RODSTAR

Modern Design and Simulation

of Rod Pumping Systems
for Deviated or Vertical Wells

3075 E. Imperial Hwy Suite 125

Brea, CA 92821 USA
Telephone #: (562) 694-3297
Fax #: (562) 694-8641
gotheta.com

Email Addresses:
Product Manager: Kevin Lo, [email protected]
Software Support: [email protected]
Sales: Christy Kukula, [email protected]
 Theta Oilfield Services, Inc., 2014.
All Rights Reserved. This manual may not be reproduced in whole or in part without the written
permission of Theta Oilfield Services, Inc.

XROD, XROD-V, RODSTAR, RODSTAR-D, RODSTAR-V, RODDIAG, XDIAG, XDIAG-V,

XDIAG-D, XBAL, XTOOLS, XANIMATE are trademarks of Theta Oilfield Services, Inc.

Third Edition, April 2014

 RODSTAR| iii

Contents
Technical Support . v
System Requirements . v

1I ntroduction 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

3 Starting and Setting Up RODSTAR 7

3.1 Starting RODSTAR. 7
3.2 Exiting RODSTAR. 8
3.3 Setting up RODSTAR. 11
3.3.2 General setup options . 11
3.3.3 Defaults, Limits, and Rod Guide Setup. 12
3.3.4 Output Options . 14
3.3.5 Pumping Unit Options. 16
3.3.6 Rod Grade Options . 19
3.3.7 Batch Mode Options. 20

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

5 Changing, Loading and Saving Data 53

5.1 Visual Input. 53
5.2 Storing Data Files. 53
5.3 Running and Viewing the Output . 54
5.3.1 Saving the output. 56
5.3.2 Running in Batch Mode. 56
5.4 Loading Data from Disk. 58
5.4.1 Viewing Previously Saved Output . 59
5.5 Manipulating Input Windows . 60

6 Rod Pump System Design 61

6.1 Understanding RODSTARs Output. 62
6.1.1 Dynamometer and Permissible Load Plots . 62
6.1.2 Torque Plot. 65
6.1.3 IPR Plot . 65
6.1.4 Report . 65
6.2 RODSTAR (Deviated Mode) Output . 70
6.2.1 Deviation Plots. 70
6.3 Rod Pump System Design Guidelines. 74
6.3.1 Shallow, High Rate Well Simulation . 74
6.3.2 Selecting the Target Production. 75
6.3.3 Avoiding Rod Compression. 75
6.3.4 Minimizing Power Consumption. 75
6.3.5 Reducing Gearbox Torque . 76
6.3.6 Using RODSTAR for Correct Equipment Sizing . 76
6.3.7 Using RODSTAR for Diagnostic Analysis. 77

6.3.8 Using RODSTAR for better Wellbore Designs. 77

 RODSTAR| v

Technical Support
Technical Support for RODSTAR is provided by
phone and e-mail to customers with a current Annual
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 Sentinel
bitlock when contacting support.

Phone Support:
Monday-Friday 8:00 AM - 4:00 PM PST.
(562) 694-3297

E-Mail Support:
[email protected]

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

RODSTAR is a powerful, easy-to-use rod in any other Windows document.

pumping system simulator and design tool. With
By taking advantage of the programs powerful
RODSTAR you can design new rod pump-
expert knowledge you can save time and come up
ing installations or make changes to existing rod
with better answers. This makes it possible to
pumping systems. It is a tool that you can use to
optimize rod string designs, find out the pumping
compare pumping units, pumping speeds, plunger
speed and plunger size you need for a target pro-
sizes, rods, motor types, etc. You can evaluate the
duction, etc. in minutes instead of hours. ROD-
effect of pump fillage, fluid level, or an out-of-bal-
STAR makes it possible to get these answers even
ance unit. Also, you can study the effect of prime
with little rod pumping expertise.
mover speed variation, stuffing box friction, etc.
RODSTAR also allows you to combine sophisti-
cated rod pumping system modeling with inflow
performance data for even more powerful capabili-
ties.
1.1 Program Features
RODSTAR remembers the information you type
There are two versions of RODSTAR: deviated when you start a case from scratch. You can exit
and vertical. This manual applies to both for RODSTAR while in the middle of entering data
most items since the programs user interface is for a new case, and RODSTAR will save the data
practically identical except for an additional input you have entered so far. This works the same way
window in the deviated version for entering the if the program crashes. The next time you start
wellbore deviation survey. The deviated version is RODSTAR, the program will ask you if you want
primarily for rod pumping systems with deviated to resume entering data. If so, you will be returned
wellbores, while the vertical version is for verticalto the data entry window you were using when you
wellbores (little to no deviation). left RODSTAR, with all the data you had entered
When the program discusses RODSTAR it already in place. RODSTAR contains data for
applies to both versions of the program. If there all common pumps, rod sizes, rod grades, pump-
are differences between the deviated and vertical ing units, tubing sizes, etc. Also, it knows when you
versions, the description in the manual will specify need slim hole couplings or a thin wall pump, what
the version (deviated, or vertical). rods fit in the tubing size you selected, the maximum
recommended pumping speed for any system design,
RODSTAR is very easy to use, flexible, customiz-
etc.
able, and fast. With a single click of the mouse you
can access any input screen at any time. You can RODSTAR can read well files created with ROD-
change an input by simply clicking on it, and when DIAG, XDIAG (Theta Oilfield Services,
you have a question, simply press ! for context Inc.s diagnostic computer programs) and XBAL
sensitive help for any input item. You can also take (Theta Oilfield Services, Inc.s pumping unit
advantage of standard Windows features such as balancing program). RODSTAR can read all the
being able to copy the dynamometer, torque plots, data contained in a RODDIAG or XDIAG file,
or IPR plots to the clipboard and then paste them including the measured dynamometer card. This
2 |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
By being able to read XBAL files, RODSTAR can warning messages help prevent errors and make
get the existing maximum counterbalance moment you aware of special requirements necessary for
based on the existing position of the counter- proper system operation.
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 your
RODSTAR can simulate any pumping system and design. Based on surface loading, rod string loading,
can accurately predict its performance. For a sys- and pump performance, RODSTAR will score the
tem you specify, the program predicts the surface 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 for
inflow performance data so that you can easily de- any rod pumping system. It can simulate wells of any
sign a pumping system for any pump intake pump depth including very deep or shallow wells. It is the
intake pressure, calculate the expected production only program of its kind that models fluid inertia
rate, pump intake pressure and pump condition for 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
when you double-click
actual motor efficiency curves, the results are very it.
accurate. You can use this capability to compare
RODSTAR.CDB Contains the costs for
the energy consumption of systems with different 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, and your company.
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
entered in Setup. Once
given pumping speed, or the target production for 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

Files ending in .RDG Case files saved by

RODDIAG.
Files ending in .XDG Case files saved by
XDIAG.
Files ending in .CBLX Case files saved by
or .XBLX XBAL
SENTINEL.INI For installations using
a Network license, this
file is located in the
program folder on the
client PC and has the
name or IP address of
the license server being
used.

The RODSTAR program is protected and cannot run

without a software sentinel supplied by Theta Oilfield
Services, Inc.. See Chapter 2 for details on how to
install the software sentinel.
 RODSTAR| 5

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
If you require assistance downloadng or installing previ-
your software, please contact support@gotheta. ous versions?
com. If the previous version is not very old (before the
new setup options were developed) then your set-
tings will be preserved.

2.2 Questions About Installation

The following are some answers to questions you
may have about installing RODSTAR.
2.3 Installing the Software
Do I need to uninstall previous Sentinel
versions of RODSTAR before I install? Your RODSTAR license is validated and protected by
No. When updating versions of RODSTAR, the a security bitlock called a Sentinel. For Stand-
program defaults to install to the C:\Program alone installations, this is a USB key that is at-
Files\Theta\RODSTAR directory. If your previ- tached to your PC. For Network Licenses, the key is
ous copy of Rodstar is in another directory, you attached only to the Network License Server.
can specify to install over it. It will not replace any RODSTAR communicates with the sentinel and
of your case files, just the old version of the pro- although the program can be copied, it will not
gram. operate without a sentinel supplied by Theta Oil-
The installation defaults to setting C:\THETA as field Services, Inc..
the common folder for your case files. Using a If the sentinel is not installed correctly, the pro-
common folder is a good idea since several of the gram will warn you that the sentinel does not ap-
Theta applications that you might have can all pear to be connected. If this occurs, make sure the
share the same case files. sentinel in properly installed and the connection is
Although a new version of RODSTAR can read not loose. If the sentinel is properly installed but is
files created with older versions, an older version of not working, it may have been damaged. Frequent
plugging and unplugging, and static electricity can
6 | Program Installation

damage the sentinel. If this occurs, contact Theta

Oilfield Services Inc. to determine if you need a
replacement. Do not discard the damaged sentinel.
Even if it is damaged, you must return it to Theta
Oilfield Services, Inc. before a replacement can be
sent out. When RODSTAR first starts, it reads
and displays the serial number of your sentinel on
the opening screen.
Theta Oilfield Services, Inc. uses Sentinel SuperPro
and Sentinel HASP for software protection. Both
USB Sentinel types can be plugged into any available
USB port or hub on the PC or it can be plugged into a
network USB switch.
 RODSTAR| 7

3 Starting and Setting Up RODSTAR

Figure 3.2 shows the RODSTAR window that

3.1 Starting RODSTAR
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

The RODSTAR Window

8 | Starting and Setting Up RODSTAR

Figure 3.2 - RODSTARs main 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-
ton. Clicking on the restore button re-sizes the
The title bar shows the name of the application and 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
The menu bar lists the available menus. A menu all information, it will display vertical or horizon-
contains a list of commands, or actions, you can tal scroll bars as necessary. You can use these scroll bars
carry out with RODSTAR. For example, click on with the mouse to view unseen portions of
the Help menu to see a list of helpful choices. entry windows that do not fit in the allotted space.
The Close button causes RODSTAR to exit. Its
The Minimize button reduces RODSTAR to
easier to click the Close button once than to select
an 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

point to a toolbar icon. company name, electricity cost, units of measure,

The toolbar (Figure 3.3) gives you quick access to standard sucker rod length, custom sucker grades,
menu commands using your mouse. When you measured pumping unit data, pumping unit and
first load RODSTAR, only some of the buttons on sucker rod cost, batch run options, printed report
the toolbar are active. When you enter data or read options, and custom summary spreadsheet formats.
a file from disk, then the print button and all the Well information - This is the fifth item on the
buttons that correspond to input windows become toolbar and shows a picture of a file cabinet. Click
active. If you load a file that contains output then here to open the well information window. When you
the report icon also activates. Otherwise, if the first load RODSTAR this icon (and the next five
file contains only input then the report icon re- icons) is inactive until you enter well informa-
mains inactive until you run the case. For a quick tion data or until you load a file from disk. The file
reminder of what each toolbar button does, simply information window contains data such as pump
place the mouse pointer on it. A small message box depth, run time, pump condition, tubing and cas-
called a tool tip appears that tells you what the ing pressures, fluid gravity, etc.
toolbar icon does. Also, the status bar shows more
Production information - This is the sixth item on
information about the same tool bar item.
Following is a more detailed explanation of each the toolbar and shows a picture of a barrel. Click
button on the toolbar from left to right: here to open the production information window
New file - This is the first button on the toolbar that has data for items such as fluid level, pump
and shows a picture of a blank page. Click on this intake pressure, target production, IPR data, etc.
button to start entering data for a new case. Pump and tubing information - This is the sev-
Open file - This is the second button on the toolbar enth item on the toolbar and shows a picture of a
and shows the standard open file icon used by most downhole pump . Click here to see data for tubing
Windows programs. Click on this button to read a size, pump type and size, tubing anchor depth, rod-
RODSTAR, RODDIAG, or XDIAG file that was tubing friction, and fluid inertia effects.
previously stored on disk. Rod string information - This is item eight on the
Save file - This is the third item on the toolbar and toolbar and shows a picture of a sucker rod. Click here
shows a picture of a diskette. Click here to save the to open the rod string information window. This is
data in memory to disk. If this is the first time you where you specify what kind of rod string you want
are saving this case, RODSTAR asks for a new RODSTAR to design for you. Also, you can enter
file name. After you save a file, or after you load your own rod string design, specify the service factor
a file from disk and make changes to it, click on you want to use, etc.
this button to quick-save the data under the same Deviation Survey Input - This is the ninth item on
file name. To save it under a different file name the toolbar and shows a picture of a deviated well-
click on File on the menu bar and then select Save bore. It is only available in deviated mode, since this is
As... the input window for the deviation survey of the well.
Setup - This is the fourth item on the toolbar. Click here see the deviation survey and also to see the
Click here to see RODSTARs Setup window. 3-D plot of the wellbore.
This allows you to specify inputs and preferences Pumping unit information - Click here to open
that normally do not change often such as: your the pumping unit information window that has
data for pumping unit type, crank rotation, stroke

