Design and Optimization of

Sucker Rod Pump Using

Prosper

Course name: computer application

Under supervision of dr. Adel Salem

Prepared by:
1. Omar Abdallah Ghareb Mostafa 17125
2. Amr Mahmoud metwaly 17126
3. Abdelrahman Mamdouh ali 18015
4. Osama Ibrahim abdelrazek 18004
 PROSPER

FULLY
COMPOSITIONAL

WELL AND PIPELINE INFLOW/OUTFLOW

MODELS RESPONSE

OUTFLOW (VLPs)
STEAM WELLS MODELS

ARTIFICAL
FLOW ASSURANCE
LIFT SYSTEMS

THERMAL INFLOW ( IPRs)

MODELLING MODELS
PERFORATION
DESIGN AND MULTILATERAL
PERFORMANCE COMPLETIONS
WELL AND
PIPELINE
MODELS

PROSPER was commercialized in the early 90’s and has been the
subject of ongoing research and development for over two decades.
Each year, new models and functionalities are added to the already
extensive list of options in this program. There are over three million
combinations of options that can be used to describe the vast majority
of physical phenomena happening in wells and pipelines.

PROSPER has evolved into the industry standard for well and pipeline
modelling due to its unrivalled sound technical basis and unique
modelling capabilities. The program today forms one of the foundation
stones of the Digital Oil Field system in real time on hundreds of fields
world-wide.

OUTFLOW
(VLPs)
MODEL

As part of the package of unique features available in PROSPER,

research being conducted since Petex was founded has resulted in
the creation of a number of proprietary multiphase flow pressure
drop models. The objective of this research has been to create
fundamentally rigorous models that overcome the limitations of
traditional models available in the industry.

Petex is uniquely placed to have access to data from all over the
world and over the years, a comprehensive database of pressure
drop measurements has been created, which allows our
researchers to compare novel physical models to real world
information.
© Petroleum Experts Ltd. 2015 e-mail: [email protected] www.petroleumexperts.com
All rights reserved

2
INFLOW (IPRs)
MODEL

A comprehensive set of inflow models complement the multiphase

flow capabilities in PROSPER, enabling Nodal Analysis calculations
to be done for virtually any type of well. There are over 20 inflow
models that have been developed over the years, that can be
applied to horizontal, vertical, deviated, multilayer and
multilateral geometries.

Furthermore, novel development has seen the realisation of unique

inflow models that account for changing PVT conditions in the well
drainage area as well as in multiple zones. This allows re-
perforation studies, analysis of skin, the application of sand control
measures and many other sensitivities to be conducted easily.

MULTILATERAL
COMPLETIONS

Alongside all of the analytically derived Inflow Performance

Relationships available in PROSPER, the Multi-Lateral IPR model is
the culmination of extensive research and has been designed
specifically for complex well completions that have undulating
trajectories across multiple producing zones.

This is the most advanced analytical IPR that exists in the industry
today and can only be found in PROSPER as another one of the many
unique features in the program.

© Petroleum Experts Ltd. 2015 e-mail: [email protected] www.petroleumexperts.com

All rights reserved

3
ARTIFICAL
LIFT
SYSTEMS

area where PROSPER has offered unparalleled modelling capabilities

to the user community for many years. Such as: Gas Lift, ESPs, HSPs,
Coil Tubing Gas Lift, PCPs, Jet Pumps, Sucker Rod Pumps. With every
new release of the program, one or more methods are added and the
capability of the existing methods are enhanced. A database of
equipment (Pumps, valves, motors etc) is available and is being
updated every year as new descriptions become available.

As part of the philosophy of sharing knowledge among operators in

the industry, Shell has contributed their proprietary perforation
optimisation tool (SPOT) which can now be found as part of the
standard toolkit of calculations in PROSPER. The objective of this
module is to allow engineers to compare the perforation charge
performance and assist in selecting the optimum perforation gun.

