreadsheet to use in cases where there are more
Theta software file which contains deviation data. than one in the Excel file as shown in Figure 4.19.
The two Theta file types that contain direction
survey data are RODSTAR files (extension .rsdx) Step 3 automatically locates the columns in the
and XDIAG-D files (extension .xddx). spreadsheet where the values are stored for the
Measured Depth, Inclination, and Azimuth as
To Import a Deviation Survey, click the Import shown in Figure 4.20.
Wizard button. Using the Import Wizard Dia-
log window, select the source of your Deviation The next step loads the data and then finishes as
Survey. In this example we are using a Microsoft shown in Figure 4.21.
Please keep in mind that for program to be able to The pumping unit ID is a unique string of letters
load the deviation data from an Excel spreadsheet, and numbers. RODSTAR displays the pumping
it must see three columns with the deviation data. unit ID along with other unit information after
These columns need to be labeled as follows: you select a unit. If you make a note of this unit
Measured Depth (ft) or MD (ft), or MD (m) ID (in the well file for example), you can use it
to specify the pumping unit instead of having to
Inclination select it from the list. This is a unique ID for each
Azimuth pumping unit in the programs database.
Clicking the Plot Survey tab on the right side Selecting a pumping unit manufacturer
of the window will display the Deviation Plot as
shown in Figure 4.23. From this screen, you can RODSTAR allows you to easily select a pumping
rotate the plot to better understand and visualize unit manufacturer and unit size with drop-down
the wellbore deviation, you can zoom in, etc. list boxes. To display the menu with all pumping
unit types available, click on the drop arrow next
to the Manufacturer field (see Figure 4.24).
4.2.6 Entering Pumping Unit Data This is a scrollable list of all units in the programs
The pumping unit input screen allows you to select database in alphabetical order. You can go to the
a pumping unit from the database that comes with
RODSTAR, or from your measured pumping unit
top of the list by pressing}. You can jump to
database (if you entered your own pumping unit the bottom of the list by pressing ~. You can
dimensions in Setup).
also move up or down by pressing O (Page up)
Another option is to enter a pumping unit ID.
or N (Page Down). A convenient way to move
42 | Running RODSTAR
through the list is to press the first letter of the option is checked, when you select a pumping unit,
unit name you want to use. For example, to locate you will see a short list containing only the unit
the National E Series pumping unit entry, you sizes you selected for your customized list for this
manufacturer.
can press n and the highlight bar will jump to
the first name in the list that starts with N. Then After you select a manufacturer you can use the
simply click on the National E Series entry. At same procedure to select the unit size you want
the top of the list of pumping unit manufactur- from the pumping unit drop-down list box . You
ers is the item (Measured pumping units). This can move through this list the same way as with
option allows you to select a unit for which you the pumping unit manufacturer selection menu.
entered geometric data in Setup. The pumping units on this menu are ordered from
largest to smallest stroke length, gearbox size, and
When you select the (Measured pumping units)
structure size. However, if the window shows the
option, RODSTAR will display a list that only
pumping unit name (for old units) the units are
shows the measured pumping units, as Figure 4.25
listed alphabetically.
shows.
When you enter a unit, the Unit ID, the program
As Figures 4.24 and 4.25 show, there is a check
automatically displays the unit that the ID cor-
box that allows you to use the custom pumping
responds to. RODSTAR displays the information
unit list instead of the main pumping unit list. If
necessary for you to correctly identify your unit.
you check this option, before you select a unit,
For example, for American conventional units you
the Manufacturer list will show a shorter list that
will see that certain unit sizes appear more than
contains only the manufacturers you selected in
once on the selection list. However, they have dif-
Setup in your custom unit list as shown in Figure
ferent cranks.
4.26. When the Use custom pumping unit list
RODSTAR| 43
How to add units to the custom pumping unit list Selecting to enter a pumping unit ID
You can use the Use custom pumping unit list The unit ID option is the fastest way to enter
check box to add units from the main list to your pumping unit information if you already know
custom list. For example, if you run across a pump- the pumping unit ID for your unit. You can see
ing unit that is not in your custom list yet, clear the pumping unit ID on the pumping unit entry
the Use custom pumping unit list check box so window after you select a unit. Once you locate
that you can use the general pumping unit list. your unit, you can make a note of its ID in the well
file. Then, the next time you want to use this unit,
After you select the pumping unit then click on you can select to enter its ID. For example, for a
the Use custom pumping unit list check box. Lufkin Mark II M-456-305-144, the unit ID is
RODSTAR asks if you want to add this pumping ML32.
unit to the custom pumping unit database. Select
Yes to add this unit to your custom list. The pro- To identify some units correctly, it is necessary
gram will add this unit to the custom list and also to know the crank number since they may have
switches to the custom list. the same API designation but different geometric
dimensions depending on crank number (primarily
This option only allows you to add units to your units made by American International Manufac-
custom list without having to do it from Setup. To turing Company).
remove units from your custom list or to add more
than one unit, go to the setup window and cus- TIP: If your unit is not listed in RODSTAR
tomize the list of units as described earlier in this and you do not have the unit dimensions, then
manual. use a unit that is closest to it. As long as you use
the same unit geometry and a unit with the same
44 | Running RODSTAR
stroke length and gearbox rating, the results shouldto use uncommon unit geometries such as the
be close to actual as long as the pumping unit is Rotaflex, then this recommendation may not be as
the same unit type as the one you selected. useful. RODSTAR makes this recommendation
without running through the predictive calcula-
If after you enter a pumping unit ID RODSTAR
displays The pumping ID you entered is not valid tions. Therefore, it may not necessarily recommend
the best pumping unit size for your application.
this means that ID you entered is not recognized
However, in most cases it should be pretty close to
by RODSTAR. This can happen for two reasons:
the size you need.
1) You entered the wrong ID such as R0 (which
There are other important factors that you must
does not exist), or CL901 instead of CL91.
consider when deciding what unit size you need.