Figure 3.3 - RODSTARs toolbar

10 | Starting and Setting Up RODSTAR

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
counterweight. This button becomes active after
a motor. Click here to open the motor information RODSTAR runs or after you load a file with saved
window that has data for electricity cost, power output. Click it to place the maximum counter-
meter type, motor type and size, moments of iner- balance moment for balanced conditions on the
tia and whether to include motor speed variation. clipboard for use in XBAL.
Previous window - This icon shows an arrow Help - This is the last item on the toolbar and shows
pointing to the left. Click it to go back to the pre- a picture of a question mark. Click this but-
vious input window. 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
Click on the Setup button on the toolbar to open
Run - This item follows the arrow icon on the RODSTARs Setup window. Another way to
toolbar and shows a picture of surface and down- access Setup is to open the Tools menu and then
hole dynamometer plots. Click here to run ROD- select RODSTAR Setup. This window as shown
STAR after entering all your data or after you in Figure 3.5 allows you to enter items that do
change an input. not normally change from run to run. Also, Setup
Report - This item follows the run icon on the allows you to customize RODSTAR by entering your
toolbar and shows a picture of a printed page. company name, default electricity cost,
Click here to view the output in memory. This custom rod grades, measured pumping units, rod
allows you to view the output saved in a file you and pumping unit cost data, and a lot more. The
just loaded from disk, or to return to the output measured pumping unit data you enter is saved
screen. If this button is inactive (dimmed) it means in the CUSTOM32.PUD file in the program
that there is no output report in memory. To make it directory; the cost data you enter for rods and
active, run the case, or load a case with saved pumping units is saved the RODSTAR.CDB
output. file in the program directory. RODSTAR stores
all other information you enter in Setup in the
Email Icon - Click on this icon to email one or
registry.
more cases to Theta Oilfield Services, in case you
have questions.
Print - This button follows the Report button on 3.3.2 General setup options
the toolbar and shows a picture of a printer. Click it
to send the output to the printer. Measurement Units
If you have entered data for a case, but havent run For measurement units you can select English,
the calculations yet, you can get a printout of your Canadian, or Metric/SI. English units are mainly
input data by itself. You get the same one-page used in the USA and South America. If you select
output, except that only the input data appears on this option RODSTAR will ask for pump depth
the page. in feet, production rate in BFPD, plunger and rod
The Print command on the File menu allows diameters in inches, etc. The Canadian option
you to select exactly which parts of the output you provides you with the common mix of English
want printed. For more information, see section and Metric units used in Canada. The Metric/
 RODSTAR| 11

SI option will cause RODSTAR to

use Metric/SI units for most inputs.
Regardless of the units you select,
you can press @ while entering
numeric data to convert from one
system of units to the other. When
you press @ to convert units, the
background of the input field box
changes color from light blue to
light green.

Show Visual Input Window

If you uncheck this checkbox you Figure 3.4 - RODSTARs Setup window
will deactivate the Visual Input fea-
ture in RODSTAR. This feature is XDIAG if you do not locate the original XDIAG
accessed through the toolbar or windows tab of the file.
menu bar. The Visual Input Window allows you to
select an input parameter by clicking on that part
of a graphical representation of the well. For more Exit Program if Idle
information on the visual input feature see section This feature was primarily designed for network li-
5.1. censes, but can be utilized to save your work if you
are away from your computer for a set amount of
time. If the checkbox is checked, the program will
Save XDIAG Imported Dyno Card to RODSTAR File exit after the set amount of time. In the case of
When opening an XDIAG file in RODSTAR, the network license, this will release the license for
the measured surface
dynamometer card is
shown in the surface
dynamometer card
graph of the output
report. This allows you
to perform a history
match to determine the
amount of friction that
is in the well. Check
this checkbox if you
would like the measured
surface dynamometer
card imported from the
XDIAG file to be saved
to the RODSTAR file.
This will allow you to
use the RODSTAR file
in the future to run in Figure 3.5 - Help for RODSTARs setup
12 | Starting and Setting Up RODSTAR

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

3.3.3 Defaults, Limits, and Rod Guide Setup Tubing pressure

The Defaults input window in Setup for the User name

vertical mode is shown in Figure 3.6. Here, Water cut
RODSTAR allows
you customize the
default information
used by the program
when you begin
entering data for a
new case. You can
also change the rod
stress loading limits
used by RODSTAR
in a steel or fiber-
glass rod design, so
that RODSTAR
will use larger rods
rather than exceed
the loading limits
you specify.
Figure 3.6 - Setting up default quantities for the vertical mode
Any of the following
items can be custom-
ized: Water specific gravity
Casing pressure The program uses the standard steel sucker rod
Company name length (typically 25 or 30 ft.) to calculate steel rod
string section lengths that are evenly divisible by it.
Electricity cost This works whenever RODSTAR designs the rods
IPR correlation string (when RODSTAR calculates a steel rod
string taper design, whether for a steel rod string,
Motor type
or a tapered steel rod section beneath a fiberglass.)
Oil gravity For Corod rod strings, RODSTAR ignores this
Plunger size number. For fiberglass rods, the program uses the
standard length of 37.5 feet. Below the defaults,
Pump condition you can set the rod loading threshold for steel and
fiberglass sucker rods. When RODSTAR designs
 RODSTAR| 13

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 with tubing. A friction coefficient value of 0.2 models
stronger rods, rebalance the string, and check the the friction between bare steel rods against steel
loading against these values again. This routine will tubing. To determine the friction value to use for
continue until either the rod loading is equal to or your selected rod guides, consult the manufacturer.
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
Here you will also see a checkbox which is labeled rod guide friction value is for your rod guides. The
Use all diameters when designing Rod String. manufacturer may tell you the rod guides have 2
RODSTAR will use a single taper in designing the times the amount of friction as bare steel on steel
rod string if it will satisfy the lifting requirement. tubing, then you would enter 2 * 0.2 which is 0.4.
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

from the well information window or the rod

3.3.4 Output Options string information by clicking those respective
buttons in this window.
RODSTAR gives you full control over what is
shown on the printed output. Using the Output
Options tab in Setup, shown in Figure 3.7, you Scoring Page
can select the items you want included on the
output. The options you select here are the items This option will generate a scoring page for the
printed by default when you select Print from output report which displays the overall score of
the File menu, or use the Print toolbar button. the design in basic letter grade format. If there are
any areas of concern for the
design which may have
caused a low score, the
software will display the
issues here and
recommend solutions
to the problems. If
the system receives a
good score without
recommendations, then the
scoring page will not be
displayed.
Figure 3.7 - Selecting output options
The system design is
items: scored on the following
You can choose from among the following:
Cover Page Balanced Gearbox Loading
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 the
setup window under defaults. The user information loading percentage displayed in this section. Be sure to
that is set in defaults (such as user name and observe the actual loading of the gearbox if the unit
company name) is your information. The items 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 or
the + button on the bottom of the output report
over-designed. If the rod loading is overloaded then the
window. After clicking the + button, you will
score is lowered severely as that will lead to premature
see the main cover page editing window. You can
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 the
down on the carrier bar. The effect is like a very large
structural loading. Similar to the rod loading score,
hammer, with the weight of the rod strong and fluid
the structure loading score is lowered
over the plunger, hitting the top of the carrier bar on
slightly if the unit is oversized and lowered severely if
each stroke.
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
the given production rate) the maximum efficiency 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
the bottom minimum stress of sinker rods or points, and a table of pressure versus production.
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 plot
bars are too long, which cause the high tension on may also show the actual (measured) surface
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

Recommended Guide Report units displayed by the program at the pumping

unit selection window. Here you can select the
This will print a report of rod guide placement
pumping unit manufacturer and the pumping unit
(depending on type of rod guides selected in the
sizes you have for each manufacturer in the field.
General section of setup).
After you customize the pumping unit list, you can
select pumping units faster since the program will
Measured Deviation Survey only show the units you have in the field instead of
displaying all the pumping units in the pumping
Selecting this option will add pages which show the unit database. This saves you time by minimizing
entered deviation survey. This is helpful if you need the time and effort required to select a pumping
to send the results to a customer or coworker that unit. For example, if you only have 12 different
does not have the digital file. If they need to sizes of Lufkin Conventional, 10 sizes of Mark
recreate the case, the deviation survey is included II, and 14 American Conventional unit sizes, you
with the rest of the well information. can setup RODSTAR to show only these units in
Overlay actual (measured) the pumping unit selection screen. To customize
dynamometer RODSTARs pumping unit list, do the following:
card 1. Click on the + symbol on the left of Pump-
If you load a RODDIAG or XDIAG case into ing Unit Options. Then, click on Custom
RODSTAR, the program can plot the surface pumping unit list. This opens the window
dynamometer card that was stored in the ROD- shown in Figure 3.8.
DIAG or XDIAG file on the same plot as the 2. Drop down the manufacturer list by clicking
predicted dynamometer card. on the down arrow next to Manufacturer:
Omit Dyno cards and Torque Plot 3. Select a manufacturer you want to add to your
from calculate results page viewing custom pumping unit list as shown in Fig-
Select this option if you would like to remove the ure 3.9. If this is a new manufacturer for the
dynamometer cards and torque plot graphs from custom list, all available pumping units will
the calculated results page. No other data will be appear in the window on the right side of the
removed from the calculated results page other screen.
than these graphs from the bottom of the page.

3.3.5 Pumping Unit

Options
Under this item, there
are two sub-items,
Customize Pumping
Unit List, and Measured
Pumping Unit List. Let
us take a look at each of
these items:
Customize

Pumping Unit
List
This option allows you
to customize the list of Figure 3.8 - Customizing the pumping unit database
 RODSTAR| 17

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
that helps identify the pumping unit type. This
middle of the screen). The program automati- is not the only way to customize the pumping
cally arranges the units in the proper order unit database. As
(largest stroke length and largest gearbox size 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.