STEAM
WELLS

Steam injection wells are becoming more common in the industry and
modelling of such systems can be done through a variety of tools in
the IPM Suite, primarily REVEAL. PROSPER is also steam enabled and
the wells to be modelled relate to steam injection systems.

© Petroleum Experts Ltd. 2015 e-mail: [email protected] www.petroleumexperts.com

All rights reserved

3
SUCKER ROD

Sucker rod pumping, also referred to as “beam pumping,” provides

mechanical energy to lift oil from bottom-hole to surface. It is efficient,
simple, and easy for field people to operate, and can be used to pump a
well at very low bottom-hole pressure to maximize oil production rates.
It is applicable to slim holes, multiple completions, and high-
temperature and viscous oils. The major disadvantages of beam pumping
include excessive friction in crooked/deviated holes, solid-sensitive
problems, low efficiency in gassy wells, limited depth due to rod
capacity, and bulky in offshore operations. Beam pumping trends include
improved pump-off controllers, better gas separation, gas handling
pumps, and optimization using surface and bottom-hole cards. This
chapter presents the principles of sucker rod pumping systems and
illustrates a procedure for selecting components of rod pumping
systems. Major tasks include calculations of polished rod load, peak
torque, stresses in the rod string, pump deliverability, and
counterweight placement.
 Design and Optimization of Sucker Rod Pump
Using Prosper
Worldwide, as conventional oil resources are depleted, beam pumping system is becoming the
common type of artificial lift method for onshore wells. Production testing of beam pumped
wells is an important diag nostic tool to detect potential production problem and for
monitoring reservoir performance. In addition, the well test data and the inflow
performance relationship (IPR) combined with the production system. Also when larger
population of beam pumping wells are connected to central batteries, it is difficult to determine
the daily production of each well or to identify the cause of low production in the battery, as
there is not any easy way to identify which well is affected. The new method
continuously infers the production and by analyzing the down hole pumps card data. The
complete design of a sucker rod pumping system is an involved trial and error process. An
"optimum" design requires that the engineer specify pump size and type; rod string size,
taper and material; surface unit type and size, gear box rating, beam rating, and stroke
length; and prime mover type and size. The procedure requires that the engineer first
assume an appropriate combination of pump, rod, unit, and prime mover and then
perform calculations which lead to refining that initial assumption.

STEPS IN THE DESIGN OF SUCKER ROD INSTALLATION

Objective: - The main objective of designing sucker rod pump is to lift the fluid from the Downhole formation. Primary
design factors that are considered when designing sucker rod pump are

1) Desired mass rate,q , bbl/day

2) Net lift of fluid, , ft
Knowing these two factors help us to estimate the optimized plunger size which results in

a) Minimum rod loads (1+α),lb

b) Minimum torque on gear box, ,in,lb

c) Minimum input power requirements, ,hp

Once plunger size is determined, tubing size ,(A t) rod sizes (Ar1,Ar2,….) and lengths (L1,L2,……), stroke size (S), pumping speed (N), torque
rating (Tp) of the unit and power rating of the prime mover (Hb) are calculated.

Such interdependency of these variables makes their selection extremely difficult if design problem were approached entirely from the
mathematical standpoint without benefit of previous experience.

Assumptions to Well Conditions:- If certain assumptions to well conditions are made then it becomes possible to prepare charts and
tables (Lubinski and Blenkarn) which greatly reduce the efforts necessary in designing a pumping installation. Generally made
assumptions are
1) Specific gravity (G) of well fluids is 1.00, and
2) Net lift (LN), working fluid level (D) and pump setting depth (L ) are same

=D+=D=L

But it must be realized that chart values may have to be adjusted to fit a particular situation. For example, tubing already present in
the well to be put on pump dictates the maximum pump size, which might be smaller than the optimum size indicated by the selection
chart.

Minimum information required for installing pump constitutes

a) Fluid production rate, q

b) Depth to pump, L
c) Working fluid level
d) which is if not known, assume to be equivalent to pump setting depth,
d) Volumetric efficiency of pump (Usually 0.8 for design purposes), Ev
e) Specific gravity of fluid, G

1.1 Following steps are involved in designing a pumping

installation
1. From maximum anticipated fluid production and estimated volumetric efficiency, calculate pump
displacement (V) V=q/Ev
2. From Fig 1 estimate API pumps size and stroke length.

