PCPumpUsersGuide PDF

PC-PUMP
An Interactive Design
& Evaluation Tool for
Progressing Cavity
Pumping Systems
Version 2.671
User Guide
Acknowledgments
C-FER Technologies (1999) Inc. (C-FER) gratefully acknowledges the cooperation, technical input, and financial assistance
received from the participating companies (the Participants) under the Joint Industry Project entitled Progressing Cavity
Pumping (PCP) System Technology Development. Without the Participants valuable contributions the development of PCPUMP would not have been possible.
License Agreement
C-FER retains all the property, rights and interest in and to the software (PC-PUMP) and the documentation (PC-PUMP User
Guide and PC-PUMP Sample Session Workbook), hereinafter collectively referred to as the PC-PUMP Package. The use of
the PC-PUMP Package is conditional on the end user (the End User) accepting the specific terms and conditions expressed
within the license agreement accompanying PC-PUMP (the License Agreement). The License Agreement includes terms
restricting the making of copies of the PC-PUMP Package and provides conditions of Limited Warranty and Limited Liability.
Copyright
C-FER retains the copyright to PC-PUMP and the PC-PUMP User Guide and Sample Session Workbook. The copying of PC-PUMP
on any medium, except as specifically allowed under the terms and conditions of the License Agreement, is strictly prohibited.
No portion of the PC-PUMP User Guide or Sample Session Workbook, in whole or in part, including text, figures, tables,
graphic illustrations, etc. can be reproduced or transmitted in any form or by any means, electronic or mechanical, including
photocopying and digital recording, without the express written permission of C-FER. Such permission shall not be
unreasonably withheld and shall be subject to providing an acknowledgment of C-FER with a full and complete reference to
the source document
PC-PUMP Software Copyright 1993-2006, by C-FER Technologies (1999) Inc.
PC-PUMP User Guide Copyright 2006, by C-FER Technologies (1999) Inc.
All rights reserved.
All rights reserved. Printed in Canada.
PC-PUMP is a registered trademark of C-FER Technologies (1999) Inc. in Canada and the United States of America.
C-FER and C-FER logo are trademarks of C-FER Technologies (1999) Inc.
IBM is a registered trademark of International Business Machines Corporation.
Microsoft and Windows are registered trademarks of Microsoft Corporation.
Hardlock is a registered trademark of Aladdin Knowledge Systems Ltd.
Adobe and Acrobat are registered trademarks of Adobe Systems Incorporated.
Disclaimer
End Users of the PC-PUMP Package are cautioned to undertake appropriate assessments for fitness of purpose and verification
of results as the PC-PUMP Package is provided AS IS and C-FER specifically disclaims any warranty that the functions
contained within PC-PUMP shall meet End User requirements or in a manner selected for use by the End User. C-FER
provides the PC-PUMP Package to End Users on the basis that PC-PUMP shall perform substantially in accordance with the PC-PUMP
User Guide and the End User acknowledges by its use of the PC-PUMP Package, that PC-PUMP and the PC-PUMP User Guide and
Sample Session Workbook, in general, are not error free and agree that the existence of such errors shall not constitute a
breach of the License Agreement.
Information within the PC-PUMP User Guide and Sample Session Workbook is subject to change without notice and does not
represent a commitment on the part of C-FER. C-FER, at its sole discretion, may produce, from time to time, modifications
and/or updates of PC-PUMP and/or the PC-PUMP User Guide and Sample Session Workbook. Such modifications and/or
updates may be made available to End Users by C-FER and may require the payment of an updating fee. C-FER does not
warrant that any future updates of the PC-PUMP Package will be error free or that all previously identified defects will be
corrected.
TABLE OF CONTENTS
Acknowledgments ...................................................................................................ii
License Agreement ..................................................................................................ii
Copyright.................................................................................................................ii
Disclaimer ...............................................................................................................ii
TABLE OF CONTENTS.................................................................................III
SUPPORT....................................................................................................... VII
Technical Support........................................................................................ vii
Customer Service ........................................................................................ viii
INTRODUCTION.............................................................................................. 1
Overview........................................................................................................ 1
User Guide Layout......................................................................................... 2
System Requirements ..................................................................................... 3
Hardware .................................................................................................................3
Software...................................................................................................................3
Installation..................................................................................................... 3
Using Hardlock Feature Codes ..............................................................................10
Automatic Upgrade Checking ...............................................................................12
Network Considerations ........................................................................................15
Copy Protection........................................................................................... 16
Standard Hardlock..............................................................................................16
PCMCIA Hardlock.............................................................................................16
Internal Hardlock ...............................................................................................16
Parallel Port Hardlock ........................................................................................17
Network Hardlock..............................................................................................17
BACKGROUND .............................................................................................. 18
Progressing Cavity Pumping Systems ......................................................... 18
Software Scope ............................................................................................ 20
Program Structure....................................................................................... 21
External Structure ..................................................................................................21
Internal Structure ...................................................................................................22
Computational Process ..........................................................................................23
Technical Considerations ............................................................................ 24

Directional Wellbores............................................................................................25
Pump Testing.........................................................................................................26
Inflow Performance ...............................................................................................28
Fluid Flow .............................................................................................................30
Single-Phase.......................................................................................................30
Multiphase..........................................................................................................33
PC-PUMP User Guide
IV
TABLE OF CONTENTS
Rod String Loading ............................................................................................... 41

Rod String Fatigue................................................................................................. 43
Rod String/Tubing Wear ....................................................................................... 44
Rod String Backspin.............................................................................................. 45
Downhole Motor Performance .............................................................................. 48
Motor Heating Effects ........................................................................................... 49
Power Cable Performance ..................................................................................... 49
Windows User Interface............................................................................... 50

Windows Control Types........................................................................................ 51
Printing .................................................................................................................. 54
Print to PDF ....................................................................................................... 55
Emailing PCP Files ............................................................................................ 56
USING PC-PUMP............................................................................................... 57
SECTION A: GETTING STARTED ...................................................................... 58
Starting the Program ................................................................................... 62
Setting Program Preferences....................................................................... 64
Paths ...................................................................................................................... 64
Program and Chart Fonts....................................................................................... 65
Units ...................................................................................................................... 67
Defaults ................................................................................................................. 68
Correlations ........................................................................................................... 71
On-Line Help ............................................................................................... 72

SECTION B: CONFIGURING THE SYSTEM ......................................................... 75
Analysis Capabilities ............................................................................................. 75
System Configuration............................................................................................ 75
Printing System Configuration Reports ............................................................. 77
Saving and Restoring Data Files ........................................................................ 77
Backwards Compatibility................................................................................... 77
Specifying Project Information .......................................................................... 79
Specifying a Wellbore Geometry ................................................................. 82

Wellbore Geometry Window................................................................................. 83
Inputting Directional Surveys & Proposals ........................................................... 84
Manual Entry ..................................................................................................... 84
Copy/Paste ......................................................................................................... 85
Survey File Import ............................................................................................. 85
Well Design Mode ............................................................................................. 85
Viewing Wellbore Geometry Information............................................................. 87
Survey Spreadsheet............................................................................................ 87
Wellbore Geometry Charts ................................................................................ 90
Geometry Summary Information ....................................................................... 90
Exporting Wellbore Geometry Files...................................................................... 91
Exiting Wellbore Geometry................................................................................... 92
Selecting Equipment .................................................................................... 94

Pumps .................................................................................................................... 94
Variable Efficiency ............................................................................................ 98
Inputting Pump Test Information..................................................................... 100
Adding Custom Pumps .................................................................................... 104
Stator Swell Model .......................................................................................... 106
PC-PUMP User Guide
TABLE OF CONTENTS
Tubulars..................................................................................................... 108
Rod Strings (Surface Drive Only) .......................................................................113
Rod Guide Optimization ..................................................................................115
Drive Equipment .................................................................................................116
Surface Drive Equipment .................................................................................116
Downhole Drive Equipment.............................................................................122
Working With Equipment Cases ................................................................ 135

Adding and Deleting Cases .................................................................................136
Using the Case Manager......................................................................................137
SECTION C: ANALYSING THE SYSTEM........................................................... 140

Getting Around Analysis............................................................................ 140
Printing Analysis Reports ....................................................................................142
Saving and Restoring Data Files ......................................................................142
Specifying Analysis Inputs ......................................................................... 144

Fluid Properties ...................................................................................................145
Single-Phase.....................................................................................................145
Multiphase........................................................................................................148
Fluid Thermal Properties..................................................................................152
Diluent Injection ..............................................................................................154
Viscous Torque ................................................................................................154
Operating Conditions...........................................................................................155
Performing Calculations ........................................................................... 161

Standard...............................................................................................................162
Equipment Comparison .......................................................................................162
Pump Comparison ...............................................................................................163
Batch Comparison ...............................................................................................164
Examining Results ..................................................................................... 168

Summary Output Parameters ...............................................................................169
Output Messages..................................................................................................171
Output Windows..................................................................................................171
Energy Flow.....................................................................................................173
Drive Equipment ..............................................................................................174
Rod Loading/Deflection (Surface Drive Systems)...........................................183
Rod/Tubing Contact (Surface Drive Systems) .................................................187
Basic Fluid Flow ..............................................................................................188
Multiphase Flow ..............................................................................................189
Key Locations ..................................................................................................191
Comparison Tables ..........................................................................................193
Comparison Charts...........................................................................................195
Comparison Table and Chart Filtering.............................................................198
Rod/Tubing Wear (Surface Drive Systems).....................................................200
Rod Fatigue (Surface Drive Systems) ..............................................................203
Backspin Analysis (Surface Drive Systems)....................................................205
Sand Settling Velocity .....................................................................................215
HELP/TROUBLESHOOTING .................................................................... 217

Input Restrictions....................................................................................... 217
APPENDICES ................................................................................................ 222
PC-PUMP User Guide
VI
TABLE OF CONTENTS
APPENDIX A: UNIT CONVERSIONS ................................................................ 223

APPENDIX B: OUTPUT REPORTS .................................................................... 224
APPENDIX C: REFERENCES............................................................................ 241
PC-PUMP User Guide
SUPPORT
Technical Support
Both new and experienced users of PC-PUMP may have questions about some technical aspect of its
operation. If this happens, your first instinct may be to call or write for help. Before you do this,
however, make sure you consult your first source of technical support - the PC-PUMP User Guide.
This guide constitutes a comprehensive reference for all aspects of the software. Answers to most
questions that will likely arise regarding the software can be found in Part 3: Using PC-PUMP. Help
is also available through PC-PUMP's on-line help feature, described in Section A of Part 3 of the
Guide. If, after consulting the guide, you still cannot find an answer to your question, you should
contact Technical Support.
Our staff can help you better if you take the following steps:
Know the version of Microsoft Windows installed on your computer.

Know the PC-PUMP version. To find this information, run PC-PUMP and select the
HelpAbout PC-PUMP menu command.
Know the serial number on the Hardlock license. This is a five digit number that is
printed on the Hardlock itself.
Call from a phone near the computer. The support analyst may need to ask you about
the program.
Be ready to re-create your problem for the support analyst.
Telephone Support
Use these technical support numbers, Monday through Friday 9:00 am to 5:00 pm (Mountain
Time) and ask for PC-PUMP technical support:
(780) 450-3300 (voice)
(780) 450-3700 (fax).
Before you send a fax, please call to let a support analyst know it is coming.
PC-PUMP User Guide
VIII
SUPPORT
Internet Support
If you have an Internet account, you can contact Technical Support through the following PC-PUMP
support account:
pcpump@cfertech.com. (e-mail address).
Alternatively, you can leave a message at the support account by visiting C-FERs home page at:
http://www.cfertech.com or http://www.pc-pump.com (URL address).
The C-FER home page also provides access to PC-PUMP technical bulletins, a frequently asked
question list, bug fixes and upgrade notices. New program releases and database updates can be
downloaded directly from this site.
Mail Support
In addition to support by phone, fax, or email, you can send reports of problems or request for
support to:
C-FER Technologies
Attn: PC-PUMP Technical Support
200 Karl Clark Road
Edmonton, Alberta, CANADA
T6N 1H2
Customer Service
You can also use the above address, telephone number and Internet address to obtain support on
non-technical matters, or customer service. Direct all of your non-technical questions and
business-related matters to the above address or phone number to the attention of PC-PUMP
Customer Service.
Call PC-PUMP Customer Service:
PC-PUMP User Guide
for information about software support and maintenance plans;

for upgrade information;
to order an upgrade;
for problems with software packages (items missing or defective); and
for general product information.
1
Part
INTRODUCTION
The PC-PUMP for Windows software (PC-PUMP) is an interactive design and performance
evaluation tool for progressing cavity (PC) pumping systems used to produce oil wells. The
software will enable you to make better decisions on PC pumping system design and operation.
Some applications of PC-PUMP are:
downhole geometric design of wellbores;

downhole and surface equipment selection and evaluation;
pump bench test data analysis;
rod string combined load and fatigue analysis;
rod string and tubing contact load and wear assessments;
workover prevention analysis;
production optimization; and
backspin safety assessments.
PC-PUMP was developed with an emphasis on the users needs for accuracy, flexibility, speed and
ease of use. Its internal framework is comprised of numerous analytical routines, empirical
relationships and the most current manufacturers equipment specifications. Integrated with a
graphical user-interface developed under Microsoft Windows, PC-PUMP allows you to perform
demanding technical evaluations in the inherently friendly Windows environment.
Overview
This User Guide is both a learning tool and a reference manual for the PC-PUMP software. If you are
either unfamiliar with PC pumping systems or inexperienced with Windows applications, this
Guide provides you with several illustrated examples to demonstrate its capabilities. A more
experienced user can use the Guide as a reference manual to help master PC-PUMPs many features.
In either case, reading the entire text is recommended.
The User Guide has been structured to help you find information quickly. Several levels of
headings are used to highlight the material covered in the subsequent text. In addition, a
comprehensive index facilitates locating topics of interest. Extensive use of illustrations, screen
PC-PUMP User Guide
PART 1: INTRODUCTION
shots, and tables has been made to assist in the interpretation of the information presented in this
Guide.
User Guide Layout

The PC-PUMP User Guide is divided into the following four parts and three appendices:
Part 1: Introduction
This part describes:

- the applications of PC-PUMP;
- the Guides general layout;
- system requirements; and
- copy protection and installation issues.
Part 2: Background
This part provides:

- an overview of PC pumping systems;
- a brief review of the objectives and scope of PC-PUMP;
- an outline of the program structure and computational process;
- discussions on key technical considerations; and
- a description of the Windows user interface.
Part 3: Using PC-PUMP
This part provides:

- comprehensive documentation on all aspects of using PC-PUMP;
- detailed instructions on program operation;
- explanations of program inputs and outputs; and
- descriptions of the windows, menus, buttons and output options.
Part 4: HELP/Troubleshooting
This part provides tables which define input restrictions.

Appendices
The four appendices provide additional information as follows:

Appendix A: Unit Conversions - provides conversion factors to convert between SI (International
System of Units) and Imperial units.
Appendix B: Output Reports - contains samples of many of the hard-copy output reports
available.
Appendix C: References - lists references cited in the User Guide.
An additional manual (Sample Sessions) containing sample PC-PUMP analyses is also included with the
software package. This document provides step-by-step examples that:
- illustrate the basic operation of PC-PUMP; and
- familiarize you with some of its capabilities.
PC-PUMP User Guide
System Requirements
To run PC-PUMP successfully your system must have, as a minimum, the following features:
Hardware
Intel Pentium-type processor that is 100% IBM compatible;

128 megabytes of Windows memory (recommended memory 256 MB).;
hard drive with at least 20 megabytes of free space (additional space should be available
after installation to save your working files);
mouse that is supported by Microsoft Windows;
display adapter and monitor supported by Microsoft Windows and capable of
functioning in VGA or higher mode at a resolution of at least 800 X 600 pixels; and
CD-ROM drive for software installation.
can run successfully with a variety of hardware configurations. However, some

hardware items have a major impact on how fast the program runs. The following items can
produce significant improvements in PC-PUMP operating speed:
PC-PUMP
faster CPU;
more memory; and
faster hard drive.
Software
Windows 95, Windows 98, Windows ME, Windows NT, Windows 2000, or Windows
XP.
Note: As a Windows-based program, PC-PUMP supports and uses the device drivers provided by
Microsoft as well as others specifically designed for use with Windows. PC-PUMP does not
provide drivers for ancillary equipment such as printers, plotters, display adapters, pointing
devices etc.
Installation
This section describes a typical installation. Please see the documentation that was sent with your
PC-PUMP package for details on any changes, such as installing an upgrade.
PC-PUMP is shipped on one compact disc. You can install it on an individual computer or in a
network environment. In either case, the best way to install PC-PUMP is to use the automatic
installation program provided with the software.
To install PC-PUMP on your personal computer:
PC-PUMP User Guide
1.
Make sure that no other major applications are running on Microsoft Windows. If you are
running Windows NT, Windows 2000, or Windows XP, you must be logged in with
administrator privileges in order to run the installation.
2.
If you are installing from a CD, insert the PC-PUMP CD into your CD-ROM drive. The
installation program should run automatically. If it does not (for example, if autorun is
disabled on your computer), you will need to run the installation program setup.exe from
the CD-ROM. In the following set of instructions, the drive designation D: has been used to
identify the CD-ROM drive or floppy drive. If your CD-ROM or floppy drive letter is not
D:, substitute the appropriate letter wherever D: appears.
Click the Start button and choose the Run option from the display list. The following
dialog box should appear:
Type d:\setup in the Run dialog box and click OK. The installation process will now
begin.
Alternatively, if you are installing from a downloaded installation program, simply
double-click on the icon for that program after downloading it. The installation
progress will begin.
PC-PUMP User Guide
Click Next and the installation will proceed.

