Visualizing Rod Design and Diagnostics

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

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 ( http://3dwellbore.com/demo ) Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 2

38000 35500 33000 30500 28000 25500 2D Time Plot 23000 20500 18000 15500 13000 10500 8000 5500 3000 500-2000 -4500 Position vs Time easy & familiar -7000-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 3

Building a 3D Time Surface Position vs Time at the pump Position vs Time at surface Distance between pump & surface (Well Depth) Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 4

Building a 3D Time Surface Position vs time at a point halfway down the well Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 5

Building a 3D Time Surface More Nodes A Node is a finite element of the rodstring Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 6

Building a 3D Time Surface Even More Nodes Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 7

Building a 3D Time Surface So Many Nodes Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 8

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. 12-15, 2017 2017 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 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 Permissible Load Calculated Pump Measured Dyno Sept. 12-15, 2017 2017 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 0-1000 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 Kr Permissible Load Predicted Pump Predicted Surface Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 11

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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 12

Tagging Illustrated in Time Position dips, at the same time load decreases significantly (Here, blue means the rods got shorter ) Sept. 12-15, 2017 2017 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 18000 15500 This is the corresponding point in time 13000 10500 8000 5500 3000 500-2000 -4500 But these features actually contribute to that surface spike -7000-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Kr Permissible Load Calculated Pump Measured Dyno Sept. 12-15, 2017 2017 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 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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 15

Predicted Dyno 9000 8000 7000 6000 Dynamic Wave Illustration 5000 4000 3000 2000 1000 0-1000 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 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. 12-15, 2017 2017 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 80 90 100 110 120 130 140 150 Kr Permissible Load Calculated Pump Measured Dyno Colored by dynamic rod stretch Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 17

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 80 90 100 110 120 130 140 150 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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 18

Waves traveling through the rods Note: Pump card is backwards because of view orientation Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 19

38000 35500 33000 30500 28000 25500 Wave Traveling Up & Down 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 Permissible Load Calculated Pump Measured Dyno Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 20

38000 35500 33000 30500 28000 25500 Complex Wave Reflections 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 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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 21

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 -7000-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Kr Permissible Load Calculated Pump Measured Dyno 1 The pump stops here 3 Which gets reflected to this load spike at the pump Sept. 12-15, 2017 2017 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 -7000-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 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. 12-15, 2017 2017 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 Interesting things are happening here, but are obscured by the plot density Animations let us view the snapshots in time Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 24

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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 25

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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 26 38000 35500 33000 30500 28000 25500 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 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 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Kr Permissible Load Calculated Pump Measured Dyno Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 27

Tag & Resulting Reflections This shows a rapid load change over a short time period. Remember, the wave in the physical rod looks different. 38000 35500 33000 30500 28000 25500 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 Permissible Load Calculated Pump Measured Dyno Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 33

Tag & Resulting Reflections Remember: This is a conceptual representation of a force wave. The physical wave does not look like this. 38000 35500 33000 30500 28000 25500 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 Permissible Load Calculated Pump Measured Dyno Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 39

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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 40

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. 12-15, 2017 2017 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? 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. 12-15, 2017 2017 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 these to not interfere Or, at least, identify cases where this load interference may create an issue Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 43

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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 44

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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 45

Extra Content Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 46

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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 47

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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 48

Max & Min Color Scaling Example Global Scaling Relative Scaling Sept. 12-15, 2017 2017 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) Narrow band indicating zero (or close to zero) Rods going up Negative Values Positive Values Rods Stopped Rods moving down Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 50

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. 12-15, 2017 2017 Sucker Rod Pumping Workshop 51

Early Drop in Load Loads decrease, then rise because the polished rod is still moving up at that point in time Sept. 12-15, 2017 2017 Sucker Rod Pumping Workshop 52 Plunger is stalled for the round-trip-time

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. 12-15, 2017 This is the end of the pump stroke 2017 Sucker Rod Pumping Workshop This is the blip Zero plunger velocity 53

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