Figure 1 Sucker rod pumping unit selection chart (Kelley and Willis, 1954).

3. From Tables 1 to 8 select tubing size (At), plunger size (AP), rod sizes (Ar) and pumping speed (N)
corresponding to pump setting depth (L).
4. Calculate fractional length of each section of the rod string, using data of Tables 9 and 10
5. Calculate the length of each section of the rod string to nearest 25 feet.
 Table 1 DESIGN DATA FOR API SIZE 40 UNIT WITH 34-INCH STROKE

(After Kelley and Willis)

Pump Depth Plunger Size Tubing Size Rod Sizes Pumping Speed
ft in. in. in. strokes/min
1000-1100 2¾ 3 ⅞ 24-19
1100-1250 2½ 3 ⅞ 24-19
1250-1650 2¼ 2½ ¾ 24-19
1650-1900 2 2½ ¾ 24-19
1900-2150 1¾ 2½ ¾ 24-19
2150-3000 1½ 2 ⅝-¾ 24-19
3000-3700 1¼ 2 ⅝-¾ 22-18

Table 2 DESIGN DATA FOR API SIZE 57 UNIT WITH 42-INCH STROKE

(After Kelley and Willis)

Pump Depth Plunger Size Tubing Size Rod Sizes Pumping Speed
ft in. in. in. strokes/min
1150-1300 2¾ 3 ⅞ 24-19
1300-1450 2½ 3 ⅞ 24-19
1450-1850 2¼ 2½ ¾ 24-19
1850-2200 2 2½ ¾ 24-19
2200-2500 1¾ 2½ ¾ 24-19
2500-3400 1½ 2 ⅝-¾ 23-18
3400-4200 1¼ 2 ⅝-¾ 22-17
4200-5000 1 2 ⅝-¾ 21-17
Table 3 DESIGN DATA FOR API SIZE 80 UNIT WITH 48-INCH STROKE

(After Kelley and Willis)

Pump Depth Plunger Size Tubing Size Rod Sizes Pumping Speed
ft in. in. in. strokes/min
1400-1550 2¾ 3 ⅞ 24-19
1550-1700 2½ 3 ⅞ 24-19
1700-2200 2¼ 2½ ¾ 24-19
2200-2600 2 2½ ¾ 24-19
2600-3000 1¾ 2½ ¾ 23-18
3000-4100 1½ 2 ⅝-¾ 23-18
4100-5000 1¼ 2 ⅝-¾ 21-17
5000-6000 1 2 ⅝-¾ 19-17
Table 4 DESIGN DATA FOR API SIZE 114 UNIT WITH 54-INCH STROKE

(After Kelley and Willis)

Pump Depth Plunger Size Tubing Size Rod Sizes Pumping Speed
ft in. in. in. strokes/min
1700-1900 2¾ 3 ⅞ 24-19
1900-2100 2½ 3 ⅞ 24-19
2100-2700 2¼ 2½ ¾ 24-19
2700-3300 2 2½ ¾ 23-18
3300-3900 1¾ 2½ ¾ 22-17
3900-5100 1½ 2 ⅝-¾ 21-17
5100-6300 1¼ 2 ⅝-¾ 19-16
 Table 5 DESIGN DATA FOR API SIZE 160 UNIT WITH 64-INCH STROKE
(After Kelley and Willis)

Pump Depth Plunger Size Tubing Size Rod Sizes Pumping Speed
ft in. in. in. strokes/min
2000-2200 2¾ 3 ⅞ 24-19
2200-2400 2½ 3 ⅞ 23-19
2400-3000 2¼ 2½ ¾-⅞ 23-19
3000-3600 2 2½ ¾-⅞ 23-18
3600-4200 1¾ 2½ ¾-⅞ 22-17
4200-5400 1½ 2 ⅝-¾-⅞ 21-17
5400-6700 1¼ 2 ⅝-¾-⅞ 19-15
6700-7750 1 2 ⅝-¾-⅞ 17-15
Table 6 DESIGN DATA FOR API SIZE 228 UNIT WITH 74-INCH STROKE
(After Kelley and Willis)