2) You have erased the pumping unit file by acci- These include: available used pumping units, ex-
dent, or the pumping unit files are not in the same pected changes in well conditions, desired pump-
directory as the program. ing speed, etc. When you enter data for a case
RODSTAR Recommended unit size for the first time and you are at the pumping unit
selection screen, RODSTAR will not only display
If you enter a target production instead of pump- the recommended unit size, but will automatically
ing speed, RODSTAR will display a recommended select the unit closest to the recommended size
pumping unit size to help you select a pumping from the available list. If you do not want to use
unit. This recommendation can be very helpful the unit recommended by RODSTAR then select
if you are designing a new pumping system and another one. The recommended unit size is a push
must decide what size unit you need. RODSTAR button, as shown in Figure 4.27. So, whenever you
recommends sizes that are closest to conventional want to return to the pumping unit size recom-
units as Figure 4.27 shows. Therefore, if you plan mended by RODSTAR, just click the button and
RODSTAR| 45
RODSTAR will automatically select the unit size in RODSTARs database, you can enter your own
that is closest to the recommended size. pumping unit dimensions. To enter the data in the
program you have to first access the setup screen
In general, the size recommended by RODSTAR
of RODSTAR (click on fourth button on toolbar).
will be close to the minimum required conventional
Then, double-click on Pumping Unit Options
unit. RODSTAR recommends only the API unit
tab and select Measured Pumping Unit List as
size. You must decide what manufacturer and
explained in section 3.3.5 in this manual. Then,
unit type to use. If you select a conventional unit
select to add a new unit to enter data for a new
and RODSTAR predicts that the gearbox will
pumping unit.
be overloaded, then try using the same size Mark
II or enhanced geometry unit. In some cases you The data you must enter consists of geometric
may be able to use a smaller unit by selecting a dimensions as defined in the API 11E publication.
geometry that is better suited for your application. You can get these dimensions from the pumping
There are several factors that determine what unit unit manufacturer or measure them yourself. Or,
is best. They include, cost, gearbox loading, system you may be able to find most of the dimensions
efficiency, rod compression, minimum polished rod you need from catalogs or blue prints. For old units
load (indicates separation of the polished rod from without an API designation on their nameplate,
the carrier bar if close to zero), etc. you may be able to put together an equivalent API
designation. Look at the gearbox nameplate for the
gearbox rating in thousands of in-lbs. Measure the
stroke length, and try to decipher additional infor-
Selecting crank hole number and crank rotation mation from the units nameplate for the structure
rating, stroke length, and structural unbalance.
After you select a pumping unit you must select If the nameplate is legible then write down the
the crank hole number, and the direction of rota- units serial number or order number. If the units
tion with the well to the right (if you are using a manufacturer is still in business, you may be able
unit that can rotate either way). For units with a to get the data you need from the serial number
required direction of rotation, like the Mark II , or order number. For help in locating dimensional
Torqmaster, Lufkin Reverse Mark, or American data for pumping units not in the manual call
Producer II, the program will not allow you to Theta Oilfield Services, Inc..
change crank rotation. For units that can rotate
either clockwise or counterclockwise, RODSTAR RODSTAR allows you to enter data for Conven-
defaults to the direction of rotation that will usu- tional, Mark II, Air Balanced, Enhanced Geom-
ally give the lowest torque. However, this default
direction of rotation may not always be ideal for
your system design. To find out for sure which
rotation is best for your system you must make
two runs: one with clockwise crank rotation and
one counterclockwise. Then look at the effect of
rotation on gearbox torque, system efficiency, rod
loading, etc.
K Distance from the center of the K Distance from the center of the
crankshaft to the center of the crankshaft to the center of the
saddle bearing (inches). Some- Sampson Post bearing (inches)
times, instead of the K dimen- H Height from the center of the
sion, pumping unit manufacturers saddle bearing to the bottom of
supply data for dimensions H and the base beams (inches)
G instead (described below). From
these dimensions and dimension I G Height from the center of the
(defined above) you can calculate crank shaft to the bottom of the
base beams (inches)
2
)
K as follows: K= ( H-G + I
2
H Height from the center of the Air Balanced Pumping Unit Data
saddle bearing to the bottom of
the base beams (inches) For these units you must also enter pumping unit
dimensions R, A, C, I, P, and K in inches. In ad-
G Height from the center of the
crank shaft to the bottom of the dition, you need data for M, S and V0.
base beams (inches)
Dimension: Description:
R Radius of the crank (inches)
A Distance from the center of the
Sampson Post bearing to the cen-
terline of the polished rod (inches)
C Distance from the centerline of the
Sampson Post bearing to the cen-
ter of the equalizer (or cross yoke)
bearing (inches)
I Horizontal distance between the
centerline of the Sampson Post
bearing and the centerline of the
crankshaft (inches) Figure 4.31 - Air Balanced
P Effective length of the pitman
arm, in inches (from the center of The API spec. 11E defines the above dimensions
the equalizer (or cross yoke) bear-
ing to the center of the crank-pin as follows:
bearing)
Dimension: Description:
R Radius of the crank (inches)
48 | Running RODSTAR
A Distance from the center of the For these units you must enter pumping unit
Sampson Post bearing to the cen- dimensions R, D, I, and K in inches and the crank
terline of the polished rod (inches) offset angle in degrees. The crank offset angle is
C Distance from the centerline of negative for these units. The structural unbalance
the Sampson Post bearing to the for belted low profile units is negligible and there-
center of the equalizer bearing fore zero because, when you disconnect the pitman
(inches) arms from the belt, there is no counterbalance
I Horizontal distance between the from the belt and bridal assembly. We define the
centerline of the Sampson Post above dimensions as follows:
bearing and the centerline of the
crankshaft (inches)
P Effective length of the pitman
arm, in inches (from the center of Dimension: Description:
the equalizer bearing to the center R Radius of the crank (inches)
of the crank-pin bearing) D Diameter of the drum (inches)
K Distance from the center of the which holds the belt
crankshaft to the center of the I Horizontal distance from the
Sampson Post bearing (inches). centerline of the saddle bearing
M Geometry constant (in2). It is the to the centerline of the crankshaft
distance from the Sampson Post (inches)
bearing to air tank bearing (dis- K Distance from the center of the
tance X in Figure 2.3) multiplied crankshaft to the center of the
by the area of the piston in the air drum bearing (inches). Sometimes,
cylinder divided by dimension A instead of the K dimension, pump-
or: X*Ap/A, where Ap is the area ing unit manufacturers supply data
of the air cylinder piston in square for dimensions H and G instead
inches. (described below). From these di-
S Pressure in the air counterbal- mensions and dimension I (defined
ance cylinder required to offset above) you can calculate K
the weight of the walking beam,
horsehead, equalizer, pitman arms, 2
)
as follows: K= ( H-G + I
2
etc. (psig).
