Visualizing Rod Design and Diagnostics

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Rodger Welch
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1 13 th Annual Sucker Rod Pumping Workshop Renaissance Hotel Oklahoma City, Oklahoma September 12 15, 2017 Visualizing Rod Design and Diagnostics Walter Phillips

2 Visualizing the Wave Equation Rod motion exists in time (and space) Dyno cards have an implicit time component Load vs. Position at equally spaced time intervals Dyno cards exist at different points in space Surface, pump, and points in between Visualizing three dimensional data is easy ( ) Sept , Sucker Rod Pumping Workshop 2

3 D Time Plot Position vs Time easy & familiar Kr Permissible Load Calculated Pump Measured Dyno Position vs Time at the pump Position vs Time at surface Lines represent two simultaneous paths in space Lets try expanding that spatial dimension Sept , Sucker Rod Pumping Workshop 3

4 Building a 3D Time Surface Position vs Time at the pump Position vs Time at surface Distance between pump & surface (Well Depth) Sept , Sucker Rod Pumping Workshop 4

5 Building a 3D Time Surface Position vs time at a point halfway down the well Sept , Sucker Rod Pumping Workshop 5

6 Building a 3D Time Surface More Nodes A Node is a finite element of the rodstring Sept , Sucker Rod Pumping Workshop 6

7 Building a 3D Time Surface Even More Nodes Sept , Sucker Rod Pumping Workshop 7

8 Building a 3D Time Surface So Many Nodes Sept , Sucker Rod Pumping Workshop 8

9 Building a 3D Time Surface Rendered as a smooth surface Note: This shape exists in time, not space Each Point X: Time Y: Depth Z: Dynamic Rod Position Sept , Sucker Rod Pumping Workshop 9

Building a 4D Time Surface Colored by Magnitude of Rod Loading Dimensions Plotted: Time Depth Rod Position Rod Load 38000 35500 33000 30500 28000 25500 23000 20500 18000 15500 13000 10500 8000

10 Building a 4D Time Surface Colored by Magnitude of Rod Loading Dimensions Plotted: Time Depth Rod Position Rod Load Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 10

Surface Colored by Rod Load Color at each time-step and rod element illustrates instantaneous rod loading 9000 Predicted Dyno 8000 7000 6000 5000 4000 3000 2000 1000

11 Surface Colored by Rod Load Color at each time-step and rod element illustrates instantaneous rod loading 9000 Predicted Dyno Kr Permissible Load Predicted Pump Predicted Surface Sept , Sucker Rod Pumping Workshop 11

12 Tagging Illustrated in Time Colored by Dynamic Relative Rod Stretch Taper Change See 2016 SRPW Talk Dynamic Relative Rod Stretch Difference in relative positions, of adjacent nodes, at the same time-step Tagging Pump Sept , Sucker Rod Pumping Workshop 12

13 Tagging Illustrated in Time Position dips, at the same time load decreases significantly (Here, blue means the rods got shorter ) Sept , Sucker Rod Pumping Workshop See 2016 SRPW Talk Dynamic Relative Rod Stretch 13

Wave Reflections 38000 An Interesting Load Spike at Surface 35500 33000 30500 28000 25500 23000 20500

features actually contribute to that surface spike -7000-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120

14 Wave Reflections An Interesting Load Spike at Surface This is the corresponding point in time But these features actually contribute to that surface spike Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 14

38000 35500 33000 30500 28000 25500 Wave Reflections Illustrated 23000 20500 18000 15500 13000 10500 8000 5500 3000 500-2000 -4500-7000 -20-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Kr

15 Wave Reflections Illustrated Kr Permissible Load Calculated Pump Measured Dyno ~1.35 seconds Wave propagation: ~0.675 seconds to travel the total rod-string length Round trip time: ~1.35 seconds Unaffected by SPM Determined from total rod length & material and wave velocity Note: Time is not a straight line in this view (Positions change at different rates) Sept , Sucker Rod Pumping Workshop 15

Predicted Dyno 9000 8000 7000 6000 Dynamic Wave Illustration

45 50 55 60 65 70 75 80 85 90 Kr Permissible Load Predicted

Effects are delayed in time by the distance Time Lag =

16 Predicted Dyno Dynamic Wave Illustration Kr Permissible Load Predicted Pump Predicted Surface Waves travel through the rod-string Effects are delayed in time by the distance Time Lag = Velocity / Distance Sept , Sucker Rod Pumping Workshop 16