3.3.6 Rod Grade Options

Entering Custom Rod
Grades
To enter a rod grade
Figure 3.11 - Entering custom pumping unit information that is not in the pro-
grams database, do the
Measured Pumping Unit List following:
Here you can enter data for pumping units that are
1. From the setup window, click on Custom
not in RODSTARs main database. If you have the
Rod Grades.
dimensions you need for these units you can enter
them here to make them a permanent part of your 2. To add a new rod grade, click on the + button
RODSTAR software. To enter dimensions for a (to the left of the pencil icon). This opens up a
pumping unit, do the following: new window where you can enter the name of
the rod you want to add, the tensile strength,
1. Click on Measured Pumping Unit List.
and the stress analysis method you want ROD-
2. Click on the + symbol (on the left of the pen- STAR to use for this rod as shown in Figure
cil symbol). This will open the window shown 3.13.
in Figure 3.11.
3. You can also specify that this is a sinker bar by
3. Enter the data in this window starting with the clicking on the Sinker bar option at the lower
pumping unit manufacturer name. left hand corner of this window.
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
5. When you are done entering data click on button.
OK. RODSTAR allows you to select any of the avail-
If you need help with one of the items you have able stress analysis methods. Once you enter a
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

in Figure 3.15, after

you select the manu-
facturer, RODSTAR
displays a mini-spread-
sheet that you can use
to enter pumping unit
costs. To enter the cost
for a pumping unit,
click on the cell to the
right of the pumping
unit and enter the cost.
When you are done
entering pumping unit
costs for the pumping
units you want, click
on OK. Or, if you
want to enter rod string
cost data, Select Rod
string costs and then
select the rod type and
Figure 3.12 - Custom pumping unit help rod grade. RODSTAR
will display a mini-
select it from the same rod grade menu that ROD- spreadsheet for you to
STAR uses for the built-in rod grades. enter the cost per foot (or per meter) for each rod
The modify (Pencil Icon) and delete (X Icon) diameter as shown in Figure 3.16. You do not have to
options allow you to change or erase custom rod enter cost data for all the rod diameters you see.
Simply enter the cost only for the rod grades and
grades you have already entered.
diameters you use.

3.3.7 Cost Database

When you click on this
item in Setup, ROD-
STAR displays a window,
shown in Figure 3.14,
that allows you to enter or
change pumping unit or
rod string costs. To enter
or change pumping unit
costs select Pumping
unit costs This makes
the window change by
showing a drop-down list
box that you can use to
select the pumping unit
manufacturer. As shown Figure 3.13 - Entering custom rod grade information
20 | Starting and Setting Up RODSTAR

3.3.7 Batch Mode Options

When you click on this
tab, RODSTAR displays
a setup page that allows
you to choose different
options relating to the
batch run capabilities of
RODSTAR. The top por-
tion of this input win-
dow allows you to select
whether you want ROD-
STAR to print the results
of each case it runs in
batch, whether to create a
summary spreadsheet file, Figure 3.14 - Cost Database Setup Window
or whether to rerun cases
that contain saved output. output check box, RODSTAR will not rerun
Also, it lets you choose what action to take when cases that have saved output. When you run
you load a file that contains custom rod grades as RODSTAR in batch mode, RODSTAR saves
shown in Figure 3.17. For example, if you want to the output in the same file as the input data. Also,
update the setup information with the data in the when you run one case at a time, you can save
file, then select the option Update Setup with files the output by saving the file to disk when you are
information. looking at the output. The option to avoid rerun-
ning cases that contain output is useful when you
If you check the Make Printouts check box,
want to create more than one spreadsheet file using
RODSTAR will print out every case you run
different spreadsheet formats. Once the files have
in batch. If you check
the Create summary
spreadsheet check
box,
RODSTAR will sum-
marize the results of all
the files you run in batch
in a Excel spreadsheet file.
If you select the
option View spreadsheet
file, after you run sev-
eral cases with the batch
process, the program will
automatically create an
Excel spreadsheet and
will load it into Excel
automatically.
If you check the Dont
re-run cases with saved Figure 3.15 - Pumping unit cost database
 RODSTAR| 21

been run with batch, each

file will contain all the
output calculations.
For example, let us assume
that there are two differ-
ent users (John and Paul)
who are running ROD-
STAR and they each have
their favorite spreadsheet
formats. John can run 20
cases in batch mode and
create a spreadsheet that
summarizes the values he
is interested in. Later Paul
can run the same cases in
batch mode and create a
Figure 3.16 - Entering rod string cost in Setup
spreadsheet with the items
he is interested in which are button to exit Setup.
different that Johns. Since John ran all 20 cases,
the files now contain both input and calculated re- If you have not created any spreadsheet formats,
sults. When Paul runs the same cases in batch, he the only format that appears is the (Default)
checks the Dont re-run cases with saved output format that RODSTAR will use when you run it
option to save time. Since the output results are in the batch mode and choose to create a summary
already saved in the RODSTAR files, Pauls batch spreadsheet file. To create a new spreadsheet for-
run will proceed very quickly since all RODSTAR mat click on the + button. This opens the spread-
has to do is extract the calculated values that Paul sheet setup window that you see in Figure 3.18.
specified in his spreadsheet format from these 20 The list on the left side shows the columns that
cases. are in the spreadsheet now and their order. The

Creating and/or Changing

spreadsheet formats
As shown in Figure 3.17,
you can click on the +
icon at the Spreadsheet
Setup section of the
batch window to add a
new batch spreadsheet
format (design of the
spreadsheet). Also, this
section lists the spread-
sheet formats you have Figure 3.17 - Batch mode options
saved. To use one of these
spreadsheet formats for your next batch run, high-
list on the right shows additional variables you
light it by clicking on it and then click the OK
can add to the spreadsheet. You can use drag and
22 | Starting and Setting Up RODSTAR

drop to move an item

from one list to the
other. For example, to
add rod string cost as
the last column in the
spreadsheet, locate it on
the table on the right
(variables are listed in
alphabetical order) and
drag it (click and hold
while moving with
the left mouse but-
ton) to the other side.
When you drag a value
into the table on the Figure 3.18 - Spreadsheet setup
left, the cursor shows
an arrow that shows
where this new value will be added. After you drop
the new item in the spreadsheet table, it remains
highlighted. Then, to move it up or down in the
list click on the Move Up or Move Down buttons
below the list of spreadsheet variables. Or, you can
click on the Remove>> button to send the high-
lighted variable back to the Available values list
on the right.
Another way to add items to your spreadsheet is by
highlighting a value on the list on the right, high-
lighting a value on the list on the left, and clicking
the <<Add Before or <<Add After buttons in the
middle of the screen. However, using the mouse is
much easier. After you are done designing the for-
mat of the spreadsheet, you can save it by entering
a name for it in the Format name: field at the bot-
tom of the screen. Then click OK to return to the
previous screen. From here, you can create another
spreadsheet format, or modify or delete one of the
existing formats.
To modify an existing format, click on its name
and then click on the edit icon (pencil). Or, to delete
an existing format, highlight it, and then click on the
delete icon (X).
 RODSTAR| 23

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 tell
STAR then do so before entering a new case (see
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.

4.1 RODSTARs User Interface An item followed by an ellipsis (...) needs

more information before taking action; normally,
RODSTAR has a user-friendly interface that the additional information is entered into a dia-
simplifies and speeds up data entry. The program log box. (For example, click on File and click on
uses standard Windows features along with other Open)
unique features we designed to make entering and
changing data as easy as possible. Figure 4.1 shows
how to access the most recently saved files and
select the file you want to load into RODSTAR. An easy way to load files you recently saved:
If you are not familiar with Microsoft Windows, RODSTAR has a most-recently-used file list on
please take some time to study your Windows the File menu, as shown in Figure 4.1. Selecting
manual. Teaching you
how to use Windows is
beyond the scope of this
manual (although many
Windows procedures are
explained). By taking the
time to understand and
learn how to use Win-
dows, you will be able to
effectively use not only
RODSTAR, but any other
Windows program.
RODSTARs interface
has most of the elements
that are common to all
Windows programs. For Figure 4.1 - The most recently saved file list
24 | Running RODSTAR

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.

4.1.1 RODSTARs Help System 4.2 Entering Rod Pumping System

RODSTAR has a powerful help system that pro-
vides context sensitive help for every input item. Data
Also, it allows you to easily locate help on any When entering data in RODSTARs input win-
subject relating to system design and simulation. It dows, it helps to know the following:
even includes a complete artificial lift glossary that
provides instant access to definitions for hundreds To replace the contents of an input box,
of artificial lift terms. Also, the help system helps
you learn how to use it by including extensive help
on itself.
Click on the Help drop-down menu to see the
Help menu choices which are:
Contents..
Index..
Search..
About RODSTAR..
To see RODSTARs version number, and your
sentinels serial number, click on About ROD-
STAR..
Click on Contents to see a list of items ROD-
STAR can provide help for. As you can see, ROD-
STAR shows text and pictures in its help screen. For
example, RODSTAR displays a picture of the toolbar
and instructs you to click on the button you want help
for. Using the mouse, you can resize or move the
Help window.
Next, click on Help and then click on Glossary to
see an alphabetical listing of artificial lift terms. To
see the definition of any of the terms in the glos-
sary, click on it. For example, click on API grav-
ity to see a definition. Also, you can click in the
list of items in the Glossary and then type a letter
to go to the terms that start with that letter. For, Figure 4.2 - RODSTARs Artificial
example, to find the definition for Permissible load
Lift Glossary
 RODSTAR| 25

Figure 4.3 - The Well Information input window

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 or
Figure 4.3. You can move this window with the 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 in
Required data input fields appear with a the Company name field. This saves you from having
yellow background. You must enter data in these 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 than
mation window. When you select this option you 15% of pump depth. Also, you can use this input to
must enter a pumping speed and IPR data in the 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
RODSTAR uses an iteration scheme to converge to API
the correct pump condition and pump fillage that gravity you enter. If you do not agree with
will result from the SPM you enter, along this
with the calculated pump intake pressure. assumption then change the oil API gravity
The Production Information window also gives to correspond to the specific gravity you want
you the option of having RODSTAR calculate the RODSTAR to simulate. For example, if you
required pumping speed based on a target produc- want to simulate water in the casing-tubing
tion you enter. However, the option of calculat-
ing the SPM from your target production is annulus instead of oil, then enter an API
only available if you select a full pump. For gravity of 10 (which corresponds to a
fluid fluid specific gravity of 1.0).
pound or gas interference, you must enter a pump-
ing speed in the Production Information window.
Percent water cut
The percent water cut input along with oil API
Other input data in the Well Information window: gravity allows RODSTAR to calculate a default
specific gravity for the produced fluid. Also, it uses this
Comment data to calculate $/bbl (or $/m3) electricity
You can enter a comment about the case. You can costs.
type up to 100 characters in the comment field.
The comment string you enter is included on the
screen and printed outputs. Oil API gravity
RODSTAR uses the oil API gravity to calculate
fluid load on the plunger and the default specific
Pump Load Adjustment (Vertical Mode gravity of the produced fluid. Also, as discussed
Only) above, RODSTAR uses this number to calculate
The pump load adjustment allows you to increase the specific gravity of the fluid in the casing-tubing
the fluid load picked up by the plunger. Usually annulus which it assumes to be 100% oil.
this is unnecessary. However, this input allows you
to account for extra downhole loads due to exces-
sive downhole friction (for example due to wellbore Fluid specific gravity
deviation), or due to the plunger effect of large RODSTAR uses the oil API gravity and per-
sinker bars. It is recommended that you use zero cent water cut you entered to calculate the default
for this number unless you have more than 1000 specific gravity of the produced fluid. The program
feet of large sinker bars such as 15/8 or 1 bars will display this value when it prompts you to enter
in 2 tubing. The value of this number in pounds the fluid specific gravity. RODSTAR calculates
is typically 5% to 10% of the pump depth in feet. the default specific gravity without considering
For example, for a pump depth of 6000 feet, enter free
a value of 300 to 600 pounds (but only if you use gas. This is okay for designing new wells since we
more than 1000 of large sinker bars). RODSTAR prefer to be more conservative. However, if you
want to simulate an existing system that produces
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-
After you finish entering data for the Well Infor- responds to each production test point can either
mation window click on the next screen button be pump intake pressure or flowing bottomhole
(right arrow) on the toolbar to open the Production pressure (in the middle of the perfs). To add a new
Information input window. To move back to the pair of Pi and Fluid production data, click on the
previous window, simply press the left arrow icon on add button (top right) icon. To delete a set of data
the toolbar. points, click on the remove icon (bottom right).