V0 Minimum air volume between the H Height from the center of the
plunger and cylinder at the bottom drum bearing to the bottom of the
of the stroke (in3). base beams (inches)
G Height from the center of the
crank shaft to the bottom of the
base beams (inches)
hydraulic pumping unit. then click on the Unknown check box and
RODSTAR will calculate it for you.
For beam pumping units except for air balanced,
Definition of Structural Unbalance
you can enter a maximum counterbalance moment
Structural unbalance is a term used for pumping in thousand inch-lbs. RODSTAR also gives you
units with walking beams. It is defined in API the option to import the maximum counterbalance
11E as the force you need at the polished rod to moment from a XBAL file or from the clipboard.
hold the walking beam horizontal with the pitman If you ran XBAL before running RODSTAR,
arms disconnected from the crank pins. This force then the value of the existing maximum counter-
is positive when acting down and negative when balance moment will be in the clipboard. Then, as
acting up. See Figure 4.34 for a visual explanation soon as you click on the Use XBAL information
of structural unbalance. Structural unbalance for button, RODSTAR will allow you to use the value
conventional units can be either positive or nega- exported by XBAL or to read a XBAL file from
tive. For Mark II units it is always negative. If you disk.
do not know the structural unbalance for the unit
For air balanced units you must enter the air cyl-
you want to simulate then enter zero. In most cases
inder pressure in psig at the bottom of the stroke.
the structural unbalance will not affect the results
For long stroke units you must enter the counter-
significantly (especially for Conventional geometry
balance weight in thousands of pounds. For these
units).
units, the option to read a XBAL file is disabled
since it does not apply.
Definition of Crank Offset Angle If you enter existing counterbalance data, ROD-
The crank offset angle (or crank phase angle) is STAR calculates and displays the permissible
the angle between a line through the crank holes load diagram for existing conditions. Also, the
and a line through the counterweight arm. Figure recommended prime mover size and overall system
4.35 shows how the crank offset angle is defined. efficiency will be for the existing conditions. If
RODSTAR expects a positive crank offset angle you select unknown for maximum counterbal-
for Mark II units and a negative one for enhanced ance moment then RODSTAR calculates all these
geometry units such as the Torqmaster, Lufkin numbers and the permissible load diagram for bal-
Reverse Mark, or American Producer II. For anced conditions only.
conventional pumping units the crank offset angle The range of allowable counterweight is differ-
is zero. ent for different Rotaflex units. RODSTAR takes
this into account when validating your entry for
counterbalance weight. For example, the mini-
Entering Counterbalance Information mum counterweight possible for the 1200 model
After you select a pumping unit or enter your own is 13,500 lbs. Therefore, if you try to enter a coun-
pumping unit data, the crank hole number, and terweight that is less than 13.5 M lbs, (M =thou-
direction of rotation, you must enter counterbal- sands) RODSTAR will warn you that the counter-
ance information. weight for this unit must be between 13.5 and 32.5
M lbs.
Entering an existing maximum counterbalance
moment allows you to simulate an existing sys-
tem to find out if the unit is overloaded or out of Changing Structural Unbalance
balance. If you only want to find the maximum
counterbalance moment required to balance the In some cases, when the pumping unit is signifi-
unit (which is usually the case for new designs) cantly oversized for the downhole equipment, you
RODSTAR| 51
may have to add counterweights on the walking ratchet prevents it from turning the other way.
beam next to the horsehead to balance the unit. Therefore, if your unit is generating electricity, you
This changes the structural unbalance from the do not get credit for it. The non-detent meter can
catalog value. RODSTAR allows you to change rotate either way and so it credits you for electricity
the structural unbalance even when you select a the pumping unit generates.
pumping unit from the programs database.
The structural unbalance field can also be used to Prime mover type selection
simulate beam balanced units. By changing the
value of the structural unbalance, you can figure Using drop-down list boxes you can select the
out how much weight you need to add or remove motor type you want to simulate. RODSTAR has
from the walking beam to balance a beam bal- motor performance and efficiency data for NEMA
anced unit. D, Sargent Ultra High Slip, Reliance Ultra High
Slip motors, and Rotaflex Multi-HP NEMA
C motors. If you select a NEMA D motor you
4.2.7 Entering Motor Information and Energy Cost can enter a motor size, or you can choose to have
RODSTAR recommend a NEMA D motor for
RODSTAR can simulate NEMA D or ultra high you. If you select an ultra high slip motor then you
slip motors and calculates power consumption must select the motor size and torque mode. If you
from actual motor efficiency curves. The program select a motor size or mode that is too small for
uses the electricity cost you enter to predict the the well conditions then RODSTAR will display
monthly electricity bill, $/bbl fluid, and $/bbl oil a warning message and will give you the option to
(based on water cut). RODSTAR defaults to the change your data.
cost number you specify in Setup. The $ symbol
here is meant to represent currency (not just US RODSTAR warns you if you select an ultra-high-
dollars). As Figure 4.36 shows, under the electric- slip motor when you have selected an air-balanced
ity cost input box there are option buttons that you or long stroke pumping unit. These units have little
can use to select the power meter type. You have or no rotating moment of inertia, so using an ultra-
two options: Detent, or Non-detent. A Detent high-slip motor does not result in any significant
KWH meter can rotate only in one direction. A differences in the calculations. Therefore, for these
52 | Running RODSTAR
units, do not select an ultra high slip motor or to less than the maximum expected speed variation
include speed variation effects. for your prime mover. Selecting to include prime
If you select a NEMA D motor type for a new mover speed variation will approximately double
case, or switch from an ultra-high-slip motor to RODSTARs run time.
a NEMA D motor, RODSTAR automatically
selects the option to recommend the motor size.
What is moment of inertia?
Although this manual is not intended to teach
Motor speed variation engineering or physics, it is important to briefly
The option to include the effect of motor speed explain moment of inertia and how it can affect
variation is only available for conventional, en- RODSTARs results. The mass moment of inertia
hanced geometry, and Mark II units. Inertia ef- of a body is a measure of its resistance to accelera-
fects are negligible for long stroke and air balanced tion. In other words, the higher the moment of
units. inertia of a body, the more difficult it is to quickly
speed it up or slow it down.
If you select not to include speed variation effects
then RODSTAR assumes constant prime mover The rotating and articulating moments of inertia
speed and will not model the effect of pumping are important in accurately simulating the behavior
unit inertia. If you choose to include speed varia- of the pumping unit and in calculating net gearbox
tion then RODSTAR gives you the option to enter torque when you use a high speed variation prime
a percent speed variation or have the program mover. The rotating moment of inertia that ROD-
calculate the speed variation for your prime mover. STAR needs is the total rotating moment of iner-
tia. This includes the individual rotating moments
of inertia of the cranks and counterweights about
Pumping unit moments of inertia the slow speed shaft of the pumping unit, the total
gear reducer inertia, and the motor rotor inertia.