3.
You will next be asked to accept the PC-PUMP licence agreement before continuing with the
installation:
PC-PUMP User Guide
Read the licence agreement (a paper copy is shipped with every copy of PC-PUMP and is also inside
the CD cover.) If you agree to the terms of the licence, select the Yes, I agree option and
click on Next.
4.
PC-PUMP User Guide
You will then be asked about the type of installation:
Generally it is recommended that you perform a Complete installation. If there are program
components that you do not wish to install, you can select the Custom option. For example, if
you already have a program which can write PDF files, you can choose not to install the PDF
writer that is supplied with PC-PUMP. Click Next to proceed.
5.
Confirm the installation location:
PC-PUMP User Guide
Click on Next to proceed.

6.
PC-PUMP User Guide
Once these settings have been made, the program is ready to be installed:
Click Next to proceed with the installation. When it is complete, the following message will
appear:
PC-PUMP User Guide
10
7.
If you do not already have the Adobe Acrobat Reader installed, you may wish to install it
when the PC-PUMP installation is complete. A free copy of Acrobat Reader is available from
Adobes website at http://www.adobe.com.
8.
You may have been given upgrade instructions if C-FER has issued a new version of PC-PUMP
since the most recent CD production run. Follow the installation instructions included with
this upgrade.
9.
Your PC-PUMP installation is now complete. Click Finish to exit the installation program.
To run PC-PUMP, click the Start button, choose the Programs menu item and select the PC-PUMP
Version 2.6 menu item, and then select the PC-PUMP Version 2.6 program icon. (Note that while
the current version at the time this User Guide was printed was V2.67, the Start Menu items refer to
V2.6.)
Using Hardlock Feature Codes

PC-PUMP Version 2.67 uses the programmability of the security Hardlock provided with the
software to control software licenses and maintenance subscriptions. Users who choose to
upgrade their software to include new features (i.e. maintenance releases, analysis modules, or
equipment database updates) will be able to do so without having to obtain a replacement
Hardlock from C-FER. A utility called featureadd.exe has been included on the PC-PUMP
installation diskettes that can be used to modify the Hardlocks active feature set.
To add a new feature to an existing Hardlock, you must first contact the PC-PUMP Sales and
Support team at C-FER to obtain Hardlock programming information for the features you wish
PC-PUMP User Guide
11
to add. As new features and updates are released, users who are eligible to receive them will
receive written notification of the updates.
Upon calling Sales and Support to add a new feature, you will be asked for your Hardlock serial
number. Each program feature is assigned a numerical code. If you are eligible, C-FER will
provide you with this code as well as an alphanumeric code that will serve as a verification key to
program your Hardlock with the selected feature. Record the feature code and the verification key
code.
Follow these steps to program your security Hardlock with a new feature:
1.
Make sure your Hardlock is attached to the USB port or parallel port on your
computer.
2.
Run the FeatureAdd.exe program from the PC-PUMP installation directory on your
computers hard disk. (This can be accessed through the Start Menu: Programs
PC-PUMP Version 2.6 FeatureAdd.) The window shown below will appear, listing
all currently active features on the Hardlock.
3.
To add a new feature, click the Add button. The following dialog box will appear:
The serial number of the currently active Hardlock is shown in the uppermost data
field.
PC-PUMP User Guide
12
4.
Type the feature code in the second data field and the verification key code
provided to you by C-FER in the third data field. Click Add to activate the feature.
5.
If you wish to add other features, repeat step 4 as many times as necessary. When
you are finished adding features, click Cancel to move back to the feature display.
The window will automatically update to show the new list of active features for the
Hardlock.
6.
Click OK to close the program. You will now be able to run the updated version
of PC-PUMP with the modified Hardlock.
Note that once you have done this, the upgraded information is stored in the Hardlock itself, and
you will not need to repeat this on any other computers you may use that Hardlock on. (You will,
however, have to upgrade the program on those computers.)
Please direct any inquiries with respect to adding new features to the PC-PUMP technical support
team at C-FER (see the Technical Support at the beginning of this User Guide).
Automatic Upgrade Checking

Many users of PC-PUMP are not using the most recent version to which they are entitled through
membership of their company in the PC-PUMP Maintenance Plan. One reason for this may be that
all our notices to users are issued only to the official contact for each company, and not to each
user individually. It is impossible for C-FER to keep a complete list of users, as Hardlocks may be
passed around within each company without C-FERs knowledge.
C-FER recommends that all users should use the most recent available version of PC-PUMP to
which they are eligible. For this reason, in V2.671, we have added a new feature, which checks to
see if newer versions are available, through an internet connection.
C-FER understands that some companies may not allow programs such as PC-PUMP to access
the internet automatically. In such cases, this feature can be turned off. The first time any user
runs PC-PUMP V2.671, a window will appear asking if this feature should be enabled:
Even if the user does not enable the feature, he/she may still manually instruct PC-PUMP to perform
a check for available upgrades, through the PC-PUMP Help menu. After performing a manual
check, the window that appears will give the user the option of turning automatic checks on again.
It is possible for a companys IT administrator to remove this capability in such a way that users
cannot turn it back on or perform manual checks. Any IT administrator wishing to remove this
PC-PUMP User Guide
13
capability should contact C-FER for more information. Users with access to the internet can
always check the PC-PUMP webpage using their web browsers (http://www.pc pump.com, click on
Upgrades) for information on the latest version PC-PUMP.
No information from a users computer is transmitted to C-FER in this process. C-FER
maintains a web page which can be read by PC-PUMP. The only thing transmitted by PC-PUMP is a
request to read that pageno different than what any browser transmits when a user wishes to
visit a website. PC-PUMP internally compares the version number stored on that website with its
own version to determine if a new version is available. PC-PUMP will also check a value on that
website to determine if the users Hardlock has been activated to run the available version. If a
new version is available, but the users Hardlock has not been activated, a message to that effect
will appear on the screen. The user can then either contact C-FER or the official contact at the
users company to obtain activation codes. Users must know their Hardlock serial number when
contacting C FER for activation codes.
If a new version is available on checking, a window similar to the following will appear:
The user has several options:

1.
Do not remind me again This option will tell PC-PUMP to continue automatically
checking for upgrades, but it will not display this window again (unless a manual check is
performed) until an even newer version is released.
PC-PUMP User Guide
14
2.
Remind me again later. Automatic checking will continue. The program will not
check again in the current calendar day, but the first time the program is run on any subsequent
day, this window will appear again.
3.
Close PC-PUMP and open the PC-PUMP upgrade web page. This option will close
since it cannot be upgraded while running, and open the PC-PUMP upgrades web page
using the default browser.
PC-PUMP,
A check box Check for upgrades at program start is also available. This check box controls the
automatic checking for upgrades.
users are warned that they should obtain the necessary activation codes before downloading and
installing the new version, as they will not be able to run the new version without the codes.
The PC-PUMP splash screen (which appears when the program is run, or HelpAbout is selected
from the program menu will contain information on the availability of upgrades as well:
In the splash screen shown above, it says: Upgrade Available. Other options include Upgrade
Checking Disabled and PC-PUMP is up to date.
PC-PUMP User Guide
15
Network Considerations
C-FER recommends installing PC-PUMP locally on computers which will be running it. Some
companies may prefer, however, to install on a network. If you are installing PC-PUMP in a network
environment, it may be convenient to place the program files in a central location. The following
steps outline the installation of the program in a network environment.
To install PC-PUMP on a network:
1.
Create a central area on the network to hold the program files using your network software.
(Please refer to the network documentation for more details on this procedure.) All users of
PC-PUMP will need read access to this area and to each of the subdirectories created.
Default Root
Directory Name
PC-PUMP
Version 2.6
Default
Subdirectory Name
Suggested
Location
Database
Network
Custom
Network/Local
Test
Network/Local
User
Local
Wellbore
Network/Local
PDF
Network/Local
Hardlock
Network/Local
The diagram above indicates the default names for the sub-directories in PC-PUMP and their
suggested locations in a network environment. The network administrator must decide
whether the custom pump, pump test, wellbore, and user directories should be local to the
user's workstation or located on a network file server. This decision will depend largely on
whether the information contained in these directories will be shared among users. For
instance, if custom pump files created by one user of the program need to be accessed by
another user then the Custom Pump directory should be located on a file server and each
user's custom pump path should be set to that location. The administrator may use file
access permissions to restrict modification where appropriate.
2.
From a workstation, assign this new network area to an unused drive letter using the network
software.
3.
Perform a normal installation using the PC-PUMP installation program, specifying this new
network area as the destination. This will copy all of the program and database files to the
network drive and create a PCPV26.INI file in the Windows directory of the workstation. It
is advisable to run PC-PUMP at this time, to ensure the PCPV26.INI file is updated properly.
4.
Copy the PCPV26.INI and FEATURES.INI files to all of the workstations that are going to
use the program.
5.
Set up all of the workstations with access to the PCPV26.EXE file that is now located in the
network area specified in Step 1.
6.
Finally, the PC-PUMP default directories on each workstation can be modified to the desired
user configurations. This is done in the Preferences dialog which is accessed using the
EditPreferences menu command from the System Configuration window. If necessary, the
PCPV26.INI file can be edited with any standard text editor.
PC-PUMP User Guide
16
7.
The Hardlock drivers must be installed on each computer that will access PC-PUMP. This can
be done by running the HLDRV32.EXE program that is found in the Hardlock directory, on
each computer that needs it.
8.
If PDF writing capability is needed, then the PDF writer can be installed on each computer
by running the INSTALL.EXE program in the PDF directory.
Note: The hardware protection device key that was provided with the software (see next section)
will need to be present on each local workstation that attempts to run PC-PUMP.
Alternatively, a network Hardlock can be used to allow a specified number of users on
the network to run PC-PUMP without a local Hardlock. See below for more information.
Copy Protection
PC-PUMP is copy-protected through the use of a hardware-based copy protection system. This
system uses a device known as a Hardlock that is attached to a USB port. (Other versions of
the Hardlock, which work in parallel ports, ISA or PCI slots, or PCMCIA slots, are available upon
request.) One Hardlock is issued with each licensed copy of the software. Random checks for the
presence of this Hardlock are made by the program during its execution. This measure prevents
unlicensed use of PC-PUMP.
The Hardlock prevents the operation of PC-PUMP on any computer to which it is not attached. The
software may reside on as many computers as you require, however, the Hardlock must be
resident locally in order to run the program.
Standard Hardlock
The standard Hardlock is included with each PC-PUMP software package. It attaches to the USB
port on your computer. If you have an older parallel port Hardlock and wish to exchange it for a
USB Hardlock, contact C-FER.
To install the Hardlock:
1.
Locate a USB port on your computer.
2.
Connect the Hardlock to this port.
3.
If the program is properly installed, you will now be able to run PC-PUMP.
PCMCIA Hardlock
For use in computers that have a PCMCIA slot, this version of the PC-PUMP Hardlock is provided
in a Type II PCMCIA card. This version of the Hardlock can be provided at a nominal cost.
Please contact PC-PUMP Customer Service for more information.
Internal Hardlock
The Hardlock that is shipped with PC-PUMP is normally connected externally to the computers
parallel port. There is also an internal version of the Hardlock, which can be provided for a
nominal cost. This card plugs into an ISA or MCA slot inside the computer and functions
identically to the external variety. This implementation is suitable for sites where protection of the
PC-PUMP User Guide
17
Hardlock from theft or relocation is desired. Please contact PC-PUMP Customer Service for more
information.
Parallel Port Hardlock

If requested, C-FER can supply a Parallel port Hardlock which plugs in to a standard parallel port.
Network Hardlock
If desired, a network version of the PC-PUMP Hardlock which can support between 1 and 250 users
is available. One computer on the network will need to be identified to act as a Hardlock Server
(please see the various configurations listed below). A network Hardlock is installed on this
machine in the same way as a normal local Hardlock and a Hardlock server program is then
executed. Once the Hardlock server is running, any other computer that can access the Hardlock
server over the network can run PC-PUMP without the need for a local Hardlock. The server will
administer licensing and allow up to the set maximum number of copies of PC-PUMP to be
simultaneously executed. This type of protection is suitable for larger installations that would like
to control the number of simultaneous users of PC-PUMP from a central location.
To obtain a network Hardlock please contact PC-PUMP Customer Service. To obtain information
or answers to any questions regarding the implementation of a network Hardlock, please contact
the PC-PUMP Technical Support Team.
PC-PUMP User Guide
2
Part
BACKGROUND
This section of the User Guide provides you with background information on: PC pumping
systems; the objectives and scope for the development of PC-PUMP; the programs structure and
computational processes; key technical considerations; and the Windows user interface. This
section is not meant to be a comprehensive review of any of these subjects. For additional
information on PC pumping systems, please consult the references listed in Appendix C. For
information on standard Windows concepts (such as the mouse, pull-down menus and so on),
refer to your Microsoft Windows User's Guide.
Progressing Cavity Pumping Systems

In the late 1920s, Rene Moineau developed the concept for a series of helical gear pumps1,2. One
of these pumps took the form of what is now known as the progressing cavity (PC) pump, screw
pump or Moineau pump. Since 1930, PC pumps have been used extensively as fluid transfer
pumps in a wide range of applications from industrial and manufacturing environments to the
surface transfer of oilfield fluids. However, with the exception of several limited field trials, it was
not until the early 1980s that a concerted effort was made to utilize PC pumps as a method of
artificial lift for the petroleum industry3. Over the last ten years, PC pumping systems have
experienced a gradual emergence as a common form of artificial lift. As of 1998, it was estimated
that there were approximately 30,000 wells worldwide operating with these systems. Presently the
major applications for PC pumping systems include:
heavy oil and bitumen production with sand cuts of up to 50%;

medium crude oil production with limits on H2S production;
light sweet oil production with limits on aromatic content;
dewatering of coalbed methane wells;
mature waterfloods;
source water wells;
mature steam drive operations; and
visual or height sensitive areas.
PC pumps are positive displacement pumps which typically consist of a helical steel rotor and a
synthetic elastomer stator bonded to a steel tube. Rotation of the rotor within the fixed stator
PC-PUMP User Guide
PART 2: BACKGROUND
19
causes a series of sealed cavities to form and move axially from the pump suction to the discharge.
The resulting pumping action moves fluid through the pump from the lower intake pressure to
the higher discharge pressure so that it can be produced to surface. Several papers5,6,7 which
describe PC pump principles and theory are listed in Appendix C.
Most PC pumping systems are rod-driven with the stator run into the well on the bottom of the
production tubing, and the rotor connected to the bottom of the rod string. To turn the rotor
downhole, the rod string is rotated at surface by means of a hydraulic or direct drive power
transmission. A typical rod-driven system is illustrated in the figure below. More recently,
downhole-driven PC pumping systems have become available. These rod-less systems use a
downhole motor and gearbox assembly to drive the rotor.
Flowline
Flowline
Prime Mover
Drivehead
Coupling/Centralizer
VSD / Transformer Equipment
Cable
Production Tubing
Rod String
Production Tubing
Rotor
Rod String/Rotor
Connection
Rotor
Stator
Pump Intake and Drive Assembly
Stator
Configuration of a typical surface drive PC

pumping system.
Motor
Configuration of a typical downhole drive

PC pumping system.
PC pumping systems possess unique characteristics which can make them preferable over other
artificial lift systems. Their most important characteristic is high overall system efficiency. PC
pumping systems typically exhibit overall efficiencies of 50 to 60%, which is higher than any of the
other major artificial lift types8. Some additional advantages of PC pumping systems include:
the ability to produce high viscosity fluids, large solids concentrations and moderate
percentages of free gas;
low internal shear rates which limit fluid emulsification by agitation;
no valves or reciprocating parts to clog, gas lock or wear;
PC-PUMP User Guide
20
PART 2: BACKGROUND
low capital and power costs;

relatively simple installation and operation as well as low maintenance; and
low profile and low noise surface equipment.
PC pumping systems also have some disadvantages compared to other forms of artificial lift. The
most prominent of these are limitations with respect to pump capacity, lift and elastomer
compatibility with produced fluids. The list below summarizes the current application limitations
and major operational difficulties associated with PC pumping systems:
limited production rates: maximum=800 m3/day (5000 bbls/day);