Remember that pressing @ converts to the op- You can get help for any input item by pressing !
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 value If you do not know what the bubble point pres-
for any field with units
has already been entered,
pressing @ will show it in
the opposite units.

4.2.2 Entering Production

Information
The Production Information
input window allows you to
enter a fluid level or pump
intake pressure as shown in
Figure 4.4. Also, you can
select to enter a pumping
speed, enter a target produc-
tion (the program will cal-
culate the pumping speed to
get the target production), Figure 4.4 - The Production Information input window
28 | Running RODSTAR

on the screen by click-

ing on the Print button
at the bottom right hand
corner of the screen, or
you return to the produc-
tion information screen by
clicking on Close.
RODSTAR offers you the
option to enter the value
of n for the Fetkovich IPR
correlation as shown in
Figure 4.6. The window
includes a check box,
labeled Calculate n, that
tells RODSTAR whether
you want to enter the
value or have RODSTAR
calculate it from your
data. If you enter only one
test point, RODSTAR
uses a value of 1.0 for n
Figure 4.5 - The inflow performance relationship (IPR) plot unless you select to input
your own value. However,
sure is, but you know the well is producing below
if you enter two or more
the bubble point pressure, then leave the bubble
point pressure field blank and click on Producing test points, RODSTAR calculates n from a log-log
below bubble point or in the check box next to plot. If you enter inflow performance (IPR) data,
it. After you enter the last piece of IPR data, click
to a different input field, press T or click on the
Update prod. button to allow RODSTAR to
calculate the maximum oil, water, and fluid pro-
duction rates and target production. Figure 4.6 - Fetkovich n value
You can see the IPR plot by clicking on the IPR
Plot... button (under the target production field).
When the IPR plot is displayed as shown in Fig- RODSTAR can calculate the pump intake pres-
ure 4.5, you can move the cyan line that you see sure using the target production you have entered
on the plot with the mouse to see the calculated (see Figure 4.7). You can select to have ROD-
production rate for any bottomhole pressure. To STAR calculate the pump intake pressure from
move this line, point to it with the mouse until the the IPR data, or if there is no IPR data available,
mouse cursor changes shape and then drag the line you can enter a pump intake pressure or fluid
to any pressure point on this plot. As you are mov- level yourself. Usually, for new systems, it is rec-
ing this line, the producing bottom hole pressure, ommended that the system be designed for the
pump intake pressure, oil production, water pro- highest possible fluid load on the plunger. This is
duction and total fluid production are dynamically accomplished by entering a fluid level that is equal to
recalculated. You can print the IPR plot you see pump depth.
 RODSTAR| 29

4.2.3 Entering Pump and

Tubing Information Data
On the third input Figure 4.7 - Options for calculating pump intake pressure
screen, you can select
the rod-tubing friction for you. The friction factors
the tubing size, tubing
calculated by RODSTAR are estimates for average
anchor depth (if anchored), pump type, plunger
friction for a vertical wellbore. If you are simulat-
size, and the upstroke and downstroke rod-tubing
friction coefficients. Also, for shallow, high rate ing a system with excessive downhole friction, you
wells, you can include fluid inertia effects. If you must enter your own rod-tubing friction coeffi-
select to include fluid inertia1 effects then you must cients for more accurate results. There are several
also enter the fluid compressibility index. For more downhole conditions that increase rod-tubing fric-
information on this option read the discussion tion such as: wellbore deviation, a well with heavy
that follows later in this section, or use the context oil production, paraffin or scale problems, etc.
sensitive help system. The most accurate way to figure out the
You can select the pump plunger size from a list rod
of standard sizes, or you can enter a non-standard tubing friction in RODSTAR is to im-
size by selecting Other from the list of plunger port a measured dynamometer card from
sizes. If you are simulating a full pump and you a
entered a target production, you can select to have RODDIAG or XDIAG file. Then,
RODSTAR recommend the pump plunger size for history-
you. This option is only available when you enter match this actual card by manually
a target production and select full pump for pump adjust-
condition. ing the friction. You do this by varying the

Please note that the pump type you select affects the upstroke and downstroke rod-tubing fric-
plunger size that the program will recommend. It tion coefficients until the surface
may be interesting to make one run with an dynamom-
insert pump type and one with a tubing pump to eter card predicted by the program
see what RODSTAR recommends. matches
the measured dynamometer card. This
technique allows you to find the rod-
Other input data in the Pump and Tubing Information tubing friction that gives the best results
window: when
simulating this system. From then on you
Rod-tubing friction coefficients can use these friction factors every time
For rod-tubing friction , the vertical mode allows you simulate this pumping system.
you to enter upstroke and downstroke friction Please note that this history-matching technique
coefficients yourself, or you can have the program works only if the dynamometer card that you mea-
calculate them for you. If you do not know what sure corresponds to a pump condition that ROD-
to enter, then choose to have RODSTAR calculate STAR can simulate (full pump, fluid pound, or gas
1 Fluid inertia effects are dynamic effects interference). For example, if the pump is worn out or
that increase fluid load on the plunger in wells less is hitting up or down, etc., then this technique will not
than 4000 feet with pump plungers larger than 2.0 work as well. This is because you will be unable to get
inches a good match between predicted and measured
dynamometer cards.
If you do not have a measured dynamometer card,
use the following guidelines for entering rod-tub-
ing friction coefficients in RODSTAR:
1. First select to have RODSTAR calculate the
rod-tubing friction coefficients for you. You
30 | Running RODSTAR

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
to increase the rod-tubing friction coefficient by
2. For heavy oil or for wells with paraffin or scale
50% to accurately simulate the additional rod-
buildup, use 2-3 times the value calculated by
RODSTAR. You can use the same guideline for tubing drag. So, if you use molded rod guides,
deviated wells when the deviation is close to the you need to enter a friction coefficient of 0.3
bottom of the wellbore. (0.2*1.5=0.3) for the section of the rod string with the
molded rod guides.
3. For deviated wells with the deviation close
to the surface you may need to enter a larger Rod guide manufacturers need to provide you with
number such as 4-6 times as high as the values friction ratio values for the different rod guides
calculated by the program. Also, it may be they make.
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 is
RODSTAR Friction Coefficients
not in compression. If it is in compression, then more
In the deviated mode, the upstroke and down- sinker bars must be used, the pumping speed need to
stroke rod-fluid damping coefficients on the pump be reduced, or both.
and tubing information window are only for fluid
When buoyancy is not included, the bottom of each
damping on rods. Also, the deviated mode allows
rod section except the last section should have a
you to enter rod-tubing friction (drag) coefficients
positive stress. Otherwise the rods may be going into
for each rod string section in the rod string input
buckling. It is normal for the very bottom of the rod
window. The default bare rod rod-tubing drag
string to be in compression if you enter a pump
friction coefficient is 0.2. The range for this value
friction that is not zero (a minimum pump friction of
is from 0.1 (for oil lubrication between smooth
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 in
each section of the rod string. You can do this by 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 the
exact magic depth for which fluid inertia be-
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 Figure 4.8 - Rod string entry options
becomes
a variable that affects the dynamic fluid load on
the
plunger. Therefore, using 90% pump efficiency RODSTAR Steel Design
gives If you select this option, RODSTAR displays
higher peak polished rod load than using 80%. a window such as the one shown in Figure 4.9.
The option to include fluid inertia effects is only Here, you can select the maximum and minimum
available if you are modeling a full pump. Please rod diameters to consider, whether to include
do not confuse fluid inertia effects with the mo- sinker bars, the service factor, and additional rod
ments of inertia of the pumping unit that have to costs.
do with gearbox torque due to prime mover speed If you want to include sinker bars then you must
variation. Fluid inertia effects refer to additional enter the diameter and length of the bar (or sinker
dynamic forces on the plunger caused by the rod). RODSTAR does not calculate the length of the
pickup and rapid acceleration of the fluid load. sinker bar section because there is no industry
RODSTAR simulates fluid inertia effects with consensus on how to design sinker bars. However,
a second wave equation that models the pressure RODSTAR will design the rod string above the
waves in the fluid in the tubing. This increases sinker bar section you specify.
simulation accuracy by accounting for pressure
RODSTAR attempts to design an optimum rod
pulses traveling up and down in the tubing fluid. string based on the rod grade and the maximum
These pressure waves have a direct affect on the and minimum rod diameters you enter. First,
pump plunger. Since the program has to do many RODSTAR figures out how many rod tapers are
additional calculations when you include fluid needed. Then, it automatically adjusts the length
inertia effects, RODSTAR may take 60%-80% of each section until the stress loading is the same
longer to run.
32 | Running RODSTAR

at the top of each rod section. This equalizes and

minimizes stress loading on the rod string. This
stress balancing approach gives the lowest cost Fiberglass/steel RODSTAR design
rod string with equally distributed stress loading, If you select the option to have RODSTAR design
for the rod grade you select. a fiberglass-and-steel rod string, you will see the
This approach works the same regardless of steel data input screen in Figure 4.10. For example, let
rod grade or type. For example, you can have us say you want to use a design with fiberglass rods
RODSTAR design a Corod rod string for semi on top followed by a tapered steel section with 1
elliptical Ultra Corods using a maximum diam- and 7/8 rods, and then 375 feet of 1 sinker bars.
eter of 17/16, a minimum diameter of 13/16, and a RODSTAR is able to design this rod string for
375 section of 1 5/8 sinker bars on the bot- you. Also, it balances the steel design under the
tom. RODSTAR uses only the rod sizes it needs. fiberglass section (for two or more rod sections) so
For example, if the loads are not high enough to that there is equal stress loading at the top of each
require the use of the 17/16 rod diameter then section as shown in Figure 4.11.
RODSTAR will go to the next size (16/16). If this This Figure shows a fiberglass-steel rod string de-
is still too big, it will use the 15/16. signed with RODSTAR. RODSTAR can design
The maximum rod loading used by RODSTAR to tapered steel rod strings under the fiberglass sec-
decide when the next larger diameter rods are tion for any type of steel rod, including non-API
needed is 95% by default. However, you can high strength rods, and Corods. If you want to
change this number if you like by going to the fine-tune a RODSTAR design, select to enter your
Setup Defaults window. own rod string design by clicking on the manual