If you select to include the effect of motor speed The articulating moment of inertia of the pumping
variation then you can enter a rotating moment unit around the saddle bearing includes the inertia
of inertia in lbs-ft2, or have the program estimate of the walking beam, horsehead, and pitman arms.
this number for you. For the articulating moment
of inertia RODSTAR defaults to a number that As mentioned above, you can either enter a rotat-
is either the actual articulating moment of inertia ing moment of inertia, or you can have ROD-
supplied by the pumping unit manufacturer, or STAR estimate it for you. To calculate accurately
an estimate based on unit size. Therefore, unless the rotating moment of inertia you must have
you have an even more accurate number for the moment of inertia data for the cranks and coun-
articulating moment of inertia, it is recommended terweights, gearbox, motor rotor, etc. Also, the
that you use the default number displayed by the rotating moment of inertia depends on the position
program. of the counterweights on the cranks. Since this
data may not be known, it is recommended that
For more accurate results, have RODSTAR cal- you let RODSTAR estimate the rotating moment
culate the prime mover speed variation. However, of inertia for you.
you can also enter a speed variation value if de-
sired. If you select to enter speed variation, ROD- Since the articulating moment of inertia depends
STAR shows a default value of 8% which corre- on the walking beam size, horsehead and pitman
sponds to a recommended average speed variation arms, it is a fixed number for any given pumping
for NEMA D motors. You can get more conser- unit. Therefore, it is easier to calculate than the
vative results by entering a speed variation that is rotating moment of inertia. RODSTARs pump-
ing unit data base contains accurate articulating
RODSTAR| 53
5.1 Visual Input then choosing Save As... This brings up a stan-
dard Windows dialog box that allows you to save
Figure 5.1 shows RODSTARs visual input facil- your file with the file name you want. RODSTAR
ity that makes it easy to locate a system parameter shows the default file name it creates from the well
you want to change. As you are entering the data name and by adding an .RSVX file name exten-
for a new case, or after you have loaded a case from sion for vertical cases or .RSDX for deviated
disk, the visual input window can be displayed by cases. If you enter data for a case in the deviated
clicking on the Visual Input button on the toolbar.
This shows an interactive picture of the pumping
system.
As you move your mouse over the picture of the
system, tool tips appear naming various parts of
the system. Whenever a tool tip is showing, you
can right-click with the mouse to get a pop-up
menu listing input variables associated with that
part of the system. This visual way of changing
data is more useful when you are changing data
in existing files or when you are making what
if... runs. If you are entering a case from scratch,
menu items that correspond to data you havent yet
entered will be disabled.
Left-clicking when a tool tip is displayed opens the
data entry window associated with the part of the
system you clicked on. Another way to change data
is to click on the Alphabetical list button at
the bottom of the visual input window. This brings
ups an alphabetical listing of all variables you can
change. You can locate the variable you want to
change by scrolling down using the mouse.
mode but do not enter deviation survey data, the output then you can view and print the output
program will save the file with an extension of without having to rerun the case.
.RSVX instead of .RSDX. You can change the
file name by typing over it, but you cannot change
the file name extension. When you type your own
file name, you do not have to type the file name 5.3 Running and Viewing the
extension. RODSTAR automatically adds this
extension for you. Output
You do not have to store your data every time After you enter all your data and you press the
you make a change. It is recommended that you Next Screen button from the motor information
save the original data and then wait until you get window, the Run button on the toolbar becomes
a good design before storing data to disk. After active. To run the program simply click on the
saving data once, RODSTAR makes it very easy Run button on the toolbar (the dynamometer card
to update the file with the data in memory with a icon to the right of the right arrow icon). Another
single mouse click on the Quick Save button on way to run the program is to click on Run on the
the toolbar. menu bar. After RODSTAR runs, it displays the
output report, as Figure 5.2 shows. At the bottom
If you save your data after running RODSTAR of this screen there are buttons that allow you to
and the output is displayed on screen, then ROD- view the dynamometer, torque, or IPR plots and
STAR saves both the input and output in the file. the report. When you select to see the dynamom-
This is advantageous because once you save the
eter plots, you can select to animate then surface mum energy consumption.
and downhole pump cards. The most common way to balance a unit is for
To look at different parts of the output you can minimum torque. However, if the gearbox is not
click the appropriate buttons at the bottom of the overloaded, you may want to balance the unit for
screen (Dynamometer, Torque, IPR Plot, Dev. minimum energy consumption instead.
Plots when using RODSTAR, or Report). When After viewing the output you can decide which
you click on Report, you can scroll up or down value of balanced counterbalance moment you
with the mouse, or you can click and drag on the want to export to XBAL (so that XBAL can
report itself. Figure 5.3 shows the bottom section calculate the counterweight positions required to
of the summary report. The summary report looks balance the unit). When you click on the Export
exactly the same as the printed report. CBM... button, RODSTAR displays the window
If you have XBAL on your computer, you can have shown in Figure 5.4 (if there are two possible ways
RODSTAR export the balanced maximum coun- to balance the unit). Click on the option you want
terbalance moment it calculates to XBAL. You and click on the OK button. RODSTAR confirms
can do this any time the calculations have been that the value of the maximum counterbalance
run (whether or not you are actually viewing them) moment has been exported by displaying the mes-
by clicking on the Export CBM button on the sage box shown in Figure 5.5.
toolbar ( ).
RODSTAR can calculate two possible ways to 5.3.1 Saving the output
balance a unit: for minimum torque, or for mini-
RODSTAR| 57
You can use RODSTAR to quickly design any rod accurate and reliable.
pumping system, compare pumping units, sucker
Because RODSTAR can predict energy consump-
rod designs, insert versus tubing pumps, clockwise
tion very accurately, you can use it to select the
versus counterclockwise crank rotation, include
most economic system designs. The following
IPR modeling in your predictions, etc. ROD-
sections explain how to apply RODSTAR to solve
STAR can calculate the pumping speed, pump
common design problems. As you become more
plunger size, and rod string design for you. Also,
familiar with RODSTAR you will discover many
it can recommend motor size and pumping unit
different applications for this powerful rod pump
size based on your target production. These power-
system design tool. RODSTARs capability to read
1. History match existing rod pumping systems report page. Also, it shows buttons on the bottom
before you make a design change. This allows of the output window that allows you to access the
you to figure out unknown quantities such as predicted dynamometer plot, torque plot, IRP plot
rod-tubing friction. (if IPR data was entered), or return to the output
report as Figure 6.1 shows.