limited lift: maximum=3000 m (9850 ft);
limited temperature capability: maximum=180C (350F);
sensitivity to fluid environment - elastomer may swell or deteriorate upon exposure to
certain fluids;
tendency of pump stator to sustain permanent damage if pumped dry even for short
periods; and
lack of experience with system design, installation and operation.
These limitations are rapidly being overcome with the development of new products and
improvements in materials and equipment design. In the correct application, PC pumping
systems provide the most economic (and in some cases the only) means of artificial lift if
configured and operated properly.
Software Scope
One of the primary advantages of PC pumping systems is their inherent ability to function
effectively in a wide range of operating environments. The applications in which they are
currently employed include variations in:
well profiles: vertical, deviated, slant and horizontal;

fluid viscosity: 1 to 100,000 cp;
fluid composition: low to high sand and water cuts as well as low to moderate gas/oil
ratios;
fluid rates: 1 to 800 m3/day (6 to 5000 bbls/day); and
temperature: 10C to 180C (50F to 350F).
However, successful operation of PC pumping systems over this range of conditions requires that
systems with different configurations be used. This can involve various types and sizes of pumps,
rod strings, tubing and surface or downhole power transmission equipment. Collectively, the
numerous equipment selection and well completion options available, variations in operating
conditions, and complex fluid flow and mechanical interactions can make the assessment and
design of PC pumping systems both difficult and time consuming. Pumping, fluid flow, wear,
loading and power transmission considerations must all be evaluated to ensure a functional design.
In new applications, this may require numerous iterations just to establish a workable system.
PC-PUMP User Guide
PART 2: BACKGROUND
21
Design optimization through manual calculations is usually impractical and, when done repeatedly,
inefficient because of the excessive time required to perform multiple parametric analyses.
PC-PUMP was
developed to automate the PC pumping system design and evaluation process. By

quickly assessing numerous design considerations, PC-PUMP enables you to make the best decisions
related to system design and operation.
PC-PUMPs development is founded on several key goals. Specifically it was decided that the
program must:
be personal computer-based;
have a graphical user interface;
facilitate convenient data input/output; and
have the capability of both on-screen and hard-copy output.
In addition to these general objectives, the following guidelines were used to direct the technical
aspects of software development:
speed (able to perform quick evaluations);

flexibility (ability to model a wide range of operational scenarios);
comprehensiveness (address all of the components which affect typical PC pumping
systems);
expandability (able to easily accommodate new equipment); and
accuracy (bench-marked against measured data).
Program Structure
To ensure compatibility, ease of use, and flexibility, PC-PUMP was developed with a fully graphical
user interface which takes advantage of the standard Windows features. In total, PC-PUMP has over
100 windows and output reports and several different calculation modes. Depending on the
particular application, you may need to access only a few windows or, in the case of a
comprehensive analysis, nearly all of them.
External Structure
external program structure has two primary modules, System Configuration and Analysis,
which provide access to all of the other areas of the program. Through the System Configuration
module you select the downhole and surface equipment as well as specify any wellbore geometry
information. The Analysis module allows you to define fluid properties and operating conditions,
perform calculations and evaluate the results. Other major areas of the program include:
PC-PUMPs
Preferences: Window which allows you to customize certain aspects of the program (e.g.
unit system, default values).
Wellbore Geometry: Several windows which permit you to specify the wellbore profile
using either an existing directional survey or a proposal you create.
PC-PUMP User Guide
22
PART 2: BACKGROUND
Equipment Selection: Series of windows that allow you to select the surface and
downhole equipment configuration.
Fluid Properties: Portion of the Analysis Inputs window which you can toggle between
single-phase and multiphase fluid flow models and enter the fluid properties.
Operating Conditions: Portion of the Analysis Inputs window in which you select the
parameters you want to specify and the ones you want the software to calculate.
Calculation: Intermediate windows that appear during multi-run calculation modes.
They allow you to select active cases and specify filtering criteria.
Comparison: Windows which let you directly compare the results from any multi-run
calculation analysis.
Output Windows: Windows that allow you to access detailed results pertaining to
specific aspects of the assessment (e.g. rod/tubing contact, multiphase flow). Note that
several of these windows facilitate supplementary analyses that are not completed until
you enter the window and provide additional input.
An assessment with PC-PUMP typically consists of:
inputting the wellbore geometry and selecting the equipment within the System
Configuration module;
moving to the Analysis module and specifying the fluid properties and operating
conditions;
performing a calculation and examining the results; and
moving back and forth between the two primary modules changing equipment and
conditions to optimize system design and operation.
Part 3 of this Guide reviews in detail all of PC-PUMPs windows, features, inputs and outputs.
Internal Structure
The internal structure of PC-PUMP consists of a comprehensive equipment database, several data
classes and numerous computational routines. When you input directional survey data,
calculations based on the minimum curvature method are used to generate a Wellbore Geometry
data class. An Equipment data class is created by linking the equipment you select with its
associated reference locations and then compiling this equipment with its detailed specifications
which are extracted from the PC-PUMP equipment databases. The last data class, Analysis, is formed
based on your selection of fluid properties and operating conditions. When you initiate the
calculation process, information in the three data classes is processed through various
computational routines to produce output which includes charts, flowcharts, reports, tables and
output warnings. The schematic of the internal program structure of PC-PUMP is shown below.
PC-PUMP User Guide
PART 2: BACKGROUND
DATA CLASS
INPUT
Directional Survey
- existing
- proposed
Downhole Drive
- drive assembly
- motor
- cable
- rod string
Equipment
Databases
Compilation
Charts
and
Flowcharts
Equipment
Tubulars & Pumps

- tubing
- casing
- tailjoint/shroud
- PC pumps
Reference Locations
- pump seating
- mid-perforation
OUTPUT
Wellbore
Geometry
Drive Equipment
Surface Drive
- prime mover
- hydraulics
- belts/sheaves
- drivehead
23
Linking
Ca
lcu
lati
on
s
Summary
Reports
and Tables
Output
Messages
Fluid Properties
- single-phase
- multiphase
Analysis
Operating Conditions
- standard
- IPR
PC-PUMPs internal program structure
When you select equipment components, their corresponding specifications are extracted from
PC-PUMPs equipment databases. These databases contain detailed information on numerous types
of PC pumps, rod strings, couplings, centralizers, rod guides, tubing, casing, driveheads, surface
hydraulic motors and pumps, downhole motors, downhole drive assemblies and power cables.
The majority of the specifications within the database have been obtained directly from the
equipment manufacturers. The exception is information for rod strings, tubing and casing which
is based on API standards51,52. Because new products are continually evolving, this database is
updated regularly to reflect these changes. Subscribers to the Maintenance Plan periodically
receive copies of these new databases either as stand-alone updates or in conjunction with
software upgrades. If an item you require is not in the database, please contact PC-PUMP Technical
Support for assistance.
Computational Process
PC-PUMPs computational process integrates all of the components which influence a PC pumping
system. Fluid flow, mechanical loading, material properties, and energy dissipation are a few of the
key considerations. Within the program, a calculation engine comprised of numerous analytical
equations and empirical relationships carries out the actual calculations. The engines
computational flow path is shown in the diagram below that illustrates how the calculation
progresses from the input parameters to the output results.
PC-PUMP User Guide
24
PART 2: BACKGROUND
Input
Parameters
Link Geometry
to Production
String
Link Geometry
to
Wellbore
Casing
Pressure
Profile
Calculations
Pump
Calculations
Tubing
Pressure
Profile
Calculations
Drive
Equipment
Calculations
Rod String
Calculations*
Summary
Parameter
Calculations
Output
Warning
Checks
Auxiliary
Calculations**
Output
Results
* Surface Drive Only

** Includes Rod String Fatigue, Rod/Tubing Wear, and Backspin Calculations
(Surface drive only)
PC-PUMPs computational flowpath
Note: The fluid flow calculations include annular and tubing pressure profile calculations, and
pump performance evaluations. The mechanical calculations include, depending on the

well configuration, rod string axial load, torque and stress calculations, rod/tubing contact
load calculations and surface or downhole power transmission computations. The
auxiliary analyses include rod fatigue, rod/tubing wear, and backspin calculations. Several
calculations (e.g. surface power transmission) depend on optional inputs and are only
executed if you input the required data. Similarly, auxiliary calculations (e.g. fatigue
analyses) are not completed until you enter specific windows and provide supplementary
input.
Technical Considerations
PC-PUMP has
the ability to comprehensively evaluate most aspects of PC pumping system design

and operation. To accomplish this, the computational algorithms in its calculation engine address
numerous technical considerations. Examples of these include: pump performance, multiphase
flow, rod/tubing wear and surface power transmission.
Part 3 of the User Guide, entitled Using PC-PUMP, discusses in detail the programs input and output.
Brief explanations of the calculation process are also included where appropriate. However, a
detailed review of all of the technical considerations associated with the program was not
considered to be within the scope of this User Guide. Information on most of these issues can be
found in references such as those listed in Appendix C.
Nevertheless, several of the key technical considerations warrant some discussion. These include
directional wellbores, pump testing, inflow performance, fluid flow, rod string loading, rod string
PC-PUMP User Guide
PART 2: BACKGROUND
25
fatigue, rod string backspin, downhole motor performance, power cable performance and motor
heating effects. This section provides an overview of these issues and how they are handled
within PC-PUMP. Although not exhaustive, this section should give you some insight into the
calculation process and the inherent assumptions and limitations. For most of the topics,
additional references are given to direct users to further information.
Directional Wellbores
Directional wellbores generally follow along a planned three-dimensional trajectory to a
predetermined bottomhole target. Their utilization is usually driven by economic and
environmental factors. Specific applications for directional wellbores include horizontal wells, pad
drilling and offshore platforms. Directional wells are typically classified as either slant, deviated or
horizontal as illustrated below.
Slant
Deviated
Horizontal
Directional well types
PC pumping systems are commonly employed in directional wells. For surface drive systems, the
hole angle and curvature inherent in these wells leads to contact between the rod string and tubing.
In some applications, this contact can induce frequent rod and tubing wear-related problems (see
discussion later in this section).
In evaluating PC pumping systems, an accurate representation of the directional wellbore profile is
essential, particularly if equipment wear is a problem. Important measures of wellbore geometry
include wellbore curvature (dogleg severity) as well as the measured depth versus vertical depth
relationship. For existing wells, directional surveys have usually been completed during drilling.
These surveys record the inclination (hole angle) and direction (azimuth) at various depths
(stations) along the wellbore. The accuracy with which the recorded survey data represents the
actual trajectory of the wellbore depends highly on the distance between the survey stations and
the type of survey instrument used49.
Measured survey data can be processed into wellbore geometry information using one of several
calculation methods as described below. For new well designs, directional proposals can be
created by applying one of the different calculation techniques in reverse.
An examination of technical literature reveals approximately 20 different calculation methods for
determining wellbore trajectory9. Historically, simpler techniques like the tangential and angle
PC-PUMP User Guide
26
PART 2: BACKGROUND
averaging methods assumed straight line approximations between survey locations. However,
with the advancements in computational power came more advanced methods, such as the radius
of curvature and minimum curvature methods, which rely on projecting the survey points onto
three-dimensional circular arcs. With the exception of the earliest techniques, all of the calculation
methods produce reasonably accurate results.
uses the minimum curvature method for both analyzing directional survey data and
creating proposals within its Wellbore Design mode. This method defines the wellbore path by
fitting consecutive survey points onto a circular arc which minimizes the maximum curvature.
The minimum curvature method has been shown to have excellent accuracy and is suitable for a
wide range of both survey spacing and overall curvature9.
PC-PUMP
Pump Testing
Pump tests are completed on new pumps to size them appropriately for their intended application.
Used pumps are tested to establish whether their performance is adequate to warrant reuse. Sizing
guidelines usually consist of a range of acceptable volumetric efficiencies at rated pressure (or
some other reference pressure), as measured on a test bench under specified conditions. Sizing
guidelines have been developed largely on the basis of experience for most field applications and
the guidelines used by individual vendors typically apply only to their products.
In a typical PC pump test, the pump is installed horizontally on a test bench and used to pump
water through a closed loop system. The intake pressure is usually fixed at a low value and a
choke on the discharge is used to regulate the pump differential pressure. The test process
consists of varying the discharge pressure while operating the pump at one or more constant
speeds. In addition to monitoring the controlled pressure and speed, the torque and fluid rate are
also measured.
Pump test data is usually compiled into a summary report that is provided to the purchaser.
Besides listing the controlled and measured values, these reports may contain other calculated
parameters such as volumetric efficiency, power and total efficiency. The format of these reports
and the displayed parameters tends to vary among the different pump vendors. A common style
of presentation format is illustrated in the chart below.
PC-PUMP User Guide
PART 2: BACKGROUND
100
27
1500
Efficiency
80
1200
900
60
Volumetric
Pump
Efficiency
40
(%)
Torque
600
Pressure
Rating
20
300
Model A BC
200 RPM
0
0
6
9
12
Pump Differential Pressure (MPa)
Total
Torque
(Nm)
0
15
Typical pump test data

PC-PUMP allows you to input pump test data, have the program evaluate it in a consistent manner
and then display the results in tabular and graphical formats. The following procedure is used by
PC-PUMP to assess pump test information:
1.
The actual pump displacement is determined based on the fluid rates measured at zero
differential pressure (Actual Pump Displacement = Fluid Rate/Pump Speed). If data is
specified for multiple test speeds, the average of the calculated displacements at zero
differential pressure will be used as the actual pump displacement
2.
Adjusted volumetric pump efficiencies are calculated for each test point based on the actual
pump displacement (Adjusted Volumetric Pump Efficiency = 100Fluid Rate/(Actual Pump
DisplacementPump Speed)).
3.
Fluid slippage rates are calculated for each test point (Fluid Slippage = Actual Pump
DisplacementPump Speed - Fluid Rate).
4.
Using all of the test data, a characteristic relationship is determined for slippage rate as a
function of differential pressure.
5.
At each test point, hydraulic torque is determined based on the actual pump displacement
and the differential pressure (Hydraulic Torque = Actual Pump DisplacementDifferential
Pressure).
6.
Friction torque is calculated as the difference between the total measured torque and
hydraulic torque (Friction Torque = Measured Torque - Hydraulic Torque).
7.
Using the test data, a characteristic relationship is determined for friction torque as a function
of differential pressure.
8.
Effective power is determined for each test point based on the hydraulic torque and speed
(Effective Power = Hydraulic TorquePump Speed).
9.
Actual power is calculated using the measured torque and pump speed values (Actual Power
= Measured TorquePump Speed).
PC-PUMP User Guide
28
PART 2: BACKGROUND
10. Total pump efficiency is determined based on the ratio of effective to actual power (Total
Pump Efficiency = 100Effective Power/Actual Power).
Pump volumetric efficiency and friction torque can have a large impact on the overall pumping
system performance. Within PC-PUMP, you have the option of inputting static values for these
pump characteristics or specifying pump test information from which they can be calculated
dynamically for the current operating conditions (i.e. pump speed and pump differential pressure).
PC-PUMP determines
volumetric efficiency and friction torque at target operating conditions using

the following procedure:
1.
Determining the fluid slippage rate at the target differential pressure (using the relationship
from Step #4 above).
2.
Calculating a predicted fluid rate based on the actual pump displacement, pump speed and
fluid slippage rate (Predicted Fluid Rate = Pump SpeedActual Pump Displacement - Fluid
Slippage Rate).
3.
Determining a volumetric efficiency (Volumetric Efficiency = Predicted Fluid Rate/(Pump