Figure 4.9 - Steel rod string design options

 RODSTAR| 33

Figure 4.10 - Fiberglass rod string design window

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

Figure 4.11 - RODSTAR Designed Fiberglass-Steel Rod String

34 | Running RODSTAR

Figure 4.12 - Selecting rod grades in RODSTAR

length and diameters of the tapered steel portion

based on the maximum and minimum diameter program design the rod string for you). This is
limits you enter. not a good option to use when you first design a
new system because it requires the most work and
RODSTAR may reject a steel rod diameter if it is not experience.
needed. For example, if you asked RODSTAR to
design a rod string with fiberglass on top, a When you select this option, you can enter data for
tapered steel section under the fiberglass, and a either steel or fiberglass rods as Figure 4.12 shows.
500 foot 1.5 inch sinker bar section on the bottom. You can enter the number of rod sections, the ser-
RODSTAR will determine the fiberglass diameter vice factor you want to use, and rod string data for
and length you need, and the steel rod section and up to ten rod sections. For each section, you can
tapers you need. If RODSTAR cannot balance the select the rod type or grade, diameter, and length.
steel rod string design because the 3/4 section is For Fiberflex fiberglass rods you can also specify
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
Another interesting capability of RODSTAR is
friction coefficient, the type of rod guide, and
that if you use continuous rods (Corod or Prorod)
number of rod guides per rod. The rod-tubing fric-
instead of regular rods under the fiberglass, it may
tion is used to calculate the friction between the
skip a rod diameter, if it has to, in order to bal-
rods and the tubing. This is different from the fluid
ance the rod string stress loading. This is not a bug. friction coefficient which is used to calculate the
Sometimes the program has to do this to success- friction between the rods and the fluid. In order
fully balance the steel portion of the rod string. to enter the number of rod guides for each section,
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
This option is primarily used for entering rod listed on the drop down list next to the rod grade
string data for an existing system you want to input field, the program knows the weight per foot
simulate, or to modify a design that RODSTAR and modulus of elasticity and will not prompt you
itself came up with (when you select to have the for them. The program warns you about rods that
 RODSTAR| 35

do not fit in the tub-

ing. Also, it warns you
if the rod string length
is shorter or longer than
the pump depth. The
total length of the rod
string can be up to 50
feet shorter than the
pump depth. However,
it cannot be longer than
the pump depth. For
example, if the pump
depth is 5000 feet, you
can enter a rod string
that is between 4950
and 5000 feet. When
entering rod string data
for the first time, ROD-
STAR shows a default Figure 4.13 - Wellbore deviation entry window
length for the last rod
section equal to the RODSTAR asks for confirmation whenever you
difference between the pump depth and the rod remove sections from the rod string, whether by using
string length you entered so far. the Remove rod section button or by reduc-
Selecting the option to enter your own rod string ing the number of rod sections.
gives you maximum flexibility. However, it re-
quires the most expertise to come up with a good
rod string design. You can use this option to select The meaning of the term Sinker Bar in RODSTAR
different rod grade or manufacturer for each rod In RODSTAR, the term sinker bar means a
section. In general, this option allows you to enter steel rod that is made specifically to be used at
any rod string design, no matter how unusual. The the bottom of the rod string for weight such as 1
minimum length you can enter for any rod section is
25 (length of a single sucker rod).
When entering the rod string data manually,
RODSTAR allows you to add and remove rod sec-
tions from anywhere in the rod string, instead of
only at the bottom. The window has icons on the
left side for inserting a rod section, for removing
a rod section, or for moving a section up or down.
For example, if you want to remove a rod section,
first click on it and then click on the Delete Rod
rod section icon.
To add a rod section, click on an existing rod sec-
tion and then click on the Insert/Add Rod Sec-
tion icon. The new section will be added below the
selected section. Figure 4.14 - Deviation entry icons
36 | Running RODSTAR

Other for the rod size.

4.2.5 Entering Wellbore Deviation Data

(Deviated Mode)

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

Figure 4.16 - Entering deviation data manually

3/8, 1, 1 5/8, etc. The term sinker rod means

a regular rod such as a 1 or 7/8 rod that is
placed on the bottom of the rod string for
weight. For a 1 or 7/8 rod to be considered a
sinker rod it must be larger than the diam-
eter of the rod above it.
When entering the rod string manually, make
sure you select Sinker bars in the list of rod
grades for sinker bars as shown in Figure
4.11. Do not select Steel rod type and then Figure 4.17 - Import Wizard Options
 RODSTAR| 37

The easiest way to enter

the data is by using the tab
key to move from field to
field.
The Add Entry and
Remove Entry but-
tons can be used as
needed. At any time
during the data entry,
you can click on the
Plot Survey tab to see
a 3-D plot of the well-
bore deviation entered
so far.
When inputting the
Azimuth, RODSTAR
recognizes both de-
Figure 4.18 - Step 1 of the Deviation Import Wizard grees (i.e. 340) and de-
grees/minutes formats
4.14 explains the meaning of the icons shown on (i.e. N20W or N20
the left side of this input window. You can activate 0W). As you continue to enter the deviation data,
these icons by clicking on them with the mouse. the program calculates the numbers in the other
columns of the deviation input window. These
numbers are Dogleg severity, True Vertical Depth
Manual Entry of Deviation Survey (TVD), North-South distance (N-S), and East-
To enter the devia-
tion survey manually,
you need to know how
many deviation points
you have and the mea-
sured depth, inclina-
tion and azimuth of
each deviation survey
point.
Start by entering
the number of sur-
vey points as shown
in Figure 4.15. As
soon as you enter this
number, the program
will created the correct
number of rows for
you to enter the data as
shown in Figure 4.16.
Figure 4.19 - Step 2 of the Deviation Import Wizard
38 | Running RODSTAR

Figure 4.20 - Step 3 of the Deviation Import Wizard

Figure 4.21 - The last screen of the Deviation Import Wizard

 RODSTAR| 39

Figure 4.22 - The deviation survey after it was imported

West (E-W) distance in feet or meters.
Double-check your data to make sure you are
entering the numbers correctly (especially if you see
dogleg severity numbers in red).
If RODSTAR is being used to analyze an exist-
ing well, the Deviation Survey Direction Toolbar
should be disabled. To disable this toolbar, click
the Setup icon, click the Defaults option, and un-
check the box labeled Show Deviation Direction
Toolbar. The Deviation Survey Direction Toolbar
is used to design a deviated well. While the toolbar
is active, the Azimuth is input in degrees and the
toolbar is utilized to designate a direction. Select
a direction first, then input the degree value. The
field will be automatically updated with the direc-
tion once the field is left.
NOTE: The NE direction is the default and will not
display any directional indicators (i.e. N20E or N20
0E will be displayed as 20).

Using the Deviation Survey Import Wizard

40 | Running RODSTAR

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.

Figure 4.23 - The 3-D Plot of the deviation Survey

Excel spreadsheet.
Click Done and view the imported deviation
Step 1 prompts you to select the file to be imported
survey data as shown in Figure 4.22.
 RODSTAR| 41

Figure 4.24 - Pumping unit manufacturer list

Please keep in mind that for program to be able to

load the deviation data from an Excel spreadsheet, it The pumping unit ID is a unique string of letters and
must see three columns with the deviation data. numbers. RODSTAR displays the pumping unit ID
These columns need to be labeled as follows: along with other unit information after you select a
unit. If you make a note of this unit ID (in the well
Measured Depth (ft) or MD (ft), or
file for example), you can use it to specify the
MD (m) Inclination pumping unit instead of having to select it from the
Azimuth list. This is a unique ID for each pumping unit in the
programs database.
Clicking the Plot Survey tab on the right side
of the window will display the Deviation Plot as Selecting a pumping unit manufacturer
shown in Figure 4.23. From this screen, you can
rotate the plot to better understand and visualize RODSTAR allows you to easily select a pumping
the wellbore deviation, you can zoom in, etc. unit manufacturer and unit size with drop-down
list boxes. To display the menu with all pumping
unit types available, click on the drop arrow next
4.2.6 Entering Pumping Unit Data to the Manufacturer field (see Figure 4.24).
This is a scrollable list of all units in the programs
The pumping unit input screen allows you to select a
database in alphabetical order. You can go to the
pumping unit from the database that comes with
RODSTAR, or from your measured pumping unit
database (if you entered your own pumping unit
top of the list by pressing}. You can jump to
dimensions in Setup). the bottom of the list by pressing ~. You can
Another option is to enter a pumping unit ID. also move up or down by pressing O (Page up)
or N (Page Down). A convenient way to move
42 | Running RODSTAR

Figure 4.25 - Measured pumping unit list

through the list is to press the first letter of the

unit name you want to use. For example, to locate option is checked, when you select a pumping unit,
the National E Series pumping unit entry, you will see a short list containing only the unit
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. same procedure to select the unit size you want
At 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). can move through this list the same way as with
This 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 structure size. However, if the window shows the
units) option, RODSTAR will display a list that pumping unit name (for old units) the units are
only listed alphabetically.
shows the measured pumping units, as Figure 4.25
shows. When you enter a unit, the Unit ID, the program
automatically displays the unit that the ID cor-
As Figures 4.24 and 4.25 show, there is a check responds to. RODSTAR displays the information
box that allows you to use the custom pumping necessary for you to correctly identify your unit.
unit list instead of the main pumping unit list. If For example, for American conventional units you
you check this option, before you select a unit, will see that certain unit sizes appear more than
the Manufacturer list will show a shorter list that once on the selection list. However, they have dif-
ferent cranks.
contains only the manufacturers you selected in
Setup in your custom unit list as shown in Figure
4.26. When the Use custom pumping unit list
 RODSTAR| 43

Figure 4.26 - The custom pumping unit list

Selecting to enter a pumping unit ID

How to add units to the custom pumping unit list
You can use the Use custom pumping unit The unit ID option is the fastest way to enter
list pumping unit information if you already know
check box to add units from the main list to your the pumping unit ID for your unit. You can see
custom list. For example, if you run across a pump- the pumping unit ID on the pumping unit entry
ing unit that is not in your custom list yet, clear window after you select a unit. Once you locate
the Use custom pumping unit list check box your unit, you can make a note of its ID in the well
so that you can use the general pumping unit list. file. Then, the next time you want to use this unit,
you can select to enter its ID. For example, for a
After you select the pumping unit then click on the Lufkin Mark II M-456-305-144, the unit ID is
Use custom pumping unit list check box. ML32.
RODSTAR asks if you want to add this pumping
unit to the custom pumping unit database. Select To identify some units correctly, it is necessary
Yes to add this unit to your custom list. The pro- to know the crank number since they may have
gram will add this unit to the custom list and also the same API designation but different geometric
switches to the custom list. dimensions depending on crank number (primarily
units made by American International Manufac-
This option only allows you to add units to your turing Company).
custom list without having to do it from Setup. To
remove units from your custom list or to add more TIP: If your unit is not listed in RODSTAR
than one unit, go to the setup window and cus- and you do not have the unit dimensions, then
tomize the list of units as described earlier in this use a unit that is closest to it. As long as you use
manual. the same unit geometry and a unit with the same
44 | Running RODSTAR

Figure 4.27 - RODSTAR recommends a unit size based on target production

stroke length and gearbox rating, the results should

be close to actual as long as the pumping unit is to use uncommon unit geometries such as the
the same unit type as the one you selected. Rotaflex, then this recommendation may not be as
If after you enter a pumping unit ID RODSTAR useful. RODSTAR makes this recommendation
displays The pumping ID you entered is not valid without running through the predictive calcula-
tions. Therefore, it may not necessarily recommend
this means that ID you entered is not recognized
the best pumping unit size for your application.
by RODSTAR. This can happen for two reasons: However, in most cases it should be pretty close to
1) You entered the wrong ID such as R0 (which the size you need.
does not exist), or CL901 instead of CL91. There are other important factors that you must
2) You have erased the pumping unit file by acci- consider when deciding what unit size you need.
dent, or the pumping unit files are not in the same These include: available used pumping units, ex-
directory as the program. pected changes in well conditions, desired pump-
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
If you enter a target production instead of selection screen, RODSTAR will not only display
pump- the recommended unit size, but will automatically
ing speed, RODSTAR will display a select the unit closest to the recommended size
recommended pumping unit size to help you from the available list. If you do not want to use
select a pumping the unit recommended by RODSTAR then select
unit. This recommendation can be very helpful another one. The recommended unit size is a push
if you are designing a new pumping system and button, as shown in Figure 4.27. So, whenever you
must decide what size unit you need. RODSTAR want to return to the pumping unit size recom-
recommends sizes that are closest to conventional mended by RODSTAR, just click the button and
units as Figure 4.27 shows. Therefore, if you plan
 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).
Then, double-click on Pumping Unit Options
will be close to the minimum required
tab and select Measured Pumping Unit List as
conventional
explained in section 3.3.5 in this manual. Then,
unit. RODSTAR recommends only the API unit
select to add a new unit to enter data for a new
size. You must decide what manufacturer and
pumping unit.
unit type to use. If you select a conventional unit
and RODSTAR predicts that the gearbox will The data you must enter consists of geometric
be overloaded, then try using the same size Mark dimensions as defined in the API 11E publication.
II or enhanced geometry unit. In some cases you You can get these dimensions from the pumping
may be able to use a smaller unit by selecting a unit manufacturer or measure them yourself. Or,
geometry that is better suited for your application. you may be able to find most of the dimensions
There are several factors that determine what unit you need from catalogs or blue prints. For old units
is best. They include, cost, gearbox loading, system without an API designation on their nameplate,
efficiency, rod compression, minimum polished rod you may be able to put together an equivalent API
load (indicates separation of the polished rod from the designation. Look at the gearbox nameplate for the
carrier bar if close to zero), etc. gearbox rating in thousands of in-lbs. Measure the
stroke length, and try to decipher additional infor-
mation from the units nameplate for the structure
rating, stroke length, and structural unbalance.
Selecting crank hole number and crank If the nameplate is legible then write down the
rotation units serial number or order number. If the units
manufacturer is still in business, you may be
After you select a pumping unit you must select able
the crank hole number, and the direction of rota- to get the data you need from the serial
tion with the well to the right (if you are using a number
unit that can rotate either way). For units with a or order number. For help in locating dimensional
required direction of rotation, like the Mark II , data for pumping units not in the manual call
Torqmaster, Lufkin Reverse Mark, or American Theta Oilfield Services, Inc..
Producer II, the program will not allow you to
change crank rotation. For units that can rotate RODSTAR allows you to enter data for Conven-
either clockwise or counterclockwise, RODSTAR tional, Mark II, Air Balanced, Enhanced Geom-
defaults to the direction of rotation that will usu-
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.