2. Detect an out-of-calibration load cell (used
to record the actual dynamometer card) by
checking for a consistent shift in actual versus
predicted dynamometer card shape. 6.1.1 Dynamometer and Permissible Load Plots
3. Detect incorrect fluid level measurements due When you click on the Dynamometer button
to foam in gassy wells. then you see the predicted surface and downhole
dynamometer card plots along with the permis-
sible load diagram as shown in Figure 6.2 . These
plots show the predicted surface and downhole
dynamometer cards, measured surface dynamom-
6.1 Understanding RODSTARs eter card from a RODDIAG or XDIAG file (if
Output you selected that option), and the permissible load
diagram. RODSTAR uses a permissible load
To maximize the benefit of using RODSTAR, diagram that shows if the gearbox or structure
it is important to understand its output. After of the pumping unit are overloaded or if the
RODSTAR runs, it displays the summary output minimum polished rod load is negative. This
is different than the traditional permissible load anced condition (for minimizing gearbox torque).
diagram that only shows whether the gearbox is Note!: The above discussion about ROD-
overloaded. This extended permissible load dia- STARs permissible load diagram refers to
gram can be made up of curved lines only, combi- beam pumping units. The permissible load dia-
nation of curved and straight lines, or straight lines gram for long stroke units such as the Rotaflex
only. If the upstroke part of the predicted surface will have straight line segments that corre-
dynamometer card exceeds the curved line of the spond to gearbox loading or structure loading.
permissible load diagram this indicates that the Please look at the structure loading number
gearbox is overloaded at that point. If the dyna- on the first page of the output and the percent
mometer card cuts into the straight line section of gearbox loading under torque analysis for the
the permissible load diagram on the upstroke, this exact percent unit loading.
indicates that the structure of the pumping unit is
overloaded because the polished rod load is larger In addition to showing whether the gearbox is
than the structure rating of the unit. overloaded, the permissible load diagram also
shows how well the pumping unit matches the
For the exact numbers of peak net gearbox torque load requirements of your system. If the predicted
and gearbox loading, look at the torque analy- polished rod dynamometer card fits nicely in the
sis section of the printout. The permissible load permissible load envelope, this indicates a good
diagram corresponds to existing conditions if you agreement between the pumping unit and the rest
entered a counterbalance moment. If you did not of the system.
enter an existing max. CB moment then the pro-
gram shows a permissible load diagram for bal- However, if the predicted surface dynamometer
card shows a trend that is opposite that of the include prime mover speed variation. If you in-
permissible load diagram, this shows that design clude speed variation the permissible load diagram
changes are necessary to avoid overloading the will tend to reflect changes in polished rod load.
pumping unit and to better match it to the rest of This is because the permissible load diagram in
the system. If the permissible load has a trend that RODSTAR includes the effect of rotating and ar-
is opposite than the predicted dynamometer card, ticulating moments of inertia. As the prime mover
it may indicate that the pumping unit you selected speed changes, this causes changes in polished rod
is not the best geometry for this application. Or, velocity and acceleration which in turn changes the
that you may have to change the spm, plunger size, polished rod load and the distance between the dy-
rod string design, or stroke length to get a better namometer card and the permissible load diagram.
match between the dynamometer card and permis- The output window has new buttons that allow
sible load diagram. you to animate the calculated dynamometer cards.
Including prime mover speed variation and inertia Figure 6.2 shows a play button (the one with the
effects will alter the shape of the permissible load double arrow) which causes small dots to move
diagram. The lines will be smoother if you do not around the surface and downhole dynamometer
cards; a stop button which makes the movement as Figure 6.4 shows. Also, it shows a line with the
stop; and a step button (the one with the single current bottom hole pressure and the test points
arrow) which lets you move the dots one time-step you entered. The line below the title of the plot
at a time, while holding the button down moves shows the correlation you selected to use for the
the dots in slow motion. This facility can be used oil IPR and if you selected the Fetkovich method,
to get a better understanding of rod stretch effects it shows the value of n. If you only enter one test
and other phenomena such as the position and point, n is set to one. If you enter two or more test
speed of the pump plunger and how this relates to points then RODSTAR calculates the value of n
the surface dynamometer card. by doing a log-log plot. For water, RODSTAR
uses a straight line IPR.
From this screen you can look at any other part of
the output by clicking the appropriate option at
the bottom of the screen. For example, to view the
torque plots click on Torque. Also, you can select 6.1.4 Report
to view the report on screen, or you can send the To see the report, click on the Report button.
output to the printer. After you are done viewing You can scroll this window using the mouse by
the output, close the screen by clicking on Close. clicking or the up or down arrows at the top or
bottom of the range bar on the right edge of the
window.
6.1.2 Torque Plot Or, you can click and drag the range bar or the
When you click on the Torque Plot button report itself with the mouse.
RODSTAR displays the net gearbox torque plots
for existing and balanced conditions. If you entered
an existing maximum counterbalance moment, Input and Output Summary
then you may see a plot with up to three curves: The summary report that appears when you first
one for existing conditions, one for balanced con- run RODSTAR shows input data on the left side
ditions for minimum torque, and one for minimum of the page and calculated numbers on the right
energy consumption. If there is no difference be- size. The top part of the printout shows the com-
tween the curve for minimum torque and the one pany name, well name, user name, date of the run,
for minimum energy, then the program shows only and comment. Following is a detailed explanation
two curves (existing and balanced). If you selected of each item on the output.
unknown max. CB moment then RODSTAR
will only show one curve if there is little difference
between balanced for min. torque vs balanced for Polished Rod Loads and Horsepower
minimum energy consumption (see Figure 6.3).
The peak and minimum polished rod loads show
Otherwise, it will show two balanced curves: one
the polished rod load fluctuation predicted by
for minimizing torque and one for minimizing
RODSTAR. The polished rod horsepower shows
energy consumption.
how much work the pumping system is putting
into the rod string to lift the predicted production
from the present fluid level to the surface.