Pump Depth Plunger Size Tubing Size Rod Sizes Pumping Speed
ft in. in. in. strokes/min
2400-2600 2¾ 3 ⅞ 24-20
2600-3000 2½ 3 ⅞ 23-18
3000-3700 2¼ 2½ ¾-⅞ 22-17
3700-4500 2 2½ ¾-⅞ 21-16
4500-5200 1¾ 2½ ¾-⅞ 19-15
5200-6800 1½ 2 ⅝-¾-⅞ 18-14
6800-8000 1¼ 2 ⅝-¾-⅞ 16-13
8000-8500 1⁄ 2 ⅝-¾-⅞ 14-13
Table 7 DESIGN DATA FOR API SIZE 320 UNIT WITH 84-INCH STROKE
(After Kelley and Willis)

Pump Depth Plunger Size Tubing Size Rod Sizes Pumping Speed
ft in. in. in. strokes/min
2800-3200 2¾ 3 ⅞ 23-18
3200-3600 2½ 3 ⅞ 21-17
3600-4100 2¼ 2½ ¾-⅞-1 21-17
4100-4800 2 2½ ¾-⅞-1 20-16
4800-5600 1¾ 2½ ¾-⅞-1 19-16
5600-6700 1½ 2½ ¾-⅞-1 18-15
6700-8000 1¼ 2½ ¾-⅞-1 17-13
8000-9500 11/6 2½ ¾-⅞-1 14-11
 Table 8 DESIGN DATA FOR API SIZE 640 UNIT WITH 144-INCH STROKE
(After Kelley and Willis)
Pump Depth Plunger Size Tubing Size Rod Sizes Pumping Speed
ft in. in. in. strokes/min
3200-3500 2¾ 3 ⅞-1 18-14
3500-4000 2½ 3 ⅞-1 17-13
4000-4700 2¼ 2½ ¾-⅞-1 16-13
4700-5700 2 2½ ¾-⅞-1 15-12
5700-6600 1¾ 2½ ¾-⅞-1 14-12
6600-8000 1½ 2½ ¾-⅞-1 14-11
8000-9600 1¼ 2½ ¾-⅞-1 13-10
9600-11,000 1 1/16 2½ ¾-⅞-1 12-10
Table 9 DATA FOR DESIGN OF TAPERED SUCKER ROD STRING

Rod sizes in string, in. Values of Ra

⅝-¾ R1 = 0.759-0.0896 AP
R2 = 0.241+0.0896 AP
¾-⅞ R1 = 0.627-0.1393 AP
R2 = 0.199+0.0737 AP
⅞-1 R1 = 0.627-0.1393 AP
R2 = 0.199+0.0737 AP
⅝-¾-⅞ R1 = 0.627-0.1393
AP R2 =
0.199+0.0737 AP
R3 = 0.175+0.0655 AP
¾-⅞-1 R1 = 0.664-0.0894 AP
R2 = 0.175+0.0478
AP R3 =
0.155+0.0416 AP
¾-⅞-1-1⅛ R1 = 0.582 – 0.1110
AP R2 = 0.158+0.0421
AP R3 = 0.137+0.0364
AP
R3 = 0.123+0.0325 AP
Table 10 PUMP PLUNGER DATA

Diameter, Area Pumping Constant,

in. sq in. bbl/day/in./spm
1 0.785 0.116
11/16 0.886 0.131
1¼ 1.227 0.182
1½ 1.767 0.262
1¾ 2.405 0.357
125/32 2.488 0.369

2 3.142 0.466
2 ¼ 3.976 0.590
2 ½ 4.909 0.728
2 ¾ 5.940 0.881
3 ¾ 11.045 1.639
4 ¾ 17.721 2.630
6. Calculate acceleration factor α = SN2/70,500
7. Determine effective plunger stroke