38000 35500 33000 30500 28000 25500 Dynamic Wave Illustration 23000 20500 18000 15500 13000 10500 8000 5500 3000 500-2000 -4500-7000 -20-10 0 10 20 30 40 50 60 70

17 Dynamic Wave Illustration Kr Permissible Load Calculated Pump Measured Dyno Colored by dynamic rod stretch Sept , Sucker Rod Pumping Workshop 17

18 Dynamic Wave Illustration Kr Permissible Load Calculated Pump Measured Dyno Overlaid from Colored calculated by wave velocity dynamic and rod distance from stretch point of interest Current time step Time delay along the given node to the wave Note: the taper change is not necessarily a source of reflections. Its just a convenient illustration. Sept , Sucker Rod Pumping Workshop 18

19 Waves traveling through the rods Note: Pump card is backwards because of view orientation Sept , Sucker Rod Pumping Workshop 19

20 Wave Traveling Up & Down Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 20

21 Complex Wave Reflections Kr Permissible Load Calculated Pump Measured Dyno 2 Causing this load spike at surface Time (Remember pump card is backwards) 1 The pump stops here 3 Which gets reflected to this load spike at the pump Sept , Sucker Rod Pumping Workshop 21

22 Complex Wave Reflections Causing another spike here 2 Causing this load spike at surface Kr Permissible Load Calculated Pump Measured Dyno 1 The pump stops here 3 Which gets reflected to this load spike at the pump Sept , Sucker Rod Pumping Workshop 22

38000 35500 33000 30500 28000 25500 Complex Wave Reflections 23000 20500 18000 15500 13000 10500 8000 5500 3000 500-2000 -4500 4 Causing another spike here 2 Causing this load spike at surface

23 Complex Wave Reflections Causing another spike here 2 Causing this load spike at surface Kr Permissible Load Calculated Pump Measured Dyno 1 The pump stops here 5 Stopping the pump again here 3 Which gets reflected to this load spike at the pump Note: There is a lot more going on through the rest of the stroke Sept , Sucker Rod Pumping Workshop 23

Animations Actual Time Dimension Renderings show entire stroke at a glance Snapshots through time, shown concurrently Useful for quick diagnosis Lost/obscured details

24 Animations Actual Time Dimension Renderings show entire stroke at a glance Snapshots through time, shown concurrently Useful for quick diagnosis Lost/obscured details Interesting things are happening here, but are obscured by the plot density Animations let us view the snapshots in time Sept , Sucker Rod Pumping Workshop 24

the vertical axis The following animation is not a direct representation

25 Wave Dynamics Waves travel inline with the rodstring Not like a plucked guitar string The following animation shows a conceptual force wave along the vertical axis The following animation is not a direct representation of physical rod motion Sept , Sucker Rod Pumping Workshop 25

26 Tag & Resulting Reflections Snapshot of the rod load & position at the time of the tag Time Delay? Note: This is not a direct representation of physical rod motion Sept , Sucker Rod Pumping Workshop Kr Permissible Load Calculated Pump Measured Dyno See Sam Gibbs book page 426 for Laws of Reflection

Tag & Resulting Reflections 38000 35500 33000 30500 28000 25500 23000 20500 18000 15500 13000 10500 8000 5500 3000 500-2000 -4500-7000 -20-10 0 10

27 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 27

28 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 28

29 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 29

30 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 30

31 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 31

32 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 32

33 Tag & Resulting Reflections This shows a rapid load change over a short time period. Remember, the wave in the physical rod looks different Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 33

34 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 34

35 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 35

36 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 36

37 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 37

38 Tag & Resulting Reflections Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 38

39 Tag & Resulting Reflections Remember: This is a conceptual representation of a force wave. The physical wave does not look like this Kr Permissible Load Calculated Pump Measured Dyno Sept , Sucker Rod Pumping Workshop 39

40 Rod Velocity vs Time Velocity animated along the rodstring The wave shown here is a local velocity change In reality, the rods look more like an accordion Pump Surface Velocity Sept , Sucker Rod Pumping Workshop 40

during the event of interest (the tag) That tension allows the wave echo to

41 Why is this important? Previous example illustrates a unique condition where the rods are in tension during the event of interest (the tag) That tension allows the wave echo to travel If the rods go into compression, the wave energy is dissipated The signal is half lost Sept , Sucker Rod Pumping Workshop 41

Caveats and Notes Dyno cards are calculated (except for measured surface cards) Maybe we are artificially imposing features on the cards through the same math How do we know for sure?