SpeedActual Pump Displacement)).
4.
Determining the friction torque at the target differential pressure (using the relationship from
Step #7 above).
The user should exercise caution when using pump test data to determine pump characteristics for
PC pumping system assessments. In many cases, bench test data is not representative of the
pumps performance in the actual downhole operating environment. For example, bench test
measurements correspond to water at a specific temperature. When installed in the field,
differences in the fluid characteristics (e.g. composition, temperature) may cause elastomer
swelling, shrinkage or expansion. These elastomer changes can cause pump volumetric efficiency
and friction values to vary significantly from those measured on the test bench. During the sizing
process, these variations are taken into consideration. For example, where stator swell is
anticipated, pump tests often exhibit very low volumetric efficiencies and friction torques
compared to the in-service values for the pump. Although you may want to examine these types
of pump tests using PC-PUMP, it is recommended that you do not use the test data for completing
system designs unless you have evidence to show that the pump characteristics will not change in
service.
Inflow Performance
Inflow into a well depends on the pressure difference between the reservoir and the wellbore.
With static reservoir pressure fixed and bottomhole flowing pressure variable, the difference
between the two, called drawdown, will determine the flow rate. Flow rate will increase with
drawdown with the maximum flow rate occurring at 100% drawdown or zero bottomhole
flowing pressure.
Considerable attention has been paid to the formulation of equations expressing the relationship
between surface fluid rate and bottomhole flowing pressure, over the practical range of
production conditions. The expression inflow performance relationship (IPR) customarily is
PC-PUMP User Guide
PART 2: BACKGROUND
29
used to define the relationship between surface fluid rate and wellbore flowing pressure. A
graphical illustration of this relationship is shown in the diagram below.
Wellbore Flowing Pressure (MPa)
25
20
15
Test Point
10
0
0
50
100
150
200
250
300
Surface Fluid Rate (m3/D)
Typical inflow performance relationship
allows the use of several of the more widely-used empirical methods for predicting an
IPR. Descriptions of these methods follow:
PC-PUMP
Straight Line (Constant PI)10: Simple IPR equation which states that the production rate is directly
proportional to pressure drawdown in the reservoir. The constant of proportionality is called the
productivity index, PI (or J in some literature), and is defined as the ratio of the flow rate to the
pressure drop in the reservoir. Because the straight line IPR is derived from Darcys law for the
steady-state incompressible flow of a single-phase fluid, its use should be limited to undersaturated
oils or water. A straight line IPR can be calculated either based on a single test point and the static
reservoir pressure (with Data Point option) or based on the productivity index and the static
reservoir pressure (PI option).
Vogel11: IPR traditionally used to describe oil well performance when both oil and gas phases may
flow in the reservoir. Vogels equation is a best-fit approximation of numerous simulated well
performance calculations. Commonly used because of its simplicity and accuracy, it only requires
the static reservoir pressure, bubble point (for undersaturated reservoirs) and a single test point.
Note that PC-PUMP applies the Vogel equation below the bubble point, and a straight-line IPR
above the bubble point.
Backpressure (Fetkovich)12: Method for calculating the inflow performance for oil wells using the
same type of equation typically used for analysing gas wells. Assuming the static reservoir pressure
is known, this method requires at least two test points. Parameters in the backpressure relation
include the flow coefficient, C, and an exponent, n, which depends on well characteristics.
Quadratic (Jones, Blount and Glaze)10: Quadratic relationship that is developed from multi-rate
test data and which attempts to characterize non-Darcy flow effects. Parameters in the relationship
include a laminar flow coefficient, C, and a turbulent flow coefficient, D. This method requires at
least two test points.
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PART 2: BACKGROUND
Standard Composite13: This relationship is well suited for determining the inflow performance of
oil wells producing water. The method uses a constant PI for the water production and adds it to
a Vogel relationship for the oil production to obtain a composite inflow performance relationship.
To use this method you need the static reservoir pressure, bubble point (for undersaturated
reservoirs) and a single test point with both water and oil production rates.
Fluid Flow
Fluid flow considerations are fundamental in the determination of pressure gradients in the
production tubing and tubing/casing annulus of an oil well. These pressure profiles affect the lift
requirement and thus impact any production equipment which may be employed. Consequently,
accurate fluid flow algorithms are essential in the design of artificial lift systems.
Pressure gradients are made up of three components. The first component, hydrostatic head or
elevation, represents the weight of the fluid column and is related to fluid density and vertical
depth. The hydrostatic head is normally the predominant component and contributes from 70 to
95% of the total pressure in most oil wells. The second component, frictional losses, is the result
of pressure losses during fluid flow. These losses occur along the length of the wellbore and are
strongly dependent on fluid viscosity and the flow geometry. Frictional losses typically account for
5 to 25% of the total pressure gradient. The final component, acceleration or kinetic energy,
occurs due to changes in fluid velocity. It is normally negligible, and becomes significant only if a
compressible phase exists at relatively low pressures.
Wellbore flow can be divided into several categories, depending on the flow geometry, fluid
properties and flow rate. First, the flow in a wellbore can be classified as either single-phase or
multiphase. In most wells the flow is multiphase, with at least two phases (e.g. gas and liquid)
present. However, some wells either contain only a single-phase or can be suitably modelled using
single-phase algorithms. Several flow geometries are also possible. In a rod-driven PC pumping
system, annular flow between the tubing and rod string as well as in the tubing and casing annulus
is most common. However, basic pipe flow occurs through any tail joints and within the tubing in
rod-less systems. The properties of the fluids, both their PVT (pressure/volume/temperature)
behavior and their rheological characteristics, are also important when assessing fluid flow. Finally,
depending on the flow rate and the fluid properties, flow in a wellbore may be either laminar or
turbulent, and this will greatly affect the flow behavior.
The different ways in which PC-PUMP addresses various flow types will be reviewed in the
remainder of this section. For the purposes of this discussion, it has been divided into singlephase and multiphase flow.
Single-Phase
In single-phase flow, the fluids are assumed to be homogeneous and are treated as being
incompressible. The hydrostatic head is calculated based on the average fluid density and the
elevation (i.e. vertical depth) change. PC-PUMP allows separate densities to be input for the tubing
and for the casing (i.e. the tubing/casing annulus). The tubing density is used in the calculation of
the dynamic pressure gradients from the perforations to the pump and throughout the tubing.
The casing density is used in the calculation of the static pressure gradient in the tubing/casing
annulus below the fluid level.
PC-PUMP User Guide
PART 2: BACKGROUND
31
For single-phase flow, the algorithms used in PC-PUMP to determine the frictional loss component
of the dynamic pressure gradient are dependent on flow rate, fluid properties and flow geometry.
Either a laminar or turbulent flow regime can exist depending on the flow rate and the fluid
properties. On the basis of their rheological properties, fluids are treated as either Newtonian or
non-Newtonian types18. Finally, the three types of flow geometry dealt with are pipe flow, annular
flow and eccentric annular flow.
Differentiation between the laminar and turbulent flow regimes is usually done on the basis of the
Reynolds number. In its simplest form, this parameter is calculated based on the fluid density,
flow velocity, pipe diameter and fluid viscosity. However, annular flow and non-Newtonian fluids
necessitate special consideration for flow geometry and additional fluid properties, respectively.
Calculation of frictional losses requires the determination of friction factor values. For laminar
flow, PC-PUMP uses the analytically derived Darcy friction factor18 which can be calculated based
only on the Reynolds number. In the case of turbulent flow, the results of extensive experimental
studies are typically used. PC-PUMP uses the Zigrang and Sylvestor14 explicit approximation to the
Colebrook equation to calculate turbulent friction factors. This correlation requires the pipe
roughness, pipe diameter and Reynolds number.
Much of the published literature on single-phase fluid flow pertains specifically to Newtonian
fluids. This implies that the applied shear stress is proportional to the shear strain rate and
viscosity is the constant of proportionality (i.e. shear stress = viscosityshear rate). However,
many of the fluids encountered in the petroleum industry do not exhibit Newtonian behavior.
Several fluid models are shown below which characterize the rheological behavior of various
viscous materials. The resistance to flow of a dilatant (shear-thickening) fluid increases with
increasing strain rate (i.e. viscosity increases with increasing shear rate). In contrast, the resistance
of a pseudoplastic (shear-thinning) fluid decreases with increasing strain rate (i.e. viscosity
decreases with increasing shear rate).
Dilatant
Shear
Stress
(psi)
Newtonian
Pseudoplastic
0
Shear Strain Rate (1/s)
Dilatant
Viscosity
(cp)
Newtonian
Pseudoplastic
0
Shear Strain Rate (1/s)
Types of fluid models
PC-PUMP User Guide
32
PART 2: BACKGROUND
Most higher viscosity petroleum fluids (>100 cp) tend to be non-Newtonian exhibiting
pseudoplastic (shear-thinning) behavior. Two different methods can be used to calculate frictional
losses for non-Newtonian fluids. The first is to substitute an apparent viscosity into the
conventional Newtonian pressure loss correlations. The second method, which is the one used in
PC-PUMP, is to first fit the fluid properties to a power-law fluid model and then use the Metzner and
Reed15 generalized approach for calculating pressure losses.
The power-law fluid model has a consistency parameter, K, which is related to the overall viscosity
and a flow index, n, which quantifies the non-Newtonian behavior. When n equals one, the fluid
behaves as a Newtonian fluid. Values of n less than one indicate a pseudoplastic fluid. Metzner
and Reed formulated a "generalized" Reynolds number for non-Newtonian flow. In the case of
laminar flow, this "generalized" Reynolds number is used in a similar fashion to the conventional
Reynolds number in determining a friction factor and pressure loss. For turbulent flow, the
"generalized" Reynolds number is substituted into an implicit smooth pipe friction factor equation
proposed by Dodge and Metzner16. To adjust this smooth pipe friction factor to represent flow in
real pipes, it is multiplied by the ratio of the rough to smooth Fanning friction factors (calculated
at the same "generalized" Reynolds number) as suggested by Govier and Aziz17.
With annular flow, the presence of an inner cylinder produces increased frictional losses relative to
standard pipe flow. Equations which describe concentric annular fluid flow can be derived
analytically18. From these equations, an effective flow diameter correlation can be determined.
Diameters calculated from this correlation can be substituted into the conventional or
"generalized" Reynolds numbers which in turn can be used in the appropriate friction factor and
pressure loss correlations.
To address eccentric fluid flow, PC-PUMP multiplies the annular pressure losses calculated above by
factors determined based on correlations developed by Haciislamoglu and Cartalos19. These
correlations use the outside rod diameter, inside tubing diameter and degree of eccentricity as
inputs. Different versions of the correlation are used for Newtonian and non-Newtonian fluids.
Frictional pressure losses in a fully eccentric geometry are approximately 50% of the annular value.
Reductions in pressure losses with increasing eccentricity are due to the presence of a larger
unrestricted flow area and its lower associated fluid shear rates and stresses.
It is important to understand the approach taken in PC-PUMP to account for water and solids in
produced fluids. The impact of sand and water content on tubing and casing fluid density can be
easily modelled using the fluid composition option in single-phase flow, in which the sand and
water cuts and associated specific gravities are specified and the densities are calculated. In this
case, the program assumes that the specified sand specific gravity is for dry sand grains, that the
porosity of the sand is 40%, and that all porous volume within the sand is occupied by water.
For all single-phase flow calculations, the produced fluid is considered to consist of two
components: oil and basic sediment and water (BS&W). The BS&W content is defined as the
sum of the sand and water cuts from a standard basic sediment and water analysis. When the
specified sand cut is non-zero, the composite IPR (water content adjustment with producing
pressure) and the advanced viscosity feature (fluid viscosity adjustment with water content) use the
BS&W content as the water phase volume percentage. Caution should therefore be used when
performing calculations and interpreting results for applications with high sand cuts (>10%).
PC-PUMP User Guide
PART 2: BACKGROUND
33
Warning: In downhole drive configurations, a combination of small clearances (between casing or

shroud and motor), high flow rates, and high viscosities may generate significant frictional pressure
losses between the perforations and pump intake. PC-PUMP will give an error message if these
pressure losses result in a calculated negative pump intake pressure.
Multiphase
Multiphase flow can be defined as the simultaneous flow of two or more phases (e.g. oil, gas, water,
sand). In an oil well, whenever the pressure drops below the bubble point, gas will evolve
resulting in gas-liquid flow. As this gas-liquid mixture flows through the production system, the
two phases will distribute in a variety of patterns. The particular pattern or "flow regime" which
occurs has a significant effect on multiphase flow behavior. Flow regime maps facilitate the
determination of flow patterns based on gas and liquid flow rates as well as fluid properties. These
inputs for the flow regime maps are obtained using empirical fluid property correlations.
Depending on the particular flow regime, different multiphase flow algorithms are used for
calculating the hydrostatic and frictional pressure gradients. The hydrostatic gradient is
determined using both gas and liquid densities and takes into account a phenomenon known as
liquid holdup. The frictional gradient is calculated using friction factors based on two-phase fluid
properties57.
In multiphase flow, the amount of pipe occupied by a phase is often different from its proportion
of the total volumetric flow rate. Typically, in upward gas liquid flow, the lighter gas phase moves
faster than the denser liquid phase. Because of this holdup phenomenon, the in-situ volume
fraction of the liquid phase will be greater than its input volume fraction. In other words, the
liquid is "held up" in the pipe relative to the gas. Liquid holdup is defined as the ratio of the
volume of a pipe segment occupied by liquid to the volume of the pipe segment. Consequently, it
is a fraction which varies from zero for all gas flow to one for all liquid flow. Another parameter
commonly used in multiphase flow is no-slip holdup. It is defined as the ratio of the liquid input
fraction to the total input fraction. When determining the hydrostatic gradient, it is important to
use an accurate liquid holdup value.
The diagram below illustrates the procedure used in PC-PUMP for multiphase flow calculations. In
the following sections, the fluid property correlations, flow pattern mapping and multiphase flow
algorithms used in the software will be described in more detail.
PC-PUMP User Guide
34
PART 2: BACKGROUND
Fluid Property Correlations

- solution gas/oil ratio
- dissolved/free gas gravities
- oil and water volume factors
- gas compressibility & gas volume factor
- insitu oil, water and gas rates
- gas/oil & gas/water surface tensions
- oil, water and gas viscosities
- oil, water and gas densities
Flow Pattern
Mapping
- superficial liquid velocity
- superficial gas velocity
- flow geometry
- liquid & gas density
- liquid & gas viscosity
- liquid surface tension
- flow pattern identification
Multiphase Flow Models

Single Phase
Liquid Flow
Pressure Traverse
- liquid holdup
- hydrostatic gradient
- frictional gradient
Bubble
Flow
Dispersed
Bubble Flow
Slug
Flow
Annular
Flow
PC-PUMP multiphase flow calculation procedure
Fluid Property Correlations

Completion of a multiphase flow assessment requires the calculation of numerous fluid properties.
These properties, several of which include density, viscosity and surface tension, are associated
with the gas, water and oil components. Many empirical correlations are available in the literature
for predicting each of these fluid properties. However, care must be taken to ensure that the
correlations are not extended beyond their range of validity. For example, many correlations were
based on data from medium to high API oils, and may not be applicable to heavy oil. During the
development of PC-PUMP, an extensive review and comparison of the publicly available correlations
was completed. Based on this work, the following correlations were selected for PC-PUMP on the
basis of being the most appropriate for oil well multiphase flow assessments.
Dissolved and Free Gas Specific Gravities - Katz et al.21
Oil Isothermal Compressibility - Vazquez & Beggs20
Oil Volume Factor - Vazquez & Beggs20
Water Isothermal Compressibility - Osif22
Water Volume Factor - Katz et al.21
Pseudo-reduced Temperature and Pressure - Sutton23
Gas Compressibility Factor - Dranchuk, Purvis & Robinson24
Gas/Oil Surface Tension - Baker & Swerdloff25
Gas/Water Surface Tension - Jennings26
Water Viscosity - McCain29
Gas Viscosity - Lee et al.30
In addition, other properties allow the user to choose which correlation to use:
PC-PUMP User Guide
PART 2: BACKGROUND
35
Solution Gas/Oil Ratio - Vazquez & Beggs20,57,60

Solution Gas/Oil Ratio - Glaso60
Solution Gas/Oil Ratio - De Ghetto et al.62
Solution Gas/Oil Ratio - Standing57,60
Bubble Point Pressure - De Ghetto et al.62
Bubble Point Pressure -Standing (1)64
Bubble Point Pressure - Standing(2)60
Bubble Point Pressure - Glaso60
Bubble Point Pressure - Vazquez & Beggs60
Dead Oil Viscosity - Glaso58,59
Dead Oil Viscosity - Ng & Egbogah27,64
Dead Oil Viscosity - De Ghetto et al.62
Dead Oil Viscosity - Beggs & Robinson28,59
Dead Oil Viscosity - C-FER/HOGS61
Dead Oil Viscosity - Kartoatmodjo58,63
Dead Oil Viscosity - Bennison58
Dead Oil Viscosity - Beal58
Dead Oil Viscosity - Egbogah & Jack58
Dead Oil Viscosity - Labedi58
Dead Oil Viscosity - Petrosky & Farshad58
Live Oil Viscosity - Beggs & Robinson28,57,59
Live Oil Viscosity - Kartoatmodjo63
Live Oil Viscosity - De Ghetto et al.62
Undersaturated Oil Viscosity - Vasquez & Beggs20,57,59,64
Undersaturated Oil Viscosity - Kartoatmodjo63
Undersaturated Oil Viscosity - De Ghetto et al.62
All fluid property correlations have been developed from databases of laboratory fluid tests.
Consequently, they have a valid range which is based on the data from which the correlation was
developed. To prevent using these correlations outside of their appropriate ranges, PC-PUMP
imposes limits on several of the multiphase fluid property input parameters. In particular, the gas
specific gravity must be between 0.55 and 1.2 and the fluid temperature between 0C and 200C.
Warnings are also issued for oil gravities less than 15API. The user-selectable correlations have
different limits, which are given below, and warning messages will be issued if these limits are
exceeded at any point in the well.
Dead Oil Viscosity
Correlation
Range of Applicability
Glaso
Ng & Egobah
deGhetto et al.
T: 15-80C (59-176F)
API: 5-58
T: 55.2-121.5C (131.4-250.7F)
API: 6-23
PC-PUMP User Guide
36
PART 2: BACKGROUND
Beggs & Robinson

C-FER/HOGS
Kartoatmodjo
Bennison
Beal
Egobah & Jack
Labedi
T: 21.1-146.1C (70-295F)
API: 16-58
T: 20-70C (68-158F)
API: 9-13.3
T: 23.9-160C (75-320F)
API: 14.4-59
T: 10-93.3C (50-200F)
API: 10-20
T: 37.8-152.2C (100-306F)
API: 32.2-48
Petrosky & Farshad