8. Using estimated volumetric efficiency, calculate the maximum probable production rate and check it
against the desired production rate
q = K SP N Ev

9. Calculate dead weight of the rod

string Wr = L1M1+L2M2+L3M3+……..
10. Calculate fluid load
Wf = 0.433G(LAP – 0.294Wr)

11. Determine peak polished rod load and check it against the maximum bean load for the
unit selected. Wmax = Wf + Wr (1+α)
12. Calculate maximum stress at the top of the rod string ad check it against the maximum permissible
working stress for the unit selected
Maximum rod stress = WMax / A3

13. Calculate ideal counterbalance effect and check it against the counterbalance available for
the unit selected Ci = 0.5Wf + Wr (1-0.127G)
14. From the manufacturer’s literature determine the position of counter weight to obtain the ideal
counterbalance effect.
15. On the assumption that unit will no more than 5 per cent out of counterbalance effect, calculate the
peak torque on the gear reducer and check it against the API rating of the unit selected
TP = (WMax - 0.95 Ci) (S/2)

16. Calculate the hydraulic horsepower, friction horsepower and brake horsepower of the prime mover and
select prime mover
Hh = 7.36 * 10-6 qGL

Hf = 6.31 * 10-7 WrSN Hb =

1.5 (Hh + Hf)

17. From the manufacturer’s literature obtain the gear reduction ratio and unit sheave size for the unit
selected, and the speed of the prime mover. From this determine engine sheave size to obtain the desired
pumping speed.
de = Zdu (N/Ne)

If at any step, the unit or any component of the unit is found to be either undersized or over-sized as to load, torque, or production
capacity, the design should be changed accordingly.

PROSPER
PROSPER is a well performance, design and optimisation program which is part of the Integrated Production Modelling Toolkit (IPM).
This tool is the industry standard well modelling with the major operators worldwide.

PROSPER is designed to allow the building of reliable and consistent well models, with the ability to address each aspect of well bore
modelling viz, PVT (fluid characterisation), VLP correlations (for calculation of flow-line and tubing pressure loss) and IPR (reservoir
inflow).
PROSPER provides unique matching features, which tune PVT, multiphase flow correlations and IPRs to match measured field data,
allowing a consistent well model to be built prior to use in prediction (sensitivities or artificial lift design). PROSPER enables detailed
surface pipeline performance and design: Flow Regimes, Hydrates Flag, Pipeline Stability Studies, Slug Size and Frequency.

2.1 APPLICATIONS:
1) Design and optimise well completions including multi-lateral, multi-layer and horizontal wells
2) Design and optimise tubing and pipeline sizes
3) Design, diagnose and optimise Gas lifted, Hydraulic pumps, PCP, Jet Pump and ESP wells
4) Flow Assurance Studies - well and surface pipelines
5) Generate lift curves for use in reservoir simulators
6) Calculate pressure losses in wells, flow lines and across chokes

Figure: - 2 PROSPER First Page (Overview)

2.2 INFLOW PERFORMANCE MODELS (IPR):
1) Multilateral well models
2) Single branch (Simple) inflows
3) Several proprietary inflow models for various fluids

Fig: -3 artificial lift design workflow in PROS

COMPUTER MODELLING OF
SUCKER ROD PUMPING
3.1 Fluid Data:
Model Black Oil
Reservoir Fluid Water and Oil
Separator Single Stage
Solution GOR 160 scf/stb
Oil Gravity (API) 25o
Gas Gravity (sp. gravity) 0.68
Water Salinity 80,000
Mole Per cent H2S 0
Mole Per cent CO2 0
Mole Per cent N2 0
Pb, Rs, Bo Correlation Glaso
Oil Viscosity correlation Beal et al
Water Cut, % 80
Equipment Data:-
1) Deviation Survey