If you entered a target production or used IPR data
6.1.3 IPR Plot to determine the target production, RODSTAR
When you click on the IPR Plot button, ROD- calculates the SPM required to get the target pro-
STAR displays separate oil, water, and fluid pro- duction.
duction versus flowing bottomhole pressure plots
RODSTAR| 67
results. Also for fiberglass rod strings, you should lated stroke length, the structural unbalance, the
keep N/No below 1.0 and above .4 for best results. crank offset angle, crank rotation with the well
to the right, and the crank hole number. If you
entered your own pumping unit dimensions for a
Prime Mover Speed Variation unit not in the programs database, if the calculated
If you select to have RODSTAR calculate the mo- stroke length is different from what you think it
tor speed variation for you then this section shows should be, check the pumping unit data to make
what this number is. For NEMA D motors this sure you entered the right dimensions. If you se-
number will vary from 2% to 14% depending on lected to include speed variation and inertia effects
motor size. For correctly sized ultra high slip mo- in the calculations, RODSTAR will also print the
tors it can be as high as 50%. If motor speed varia- rotating and articulating moments of inertia.
tion is not considered then this will be indicated
on the output report.
Torque Analysis and Electricity Consumption
In this section, the program prints the predicted
peak gearbox torque, percent gearbox loading,
Pumping Unit Data cyclic load factor, maximum counterbalance mo-
ment, and counterbalance effect. Also, it calculates
This section (see Figure 6.5) shows the pumping electricity consumption. RODSTAR predicts the
unit you selected, the pumping unit ID, the calcu- KWH consumed per day, the estimated monthly
bill, and cost per barrel of fluid and per barrel of smaller this number is, the more uniform the net
oil per day. Use the cost per barrel numbers when gearbox torque is. Also, a smaller cyclic load factor
comparing system performance to ensure a valid will result in higher system efficiency because of
comparison. This is because a system that shows less thermal losses in the motor.
a lower monthly bill may also be producing less
fluid.
Tubing, and Pump Information
If you enter a non-zero maximum counterbalance
moment the program calculates the above num- Here you see the tubing inside and outside di-
bers for both existing and balanced conditions. If ameters, the anchor depth, the calculated tubing
the existing max. CB is unknown, it will calculate stretch, the upstroke and downstroke rod-tubing
the above numbers for balanced conditions only. friction factors you entered or that were calculated
RODSTAR has the capability to balance pumping by RODSTAR, pump load adjustment., etc. Also,
units for minimum torque and minimum energy. If this section shows the pump depth, the pump
the maximum counterbalance moment for mini- type, and plunger size.
mum energy equals the one for minimum torque RODSTAR uses the pump volumetric efficiency
then the program shows only one recommendation you enter to calculate the expected production rate.
for balanced conditions. However, if the two values When you ask the program to calculate the spm
are more than 2% different then it shows two bal- by entering a target production, it will calculate a
anced columns: One for minimum torque, and one larger spm if you enter 80% pump efficiency than
for minimum energy. The torque plots show how when you enter 90% pump efficiency.
net gearbox torque changes throughout the pump-
ing cycle for existing and balanced conditions.
To maximize gearbox life you must keep gearbox Tubing, Pump and Plunger Calculations
loading less than 100%. The cyclic load factor This section shows tubing stretch and production
indicates how smooth the gearbox torque is. The loss due to tubing stretch, gross pump stroke, the
pump spacing recommendation, minimum re- to use a design with a negative bottom minimum
quired pump length, and recommended plunger stress on the fiberglass section even with buoyancy
length. The pump spacing recommendation should effects included. Compressive loading will cause
be used as follows: fiberglass rods to part. Also, to maximize rod
life, stress loading must be less than 100% in all
After working on the well and before you
cases. For sinker bars, RODSTAR calculates stress
are ready to restart the pumping unit, make
loading, top maximum and top minimum stresses
sure the tubing is full of fluid. Then lower the
based on the elevator neck or pin undercut diam-
rod string slowly until it tags bottom. Then
eter of the sinker bars. However, RODSTAR still
raise the rod string a distance equal to the one
uses the full body diameter in the calculation of
recommended by RODSTAR next to: Pump
stress at the bottom of the sinker bar section.
spacing (in. from bottom): Then, attach the
polished rod to the bridle with the unit stopped
at the very bottom of the downstroke. Rod String and Pumping Unit Cost Analysis
Please note that the working fluid level makes a This section shows the cost of each rod section as
big difference in pump spacing and pump length. well as the total rod string cost (see Figure 6.6).
This is especially true for fiberglass rods since the Also, below the rod string cost is the pumping
plunger travel is strongly dependent on fluid load unit cost. RODSTAR shows the cost information
on the plunger. only if you select this option in Setup. You must
first enter rod string and pumping unit cost data in
Setup before RODSTAR can show you accurate
Rod String Design and Stress Analysis
cost information here.
This section shows the rod string design and ser-
vice factor you selected, the calculated percent rod
loading for each rod section, the maximum and Inflow Performance Relationship Information
minimum stresses at the top, and the bottom min- This section shows the correlation used for oil
imum stress for each rod section. To ensure your IPR, mid-perf depth, the static bottomhole pres-
rods are in tension, do not include buoyancy effects sure, and the bubble point pressure (if entered) or
(this should always be the case for steel rods). whether the well is producing below the bubble
Then, make sure there are no negative stresses on point pressure. Also, it shows a table of input test
any other rod section other than the sinker bar sec- point data of flowing bottomhole pressure versus
tion on the bottom of the rod string. measured production, and a table of pressure vs.
If you are using fiberglass rods you would not want production table. As Figure 6.7 shows, this table
RODSTAR| 71
shows separate oil, water, and fluid production the bottom. It will display the first deviation
rates for different pump intake pressures. related plot as shown in Figure 6.9. This plot
shows side load as a function of measured depth.
All deviation plots show colored lines that
correspond to different sections of the rod string.
6.2 RODSTAR (Deviated Mode) The calculated side load affects is used by the
program to determine the number of rod guides
Output and their spacing, using rod guide manufacturer
In addition to the output quantities discussed recommendations. Click on the Next button
above, the deviated mode calculates and prints on the bottom of this plot to see the rest of the
numbers and plots that are related to wellbore deviation-related plots.
deviation. Following is an explanation of these The next plot is the maximum and minimum axial
outputs that are unique to the deviated mode. loading. This plot shows how the maximum and
minimum rod loads change as a function of mea-
sured depth.