Entering your own pumping unit data

Figure 4.28 - Conventional/Enhanced
If the pumping unit you want to simulate is not
46 | Running RODSTAR

offset angle in degrees. For enhanced geometry

units the crank offset angle must be negative. In
the software, Beam Balanced units are balanced
using structural unbalance. This is because they are
balanced using beam weights as opposed to crank
weights. The API spec. 11E defines the above
dimensions as follows:

Figure 4.29 - Beam Balanced

etry, or Long Stroke units. When you enter your

own pumping unit dimensions, RODSTAR cal-
culates and displays the stroke length based on the
dimensions you enter. For all pumping unit types
you must first enter the name of the manufacturer,
the unit name or model number, the gearbox rat-
ing in thousands of inch pounds, the structure
rating in hundreds of pounds, and the maximum
stroke length in inches. From these numbers
RODSTAR puts together the API pumping unit
designation. The API pumping unit designation is
a standard way of describing the size and capacity
of pumping units as the following example ex-
plains:
Figure 4.30 - Mark II
The first number is the gearbox rating in thousand
inch-pounds. In this example the gearbox rating is
320,000 inch-lbs. The second number is the struc- Description:

Dimension:
ture rating in hundreds of pounds. In this case the R Radius of the crank (inches)
structural rating is 256. This means that to avoid A Distance from the centerline of the
overloading the structure of the unit, polished rod saddle bearing to the centerline of
load must not exceed 25,600 lbs. The last number the polished rod (inches)
shows the maximum stroke length of the unit in C Distance from the centerline of the
inches (100 inches in this case). Following is an saddle bearing to the centerline of
explanation of the rest of the data needed for each the polished rod (inches)
unit type: I Horizontal distance from the
centerline of the saddle bearing
to the centerline of the crankshaft
Conventional, Enhanced and Beam (inches)
Balanced Geometry Pumping Unit Data P Effective length of the pitman arm,
in inches (from the center of the
For these units you must enter pumping unit equalizer bearing to the center
dimensions R, A, C, I, P, and K in inches, the of the crank-pin bearing)
structural unbalance in pounds, and the crank
 RODSTAR| 47

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)

K as follows: K=
(H-G)2+I2
H Height from the center of the Air Balanced Pumping Unit Data
saddle bearing to the bottom of
For these units you must also enter pumping unit
the base beams (inches)
G dimensions R, A, C, I, P, and K in inches. In ad-
Height from the center of the dition, you need data for M, S and V0.
crank shaft to the bottom of the
base beams (inches)

Mark II Pumping Unit Data

For Mark II units you must also enter pumping unit
dimensions R, A, C, I, P, and K in inches, the
structural unbalance in pounds, and the crank offset
angle in degrees. This angle is positive for Mark II
units. The API spec. 11E defines the
above dimensions as follows:

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 equalizer (or cross yoke) bear- The API spec. 11E defines the above dimensions as
ing to the center of the crank-pin 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 for
the Sampson Post bearing to the 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,
(H-G)2+I2
V0 etc. (psig). as follows: K=
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)

Long Stroke Pumping Unit Data

For these units you must enter the sprocket
diameter (D), the centerline distance between
the top and bottom sprockets (distance C), the
Figure 4.32 - Belted Low Profile pitman arm length (P) if one exists (usually this
is zero), and the top drum diameter ratio (usually
equal to 1). You can see a diagram of the dimen-
Belted Low Profile Pumping Unit Data sional data you need by pressing F1 in any input
 RODSTAR| 49

Figure 4.34 - Definition of structural unbalance

Tip: To predict energy consumption more ac-

curately for hydraulic units using the long stroke
pumping unit model, input a pitman arm length of
zero and a drum diameter ratio of 2.
Another thing to keep in mind is that even though the
Figure 4.33 - Dimensions for long stroke combination of C and D dimensions deter-
units mines the stroke length of long stroke units, the
ratio of C/D determines the acceleration and de-
field, or you can take a look at Figure 4.33. celeration of the polished rod. For the long stroke
geometry shown in Figure 4.33, when the connec-
You can also use this pumping unit model tion point between the belt and the chain touches
to the sprocket, the polished rod speed changes
simulate any non-beam pumping unit (accelerates or decelerates). When the connection
with a point leaves the sprocket (C section in Figure 4.33)
long, slow stroke. You can do this by entering the speed is constant. Therefore, different com-
data that will produce the same stroke length as binations of C and D dimensions may be needed
the unit you want to model. The stroke length of a to correctly simulate the polished rod motion of a
long stroke unit is given by:
Stroke = C + D
For example, to simulate a hydraulic pumping unit
with a stroke length of 200 inches, you can enter a
sprocket diameter (D) of 20 inches and a centerline
distance between sprockets equal to 180 inches.
If you use this approach to design a system with a
hydraulic unit then the torque calculations, energy
consumption, and other results that depend on
torque will be incorrect or meaningless. However,
the predicted polished rod dynamometer card,
polished rod horsepower, stress analysis, etc. will be
valid. This technique can be used as long as the
Figure 4.35 - Definition of crank offset angle
upstroke and downstroke polished rod velocities of
the hydraulic or long stroke unit you want to
simulate are approximately equal.
50 | Running RODSTAR

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
you want to simulate then enter zero. In most cases For air balanced units you must enter the air cyl-
the structural unbalance will not affect the results inder pressure in psig at the bottom of the stroke.
significantly (especially for Conventional geometry For long stroke units you must enter the counter-
units). balance weight in thousands of pounds. For these
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 is The range of allowable counterweight is differ-
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

Figure 4.36 - Entering motor information

may have to add counterweights on the walking

beam next to the horsehead to balance the unit. ratchet prevents it from turning the other way.
This changes the structural unbalance from the Therefore, if your unit is generating electricity, you do
catalog value. RODSTAR allows you to change not get credit for it. The non-detent meter can rotate
the structural unbalance even when you select a either way and so it credits you for electricity the
pumping unit from the programs database. pumping unit generates.
The structural unbalance field can also be used to
simulate beam balanced units. By changing the Prime mover type selection
value of the structural unbalance, you can figure
out how much weight you need to add or remove Using drop-down list boxes you can select the
from the walking beam to balance a beam bal- motor type you want to simulate. RODSTAR has
anced unit. motor performance and efficiency data for NEMA
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 can simulate NEMA D or ultra high RODSTAR recommend a NEMA D motor for
slip motors and calculates power consumption you. If you select an ultra high slip motor then you
from actual motor efficiency curves. The program must select the motor size and torque mode. If you
uses the electricity cost you enter to predict the select a motor size or mode that is too small for
monthly electricity bill, $/bbl fluid, and $/bbl oil the well conditions then RODSTAR will display
(based on water cut). RODSTAR defaults to the a warning message and will give you the option to
cost number you specify in Setup. The $ symbol change your data.
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 two
or no rotating moment of inertia, so using an ultra-
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 for
include speed variation effects. your prime mover. Selecting to include prime mover
speed variation will approximately double
If you select a NEMA D motor type for a new
RODSTARs run time.
case, or switch from an ultra-high-slip motor to
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
explain moment of inertia and how it can affect
The option to include the effect of motor speed
RODSTARs results. The mass moment of inertia of
variation is only available for conventional, en-
a body is a measure of its resistance to accelera-
hanced geometry, and Mark II units. Inertia ef-
tion. In other words, the higher the moment of
fects are negligible for long stroke and air balanced
inertia of a body, the more difficult it is to quickly
units.
speed it up or slow it down.
If you select not to include speed variation effects
The rotating and articulating moments of inertia
then RODSTAR assumes constant prime mover
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 a torque when you use a high speed variation prime
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
variation then you can enter a rotating moment The articulating moment of inertia of the pumping
of inertia in lbs-ft2, or have the program estimate unit around the saddle bearing includes the inertia
this number for you. For the articulating moment of the walking beam, horsehead, and pitman arms.
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 the
an estimate based on unit size. Therefore, unless 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 of
program. the counterweights on the cranks. Since this
data may not be known, it is recommended that you
For more accurate results, have RODSTAR cal- let RODSTAR estimate the rotating moment of
culate the prime mover speed variation. However, 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

moment of inertia values that were either obtained

from unit manufacturers, or were estimated based on
unit size. The articulating moment of inertia from the
pumping unit database appears as the default number
when the program prompts you for the articulating
moment of inertia.
Including speed variation and moments of inertia
will usually result in lower predicted peak gearbox
torque, lower peak polished rod load, and higher
minimum polished rod load. This is because a
high speed variation prime mover slows down as
the torque on it increases. The rotational inertia of
cranks and counterweights causes a release of ener-
gy that lowers the torque the gearbox must supply.
The articulating inertia adds torque to the gearbox
since it opposes the acceleration of the walking
beam and horsehead. However, the effect of the
articulating moment of inertia is usually small
compared to the effect of the rotating moment
of inertia. When the prime mover slows down in
response to high torque, it causes the polished rod
to slow down as well. This results in lower dynamic
forces and therefore lower peak polished rod load.
54 | Changing, Loading and Saving Data

5 Changing, Loading and Saving Data

then choosing Save As... This brings up a stan-

5.1 Visual Input
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.

5.2 Storing Data Files

After you finish entering data for a system, you can
save the data to disk by clicking on the Quick Save
button on the toolbar (third from left with diskette
icon), or by selecting File from the menu bar and Figure 5.1 - RODSTARs Visual Input window
 RODSTAR| 55