Live Oil Viscosity
Correlation
Beggs & Robinson
Kartoatmodjo
deGhetto et al.
Rs: 3.56-368.7 m/m (20-2070 scf/bbl)
Rs: 0-514.7 m/m (0-2890 scf/bbl)
Rs: 3.07-114 m/m (17.21-640.25 scf/bbl)
API: 6-23
Undersaturated Oil Viscosity

Correlation
Vasquez & Beggs
Kartoatmodjo
170.3-49440 kPaa (24.7-7170.7 psia)
deGhetto et al.
P: 100-5186 kPaa (14.5-752.2 psia)
Pb: 1441-27731 kPaa (209-4022 psia)
od: 7.7-1386.9 cp
API: 6-23
Solution GOR
Correlation
Vasquez & Beggs
Glaso
deGhetto et al.
T: 10-148.9C (50-300F)
P: (58-6050 psia)
SGgas: 0.574 or higher
API: 17.9-51.1
T: 55.2-121.1C (131.4-250F)
API: 6-23
SGgas: 0.623-1.517
Standing
Bubble Point
Correlation
PC-PUMP User Guide
PART 2: BACKGROUND
deGhetto et al.
Standing (1)
Standing (2)
Glaso
37
T: 55.2-121.1C (131.4-250F)
API: 10-22.2
GOR: 3.07-114 m/m (17.21-640.2 scf/bbl)
SGgas: 0.623-1.517
T: 10-148.9C (50-300F)
API: 17.9-51.1
SGgas: 0.574 or higher
Vasquez & Beggs

Water and sand content in the produced fluid are lumped together as the BS&W content (basic
sediment and water) for multiphase flow. This value is the sum of the sand and water cuts from a
standard basic sediment and water analysis. The BS&W Content variable is used in any flow
calculations which make use of the volume or mass percentage of water in the mixture.
Because the dead oil viscosity correlations may not be appropriate for all crude oils, PC-PUMP allows
you to override the default dead oil viscosity correlation with customized temperature-sensitive
dead oil viscosity data using the Advanced Viscosity feature. In this case, the live oil viscosity is
still obtained from the dead oil viscosity data by use of a correlation.
Flow Pattern Identification and Mapping
The manner in which the liquid and gas are distributed in the pipe has a significant affect on the
nature of the multiphase flow. The "flow regime" or flow pattern is a qualitative description of the
phase distribution. Flow pattern maps can be formulated based primarily on liquid and gas
superficial velocities to allow the identification of different flow regimes. The flow pattern maps
and their associated patterns vary for upward vertical/inclined, downward vertical/inclined and
horizontal flow. In gas-liquid vertical/inclined upward flow, four flow patterns are generally
agreed upon: bubble, dispersed bubble, slug and annular flow. A typical flow pattern map for this
type of flow is shown below.
PC-PUMP User Guide
38
PART 2: BACKGROUND
10
Flow Conditions
Superficial Liquid Velocity (m/s)
Dispersed
Bubble Flow
Flow Diameter
Hole Angle
Liquid Density
Gas Density
Liquid Viscosity
Gas Viscosity
Surface Tension
76 mm
0
900 kg/m^3
10 kg/m^3
20 cp
0.043 cp
30 dynes/cm
Bubble
Flow
Annular
Flow
0.1
Slug
Flow
0.01
0.001
0.01
0.1
10
100
Superficial Gas Velocity (m/s)
Typical flow pattern map
With bubble and dispersed bubble flow, the liquid phase is continuous and the free gas phase is
present only as relatively small bubbles. While the bubble flow regime occurs at low liquid
velocities (allowing the gas bubbles to move faster than the liquid), the dispersed bubble regime is
characterized by high turbulence, and both phases move together as a homogeneous mixture. In
slug flow, although the liquid phase is still continuous, the gas coalesces to form large bubbles
which almost fill the pipe cross section. The gas bubble velocity is greater than that of the liquid
that moves in slugs between the long gas bubbles. In annular flow, the gas phase is continuous
and occupies the center of the pipe. Some of the liquid is entrained as droplets in the gas phase,
and some coats the pipe wall as a liquid film.
Recently, physical models have been developed which allow the analytical prediction of flow
patterns and their associated transition boundaries for steady state gas-liquid flow. Based on flow
rates, fluid properties and flow geometry, flow pattern maps can be generated. The basic work on
pattern transitions for upward two-phase flow was completed by Taitel et al.31. Later,
modifications to the transitions were made by Barnea et al.32,33 to extend the applicability of the
model to inclined flows. Results from these two works form the basis for flow pattern
identification within PC-PUMP. The model which is integrated into the software encompasses the
four common flow patterns defined above and exhibits smooth transitions through a wide range
of pipe inclinations (from vertical to 75). Care should be taken when modeling multiphase flow
in wells with inclinations that approach horizontal. While the multiphase flow correlations in
PC-PUMP are intended for upward inclined pipe flow for hole angles between 0 and 75, they will
give reasonable results for hole angles up to 88. The software will not perform multiphase flow
analyses if any part of the production tubing has an inclination of greater than 90 degrees
(downward flow).
PC-PUMP User Guide
PART 2: BACKGROUND
39
Multiphase Flow Models

Numerous correlations and models have been developed for predicting multiphase flow behavior
in wells. However, they all share the common primary objective of determining accurate
hydrostatic and frictional pressure gradients. In accomplishing this, some models predict
important flow characteristics such as the liquid holdup.
The early multiphase flow models incorporated single-phase flow equations with mixture variables
and did not consider liquid holdup or address distinct flow patterns. Examples of these
homogenous models are Poettmann & Carpenter34 and Fancher and Brown. Extensive
experimentation resulted in the development of generalized empirical correlations (e.g. Duns &
Ros35, Hagedorn & Brown36, Beggs & Brill37). These formulations incorporated liquid holdup
correlations and established basic flow patterns. Subsequently, simple mechanistic models (e.g.
Orkiszewski38, Aziz et al.39) began to consider the fundamental flow mechanisms. Most recently,
comprehensive mechanistic models have been developed which incorporate elaborate flow
pattern prediction models and treat the physical flow mechanics rigorously. Their scope also tends
to be broader, including in some cases annular and inclined flow. Hasan & Kabir40, Ansari et al.41
and the proprietary Shell models42 (MMSM & GZM) are examples of these comprehensive
mechanistic models.
PC-PUMP required a multiphase flow model with which to determine pressure gradients and flow
characteristics for fluid flowing through the production tubing as well as the tail joints. A review
of several comparative studies42,43 revealed that Ansaris comprehensive mechanistic model is one
of the most accurate models available (for upward flow) in the public domain. Consequently, this
model was selected to form the basis for the flow algorithms included in PC-PUMP.
Static Annular Pressure Gradient

In order to assess a well with two-phase gas-liquid flow, it is also necessary to evaluate the static
pressure gradient in the tubing/casing annulus. It is essential that this gradient is calculated
accurately since it determines the pressure at the pump or tail joint intake which in turn affects the
distribution of gas flow up the annulus and production tubing. The gas flow up the annulus is
denoted by the casing gas rate and expressed in cubic meters per day at standard conditions (i.e.
101.7 kPa and 15.6C). Gas flow up the production tubing is characterized by the tubing gas/oil
ratio (GOR) which refers to the GOR when all of the gas in the tubing is in solution. The casing
gas rate and tubing GOR have significant effects on the pressure profiles within the tubing/casing
annulus and production tubing, respectively.
pressure gradient calculations depend on the system configuration. The diagram below
illustrates how the relative locations of the production string intake (i.e. tubing or tail joint) and
perforations impact the two-phase flow behavior.
PC-PUMPs
PC-PUMP User Guide
40
PART 2: BACKGROUND
Tubing
Flow Rate
Total
Casing + Tubing
Gas Rate = Gas Rate Gas Rate
Casing
Gas
Rate
Tubing
Oil Rate
Tubing
Water Rate
Total Gas Rate (@ Std. Cond.)

Producing
=
GOR
Total Oil Rate (@ Std. Cond.)
Solution
= Producing - GOR * Oil
GOR
Rate
(Perfs)
Tubing
GOR
Solution
GOR
(Perfs)
Casing
Gas
Rate
Tubing
GOR
Tubing
GOR
Solution GOR
(Prod. Intake)
Solution
GOR
(Perfs)
Solution GOR
(Prod. Intake)
Gas
Casing
Gas
Rate
Solution
= Producing - GOR
Tubing
GOR
GOR (Prod. Intake)
Free Gas
Oil Separation
* Rate
*
100
Casing
Gas
Rate
Free Gas
(Prod. Intake)
Oil
Perforations ABOVE
Production String Intake
Solution
GOR
+
(Prod. Intake)
Producing - Solution
GOR
GOR
(Prod. Intake)
Oil
* Rate*
Free Gas
1- Separation
100
Free Gas
(Prod. Intake)
Solution
GOR
(Perfs)
Water/Oil
Water
Perforations BELOW
Production String Intake
The following two sub-sections describe the flow behavior for system configurations with the
perforations above and below the production string intake. This includes the basic theory and
assumptions used by PC-PUMP is completing the multiphase flow evaluations.
Perforations Above Production String Intake
Consider a configuration where the perforations are above the production string intake. If the
pressure at the perforations is equal to or above the bubble point of the fluid, there will be no free
gas present and the solution GOR will be equal to the producing GOR. However, if the pressure
at the perforations is below the bubble point, there will be free gas at the perforations and the
solution GOR will be less than the producing GOR. By default, PC-PUMP assumes that, when the
perforations are above the production string intake, the free gas at the perforations is diverted up
the annulus and yields a casing gas rate. Note, however, that narrow annuli can create high flow
velocities that pull gas down into the intake along with the liquid stream. PC-PUMP therefore
gives you the ability to override the assumption that all the free gas at the perforations travels up
the casing.
With the perforations above the production string intake, the pressure at the string intake is always
higher than at the perforations. Consequently, the solution GOR at the intake (i.e. the tubing
GOR) is equal to that at the perforations. In addition, since all of the free gas is assumed to have
been separated above at the lower pressure perforation location, there is no free gas at the
production string intake, unless this assumption is overriden by the user. Note, however, that if
the pumping system configuration includes a tail joint (or a shroud around a downhole motor), the
reduction in pressure along its length can result in gas evolution and free gas being present at the
pump intake.
In calculating the annular pressure gradient, the starting point is the surface casing head pressure.
The gas gradient is calculated from surface down to the gas/liquid interface (i.e. fluid level) based
on standard gas compressibility correlations23,24. Next, the gradient is determined for the liquid
column. In this configuration, where the perforations are above the production string intake, it is
PC-PUMP User Guide
PART 2: BACKGROUND
41
assumed that the annular area above the perforations contains only oil since its density is lower
than that of water. However, this oil column will be lightened by any gas venting up through the
annulus. To address this effect, Godbey and Dimons mechanistic model44 is used to calculate the
gas void fractions based on the bubble rise velocity through the stagnant oil column. Using the
gas void fraction, fluid densities and pressure gradients are determined which consider the upward
gas flow. For the annular column between the perforations and pump intake, the fluid
composition (i.e. oil and water) is assumed to be of the same ratio as the produced fluids. In this
interval, hydrostatic pressure gradients are determined based on the density of a homogeneous
gas-liquid mixture. Note that friction pressure losses in the tubing/casing annulus are also
considered in PC-PUMP Version 2.63.
Perforations Below Production String Intake
Next, consider the configuration where the perforations are below the production string intake. If
the pressure at the production string intake is above the bubble point of the fluid, no free gas will
evolve and the solution GOR will be equal to the producing GOR. In this case, the tubing GOR
will also be equal to the producing GOR and the casing gas rate will be zero.
However, if the pressure at the intake is below the bubble point, free gas will be present and the
solution GOR will be lower than the producing GOR. Some of this free gas will enter the
production string, move upwards through the pump and travel to surface via the tubing. PC
pumps can handle free gas, however, it results in reduced volumetric efficiencies and, in severe
cases, may cause permanent pump damage. Fortunately, through natural separation, typically 30%
to 60%45 of the free gas present at the production string intake is diverted up the tubing/casing
annulus. To further improve separation efficiency, gas separators are sometimes installed.
When free gas is present at the production string intake, the tubing GOR may be higher than the
solution GOR at this location because a portion of the free gas may enter the production string.
The casing gas rate is comprised of any free gas diverted up the annulus (see the above diagram).
Determination of the annular pressure gradient with the perforations below the production string
intake is similar to that described previously for perforations above the intake. The gradient for
the gas column is calculated in an identical fashion. Next, the oil column from the gas/liquid
interface down to the production string intake is determined in the same way as the oil column
from the gas/liquid interface to the perforations in the prior configuration. Finally, the gradient
from the intake down to the perforations is computed. This is done in the same manner as the oil
column above, except that instead of pure oil, the oil/water ratio is assumed to be of the same
ratio as the produced fluids.
Rod String Loading

Rod strings are used in surface-driven PCP applications to transfer power from the surface
equipment to the pump. Rod string design considerations have become increasingly important
with the use of PC pumps in higher lift applications and the development of PC pumps with
increasingly higher displacements. Inadequately designed rod strings will often lead to operational
problems, equipment failures and costly workovers.
PC-PUMP User Guide
42
PART 2: BACKGROUND
There are three main sources of rod string loading in PCP applications. The primary loading is
torsional, but axial and bending loads may also contribute to more severe stress states.
Torsional loading in rod strings is caused primarily by the differential pressure acting across the
pump (hydraulic torque). Friction in the pump due to the interference fit between the rotor and
stator may also contribute a significant amount of torque (friction torque). Additional torsional
loading occurs due to friction in the rod/tubing contact in directional well applications. In highviscosity fluid cases, rod strings may also experience resistive torque due to fluid shear in the
region between the rods/couplings and tubing.
Axial loading (tension) in rod strings is generated by the differential pressure acting across the PC
pump and by the weight of the rod string. The latter component becomes more severe towards
the top of the well. Some compressive axial load may also be encountered if the fluid is of an
adequate viscosity to cause area uplift forces on the faces of couplings and/or centralizers and
surface uplift forces due to fluid shear on the surfaces of the rod string components.
The figure below summarizes the major sources of torque and axial load in a PC pumping
application.

Surface
Rod String Axial Load
Rod String Torque
Pump
Torque Components
Pump Hydraulic (Tubing Head Pressure)
Pump Hydraulic (Hydrostatic Pressure)
Pump Hydraulic (Flow Losses)
Pump Friction
Resistive

Polish Rod
Axial Load
Polish Rod
Torque
Surface
Pump
Axial Load Components

Pump Axial (Tubing Head Pressure)
Pump Axial (Hydrostatic Pressure)
Pump Axial (Flow Losses)
Rod Weight
Uplift Forces
Rod string torque and axial load components
Bending loads have typically been regarded as insignificant compared to torsional and axial
loadings. This is primarily because wellbore curvatures are usually not severe enough to cause any
significant amount of bending stress. However, an investigation completed by C-FER has shown
that tension in the rod string can magnify the rod curvature near sucker rod couplings to be five or
more times the wellbore curvature. This is largely due to the difference in stiffness between the
couplings and the rod body as well as the rod body standoff from the production tubing wall near
points of coupling-tubing contact. Consideration of bending loads is especially critical in fatigue
evaluations.
PC-PUMP User Guide
PART 2: BACKGROUND
43
There are a number of methods typically used to determine the severity of the rod loading. The
majority of design methods start by calculating an effective (overall) stress in the material caused
by the combination of torsional and axial loadings. PC-PUMP uses the von Mises criterion47 (also
referred to as the Maximum Distortion Energy criterion) to determine the maximum effective
stress in the cross-section of the rod. This stress is then compared to the elastic stress limit (yield
strength) of the material. Elastic-based design procedures normally limit the rod stress level to the
material's yield strength.
A second loading analysis method, based on plasticity theory, has been included in the PC-PUMP rod
string loading calculations. Rod strings can typically withstand 20 to 30 percent more torque than
that determined using elastic design theory before failure will occur. Normally this reserve capacity is
used as a safety factor that protects the rod string against failure during severe loading conditions
such as startup or fluid or sand slugging. It may also serve to protect the rods against fatigue
failures. The deformation-based theory used in PC-PUMP is intended to indicate how severe the
calculated rod loading is relative to the most severe loading the rod could withstand, with no safety
factor. The loading limit is determined by a maximum allowable plastic strain value of 0.2 %.
PC-PUMP calculates the torque, axial load, and effective curvature at each segment of the rod string.
The elastic-based loading analysis method is used to determine the effective stress in each rod.
The elastic and deformation-based theories are then used to determine the maximum allowable
torque at the material yield strength and at the plastic deformation limit, respectively.
As an indication of overall elastic rod loading severity, the program calculates the elastic design factor,
or EDF, which is the ratio of the effective stress in the rod to the material yield strength. Plastic
design severity is quantified by the deformation design factor, or DDF, which is the ratio of the actual
rod torque to the maximum allowable rod torque defined by the deformation-based design
method.
Manufacturers were given the opportunity to decide whether the rod stress calculation in PC-PUMP
should be applied to their rods. Therefore, some rods may use the above formulations, while
others report load as a per cent of rated load. Some rods use both methods, and may have slightly
different results in each method.
Rod String Fatigue