MD, ft TVD, ft
0 0
3500 3500
2) Downhole Equipment:-

EquipmentTy Measured Tubing Tubing Inside Tubing Casing Casing Inside

pe,ft Depth,inch ID,inch Roughness,inch OD,inch ID,inch Roughness,inch
Xmas 0 N/A N/A N/A N/A N/A
Tubing 3500 2.441 0.0012 2.625 6.3 0.0012
3) Geothermal Gradient:-

Measured Depth in ft Static Ambient Temperature

0 60
3500 130

Overall Heat Transfer Coefficient: 8 Btu/h/ft2/F

3.2 INFLOW PERFORMANCE RELATION:

Inflow Performance Data:-

Reservoir model PI Entry

Reservoir pressure 1500 psig
Reservoir Temperature 130 degF
Water Cut 80 %
Total GOR 160 scf/stb
3.3 SRP-DESIGN PARAMETERS:
Anchored Tubing Yes
Pump depth 3500 ft
Pump Diameter 2 inches
Surface stroke length 48 inches
Pump Speed 12 strokes / minutes
Rode Selection - Rod type: Steel Rods
Rod Number ROD99/04
Gas Anchor Method Entered
Gas Anchor Efficiency 0.8 (fraction)
Type Poor Boy
Annulus Area 1.5 in2
Further deign parameters are:
Calculation mode: Enter Production Rate, Estimate Stroke Rate
Pumping Unit Selection: LUFKIN C-320-305-100 LC044
Rod Grad: D
Service Factor: Non-corrosive
Pump Intake Pressure Method: Entered
Mid Perforation Depth: 3500 ft
Design Input - Unit type: Conventional Clockwise
Design Input - Anchored tubing Yes
Design Input – Mid Point Perforation depth 3500 ft
Design Input - Pump Depth 3500 ft
Design Input – Pump Volumetric Efficiency: 80%
Design Input - Unit Efficiency 75%
Design Input - Pump Diameter 2"
Design Input - Surface Stroke length 48 "
Design Input -Bottom Hole Temperature 130 degF
Design Input - Well Head Temperature 90 degF
Design Input - Well Head Pressure 100 psig
Figure: - 4 Complete Design of Sucker Rod Pump (SRP)
3.4 DESIGN RESULTS.
Frictional Power 9.14756 (hp)
Polished Rod Power 12.753 (hp)
Name Plate Power 19.1823 (hp)
Work Done By Pump 6337.36 (lbf)
Work Done By Polished Rod 23914.6 (lbf)
Top Rod % Of Goodman Diagram 68.8292 (percent)
Top Rod Loading 71.4076 (percent)
Volumetric Efficiency 80.1768 (percent)
Actual Liquid Production Rate 421.347 STB/day
Cyclic Load Factor 1.20331
Peak Polished Rod Load 21402.8 (lbf)
Minimum Polished Rod Load 2479.32 (lbf)
Pump Stroke Length 49.7679 (in)
Static Stretch 2.16758 (in)
Plunger OverTravel (Ep) 5.89969 (in)
Fluid Load (Fo) 1539.01 (lbf)
Weight Of Rods In Fluid (Wrf) 11250.7 (lbf)
Total Load (Wrf + Fo) 12789.7 (lbf)
Maximum Torque 322693 (lb.ins)
Fo/SKr 0.044102
1/Kr 0.0013755
CounterWeight Required (CBE) 12741.4 (lbf)
CounterWeight Position 29.7482 (in)
Damping Factor 0.16008
Stress (Max) 21531.5 (psi)
Stress (Min) 2494.23 (psi)
Stress (Max Allowable) 30153 (psi)
Torsional Effectiveness (ITE) 15.3744 (percent)
Lift Efficiency (LE) 75.1964 (percent)
Economic Index (EI) 596.838
3.5 ROD SENSITIVITY RUN:
Following picture and plot shows the variation of production rates and horse power requirements with rod types.
3.6 PUMPING SPEED SENSITIVITY:
In the same way, different pumping speeds on the behalf of vertical lift performance can be checked.

2. INFLOW (IPR) V
OUTFLOW (VLP) PLOT