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

Figure 5.2 - Summary output report - upper half

56 | Changing, Loading and Saving Data

Figure 5.3 - Summary output report - lower half

eter plots, you can select to animate then surface

and downhole pump cards. mum energy consumption.
To look at different parts of the output you can The most common way to balance a unit is for
click the appropriate buttons at the bottom of the minimum torque. However, if the gearbox is not
screen (Dynamometer, Torque, IPR Plot, Dev. overloaded, you may want to balance the unit for
Plots when using RODSTAR, or Report). When minimum energy consumption instead.
you click on Report, you can scroll up or down After viewing the output you can decide which
with the mouse, or you can click and drag on the value of balanced counterbalance moment you
report itself. Figure 5.3 shows the bottom section want to export to XBAL (so that XBAL can
of the summary report. The summary report looks calculate the counterweight positions required to
exactly the same as the printed report. balance the unit). When you click on the Export
If you have XBAL on your computer, you can have CBM... button, RODSTAR displays the window
RODSTAR export the balanced maximum coun- shown in Figure 5.4 (if there are two possible ways
terbalance moment it calculates to XBAL. You to balance the unit). Click on the option you want
can do this any time the calculations have been run and click on the OK button. RODSTAR confirms
(whether or not you are actually viewing them) by that the value of the maximum counterbalance
clicking on the Export CBM button on the moment has been exported by displaying the mes-
sage box shown in Figure 5.5.
toolbar ( ).
RODSTAR can calculate two possible ways to
balance a unit: for minimum torque, or for mini- 5.3.1 Saving the output
 RODSTAR| 57

to run in batch, click on the first

file and then, while pressing S,
click on the last file in the list. Or,
you can click on the first file and
then drag the mouse to highlight
all the files you want to run (it must
be a continuous group). To select
individual files, click on the files you
Figure 5.4 - Exporting the maximum CB moment want to select while pressing C. The
selected files are highlighted
If you save the file while the output is being dis- as Figure 5.6 shows. When you are
played on the screen, RODSTAR saves the output done selecting files, click OK.
along with the input in the same file. Then, you can At this point, RODSTAR will display the option
load a file with output and you can display and print
box in Figure 5.7 asking you to choose the options
the output without
having to rerun the pro-
gram. To save the output,
click on the quick save
icon on the tool bar, or
select File on the menu
bar and then select Save
As..
When you load a file that
has output saved, the
program will tell you that
output results are avail- Figure 5.5 - Maximum CB moment exported
able on the status bar (at
the bottom of the RODSTAR window). you want for the batch run. The first option causes
RODSTAR to create printouts for all the files
it runs. This option is unselected by default. The
5.3.2 Running in Batch Mode second option causes RODSTAR to create a sum-
mary spreadsheet file for all the cases it runs. The
You can run more than one case at a time by se- option to view the spreadsheet in Excel means that
lecting to run two or more files in batch mode. The once the cases are processed and the spreadsheet is
batch mode starts automatically when you select created, RODSTAR will automatically load Excel and
to load more than one file. This capability allows display the results for you.
you to make an unlimited number of RODSTAR
runs automatically, and without you having to be The next option allows you to save the output
at the computer. RODSTAR even allows you to reports in PDF format. The reports will be saved
schedule the batch run to start at any time (from in the same folder as the RODSTAR files are cur-
the Setup window). rently stored. For example, if the RODSTAR files
that you are running in batch are located at C:\
To start the batch, select to open a file (either by THETA, then you will find the PDF files of the
clicking the Open File toolbar button, or by select- output reports in the same folder after the batch
ing Open from the File menu). This brings up run.
the open file dialog box. To select a group of files
58 | Changing, Loading and Saving Data

STAR uses the default

spreadsheet format that
comes with RODSTAR
and contains the most
common system design
comparison variables.
The option Dont re-
run cases with saved
output allows you to
create different summary
spreadsheet files with the
same set of RODSTAR
files. When you select
this option RODSTAR
runs very fast in batch
because all it has to do
is extract the calculated
values that have already
been saved in the ROD-
Figure 5.6 - Selecting files for a batch run STAR files and enter
them in the spreadsheet.
The last option allows you to specify whether you When RODSTAR starts
want RODSTAR to rerun cases with saved output or to run the files you selected, it displays a batch run
not. log window such as that shown in Figure 5.9 that
If you do not select the option View spreadsheet in shows the number of files you selected, the number
Excel when you click on Proceed, ROD- of runs that have been completed so far, and the
STAR asks you for Excel file name as shown in overall percent completion. RODSTAR shows the
Figure 5.8. Otherwise, if you select to view
spreadsheet in Excel, RODSTAR starts running in
batch immediately.
Creating a summary spreadsheet is very useful
because it allows you to summarize many runs in a
very concise way. After the results are in a
spreadsheet file, you can plot one variable versus
another, you can sort the spreadsheet columns by
rod string cost, system efficiency, energy cost per Figure 5.7 - Batch run options
barrel of oil, etc. There is no limit to what you
can do with the results. name of each file that it runs. RODSTAR prints
The spreadsheets that RODSTAR create summa- warnings or errors after the name line while run-
rize the results of all the runs and loads it directly ning each case. After each new run is complete, the
into Excel. Under the Setup window you can de- program prints ** Run Complete **.
sign and save an unlimited number of spreadsheet This is a useful record of the cases that ROD-
formats. If you do not specify a spreadsheet format STAR ran and any warning or errors generated
before running many cases in batch mode, ROD- while running them. You can cancel a batch run
 RODSTAR| 59

at any time over-

by clicking night.
on Cancel.
The program
will stop after
it finishes 5.4
running the
current case
and it will
display a mes-
sage box that
says: The
batch run was
canceled.
We recom-
mend print-
ing the batch
run log,
especially
when running
many ROD- Figure 5.8 - Selecting a spreadsheet file to create
STAR cases.
The batch run log shows what files you ran, and
any errors or warnings for each case. To view an Loading Data from Disk
output report of one of
your cases, double click
the blue title bar which
displays the directory
and the file name. To
return to the batch run
log click the Close
button on the bottom of
the output window.
The batch run capabil-
ity is especially useful
for the deviated mode
because it requires more Figure 5.9 - A batch run log
calculations than the
vertical mode. Because
of the complexity of the calculations for deviated After you enter data and store a file you can easily
wellbores, RODSTAR runs may rake a minute modify it by loading it back in memory. Also, you
or two to run in most cases and sometimes even can load a file with saved output and view or print
longer. Therefore, using the batch process can save the output results without having to rerun a case.
you from having to wait for each case to run. You You can do this by:
can have your case execute while at lunch or even - Clicking on the Open button on the toolbar (sec-
60 | Changing, Loading and Saving Data

ond from left).

- Clicking on File on
the Menu bar and then
on Open, or by pressing
C+ o.
Also, RODSTAR keeps
track of up to nine of
the most recent files
you saved or loaded and
allows you to quickly
load any of them. To see
a list of these files click
on the drop-down icon
between the file open
and file save icons on the
tool bar and then click
on the file you want to
load. Or, you can click Figure 5.10 - Selecting a file to open
on File from the menu
bar and select Recent acter of the file you are looking for. For example,
Files if you are looking for well name PR101.RSVX,
If there is data in memory, RODSTAR will warn
click in the list once, and then press p and the
you that loading new data will erase the existing
program will jump to the first file in the list that
data in memory. This alerts you and helps pre-
starts with P.
vent accidental loss of your data before you have a
chance to save it.
RODSTAR has a powerful and easy-to-use file 5.4.1 Viewing Previously Saved Output
management system. When you select to load data
from disk, RODSTAR displays the current path When you load a file that contains output you
and a list of files in the current directory in alpha- can display the output without having to rerun
betical order. Also, RODSTAR allows you to read the case. When you load a case that contains
RODDIAG files, XDIAG files, and even older input data only (no output results were saved),
RODSTAR files. RODSTAR displays a list of the RODSTAR displays the first input window (well
file type you selected in the current directory as the information). Also, the report and print icons on the
Figure 5.10 shows. toolbar are not available. However, when you load a
file that contains both input and output, RODSTAR
To load one of these files, double click on it, or does not open any input windows. The status bar at
click on it once and then click on OK. If the file the bottom of the screen shows a message like the
you want is not in the current directory, you can following:
easily move to any directory on any drive in your
system since this window also lists sub directories, Successfully loaded file: C:\Theta\RODSTAR
and system drives. cases\special cases\abc#1.rsvx (output results are
available).
If your current directory contains many ROD-
STAR files, it may be faster to press the first char- Also, the report and print icons on the tool bar are
active. To see the output without having to re-run
 RODSTAR| 61

Figure 5.11 - Minimized input windows

the case, click on the report icon on the tool bar. To

print the output, click on the printer icon (next to the
email icon).

5.5 Manipulating Input Windows

RODSTAR is a standard Microsoft Windows ap-
plication and it allows you to manipulate the input
windows several different ways. After entering
data for all the input windows, or after you load
a file from disk, you can display one window at a
time, you can open all windows, or you can ar-
range them any way you want as explained below:
After entering data for a case or after load-
ing a file from disk, click on each windows icon on the
toolbar. This loads all input windows.
You can click on the minimize button of
each form to minimize them into icons at the
bottom of the main window as Figure 5.11 shows.
To open any of the minimized windows, double
click on its icon or click on it once and then select
Restore.
You can use the mouse to resize windows,
or to drag a window or an icon anywhere in the
RODSTAR main window.
62 | Rod Pump System Design

6 Rod Pump System Design

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

Figure 6.1 - RODSTAR Summary Report

RODDIAG and XDIAG files and overlay the

ful features help you design rod pumping systems
measured dynamometer card on the same plot as
faster than ever before. Also, because RODSTAR
the predicted one is very useful. With this capabil-
uses state-of-the-art design algorithms, it is very
ity you can:
 RODSTAR| 63

1. History match existing rod pumping systems report page. Also, it shows buttons on the bottom of
before you make a design change. This allows the output window that allows you to access the
you to figure out unknown quantities such as predicted dynamometer plot, torque plot, IRP plot (if
rod-tubing friction. 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
it is important to understand its output. After structure
RODSTAR runs, it displays the summary output of the pumping unit are overloaded or if the
minimum polished rod load is negative. This

Figure 6.2 - Dynamometer plots and Permissible Load diagram

64 | Rod Pump System Design

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
nation of curved and straight lines, or straight lines
dia-
only. If the upstroke part of the predicted surface
gram for long stroke units such as the Rotaflex
dynamometer card exceeds the curved line of the
will have straight line segments that corre-
permissible load diagram this indicates that the
spond to gearbox loading or structure loading.
gearbox is overloaded at that point. If the dyna-
Please look at the structure loading number
mometer card cuts into the straight line section of
on the first page of the output and the percent
the permissible load diagram on the upstroke, this
gearbox loading under torque analysis for the
indicates that the structure of the pumping unit is
exact percent unit loading.
overloaded because the polished rod load is larger
than the structure rating of the unit. In addition to showing whether the gearbox is
overloaded, the permissible load diagram also
For the exact numbers of peak net gearbox torque shows how well the pumping unit matches the
and gearbox loading, look at the torque analy- load requirements of your system. If the predicted
sis section of the printout. The permissible load polished rod dynamometer card fits nicely in the
diagram corresponds to existing conditions if you permissible load envelope, this indicates a good
entered a counterbalance moment. If you did not agreement between the pumping unit and the rest of
enter an existing max. CB moment then the pro- the system.
gram shows a permissible load diagram for bal-
However, if the predicted surface dynamometer

Figure 6.3 - Torque plot

 RODSTAR| 65

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

Figure 6.4 - Inflow performance relationship (IPR) plot

66 | Rod Pump System Design

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 run
one for existing conditions, one for balanced con- RODSTAR shows input data on the left side of the
ditions for minimum torque, and one for minimum page and calculated numbers on the right size. The
energy consumption. If there is no difference be- 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 of
two curves (existing and balanced). If you selected 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 the
Otherwise, it will show two balanced curves: one
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