Mechanical components which are subject to alternating loads are susceptible to metal fatigue.
Repeated variations in stress tend to cause small cracks to eventually propagate far enough to
cause complete component failure. Fatigue failures can occur even if the peak stress level in the
material is below the yield strength. Use of the analytical capabilities in PC-PUMP will help to
determine if there is potential for fatigue failures to occur in a particular PCP application.
Fatigue analyses typically attempt to estimate the operating life of a component. The fatigue life of a
component is affected by the average (mean) stress it experiences, the magnitude of fluctuations in
the applied stress, and the frequency of these stress fluctuations. Fluctuations coupled with a high
mean stress cause more severe fatigue damage than fluctuations of a similar magnitude but with
no mean stress. Some steels exhibit an endurance limit, the maximum alternating stress that will
result in an "infinite" fatigue life. Designing for alternating stress levels below the endurance limit
PC-PUMP User Guide
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PART 2: BACKGROUND
serves as an excellent design criterion. Unfortunately, however, this infinite fatigue life concept
does not apply to many medium and high strength steels (which sucker rods are often made of),
nor does it apply in corrosive environments. PC-PUMP does not consider the possibility of infinite
fatigue life.
The operating conditions in many PC pumping applications expose the rod strings to severe load
fluctuations. Variations in pump discharge pressure caused by gas in the production tubing or
increases in pump friction due to sand or fluid slugs can cause significant fluctuations in pump
torque and axial load. Rods in deviated wells undergo rotating bending stresses at the rotational
frequency of the pump. It is important to consider fatigue analyses when these loading conditions
occur. The figure below shows field measurements of very severe load fluctuations caused by gas
slugging.53
Axial Load
Torque
10,000
1,000
900
8,000
800
6,000
600
500
4,000
400
Torque (ft-lbs)
Axial Load (lbf)
700
300
2,000
200
100
8:00
8:30
9:00
9:30
10:00
10:30
11:00
11:30
12:00
Time
Field measurements of severe torque and axial load fluctuations
The PC-PUMP software is capable of performing fatigue analyses for entire rod strings (sucker rod or
continuous rod). The rod axial load, torque, and effective curvature are coupled with rod
geometry, material properties, and a user-specified indication of possible alternating loads to
determine the expected fatigue life at each segment in the rod string. Because both high and low
frequency fluctuations may be present, the Palmgren-Miner rule47,48 has been employed to model
the overall fatigue damage per unit time.
Rod String/Tubing Wear

Directional and horizontal wells produced with PC pumping systems are prone to frequent rod
string and tubing wear-related problems. These problems can result in costly workovers and lost
PC-PUMP User Guide
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45
production. Wear problems can be minimized by limiting the curvature in directional wells and by
using rod guides, centralizers, or continuous rod.
Rod string and tubing wear rates are typically governed by four factors:
Rod/tubing contact loading - deviated wellbores lead to contact between the rod string and the
production tubing. The amount of wear at any contact point will depend on the contact
force between the rod string element and the tubing surface.
Rod/tubing configuration - the contact loading generated between the rod string and tubing is
dependent on the inside diameter of the tubing and the rod string configuration. Continuous
rod tends to follow the tubing surface because there are no connections to offset the rod
body from the tubing wall as there are in standard sucker rod strings. Rod guides and
centralizers used with standard rods may increase the wall standoff, but may also distribute
the contact loading over several locations as opposed to only at the rod couplings. Since the
rod element contact force is distributed over the surface contact area, wear will be reduced if
the total contact area is increased. This can be done by adding more guides or selecting
longer guides. Tubing wear rates will also depend on the coupling/centralizer/rod guide
material. Field trials have shown that urethane rod guides or centralizers reduce the amount
of tubing wear, but they should not be used where contact loads exceed 220 N (50 lb).
However, you should contact the product manufacturer for detailed load specifications and
limits.
Produced fluid conditions - studies indicate that the amount of sand in the wellbore fluid has a
significant effect on the wear rate of tubing and rod string components.50 The sand cut of a
fluid is determined using a basic sediments and water (BS&W) analysis.
Rod string rotational speed - wear rates are proportional to the relative speed of the contacting
surfaces. Larger diameter components have higher surface velocities than small components,
and therefore tend to cause more wear per revolution.
PC-PUMP has a separate wear analysis module that will estimate wear rates along the length of the
rod string based on the factors listed above. Wear analyses are completed outside the basic
calculation routine at the users discretion. Rod/tubing contact loading is calculated based on the
wellbore geometry and the calculated axial load at each point in the rod string. The rod string and
tubing configurations are specified when the user chooses production tubing and rod string
components in the Equipment Configuration window. Produced fluid conditions are specified in the
wear analysis module. The rod string rotational speed is specified in the Analysis window along
with other system operating conditions.
The wear analysis module uses an empirical relationship based on field data collected in C-FER
studies.49,50 The wear rate at any contacting element is linearly proportional to the distributed
contact loading at that point and it varies exponentially with the sand cut of the fluid.
Rod String Backspin

The development and use of larger displacement and higher pressure capacity PC pumps has led
to a substantial increase in the magnitude of the torsional strain and fluid energy that becomes
stored in the production system during normal pumping operations. The stored energy is released
whenever the PC pump system is shut down due to routine operator intervention or automatic
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PART 2: BACKGROUND
power cut-off such as in overload cases where the pump seizes or sands up. Over the past few
years, several incidents have occurred where uncontrolled backspin of the drivehead has led to
explosive sheave fragmentation. In a few of these cases, personnel were struck by sheave
fragments and seriously injured. This has led to a heightened awareness by both equipment
manufacturers and operators of the need to ensure the surface equipment (particularly the braking
system) is properly sized for each application, and to implement operating and workover
procedures which enhance worker safety.
Backspin occurs whenever a surface-driven PC pumping system shuts down. When the power
supply to the drive is lost or interrupted, the potential energy that remains in the system will cause
the surface equipment and drive string to accelerate in the direction opposite to its normal
operating mode. In many applications, if unrestrained by the surface drive/brake equipment,
backspin speeds can increase to the point where the drivehead sheaves or motor fans will
fragment and explode radially outward due to the high centrifugal forces that are generated.
There are typically two different types of backspin events: (1) when the pump rotor seizes within
the stator (seized pump scenario); and (2) routine shut-down of the pumping system (normal
shutdown scenario). In the seized pump case, the pump stops turning and the torsional strain
energy (twists) stored in the rod string causes the system to start spinning in the reverse direction
until all of the energy has been dissipated. The response period is generally quite short and little
fluid drains from the production tubing due to the seized pump condition. In the normal
shutdown case, the fluid remaining in the production tubing drains back to the well through the
pump, causing both the pump and drive system to accelerate backwards. This continues until the
fluid energy in the tubing (i.e. fluid level) is balanced by the fluid column in the annulus and the
pump friction, which can take anywhere from several minutes to hours, depending on the
circumstances.
Most driveheads are equipped with some type of backspin retarder or brake system which is used
to limit backspin speeds to the allowable speed ratings of the drivehead and sheave components.
However, it is important for operators to ensure that the brake specifications of the drive
equipment they install are adequate for their specific application conditions under both of the
backspin scenarios described above.
The following factors affect the backspin response of a surface driven PC pumping system:
Surface Equipment Friction: Friction in the rotating surface equipment acts to slow the system
down during the backspin.
Drive System Inertia: The nature of the backspin response is partially governed by the mass
moment of inertia of the sheaves, motor and gear box. Systems with high mass moment of
inertia values accelerate more slowly than low-inertia systems. Most of the inertia in a PC
pump drive is concentrated in the driven (large) sheave and the electric motor.
Brake Response: The amount of torque applied by the brake system as a function of both speed
and brake temperature. The maximum backspin speed and the duration of the backspin
period both depend on the brake response.
Brake Characteristics: Several different brake characteristics affect the backspin response of the
system. In addition to the brake response (described above), the location within the drive
system, heat capacity, activation speed, and energy dissipation characteristics of the brake, as
PC-PUMP User Guide
PART 2: BACKGROUND
47
well as the maximum allowable brake temperature, contribute to system performance. For
several of the brake system designs in current use, the temperature of the brake plays an
important role (especially in the normal shutdown scenario) because it governs the amount of
braking torque provided at different speeds. In addition, proper drive selection and
performance is important to ensure that the temperature limits imposed by wellhead
operating environment regulations and by the functional limits of the mechanical
components in the system are not exceeded under worst case conditions.
Seized Pump Torque: (seized pump case only) The maximum torque stored in the rod string
when the backspin commences, which will be governed by one of the following three
conditions: (1) rod torque corresponding to the maximum motor output torque; (2)
maximum rod torque capacity; or (3) torque corresponding to controller limits. The seized
pump torque represents the amount of potential energy stored in the rod string that must be
dissipated during the backspin event. Higher torque values generally lead to faster peak
speeds and longer backspin periods.
Rod String/Tubing Properties: In the seized pump case, the rod string diameter, shear modulus,
and length contribute to the stiffness of the system. The same is true in the normal
shutdown case, but the rod string configuration also affects the amount and dissipation of
stored fluid energy by influencing the fluid volume within the tubing and contributing to the
flow losses that occur when the fluid drains back to the wellbore through the pump.
Tubing and Casing Fluid Levels and Fluid Densities: (normal shutdown case only) The
differences between the levels and average densities of the fluid columns within the tubing
and the casing/tubing annuli define the differential pressure that exists across the PC pump
throughout the backspin period (i.e. the backspin driving force). The fluid level in the tubing
is generally assumed to start at 0 mKB (i.e. surface), although additional flow line and tank
volumes may also drain back to the well in some cases. The initial casing fluid level is
assumed to be the operating fluid level.
Pump Displacement: (normal shutdown case only) The nominal displacement of the PC pump.
High displacement pumps produce more hydraulic torque than low displacement pumps at a
given pump differential pressure. In the normal shutdown case, this is important because it
dictates the amount of driving torque produced by the fluid column within the tubing.
Pump Friction Torque: (normal shutdown case only) Torque required to overcome the
mechanical rotor/stator friction as well as hydraulic losses within the pump. Friction torque
acts against the direction of rotation and therefore serves to dissipate energy and slow the
system down during backspin.
Pump Volumetric Efficiency: (normal shutdown case only) The ratio of the flow rate under
normal operating conditions to the flow rate calculated based on the nominal displacement
and speed of the pump. A constant pump efficiency is used in the backspin analyses.
Fluid Properties: (normal shutdown case only) The density of the fluid in the tubing and wellbore
affects the pump differential pressure as noted above. The viscosity of the produced fluid
also impacts backspin response by controlling the amount of energy dissipation that occurs
due to flow losses in the tubing and in the casing/tubing annulus.
PC-PUMP includes an analysis module that allows you to complete simulations of backspin response
for both the seized pump and normal shutdown cases. This module can be used to assess the
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48
PART 2: BACKGROUND
backspin behavior associated with different well profiles, completion equipment, operating
conditions and manufacturer brake specifications. In addition, the program gives you the option
of conducting sensitivity analyses to assess the effects that changes in key operating parameters
will have on the backspin response. Warning - it is important to recognize that the results
predicted by PC-PUMP provide no guarantee against the occurrence of an uncontrolled backspin
event or sheave failure.
Downhole Motor Performance

Downhole electrical motor performance is normally described by curves supplied by the motors
manufacturer. Speed, efficiency, power factor and motor winding temperature curves are
specified in relation to the percent of rated power of the motor, as illustrated in the chart below.
Efficiency
Power Factor
Temperature Rise
Speed
100
1800
90
80
Efficiency (%)
1750
70
Power Factor (%)

60
Motor
Winding
Temperature
Rise (C)
1700
Speed
(RPM)
50
40
1650
30
20
1600
10
1550
0
10
20
30
40
50
60
70
80
90
100
% Rated Motor Load
Sample downhole motor performance curve
Within PC-PUMP, you have the option of using motor performance curves in the calculations or
specifying fixed values for motor slip, efficiency, power factor and temperature increase. You may
use performance curves that are available from the equipment database, or you may specify motor
testing information you have access to.
Downhole motor curves are generally only available at the motor nameplate frequency and must
be scaled appropriately when the motor is to be operated at a different frequency. The following
procedure is used by PC-PUMP:
PC-PUMP User Guide
1.
The motor rated power and voltage are assumed to be proportional to the operating
frequency;
2.
The motor load, in terms of percent of rated power, is calculated from the computed motor
shaft power and the scaled motor rated power;
PART 2: BACKGROUND
49
3.
Motor slip is calculated from the torque and frequency, or frequency is calculated from the
speed and torque;
4.
The efficiency is calculated from the torque and frequency;
5.
The power factor is calculated from the slip and frequency; and
6.
The temperature rise is calculated from the power and efficiency.
It should be noted that these relations are only approximations of the actual motor behavior. The
motor manufacturer should be contacted in the event that there is a large difference between the
operating frequency and the frequency for which motor information is available.
Motor Heating Effects

A submersible electric motor usually generates a significant quantity of heat during operation
downhole. To prevent the motor from burning due to excessive operating temperature, this heat
must be dissipated by the produced fluids flowing past the motor.
In downhole drive applications, two parameters related to motor cooling are of interest: the
operating temperature of the motor windings and the temperature increase of the produced fluid
past the motor. While the motor windings temperature must be kept below the value specified by
the motor manufacturer, the temperature increase of the produced fluids provokes changes in
important fluid physical properties, such as viscosity, which can affect the performance of the
entire system.
Heat transfer routines are included in PC-PUMP to allow these parameters to be estimated on the
basis of physical principles.54 The routines implement an improved version of the procedure
initially proposed by Powers.55 The increase in the produced fluid temperature is obtained by
equating the heat dissipated by the motor to the heat absorbed by the produced fluid. The
temperature difference between the motor skin and the bulk of the produced fluid is a function of
the amount of heat to be dissipated and the calculated convective heat transfer coefficient. This
coefficient depends heavily on the flow regime (laminar or turbulent), flow velocity past the motor
and the physical properties of the fluid. The motor winding temperature increase above the motor
skin temperature is given by the motor performance curves, as a function of motor load.
Within PC-PUMP, motor heating calculations are optional. When you choose to consider the motor
heating effects, you must specify the appropriate fluid properties. The program will model the
fluid temperature increase as it passes by the motor and will account for the corresponding
changes in the fluid physical properties.
Power Cable Performance

In downhole drive applications, it is important to monitor the voltage drop through the cable and
the cable conductor temperature. An excessive voltage drop through the cable not only affects
negatively the overall system efficiency, but can also cause motor start up problems. Power cable
insulation materials have temperature limits, and the conductor temperature must be maintained
below the limits specified by the manufacturer to avoid failures.
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PART 2: BACKGROUND
Power cable performance is normally described by ampacity curves supplied by the cables
manufacturer. The voltage-drop is specified as a function of the current and the conductor
temperature. The conductor temperature is specified as a function of the current and the ambient
temperature. Within PC-PUMP, you have the option of using power cable ampacity curves available
in the equipment database, or providing your own information on cable performance. When you
provide information on cable performance, PC-PUMP performs a regression on the set of data to
identify a set of cable performance parameters, such as the electrical resistance at a reference
temperature, which are then used in the calculations.
Windows User Interface

user interface provides a number of features that make it easy to quickly generate the
needed results. This section reviews the key components of the user interface and begins by
providing an overview of the typical window format for the Windows operating systems. Next,
functional descriptions are given of the different control types that are integrated into the program
screens and dialog boxes. Finally, printing and printer setup are discussed.
PC-PUMPs
For information on specific PC-PUMP features, refer to Part 3 of this User Guide which provides a
comprehensive review of all aspects of the software.
A typical window consists of a title bar, menu bar, status bar and display area. Program windows
from PC-PUMP are shown below.
Windows screen
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51
The title bar displays the name of the program as well as the current window. By dragging the title
bar, the entire window can be moved around on the desktop. If more than one window is open,
the title bar for the active window will have a different color than the other title bars.
The control-menu box is in the upper-left corner of the windows. It is activated with a single click
of the mouse and can be used to move, size and close a window. By double clicking the controlmenu box, you can close the current window.
The maximize and minimize buttons are located in the upper right-hand corner of each window.
The maximize button is the middle of three buttons. Clicking the maximize button enlarges the
active window so that it fills the entire desktop. When a window is enlarged, the maximize button
is replaced with a restore button. Clicking the restore button returns the window to its previous
size. The minimize button is the innermost of the three buttons. Clicking the minimize button
reduces the window to an icon on the task bar.
The menu bar allows the selection of menu commands from the current window. The following
are four ways in which menu commands can be chosen:
Click method. Click the menu name using the left mouse button. When the menu
drops down, click the desired command.
Click and drag method. Position the cursor on the menu name, press and hold the left
mouse button while you move the cursor down to the desired command, and then
release the button.
Access key method. The access key method requires no mouse action. Hold down the
Alt key while you type the underlined letter in the menu name, then type the underlined
letter in the command name.
Direction key method. The direction key method requires no mouse action. Press Alt
or F10 to choose the menu bar, then use the left and right arrow keys to choose the
menu desired. With the correct menu chosen, use the up and down arrow keys to
choose the desired command, then press Enter. The Esc key will back you out of the
menu selections one level at a time.
The large area below the title or menu bar of the window is the display area. This is where the
majority of the input and output is displayed.
Along the bottom of the window is the status bar. It displays information about computer
configuration settings as well as current status of the program.
Windows Control Types

