Training Module Describe and Operate Beam Pump Module A Describe and Monitor Wellhead, Sucker Rod String, and Subsurface Pump Human Development Consultants Ltd. Cover Photo Courtesy of Husky Energy Human Development DESCRIBE AND OPERATE BEAM PUMP Consultants Ltd. Module A Describe and Monitor Wellhead, Sucker Rod String, and Subsurface Pump © HDC Human Development Consultants Ltd. All rights reserved. No part of this publication may be copied, reproduced, stored in a computer or retrieval system, published, distributed, or transmitted in any form or by any means whatsoever, including without limitation by mechanical means, photo copying, recording, digital or electronic media, the Internet, or otherwise, without the express prior written permission of HDC Human Development Consultants Ltd. (HDC). 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HDC does not make any representations, guarantees, or warranties of any kind whatsoever with respect to the content hereof and the results to be achieved by implementing the procedures (task steps) herein. To the maximum extent permitted by applicable law, in no event shall HDC be liable for any damages whatsoever (including without limitation, direct or indirect damages for personal injury, damages to the environment, damages to business property, loss of business profit, or any other pecuniary loss). The use of the information and procedures (task steps) herein is undertaken at the sole risk of the user. ISBN 1-55338-022-3 Canadian Cataloguing in Publication Data 1.. 2.. 3. I. HDC Human Development Consultants. T55.U84 2003 363.11 C2003-901115-1 This training kit consists of the following parts: ♦ Training Module and Self-Check ♦ Blank Answer Sheet ♦ Knowledge Check and Answer Key ♦ Walkthrough Published by HDC Human Development Consultants Ltd. Published in Canada HDC Human Development Consultants Ltd. Website: www.hdc.ca E-mail: [email protected] Phone: (780) 463-3909 Master November, 2007 Human Development DESCRIBE AND OPERATE BEAM PUMP Consultants Ltd. Module A Describe and Monitor Wellhead, Sucker Rod String, and Subsurface Pump Foreword Beam pumps are used to lift a variety of liquids from subsurface wells to the surface. Beam pumps are commonly used at: oil wells to lift the oil to the surface gas wells to remove accumulated water which would prevent the gas from entering the wellbore coal bed methane wells to remove water from coal seams While HDC’s Describe and Operate Beam Pump series of training kits addresses beam pumping oil wells, the content applies to any beam pumping application. The series consists of four modules, listed below. These modules are designed to address the needs of oil well operators responsible for operating, monitoring, and optimizing existing beam pumping oil wells. The modules are task focused (i.e., center around what the operator does, why he/she does it, when he/she does it, and how). The modules are sequential: Module A is a prerequisite to Module B and so on. The four modules in the series are: Module A—Describe and Monitor Wellhead, Sucker Rod String, and Subsurface Pump Module B—Describe and Monitor Pumpjack and Prime Mover Module C—Describe Beam Pump Operation Module D—Optimize Beam Pump Operation Modules A and B include: descriptions and principles of operation of typical surface and subsurface beam pumping oil well equipment operating variables reasons for specific operating requirements causes for variables to change, consequences, symptoms, and operator responses to abnormal operations monitoring tasks related to the equipment a walkthrough where the operator identifies the equipment at his/her site self-check review questions a stand-alone knowledge check Master November, 2007 Page I Human Development DESCRIBE AND OPERATE BEAM PUMP Consultants Ltd. Module A Describe and Monitor Wellhead, Sucker Rod String, and Subsurface Pump Module C provides: a description of a typical beam pump wellsite an overview of beam pump oil well safety production monitoring and record keeping a description of routine beam pumping tasks: – respond to oil well shutdowns – start up pumpjack oil well (engine) – start up pumpjack oil well (motor) – check pressure safety switch – pig flowlines – put sucker rod