6.2.1 Deviation Plots
The buckling tendency shows the buckling ten-
After RODSTAR runs, it will display the dency load as a function of measured depth. It is
summary output page as shown in Figure 6.8. generally accepted that buoyancy does not cause
When you click on the Dev. Plot button on buckling. The bottom of the rod string is sub-
72 | Rod Pump System Design
surface of the well will result in a larger side load If you click on the Report button shown in
as compared to the same dogleg severity close to Figure 6.8, the program will show you a one-page
the bottom of the hole. This is because the tension summary of all the deviation plots as shown in
in the rods is much higher at the surface and thus, Figure 6.10. This page looks exactly the same as
it results in larger side loads as compared to the the printed page when you print the report. You
bottom of the rod string where axial load is much can also page up or down using the up or down ar-
lower and therefore the rods can go around the row keys at the top of the report page to see all of
bent more easily. the report pages, including the rod guide spacing
The rest of the deviation plots show different views recommendation pages.
of the wellbore.
6.2.2 Rod Guide Recommendation Output a slower pumping speed. However, a large pump
will increase rod loading and gearbox torque.
RODSTAR shows rod guide spacing recommen-
Also, a large pumping unit must be used. This will
dations depending on the calculated side load and
increase capital cost. On the other hand, a small
the type of rod guides you selected in Setup as
pump demands a faster pumping speed and longer
shown in Figure 6.10. These are the last pages of
stroke to maintain production. This increases ener-
the output report. RODSTAR also shows you the
gy consumption but reduces the required pumping
recommended placement of the rod guides using
unit size. Usually, you must reach a compromise
a 3D plot of the deviation survey. If you manually
between efficiency, rod loading, pumping unit size,
enter the number of guides per rod, this 3D plot
and cost.
will show your entered data. If RODSTAR cal-
culates the rod guide placement for you, then the A very important aspect of system design is pump-
programs recommendation is plotted on the 3D ing rate. If you know the maximum production
graph. rate you can expect then design the pumping sys-
tem for a production rate a little higher than that.
This ensures enough pump capacity to account for
normal pump wear and inaccurate data. However,
6.3 Rod Pump System Design if the pumping rate is substantially higher than
what the well is capable of producing, then the
Guidelines well will pump off. Fluid pound is a problem that
results from the common practice of over-design-
When designing a rod pumping system you
ing the pumping capacity. Fluid pound is damag-
must specify the equipment, strokes per minute,
ing to pump, rods and pumping unit. If you do not
and stroke length required to get the desired
take steps to minimize fluid pound it will reduce
production at the lowest possible cost. In your
efficiency and equipment life. You can reduce fluid
efforts to select the best system design for your
pound by slowing down the unit, shortening the
well you will be mostly concerned with the
stroke length, using a smaller pump, or by install-
following parameters:
ing a percentage timer or pump off controller.
Production Rate Because RODSTAR can simulate fluid pound,
Capital costs you can use it to see what will happen if the well
pumps off.
Rod loading
Gearbox loading
System efficiency and power costs 6.3.1 Shallow, High Rate Well Simulation
Ideally, the system you select will give the highest RODSTAR can simulate any pumping unit geom-
present value profit after tax, considering capital etry and gives accurate results for any pump depth
and operating costs. Up to now, rod system design or production rate. This is especially significant
was a tedious trial and error process that usu- for shallow well applications because conventional
ally resulted in a system that could be far from design computer programs such as the API RP
ideal. Since achieving an optimum design requires 11L and other wave equation programs give poor
equipment and data that may not be available, only results. This is because at shallow depths, polished
the most obvious system parameters are usually rod load is increasingly dependent on the dynamic
considered. In most cases production rate is of effects of fluid in the tubing. This is especially
highest priority, followed by rod loading, gear- true for high production rate shallow wells (pump
box loading, and energy cost. If electricity cost is depth less than 4000 feet with larger than 2.00
high, you can lower it by using a larger pump and plunger).
76 | Well Information
To accurately simulate these wells, RODSTAR uses 6.3.3 Avoiding Rod Compression
two wave equation models simultaneously, one for the
RODSTAR calculates rod stresses at the top and
rod string and one for the fluid in the tubing. This
bottom of each rod section. It calculates the maxi-
unique capability allows very accurate predictions.
mum and minimum stress at the top of each rod
RODSTAR can predict the expected surface and
section in order to calculate the percent stress load-
downhole dynamometer card shapes common to
ing. It also calculates the minimum stress at the
shallow, high rate wells. When designing shal-
bottom of each rod section. The bottom minimum
low high rate wells it is recommended that you
stress shows if the rods are in compression.
use pump efficiencies of 90%-95% to avoid under-
predicting peak polished rod load, torque, etc. Steel rods can tolerate some compressive force but
This higher pump efficiency will result in higher fiberglass rods cannot tolerate any compression
fluid velocity in the tubing and higher fluid iner- at all. This is why fiberglass rods must have steel
tia forces on the plunger. However, when you are rods or sinker bars at the bottom. The weight of
trying to history match an existing system, you the sinker bars overcomes the opposing hydrostatic
may need to use a pump efficiency of less than 90% force and pump friction. If correctly designed, the
to better match the actual pump slippage of your sinker bars or steel rods ensure that the fiberglass
system. rods are always in tension.
Although steel rods can be subjected to some com-
pression without adverse effects, excessive negative
6.3.2 Selecting the Target Production stresses can cause buckling problems. The recom-
To avoid severely over-sizing the displacement mended way to use RODSTAR to determine if
capacity of your pumping system, design it with a your rods may be subjected to compression is to
pump efficiency of 80%-85% or even 75% if you run the program without including buoyancy
expect the downhole pump to wear out quickly. effects. Then, add sinker bars or sinker rods to
This ensures that you will get your production overcome the negative stresses at the bottom
without grossly over-designing the system. section of the rod string (above the sinker bar
section) . Other ways of minimizing buckling
To minimize energy consumption and stress load- problems include using smaller pumping speeds
ing, use the largest plunger diameter and slow- and avoiding use of small diameter rods such as
est pumping speed combination possible without 5/8 or even .
overloading the rod string and pumping unit. If
you have to make a choice between stress loading
and power consumption, opt for lower stress load-
ing especially if you are close to 100% since rod
6.3.4 Minimizing Power Consumption
breaks are more costly than a slightly lower system In general, the slower the pumping speed and the
efficiency. larger the pump plunger size, the less energy the
pumping system will use. However, minimizing
Note that these are only general guidelines. Eco-
energy consumption must not be the sole purpose
nomics and local field conditions may require a
of system design because a large pump plunger
different design philosophy than the one described
diameter will result in large polished rod load and
above. Regardless of your objectives and design
gearbox torque. This will require the purchase of a
philosophy, with RODSTAR you can design rod
larger unit, larger rods and bigger prime mover. To
pumping systems faster and more accurately than
come up with the best pumping system design you
with any other computer program.
must consider the economics of the whole system
and whether you plan to use existing equipment or
buy new ones.