Within the PC-PUMP screens and dialog boxes, there are several key Windows control types. These
include check boxes, command buttons, display boxes, drop-down list boxes, edit boxes, list
boxes, tab bars and toggle buttons. Descriptions of each of these follows:
Check Boxes
Check boxes are used to present options. You can select and deselect them with a single click.
When a check box is selected, it contains a check mark. Two such check boxes that appear in
PC-PUMP are shown below:
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PART 2: BACKGROUND
Check boxes
Command Buttons
Command buttons are used to initiate actions. For example, clicking a button may close a
window, open a dialog box or trigger a series of calculations. The currently selected button has a
border that is darker than the other buttons. You can choose the selected button simply by
pressing the Enter key. A number of command buttons from PC-PUMP are displayed below:
Command buttons
Display Boxes
These boxes are used to display information. They differ from the edit boxes described below in
that they you cannot type anything in them. When necessary, they will have horizontal and
vertical scroll bars to allow you to access all of the information. Several display boxes from
PC-PUMP appear below:
Display boxes
Drop-Down List Boxes

A drop-down list box appears initially as a rectangular box containing the current selection. When
you select the down arrow at the right of the list box, a list of available choices appears. If there
are more items than can fit in the box, scroll bars are provided. You choose the desired item by
highlighting it and then clicking it with the mouse or by scrolling to it with the up and down
arrows on the keyboard and then clicking the Enter key. Two drop-down list boxes in PC-PUMP are
shown below:
Drop-down list boxes
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53
Edit Boxes
Edit boxes, which are also referred to as text boxes, allow the direct entry of values. When you
move to an empty text box, an insertion point (i.e. flashing vertical bar) is displayed. The typed
text appears at the insertion point. Two edit boxes from PC-PUMP are shown below:
Edit boxes
List Boxes
A list box displays a list of choices. If there are more choices than can fit in the box, scroll bars are
provided so you can move rapidly through the list. Usually, you can select only one item in a list
box. However, in some cases, you can select multiple items. To select a single item, simply
highlight it. To select multiple items, select the first item and then drag the cursor to the last
desired item. Another method is to click the first desired item, press and hold down the Shift key,
and then click the last item you want. A third method is to click the first desired item, press and
hold down the Ctrl key, and then click any other items you want. Two list boxes that appear in
PC-PUMP are displayed below:
List boxes
Tab Bars
Tab bars allow you to switch the current window or dialog between different displays. They are
usually located on the bottom of the window and the desired display is selected by clicking on the
tab. When all of the tabs can not be displayed at once, scroll ears appear on the end of the tab
bar. When you click these ears, the tabs will be shifted in one direction or the other. One of the
tab bars in PC-PUMP is illustrated below:
Tab bar
Option Buttons
Option buttons represent a group of mutually exclusive options (that is, you can select only one
option at a time). If you already have an option selected, your current selection replaces it. The
selected option button contains a black dot. Two of the option buttons that appear in PC-PUMP are
shown below:
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PART 2: BACKGROUND
Option buttons
Charts
The majority of analysis results in PC-PUMP are shown using charts. You can use the following
features to help in evaluating the data presented in a chart:
1.
Clicking and holding down the left mouse button within the chart area provides a series of
crosshairs that move with the cursor to help in evaluating the data presented.
2.
Double-clicking the left mouse button on a data point displays the name of the data series
and numeric x and y values for the selected point.
3.
Clicking and holding the left mouse button on a chart boundary allows you to move the chart
boundary.
4.
Clicking the right mouse button once within the chart area provides a chart scaling dialog box
(shown below) that allows you to select the maximum and minimum values for each axis as
well as the spacing of gridlines.
Chart scaling dialog box
Printing
Most of the windows, dialog boxes and charts in PC-PUMP can be printed as displayed. In addition,
there are also several special summary reports. To obtain hard-copy output, you use either the
FilePrint command in the menu bar or the Print command button (where available). After
you have initiated a print job, the standard Print dialog box shown below will appear:
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PART 2: BACKGROUND
55
Printer dialog box
The initially selected destination is the default printer set in Windows. You can, however use any
printer or plotter that is currently installed and active in Windows. To specify a device for printing
or plotting, click the Setup... button to bring up the Print Setup dialog box displayed below:
Print Setup dialog box
From this window you can select from any of the currently active printers. The Options... button
provides access to the installed printers hardware parameters. These parameters will vary
depending on the selected printer.
The Print Setup dialog box also allows you to override the default paper orientation and select
paper size and source.
Print to PDF
A second option for printing (other than to the printer) is available. This is Print to PDF. Users
of PC-PUMP will now be able to print directly to PDF files. (This would only be possible before if a
third-party product was installed on the users computer.) PDF files can easily be sent
electronically to colleagues or clients, and this may be a more convenient method of sharing
PC-PUMP output than through paper copies.
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PART 2: BACKGROUND
In the File menu in PC-PUMP s System Configuration or Analysis windows, or in the Pump Options
menu of the Pump Selection Window, there is a new option, Print to PDF, immediately below
Print. When this is selected, the following window appears:
If OK is clicked on, the print-out will be sent to the specified PDF file. The check box Append
to File is available so that other print-outs can be sent to the same file. If Append to File is
turned on, PC-PUMP will add the current print-out to the specified file (if it exists). You will also be
able to print subsequent pages to the PDF file from other applications (e.g. Microsoft Word), as
well as from PC-PUMP. To do this, you must select PDF Compatible Printer Driver from the list
of printers available in the Print dialog box in the application. Note the first page in any PDF file
from this option must be printed from PC-PUMP.
Emailing PCP Files
You can email a PCP file to a colleague or client simply by using the FilePrint command.
PC-PUMP User Guide
3
Part
USING PC-PUMP
PC-PUMP can help you make better decisions regarding PC pumping system design and operation.
However, to use PC-PUMP effectively and to maneuver among its numerous windows, you should
first be familiar with the programs general layout and many features.
This part of the User Guide takes you through the general architecture of the program to acquaint
you with PC-PUMPs capabilities. It describes all of the available windows including their menus,
buttons, inputs and outputs. If you are a new user, a quick overview of this part of the Guide will
be helpful before you use the software. Conversely, if you are experienced with the software, this
section will be an excellent reference source on PC-PUMPs features.
For ease of use, this portion of the User Guide has been divided into the following three sections:
Section A: Getting Started - provides a general introduction to PC-PUMP and shows you how the
software can be customized by individual users.
Section B: Configuring the System - describes how to specify wellbore geometry data and select
equipment.
Section C: Analysing the System - describes how to specify fluid properties and operating
conditions, perform calculations and examine results.
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58
SECTION A: GETTING STARTED
Section A: Getting Started

The current version of PC-PUMP is configured around two primary modules:
System Configuration; and

Analysis.
Analysis Inputs
File
Edit
Analysis
Windows
Help
Inputs - Fluid Properties
Inputs - Operating Conditions
Single Phase
Multiphase
IPR
Equipment Case
Drive Location
Advanced Viscosity
Surface
Downhole
System Configuration
File
Edit
Equipment
Windows
Drive Location:
Pump Model
Calculation
Help
Standard
Surface
Surface
Equipment
Selection
Surface Equipment Specifications
Rod String
Selection
Rod String Specifications
Equip. Comp.
Equipment Cases
Pump Comp.
Configuration
Calculate
Batch Comp.
Analysis Inputs
Tubing / Casing
Selection
Analysis Outputs
Pump
Selection
Tubing/Tail Joint Specifications
Casing Specifications
File
Edit
Analysis
Windows
Summary Input Parameters:
Help
Summary Output Parameters:
Energy Flow
Drive Equipment
Wellbore Geometry
Wellbore Geometry Output
Rod Loads/Defl.
Pump Specifications
Rod/Tubing Contact
Basic Fluid Flow
Analysis
Multiphase Flow
Key Locations
Comparison Tables
Comparison Charts
Rod/Tubing Wear
Rod Fatigue
Backspin Analysis
Ouput Messages:
Configuration
Analysis Outputs
PC-PUMPs primary modules
An assessment with PC-PUMP typically consists of:
inputting the wellbore geometry and selecting the equipment within the System
Configuration module;
moving to the Analysis Inputs window and specifying the fluid properties and operating
conditions;
performing a calculation and examining the results in the Analysis Outputs window; and
moving back and forth between the primary modules changing equipment and
conditions to optimize system design and operation.
PC-PUMP can be used to perform a wide range of assessments related to PC pumping system design
and operation. To use PC-PUMP effectively, you must know what information you need and how to
enter it in order to get the results you require.
PC-PUMP User Guide
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59
To satisfy a diverse group of users, PC-PUMP was developed with numerous process paths. These
paths range from relatively simple to quite complex. An example of a simple assessment would be
an evaluation of an existing well to examine the impact of a tubing head pressure increase on rod
string loading. In this case, only the existing downhole equipment configuration as well as the
operating conditions need to be specified to examine the maximum rod stress. Such an evaluation
could likely be completed in a few minutes. In contrast, designing a new horizontal well might
require evaluations of several well geometries, numerous equipment configurations and a range of
operating scenarios. To address all of the design considerations and determine an optimal system
could take several hours.
In preparing to use PC-PUMP (particularly for the first time), you should first assess your situation by
asking yourself the following questions:
What input data and constraints do I have?

What am I trying to determine/evaluate?
To what degree do I need to optimize the system performance?
It is inappropriate to evaluate every aspect of a PC pumping system in most cases, and attempts to
do so will also likely lead to frustration as you try to locate all of the necessary inputs. In
undertaking an assessment, you should only determine what you need and only to the degree of
accuracy to which you need it.
There is, however, a minimum set of information that you must provide PC-PUMP to complete the
most fundamental analysis. This minimum requirement includes specifying the following items:
rod string (surface drive cases), tubulars, and pump;

pump seating and mid-perforation depths;
single-phase fluid properties; and
standard operating conditions.
Any supplemental analysis must consequently be supported by the appropriate input conditions.
For more advanced analysis or additional output requirements, you may be required to provide
the otherwise optional input for:
wellbore geometry;
pump test data;
prime mover and power transmission equipment;
multiphase fluid properties;
fluid thermal properties;
inflow performance relationship (IPR);
rod string installation space-out temperature;
rod string/tubing wear correlations;
rod string fatigue loading parameters; and
brake and drive system characteristics for backspin analyses.
The flow chart shown below summarizes the input requirements for PC-PUMP.
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Multiphase Fluid
Properties
Inflow Performance
Relationship (IPR)
Tubulars and Pumps
Single-Phase Fluid
Properties
Standard Operating
Conditions
Wellbore Geometry
Fluid Thermal
Properties
Drive Equipment*
Calculation
and
Results
Minimum Data Input
* Drive equipment is required in downhole drive configuration
PC-PUMP input requirements
Throughout the remainder of this part of the User Guide, information will be presented to you with
graphics displays replicating the on-screen windows. As the discussion proceeds, you will be
continually guided along through the various windows and flow paths of PC-PUMP. During this
time, you will be shown how to specify input data as well as how to review results. In this manner,
the inner workings and interrelationships of PC-PUMP will be demonstrated to you.
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Starting the Program

If you have installed PC-PUMP according to the instructions in Part 1 of this Guide, a PC-PUMP
program group should be located in the Start Menu. Note that in order to use the software, you
must have the Hardlock properly installed.
When you start the program, a PC-PUMP title screen similar to that shown below should appear on
your screen. The version number of the software appears in the circle near the middle of the
image. In the bottom portion of the screen, information will appear as to the licensed company
name and associated serial number. This information is read by the program from your Hardlock.
To continue to the main program windows, click anywhere on the title screen.
PC-PUMP title screen
After you close the title screen, you will be in the System Configuration window. From here you can
set program preferences, as shown in the next sub-section, or proceed directly to configuring a
PCP system, as is discussed in Section B.
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Setting Program Preferences

PC-PUMP provides you with the flexibility to customize several aspects of the program. This is done
through the Preferences dialog which you can access from the System Configuration window using
the EditPreferences menu option. Tabs on the bottom of the Preferences dialog move you
between its various sections that are described below. You have the ability to set program
preferences for paths, program fonts, chart fonts, units and defaults. Once you have made any
desired changes, clicking the OK button will return you back to the original window and activate
any changes. Selecting the Cancel button will return you back without making any changes to
your preferences settings.
Note: Your program preferences are stored in the PCPV26.INI file and will be used whenever
you run the program.
Paths
The Paths portion of the Preferences dialog, shown below, allows you to specify the location of
program databases and saved files. You can either type in paths directly or use the Browse button
to search through your directory structure until you locate the desired path. The following paths
can be specified within the Preferences dialog:
Saved Files: Default location of any data files you save.

Equipment Databases: Location of the PC-PUMP equipment database files. If moved, the
new location of the database files must be specified here for the program to operate
correctly.
Wellbore Geometry Files: Default location of any wellbore geometry files that are
imported or exported.
Custom Equipment Databases: Location of any custom equipment models you create.
Equipment Test Data Files: Default location of any saved equipment test data files,
such as pump tests and motor tests.
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Preferences paths
Program and Chart Fonts

The Program Fonts and Chart Fonts portions of the Preferences dialog allows you to customize
PC-PUMPs display and printing.
The following fonts can be specified within the Program Font portion of the Preferences dialog:
Screen Fonts - Spreadsheets: Font that is used in all of the imbedded spreadsheets
Screen Fonts - List Boxes: Font that is used in all of the programs list boxes.
Screen Fonts - Main Display: Primary display font for all windows and dialogs.
Printer Fonts - Main Printing: Primary font that is used in printed output reports.
Printer Fonts - Headers and Footers: Font that is used for the headers and footers in
any printed report.
Similarly, the fonts listed below can be designated within the Chart Font portion of the
Preferences dialog:
Large Chart Fonts - Main Title: Main title font for all large (full screen) charts.
Large Chart Fonts - Axis Titles and Legend: Font used for axis titles and legend on
large (full screen) charts.
Large Chart Fonts - Axis Labels: Font that is used for axis labels on large (full screen)
charts.
Small Chart Fonts - Main Title: Main title font for all small (imbedded) charts.
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Small Chart Fonts - Axis Titles and Legend: Font used for axis titles and legend on
small (imbedded) charts.
Small Chart Fonts - Axis Labels: Font that is used for axis labels on small (imbedded)
charts.
Preferences program fonts
You can change fonts for a given field by clicking its corresponding Font button. You can then
choose a specific font type and size from the selection box that appears (shown below). Although
there is also an input for font style, it will be overwritten by the main program. The font types and
sizes available within the font selection box are the Windows fonts currently installed on your
computer.
In some cases, the selected font type/size combinations may not display or print correctly because
specific portions of text are too large to fit into their assigned region. Whether or not a certain
font will display correctly, will depend on the display resolution in which you are operating. The
on-screen appearance of the selected fonts will be shown in the sample section of the font
selection box as well as in a box in the Preferences dialog. When making font type selections,
keep in mind that true type fonts are scaleable and offer a wider range of sizes.
During original program installation, default fonts are set based on your display resolution. In
order to make them applicable to all systems, these defaults are based on the fonts shipped with
the basic Windows software. It would be wise to make a note of the existing values before
making any changes to these, in case you need to restore them later.
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Font selection box
Units
The Units portion of the Preferences dialog allows you to customize the programs display units.
The Units screen shown below lists numerous categories which can be individually set to either SI
or Imperial units. The headings of the two groups are buttons which allow you to set all of the
categories to either SI or Imperial units with a single click. Once a selection has been made, all
future screen displays and reports will follow the new convention.
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Preferences unit selection
Defaults
The Defaults portion of the Preferences dialog allows you to specify default values for the
following program parameters:
PC-PUMP User Guide
Pump Friction (Static): Mechanical frictional torque in the pump. If a pump test is not
specified, this constant value is combined with the hydraulic torque to determine the
total pump torque.
Volumetric Efficiency (Static): The volumetric efficiency of the pump. If a pump test is
not specified, this constant value is used to calculate the fluid rate from the pump speed
or vice versa.
Gas Specific Gravity: Specific gravity (relative to air at standard conditions) of the
produced gas.
Water Specific Gravity: Specific gravity (relative to water at standard conditions) of the
produced water.
Sand Specific Gravity: Specific gravity (relative to water at standard conditions) of the
produced sand. (This refers to the relative density of a sand grain, not a quantity of sand
grains that has porosity.)
Tubing Roughness: Average absolute wall roughness of the tubing and tail joints. Used
in frictional pressure loss calculations. Note that a value of 0.1829 mm (0.0006 ft.) is
recommended for downhole oilfield applications46.
69
Free Gas Separation (intake above perfs): Percentage of free gas at either the pump, tail
joint, or shroud intake that is separated and diverted up the casing/tubing annulus.
Used in multiphase flow calculations to determine the annular and tubing gas rates. For
natural separation, a value of 30-60% is recommended45. This value is used when the
pump, tail joint, or shroud intake is above the perforations.
Free Gas Separation (intake below perfs): Similar to the value above, except that this
value is used when the pump, tail joint, or shroud intake is below the perforations. The
default value here when PC-PUMP is installed is 100%--this means that any free gas at the
perforations is assumed to go up the casing. In some cases (e.g. if the clearance between
the tubing and casing is small, causing high flow velocities which can pull gas down) a
value less than 100% may be appropriate.
Power Supply Frequency: Frequency of input supply power. Typically 60 Hz in North
America and 50 Hz in Europe and South America. Used in electric motor calculations.
Supply Voltage: Line-to-line voltage of input power. Used in surface prime mover
calculations.
Energy Cost: Unit power cost. Used in daily energy cost calculations. The currency
unit is defined through the Regional and Language Options Tool in the Microsoft
Windows Control Panel. Note that the currency unit is replaced, not converted, when
opening a file saved using a different currency unit.
Gas Specific Heat: Specific heat of produced free gas. Used in heat transfer calculations
for multiphase flow.
Kelly Bushing Offset: The vertical distance between the drilling rigs Kelly Bushing and
the wellhead.
For most of these parameters, the default value only represents an initial value and changes can be
made to the parameter within other program windows. However, for the gas specific heat and
tubing roughness parameters, the Preferences dialog is the only place where they can be set.
Changes made to the default values and switches become active once you exit the Preferences
dialog using the OK button. However, changes in the values will not be reflected in any of the
PC-PUMP output until after you have recalculated the results.
During original program installation, the defaults are set to:
Pump Friction (Static): = 108 Nm (80 ftlbs)