System Efficiency and the structural capacity of the pumping unit

(the middle number in the API pumping unit
The system efficiency is calculated by regarding
designation).
the whole pumping system as a black box with
electricity going in and produced fluid coming out.
This number shows how efficiently the system con- Buoyant Rod Weight
verts electric power to work needed to lift the pro-
duced fluid to the surface. A system efficiency of Buoyant rod weight shows how much the rod
45% or above is excellent. In General, deeper wells string weighs in fluid. Since the rod string is im-
will have lower efficiencies than shallow wells since mersed in the fluid inside the tubing, it weighs
less than in air. You can compare this number to
deep wells have more rod-tubing frictional loses.
a measured standing valve load. A good standing
Efficiencies of 35%-45% are average, while system
valve check should be close to the weight of rods
efficiencies of less than 35% are poor and can usu-
in fluid as calculated by RODSTAR for a pump
ally be increased by using a longer, slower stroke
that is in good mechanical condition. If these two
(with larger pump plunger).
numbers differ by more than 10% and the standing
valve is in good condition, it may be an indica-
Permissible Load HP tion that the load cell is out of calibration or that
the standing valve load was incorrectly measured.
Permissible load horsepower is defined as the area Also, the sum of the buoyant rod weight plus fluid
bounded by the upper permissible load line, lim- load on the pump should be close to the traveling
ited by the structural rating of the pumping unit and valve load for a good pump.
the lower permissible load line, limited by zero
minimum load.
The ratio PLHP/PRHP (permissible load HP N/No and Fo/Skr
divided by polished rod HP) is a number that The dimensionless numbers N/No and Fo/SKr
should be as large as possible without overloading are defined in API RP 11L1 . N/No is the ratio
the pumping unit. The larger this number is, the of pumping speed to natural frequency of the rod
more of the pumping unit potential capacity you string. Fo/SKr is the rod stretch caused by the
are using. static application of fluid load, as a percent of the
polished rod load stroke. In general, the higher
the Fo/Skr is, the shorter the pump stroke will be.
Fluid load on Pump Also, the higher the N/No the larger the pump
Fluid load on the pump shows how much fluid stroke is. These numbers also relate to system ef-
load the plunger is carrying on the upstroke. This ficiency. In general, the larger N/No is, the lower the
is a function of pump depth, fluid level from sur- efficiency will be. The larger the Fo/SKr is,
face, and plunger size. Fluid load on the pump is a the better the system efficiency is. However, this
function of pressure difference across the plunger relationship is not linear.
and pump plunger diameter. For low Fo/Skr numbers (below 0.25) fiberglass-
steel rod strings will have very low system efficien-
cies and should be avoided. For fiberglass rods try
to keep Fo/Skr above 0.3 and below .8 for best
Unit Structural Loading
1 API RP 11L (Third Edition) Recommended
Pumping unit Structural Loading indicates wheth- Practice for Design Calculations for Sucker Rod
er or not the pumping unit structure is overloaded. Pumping Units. American Petroleum Institute,
This is a function of the peak polished rod load Dallas TX.
68 | Rod Pump System Design

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

Figure 6.5 - Section of RODSTAR Output Report

 RODSTAR| 69

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 less
comparison. This is because a system that shows 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 by
RODSTAR has the capability to balance pumping RODSTAR, pump load adjustment., etc. Also, this
units for minimum torque and minimum energy. If 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 you
then the program shows only one recommendation enter to calculate the expected production rate. When
for balanced conditions. However, if the two values you ask the program to calculate the spm by entering
are more than 2% different then it shows two bal- a target production, it will calculate a larger spm if you
anced columns: One for minimum torque, and one enter 80% pump efficiency than when you enter 90%
for minimum energy. The torque plots show how 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

Figure 6.6 - System cost analysis

70 | Rod Pump System Design

Figure 6.7 - IPR report

pump spacing recommendation, minimum re-

quired pump length, and recommended plunger to use a design with a negative bottom minimum
length. The pump spacing recommendation should stress on the fiberglass section even with buoyancy
be used as follows: effects included. Compressive loading will cause
fiberglass rods to part. Also, to maximize rod
After working on the well and before you
life, stress loading must be less than 100% in all
cases. For sinker bars, RODSTAR calculates stress
are ready to restart the pumping unit,
loading, top maximum and top minimum stresses
make
based on the elevator neck or pin undercut diam-
sure the tubing is full of fluid. Then lower
eter of the sinker bars. However, RODSTAR still
the rod string slowly until it tags bottom.
uses the full body diameter in the calculation of
Then raise the rod string a distance equal to
stress at the bottom of the sinker bar section.
the one recommended by RODSTAR next
to: Pump spacing (in. from bottom):
Then, attach the polished rod to the bridle Rod String and Pumping Unit Cost Analysis
with the unit stopped at the very bottom of
the downstroke. This section shows the cost of each rod section as
well as the total rod string cost (see Figure 6.6).
Please note that the working fluid level makes a big Also, below the rod string cost is the pumping
difference in pump spacing and pump length. This unit cost. RODSTAR shows the cost information
is especially true for fiberglass rods since the only if you select this option in Setup. You must
plunger travel is strongly dependent on fluid load first enter rod string and pumping unit cost data in
on the plunger. Setup before RODSTAR can show you accurate cost
information here.
Rod String Design and Stress Analysis
This section shows the rod string design and ser- Inflow Performance Relationship Information
vice factor you selected, the calculated percent rod This section shows the correlation used for oil
loading for each rod section, the maximum and IPR, mid-perf depth, the static bottomhole pres-
minimum stresses at the top, and the bottom min- sure, and the bubble point pressure (if entered) or
imum stress for each rod section. To ensure your whether the well is producing below the bubble
rods are in tension, do not include buoyancy effects point pressure. Also, it shows a table of input test
(this should always be the case for steel rods). point data of flowing bottomhole pressure versus
Then, make sure there are no negative stresses on any measured production, and a table of pressure vs.
other rod section other than the sinker bar sec- production table. As Figure 6.7 shows, this table
tion on the bottom of the rod string.
If you are using fiberglass rods you would not want
 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 on
above, the deviated mode calculates and prints 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-

Figure 6.8 - RODSTAR (Deviated Mode) First Displayed Page

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

Figure 6.9 - Side Load Plot

jected to negative loads because of pump friction

and other frictional effects due to wellbore devia-
tion. According to a paper titled Interpretation of
Calculated Forces on Sucker Rods by J.F. Lea and
P.D. Pattillo, published in SPE production and Fa- In the same paper referenced above, the author
cilities, February 1995, the critical load necessary to shows a table of critical forces and length that will
buckle a rod string is calculated as follows: cause rods to buckle. According to this table, a 3/4
rod would buckle if it subjected to a negative load
of only 37.2 lbs and if at least 26.1 feet of the 3/4
section is in compression. For 7/8 rods, buckling
would occur if the negative force on the bottom
is 56.2 lbs and the negative portion is longer than
28.9 feet long. As these examples show, the only
Where:
way to be sure the rods will not buckle is to keep
w = rod weight in fluid them in tension.
I = moment of inertia of cross section (in4)
The Dogleg severity in degrees per 100 feet, rep-
E= elastic modulus of rod = 30.5x10 psi for steel resents the rate of change in the inclination and
azimuth of the bore hole with respect to measured
The Moment of inertia of the rod section (I depth. Dogleg severity is not used to calculate side
above) can be calculated as follows: load. The Dogleg severity plot is a useful guide
that shows how sharply the curvature of the well-
bore changes. The same dogleg severity close to the
 RODSTAR| 73

Figure 6.10 - Deviation plot page

74 | Well Information

surface of the well will result in a larger side loadIf 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 the
it results in larger side loads as compared to 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 bent row keys at the top of the report page to see all of the
more easily. report pages, including the rod guide spacing
The rest of the deviation plots show different views recommendation pages.
of the wellbore.

Figure 6.11 - 3D rod guide recommendation plot

 RODSTAR| 75

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, you
Capital costs 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 or
and operating costs. Up to now, rod system design 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
RODSTAR calculates rod stresses at the top and
the rod string and one for the fluid in the tubing.
bottom of each rod section. It calculates the maxi-
This
mum and minimum stress at the top of each rod
unique capability allows very accurate predictions.
section in order to calculate the percent stress load-
RODSTAR can predict the expected surface and
ing. It also calculates the minimum stress at the
downhole dynamometer card shapes common to
bottom of each rod section. The bottom minimum
shallow, high rate wells. When designing shal-
stress shows if the rods are in compression.
low high rate wells it is recommended that you
use pump efficiencies of 90%-95% to avoid under- Steel rods can tolerate some compressive force but
predicting peak polished rod load, torque, etc. fiberglass rods cannot tolerate any compression
This higher pump efficiency will result in higher at all. This is why fiberglass rods must have steel
fluid velocity in the tubing and higher fluid iner- rods or sinker bars at the bottom. The weight of
tia forces on the plunger. However, when you are the sinker bars overcomes the opposing hydrostatic
trying to history match an existing system, you force and pump friction. If correctly designed, the
may need to use a pump efficiency of less than 90% sinker bars or steel rods ensure that the fiberglass rods
to better match the actual pump slippage of your are always in tension.
system. Although steel rods can be subjected to some com-
pression without adverse effects, excessive negative
stresses can cause buckling problems. The recom-
6.3.2 Selecting the Target Production mended way to use RODSTAR to determine
To avoid severely over-sizing the displacement if
capacity of your pumping system, design it with a your rods may be subjected to compression is
pump efficiency of 80%-85% or even 75% if you to
expect the downhole pump to wear out quickly. run the program without including
This ensures that you will get your production buoyancy
without grossly over-designing the system. effects. Then, add sinker bars or sinker
To minimize energy consumption and stress load- rods to
ing, use the largest plunger diameter and slow- overcome the negative stresses at the
est pumping speed combination possible without bottom
section of the rod string (above the sinker
overloading the rod string and pumping unit. If
bar
you have to make a choice between stress loading
section) . Other ways of minimizing buckling
and power consumption, opt for lower stress load-
problems include using smaller pumping speeds
ing especially if you are close to 100% since rod and avoiding use of small diameter rods such as
breaks are more costly than a slightly lower system 5/8 or even .
efficiency.
Note that these are only general guidelines. Eco-
nomics and local field conditions may require a 6.3.4 Minimizing Power Consumption
different design philosophy than the one described
In general, the slower the pumping speed and the
above. Regardless of your objectives and design
larger the pump plunger size, the less energy the
philosophy, with RODSTAR you can design rod
pumping system will use. However, minimizing
pumping systems faster and more accurately than
energy consumption must not be the sole purpose
with any other computer program.
of system design because a large pump plunger
diameter will result in large polished rod load and
gearbox torque. This will require the purchase of a
larger unit, larger rods and bigger prime mover. To
come up with the best pumping system design you
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 get are very sensitive to fluid load. When the fluid
the most economic pumping system based on your level is above the pump, the fluid load on the pump
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, it ter card making it fatter. This in many cases brings
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
Sometimes, using the largest unit stroke may not fiberglass rods you should run system simulations
be the best way to maximize production since it using different fluid levels (within the expected
can result in severe gearbox overload. If this oc- fluid level range) to see which fluid level results in
curs you may be able to use the next smaller unit the highest loads and largest required motor size.
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-
erably by asking RODSTAR to design a rod string
Also, you can reduce gearbox torque with an ultra
for you. Even if you do not plan to use the design
high slip motor. RODSTAR can predict the gear-
RODSTAR recommends, it is easy to grab
box torque depending on the pumping unit size and
RODSTARs recommended design and modify
ultra high slip motor size. Also, RODSTAR can
it. To do this, after the program runs, go to the
calculate the motor speed variation and power
rod string entry screen and select the Manual rod
consumption very accurately.
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 to 6.3.7 Using RODSTAR for Diagnostic Analysis
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) for can be a very powerful diagnostic aid, when used in
fluid level at the pump. This ensures that the conjunction with RODDIAG or XDIAG. This is due
equipment you plan to use will not be overloaded if to the powerful overlay feature that allows direct
the fluid level drops in the future. 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 the
downhole problems such as a worn pump, leaking 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, a
deviated wells to minimize side loads, rod-tubing
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