RODSTAR| 77
RODSTARs power and ease of use allows you to are very sensitive to fluid load. When the fluid
get the most economic pumping system based on level is above the pump, the fluid load on the pump
your economic criteria. Because RODSTAR calcu- is reduced. This causes a longer pump stroke which
lates the predicted energy consumption, rod sizes, in turn affects the shape of the surface dynamome-
rod loading, and recommends a pumping unit size, ter card making it fatter. This in many cases brings
it provides you with the data you need for sound the predicted surface dynamometer card closer to
economic decisions. the permissible load diagram causing the gearbox
load to increase. Also, when the area of the surface
dynamometer card increases, the system requires
6.3.5 Reducing Gearbox Torque a larger motor size. This means that when you use
fiberglass rods you should run system simulations
Sometimes, using the largest unit stroke may not using different fluid levels (within the expected
be the best way to maximize production since it fluid level range) to see which fluid level results in
can result in severe gearbox overload. If this oc- the highest loads and largest required motor size.
curs you may be able to use the next smaller unit
stroke and speed up the unit to get your produc- Using different fluid levels also affects the calculat-
tion without overloading the gearbox. Another way ed pump stroke length and therefore the required
of reducing gearbox loading is by using a smaller pump length and pump spacing . RODSTAR can
pump plunger. Another way is to use a lighter rod recommend a NEMA D motor size based on the
string by using either high strength steel or fiber- fluid level or pump intake pressure you enter.
glass rods. TIP: You can speed up your system design consid-
Also, you can reduce gearbox torque with an ultra erably by asking RODSTAR to design a rod string
high slip motor. RODSTAR can predict the gear- for you. Even if you do not plan to use the design
box torque depending on the pumping unit size RODSTAR recommends, it is easy to grab
and ultra high slip motor size. Also, RODSTAR RODSTARs recommended design and modify
can calculate the motor speed variation and power it. To do this, after the program runs, go to the
consumption very accurately. rod string entry screen and select the Manual rod
string entry option. The program will default to
the rod string it calculated, and it will display this
data as if you had entered it yourself. So, you can
6.3.6 Using RODSTAR for Correct Equipment Sizing
simply change only the data you want to modify.
When designing a new rod pump system you must Please keep in mind that RODSTAR expects the
ensure that the system you select has sufficient ca- length of the rod string you enter to be within 50
pacity to produce the well under the heaviest loads feet of the pump depth. However, it cannot be
possible during its operating life. For most systems longer than the pump depth.
this will occur when the fluid level is at the pump.
Therefore, even if you do not expect the fluid level 6.3.7 Using RODSTAR for Diagnostic Analysis
to be at the pump, it is a good idea to design the Although RODSTAR is primarily a design tool it
pumping system (especially when using steel rods) can be a very powerful diagnostic aid, when used
for fluid level at the pump. This ensures that the in conjunction with RODDIAG or XDIAG. This
equipment you plan to use will not be overloaded if is due to the powerful overlay feature that allows
the fluid level drops in the future. direct comparison of predicted versus measured
For systems with fiberglass-steel rod strings, you dynamometer cards.
may get higher gearbox torque loads and higher
polished rod horsepower when the fluid level is Using RODSTARs Dynamometer Overlay Feature
above the pump. This occurs because fiberglass rods This feature has many different uses. For example,
78 | Well Information
it can help you figure out if your load cell is out damping coefficients for upstroke and downstroke
of calibration, if the fluid level you measured was and also the friction coefficient between rods and
incorrect, etc. RODSTAR can help you find these tubing for each section in the rod string. This
problems by comparing the shape and load range allows you to better simulate use of different rod
of the measured dynamometer card versus the one guides, or more exactly match the correct friction
predicted by the program. Also, it can help verify between rods and tubing for a better match with
downhole problems such as a worn pump, leaking the measured dynamometer card.
traveling or standing valves, deep rod parts, stuck
pump etc. You can simulate a worn out pump or a
deep rod part by entering a fluid level of zero feet 6.3.8 Using RODSTAR for better Wellbore Designs
from surface. This will result in zero fluid load on
the pump plunger. RODSTAR can be a very useful tool in helping
you optimize the wellbore trajectory of your
RODSTAR cannot simulate a traveling valve leak, deviated wells to minimize side loads, rod-tubing
a hole in the pump barrel, or a sticking pump. wear and buckling, and to reduce lifting costs by
But, it can predict what the dynamometer card improving system efficiency.
should look like if there were no problems. Then,
by comparing the actual dynamometer card shape The optimum wellbore path will be different for
with the theoretical shape, you can have more each well, but by using RODSTAR you can deter-
confidence in your diagnosis of the problem. For mine which is the best wellbore trajectory by trial
example, if you have a traveling or standing valve and error. Normally, wellbores that avoid sharp
leak or a worn out pump, then the pump will be turns and abrupt builds to the deviated section will
doing less work and the surface dynamometer card produce better results.
will have less area than the theoretical polished rod With careful planning and wellbore path control,
dynamometer card. deviated well design can be improved with ROD-
If the pump is sticking, or if there is more friction STAR.
than normal between rods and tubing (due to par-
affin, scale, etc.), the measured dynamometer card
will be fatter than normal. The theoretical polished
rod dynamometer card predicted by RODSTAR
(for average friction calculated by the program)
will be smaller than the measured dynamometer
card. By entering a larger rod-tubing friction coef-
ficient you can get a better match between actual
and predicted dynamometer cards. This technique
helps you figure out what rod-tubing friction factor
to use for better simulation of your rod pumping
wells.
Rod-tubing friction is especially important
for fiberglass rods. Higher friction than
normal may actually reduce the area of the
predicted surface dynamometer card because
it causes the rods to stretch which results in a
small stroke at the pump.
RODSTAR allows you to change the rod-tubing
Theta Oilfield Services, Inc., 3075 E. Imperial Hwy Suite 125, Brea, CA 92821 USA
Phone: (562) 694-3297 | gotheta.com