42 Caveats and Notes Dyno cards are calculated (except for measured surface cards) Maybe we are artificially imposing features on the cards through the same math How do we know for sure? HWDDDA (downhole dynamometer project) Consider wave travel time when analyzing dynos Time is hard to see on a dyno, but easy on the position graph Sept , Sucker Rod Pumping Workshop 42

Round Trip Time Wave velocity is not dependent on SPM But SPM dictates when load-changing forces are applied at the pump & surface Maybe we can optimize

43 Round Trip Time Wave velocity is not dependent on SPM But SPM dictates when load-changing forces are applied at the pump & surface Maybe we can optimize these to not interfere Or, at least, identify cases where this load interference may create an issue Sept , Sucker Rod Pumping Workshop 43

44 Future Work Deviated well support Colors could indicate side-load or energy loss around bends Visualize hotspots in rod wear Node lines could be colored in addition to the plot surface 5 th dimension of data Example: DLS or sideload at given depth Sept , Sucker Rod Pumping Workshop 44

45 Conclusions 3D visuals are fun and interactive Better understanding of how the wave equation works Identify difficult-to-conceptualize features Where & when the rods stop (rod velocity) Wave Interference can the wave increase loading at some point in the well? Fluid pound at the sweet spot of the wave travel time from the surface? Sept , Sucker Rod Pumping Workshop 45

46 Extra Content Sept , Sucker Rod Pumping Workshop 46

47 Color Scales Easy way to denote a range of values Colors represent scaled values from 0-100% 0% (Min Value) 100% (Max Value) Alternative Color Scale Examples Sept , Sucker Rod Pumping Workshop 47

48 Max & Min for Color Scaling? Max & Min can be defined globally or locally Example: Scale relative to absolute loading +30,000 lbs at surface -1,000 lbs at the pump Normalized relative to local max/min Max at surface is the same color as max at pump Useful for non-load data Probably won t see much blue at surface Probably won t see much red at the pump Waves show up a bit clearer (plot dependent) Sept , Sucker Rod Pumping Workshop 48

49 Max & Min Color Scaling Example Global Scaling Relative Scaling Sept , Sucker Rod Pumping Workshop 49

Centralized (Zero Based) Scaling Useful for data that crosses zero (i.e. velocity) Data scaled around zero Min Zero = Red (negative numbers) Zero Max = Green (positive numbers)

50 Centralized (Zero Based) Scaling Useful for data that crosses zero (i.e. velocity) Data scaled around zero Min Zero = Red (negative numbers) Zero Max = Green (positive numbers) Narrow band indicating zero (or close to zero) Rods going up Negative Values Positive Values Rods Stopped Rods moving down Sept , Sucker Rod Pumping Workshop 50

51 What s the little blip on pump cards? This drop in predicted pump card load has always confused me This valley and this peak Sept , Sucker Rod Pumping Workshop 51

52 Early Drop in Load Loads decrease, then rise because the polished rod is still moving up at that point in time Sept , Sucker Rod Pumping Workshop 52 Plunger is stalled for the round-trip-time

53 Velocity vs. Time Pump velocity falls faster than surface velocity But the PR is still moving up, but decelerating So the pump moves up just a bit more Sept , 2017 This is the end of the pump stroke 2017 Sucker Rod Pumping Workshop This is the blip Zero plunger velocity 53

54 Copyright Rights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Sucker Rod Pumping Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), rights to: Display the presentation at the Workshop. Place it on the web site, with access to the site to be as directed by the Workshop Steering Committee. Place it on a CD for distribution and/or sale as directed by the Workshop Steering Committee. Other use of this presentation is prohibited without the expressed written permission of the author(s). The owner company(ies) and/or author(s) may publish this material in other journals or magazines if they refer to the Sucker Rod Pumping Workshop where it was first presented. Sept , Sucker Rod Pumping Workshop 55

55 Disclaimer The following disclaimer shall be included as the last page of a Technical Presentation or Continuing Education Course. A similar disclaimer is included on the front page of the Sucker Rod Pumping Web Site. The Artificial Lift Research and Development Council and its officers and trustees, and the Sucker Rod Pumping Workshop Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Sucker Rod Pumping Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained. The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials. The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, noninfringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose. Sept , Sucker Rod Pumping Workshop 56

Sideload and Wear in Rod Pumped Deviated CBM Wells

8 th Annual Sucker Rod Pumping Workshop Renaissance Hotel Oklahoma City, Oklahoma September 25-28, 2012 Sideload and Wear in Rod Pumped Deviated CBM s Tom Cochrane, Joe Colley, Elizabeth Kane ConocoPhillips