pump on tap – shut down pumpjack oil well; lock out; secure for maintenance – change pumpjack stuffing box self-check review questions a stand-alone knowledge check a stand-alone checklist for monitoring beam pump operation Module D provides: a description of well performance analysis a description of pumping system analysis a description of pumping oil well diagnostics: – fluid level detector – dynamometer – pumpjack load analysis a description of pumping unit adjustments: – balance the pumping unit – change pumping speed – change stroke length – lower/raise sucker rod string – adjust casing gas or downstream pressure a description of the operator’s role in optimization self-check review questions a stand-alone knowledge check a stand-alone troubleshooting table for beam pump operation Master November, 2007 Page II Human Development DESCRIBE AND OPERATE BEAM PUMP Consultants Ltd. Module A Describe and Monitor Wellhead, Sucker Rod String, and Subsurface Pump Contents Foreword 1 Training Objectives 1 Introduction 1 1 Wellhead and Flowlines 3 2 2.1 Well Components 3 2.2 Wellhead 6 2.3 Blowout Preventer 11 2.4 Pressure Safety Switch 12 2.5 Stuffing Box Assembly 14 Sucker Rod String 17 3 3.1 Polished Rod 17 3.2 Sucker Rod String 21 Sucker Rod Pump 30 4 4.1 Sucker Rod Pump Principle of Operation 31 4.2 Types of Sucker Rod Pump 32 4.3 Sucker Rod Pump API Designation 35 4.4 Sucker Rod Pump Problems 37 Corrosion 39 5 5.1 Monitor Corrosion 39 5.2 Chemical Corrosion 40 5.3 Electrochemical Corrosion 40 Master November, 2007 Page i of ii Human Development DESCRIBE AND OPERATE BEAM PUMP Consultants Ltd. Module A Describe and Monitor Wellhead, Sucker Rod String, and Subsurface Pump Contents (continued) Wax, Scale, Sand, and Hydrates 41 6 6.1 Wax 41 6.2 Scale 44 6.3 Sand 44 6.4 Hydrates 45 6.5 Chemical Injection 47 Self-Check 49 7 Self-Check Answers 59 8 Master November, 2007 Page ii of ii Human Development DESCRIBE AND OPERATE BEAM PUMP Consultants Ltd. Module A Describe and Monitor Wellhead, Sucker Rod String, and Subsurface Pump Upon completion of this training kit, you will be able to: Training ¾ Describe the wellhead and piping used for beam pumping oil wells: Objectives − well components − wellhead − blowout preventer − pressure safety switch − stuffing box assembly ¾ Describe the sucker rod string: − polished rod − sucker rod string ¾ Describe the subsurface pump: − sucker rod insert pump − tubing pump ¾ Describe corrosion, wax, scale, and hydrate control 1 Introduction When the pressure in an oil-producing reservoir is high, the oil Artificial lift is used flows naturally to the surface. However, when a reservoir does widely: not have enough pressure to produce by natural energy, a - at oil wells to move the oil to the surface means of artificial lift is used to lift the oil from the reservoir to - at gas wells to remove the surface. Artificial lift methods include: accumulated water beam pump (rod pump) which would prevent the progressive cavity pump gas from entering the wellbore electric submersible pump (ESP) - at coal bed methane gas lift wells to remove water plunger lift from the coal seams hydraulic pump Beam Pumping Systems Beam pumping is the most common type of artificial lift—some estimates claim that as many as 85% of artificial lift wells are equipped with beam pumps. Master November, 2007 Page 1 of 59 Human Development DESCRIBE AND OPERATE BEAM PUMP Consultants Ltd. Module A Describe and Monitor Wellhead, Sucker Rod String, and Subsurface Pump Beam pumping systems consist of (see Figures 1 and 2): the wellhead and flowlines the beam pumping system, which consists of: – a beam pumping unit (pumpjack) at the surface – a pump at the bottom of the well – a sucker rod string which connects the pumpjack and pump – a prime mover (electric motor or internal combustion engine) which provides the energy for pumping the well Figure 1—Beam Pump at an Oil Well HDC Photo Beam pumping systems: are mechanically simple and durable and can run problem- free for a long time can be adapted to a variety of well conditions can be automated, when powered by an electric motor Beam pumping systems are recommended for low volume, shallow-to-medium depth oil wells pumping light to medium crude oil.