Pump Volumetric Efficiency = 100%
Gas Specific Gravity = 0.70
Water Specific Gravity = 1.00
Sand Specific Gravity = 2.65
Absolute Pipe Wall Roughness = 0.1829 mm (0.0006 ft.)
Free Gas Separation (intake above perfs) = 40%
Free Gas Separation (intake below perfs) = 100%
Supply Frequency = 60 Hz
Supply Voltage = 460 V
Energy Cost = 0.050 $/kWh
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Gas Specific Heat = 1.85 kJ/kgK

Kelly Bushing Offset = 0 m
Note that there are also three check boxes on the Defaults tab. The first, Use Rod String in Flow
Calculations should normally be turned on. If it is turned off, the effect of the rod string,
including any couplings or rod guides, on the flow losses will not be considered. This normally
only used if you want to simulate a downhole drive system without actually entering downhole
drive equipment. Note that if you do this, you still need to enter a rod string. PC-PUMP will print an
output message for every calculation where this option is turned on.
The next check box, Use User Path For Default File Save/Load Path is normally turned off.
When it is turned off, the File Open and File Save dialogs will always default to the directory
which was last used to open or save a file. When it is turned on, these dialogs will always default
to the path specified in the Paths tab of the Preferences Window.
The final check box, Display Output Messages After Calculate controls the feature whereby the
Output Messages appear in a separate window which must be clicked on to acknowledge the
messages after each calculation. If you dont like this feature, you can turn it off here. If it is
turned off, the Output Messages are still available for viewing. Note that some important
messages can be displayed as Output Messages, and you should always read them, whether or not
you decide to turn this feature off.
Preferences default values and switches
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Correlations
The final tab in the Preferences dialog is for selecting default multiphase fluid properties
correlations. There are five properties for which you can select a correlation. These are:
Dead Oil Viscosity: The viscosity of the oil with no dissolved gas in it.
Live Oil (Saturated) Viscosity: The viscosity of the oil when fully saturated with gas (i.e.
below the bubble point).
Undersaturated Oil Viscosity: The viscosity of the oil when containing some gas, but
not fully saturated with gas (i.e. above the bubble point). This should always be between
the dead oil and live oil viscosities.
Solution GOR: The amount of gas in solution in the oil.
Bubble Point: The pressure at which gas starts to come out of solution in the oil.
The dialog is shown below. The correlations shown are the defaults when PC-PUMP is installed.
These can be changed in this dialog, so the selected correlations will be used by default in all future
cases, or they can be changed in each individual case, using a similar dialog box to be described
later.
Default Correlations
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On-Line Help
To make using PC-PUMP easier, an electronic copy of this User Guide is installed with PC-PUMP. You
can open the on-line copy of the manual at any time within PC-PUMP by pressing the F1 key or
using the HelpPC-PUMP Help menu item. Acrobat Reader has its own help page which you
can access through the HelpReader Online Guide menu item within Acrobat Reader. When
you first open the on-line manual, it will start at the title page. On the left side of the screen is a
table of contents (if the Bookmarks tab is selected). This table is expandable; to see subsection
headings within each section, click on the + symbol beside a title. In some cases there are two
or even three levels of headings nested inside one another. The figure below shows the Acrobat
Reader with some items on the table of contents expanded.
Acrobat Reader
Note that you can use the mouse to change the width of the table of contents, if some of the titles
are obscured. If you click on any title in the table of contents, that section of the manual will be
displayed. A useful feature of the Acrobat Reader program is its find utility. You can access this
by clicking on the binocular icon, or though the Edit menu in Acrobat Reader, or by pressing
Ctrl-F. This utility allows you to search for text within the User Guide.
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SECTION B: CONFIGURING THE SYSTEM
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Section B: Configuring the System

Once you have established your input data/constraints and have determined your output
requirements, you are ready to actually use PC-PUMP. The starting point for most of your
assessments will be the System Configuration module. In this portion of the program, you specify
wellbore geometries and select equipment. You can also setup equipment cases and save and
restore data files.
Analysis Capabilities
PC-PUMP Version 2.67 has been designed to model both conventional surface drive and downhole
drive PCP systems. The downhole drive analysis capability is available as an add-on module that
must be purchased separately. The downhole drive analysis module functions similarly to the
surface drive module. Descriptions in this Guide cover both drive types.
System Configuration
System Configuration is one of the two primary modules in PC-PUMP. When you first start the
software you will arrive at this portion of the program after the title screen. The System
Configuration window serves as the main window for accessing and entering information about the
wellbore, and downhole and surface equipment. Buttons on the schematic on the left side of the
window lead to individual equipment selection windows. When you return from these areas,
summaries of the selected equipment are displayed in an adjacent portion of the main screen. Any
equipment selection window may also be accessed by clicking on the button above the
corresponding summary box. In the lower left-hand corner of the window, another button
provides access to the Wellbore Geometry portion of the program. Information on the currently
specified wellbore is listed in a box below this button. An area in the upper right-hand portion of
the window allows you to setup equipment cases for analysis. In the bottom of the window, there
are three edit boxes in which you must input the pump seating depth (i.e. bottom of pump), the
mid-perforation location, and the Kelly Bushing Offset. The Kelly Bushing Offset is the vertical
distance between the drilling rigs Kelly Bushing and the wellhead. All measured depths in
PC-PUMP are measured relative to the Kelly Bushing; if this is not right at the wellhead, the offset
must be entered. The large Analysis button in the lower right-hand corner of the window moves
you to the Analysis module.
The appearance of the System Configuration window changes with the type of drive system selected.
The System Configuration windows for surface drive and downhole drive modes are shown below.
These windows provide you with access to all of the other windows and dialogs in the module.
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System Configuration windows for surface drive (top) and downhole drive (bottom)
To switch between the surface drive and downhole drive analysis modes, you can toggle the
Drive Location button at the top of the System Configuration window between Surface and
Downhole. Note that the rod string summary disappears when the downhole drive version of
the window is active.
The menu bar for the System Configuration window is shown below. The File menu allows you to
save and restore files as well as print the System Configuration report. The Edit menu allows you
to access the Preferences dialog. The Equipment menu provides access to the various equipment
dialogs. The Window menu allows you to move between PC-PUMPs main windows.
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System Configuration menu bar
Printing System Configuration Reports
PC-PUMP creates a Wellbore Diagram report that can be printed by selecting the FilePrint menu
command while in the System Configuration window. This report includes summary information on
all selected equipment as well as the wellbore geometry (if specified). Note that the report will
only contain the current equipment case. If you have not entered a well name in the Project
Information dialog (described below), you will be prompted for the well name before you print.
An alternative report is the System Configuration report (this was used instead of the Wellbore
Diagram in versions of PC-PUMP up to V2.61, and is still available for those who prefer it). This can
be printed using the EditEquipment Summary menu command. A sample of a System
Configuration report is included in Appendix B. You can also print the Wellbore Diagram to a
PDF files by selecting FilePrint to PDF.
Saving and Restoring Data Files

PC-PUMP allows
you to save and restore your assessments in the form of data files. A single saved
file will contain all of your input information including wellbore profile data, equipment
specifications, fluid properties and operating conditions.
To save a data file, select the File Save menu command or press CTRL-S on the keyboard, and
enter a filename to use. If the file has previously been saved, PC-PUMP will use that file name. File
Save As can be used for two purposes: to store an existing file under a new name, or to save a
file in a format compatible with an older version of PC-PUMP, using the drop down box labelled
Save as type. The default file extension .pcp is recommended, so that PC-PUMP can recognize the
file as a PC-PUMP data file.
To open a data file, use the File Open menu command and select the desired file name. Once
you press the OK button in the File Open dialog box, the information will be loaded and PC-PUMP
will load all of the wellbore, equipment, fluid properties and operating conditions that were saved.
Backwards Compatibility
PC-PUMP V2.67
is backwards compatible to V2.0, meaning V2.67 can open data files saved by all
previous versions after V2.0. The substantial differences in both the program and the data
structure do not allow V2.67 to open old V1.0 and V1.1 data files.
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Previous versions of PC-PUMP are unable to open V2.67 files. However, data files can be saved in a
format that is compatible with previous versions using the File Save As menu command and
selecting the appropriate version using the drop down box labelled Save as type. Note that data
files stored in an older version format will not contain features specific to V2.67.
Save as type drop down box
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Specifying Project Information

If you wish to save project details in your working data files and on your printed output reports,
you can do so using PC-PUMP's Project Information window. The window can be accessed by selecting
the Edit - Project Information menu command.
Project Information window
The following fields are available for specifying project information:
Project Name - The name of the project you are working on. The information in this
data field will be printed as the center header on every output report printed from
PC-PUMP when you are using the active file.
Created By - The person or company who created the PC-PUMP data file.
Modification Date - The date of the latest modifications to the data file. This data field
is automatically filled in by the program.
Comments - Any other information you wish to attach to the file.
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Specifying a Wellbore Geometry

When assessing a directional well, it is important to have an accurate representation of its wellbore
geometry. During drilling, or in some cases after the well has been completed, a directional survey
is obtained for these wells. These surveys consist of a series of measured depth, hole angle and
azimuth measurements taken from surface to the bottomhole location. By processing this survey
data using a standard calculation procedure (see Technical Considerations-Wellbore Geometry),
an array of parameters that characterize a wells directional profile can be generated.
Within the Wellbore Geometry portion of PC-PUMP, you can input, process and display either
existing or proposed directional well geometries. As illustrated in the flowchart below, this is
accomplished through a main window and several dialogs. The following sub-sections show you
how to use the Wellbore Geometry window, input directional surveys and proposals and view the
wellbore profile information.
Note: You can bypass this portion of the program when assessing vertical wells.
Wellbore Geometry
File
Edit
Wellbore
Window
Design

Wellbore Geometry Charts
Help
Charts
Summary
MD vs DS
MD vs HA
MD vs AZM
Plan View
Well Design Mode
Summary
OK
Wellbore Geometry portion of PC-PUMP
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Charts
OK
Vert. Sect. Curv. Comp.
83
Wellbore Geometry Window
To access the wellbore geometry portion of PC-PUMP, click the Wellbore Geometry button in the
lower left-hand corner of the System Configuration window. The main Wellbore Geometry window
shown below will appear on screen.
Main Wellbore Geometry window
The main Wellbore Geometry window is comprised primarily of a large survey spreadsheet. In
this spreadsheet, parameters to the left of the solid dividing line represent input parameters while
those to the right are calculated parameters. Above the left-hand side of the spreadsheet is a
description box in which you can type comments that will be included in any printed output. At
the top of the spreadsheet on the right-hand side are the Well Design, Charts and Summary
buttons that allow you to access the other wellbore geometry dialogs and the Calculate button
which calculates the survey data from the inputs parameters.
The menu bar for the main Wellbore Geometry window is shown below. The File menu allows
you to print the Wellbore Geometry Summary report. Through the Edit menu, you can insert,
delete and clear data in the survey spreadsheet. The Wellbore menu provides access to the
Wellbore Design, Charts and Summary dialogs as well as file import and export capabilities. The
Window menu allows you to switch between the main PC-PUMP program windows.
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Wellbore Geometry menu bar
The buttons and menu items pertaining to wellbore geometry are described in the following subsections.
Inputting Directional Surveys & Proposals

You can input directional well profile information into
methods:
PC-PUMP using
any of the following three
manual entry;
copy/paste from a spreadsheet;
survey file import; and
Well Design mode.
For an existing well, the directional survey information can be either input manually or imported
provided that it exists in a suitable format. For proposed wells, you can use the Well Design mode
to create directional proposals.
Manual Entry
To enter data manually, type the directional survey information directly into the spreadsheet in the
main Wellbore Geometry window. Starting at 0 mKB/ftKB, input the measured depth, hole
angle and azimuth values for each survey station.
Measured depth values must be entered in sequence from top to bottom. Hole angle values must
be expressed as decimals. For example, a hole angle in degrees and minutes (e.g. 3030) must be
converted to its decimal equivalent (e.g. 30.5). Similarly, azimuth values must be entered as
decimal values measured clockwise in degrees from the true north (0) position. For example, a
bearing of N3015W must be entered as 329.75. Once you have entered the desired survey data
into the spreadsheet, click the Calculate button in the upper right-hand corner of the window to
update the survey spreadsheet with the additional calculated wellbore geometry parameters.
To change any of the input data, select the specific cell and enter a new value. Survey stations can
be deleted by highlighting their corresponding rows and using the EditDelete menu command.
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Up to 100 rows can be entered manually. Closing and re-entering the Wellbore Geometry
window will automatically add an additional 100 blank rows for manual entry. Blank survey
stations can be inserted at any point by selecting the row below the desired insertion point and
selecting the EditInsert menu command. The EditClear All menu command clears all of
the data from the spreadsheet. Following any data revisions, you must click the Calculate button
to update the survey spreadsheet.
Copy/Paste
You can copy survey data from a spreadsheet, such as Microsoft Excel, and paste it into PC-PUMP.
Copy only the cells containing the three input parameters (measured depth, hole angle, and
azimuth), and paste them into the spreadsheet in PC-PUMP, using Ctrl-v.
Survey File Import

You can import directional survey data directly into the wellbore geometry spreadsheet, provided
that it has either been previously exported or is available on disk in a format that PC-PUMP can read.
This survey file import is completed using the WellboreImport Wellbore menu command and
selecting one of the available formats. PC-PUMP currently supports the following import formats:
PC-PUMP: Reads PC-PUMP V1.0 and V1.1 saved wellbore files as well as PC-PUMP V2.x
exported wellbore files.
Text Delimited: Reads files that are in text delimited format. The first line must contain
the file description, the second line the word SI or IMPERIAL (capital letters must be
used) to indicate the corresponding units, and the subsequent lines the measured depth,
hole angle and azimuth values of successive survey stations. The figure below illustrates
the correct data format.
Example of ASCII Text Import Format
IMPERIAL
0
0
30
0
60
0
90
0.5
120
2.1
150
4.2
180
6.8
210
8.4
240
10
270
10.7
300
11.3
0
85
85
84
83
83
82
82
82
81
80
Text delimited import format
Well Design Mode

Actual directional survey data is not available when either designing a new well or evaluating a
proposed well. In these situations, you can use PC-PUMPs Well Design mode to create directional
survey data for these wells. The Well Design dialog is accessed from the main Wellbore
Geometry window either through the WellboreWell Design menu command or by clicking
the Well Design button.
Within Well Design mode, you can construct directional wellbores using a series of discrete
segments. For each segment, enter a length, build rate and plan curvature into the spreadsheet.
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Positive build rates correspond to a wellbore that is increasing angle while positive plan curvature
corresponds to a wellbore that is moving left to right in plan view. Values of zero may be
specified for build rate (for a vertical or tangent segment) or plan curvature (i.e. for a segment
straight in plan). In the case of a slant well, an initial hole angle can be input in the upper left-hand
portion of the Well Design dialog. An initial azimuth can also be specified. An example of typical
well design data is shown below.
Well Design mode dialog - data display mode
When you click the Calculate button located in the upper right-hand corner of the dialog, each
segments measured depth, hole angle, azimuth, dogleg severity, vertical depth, horizontal distance,
latitude and departure is computed and displayed. Note that, with the exception of the dogleg
severity, these are all cumulative values. A row at the bottom of the spreadsheet labelled Final
shows the values at the bottom of the specified well.
You can also examine the designated well profiles graphically by toggling the display mode at the
top of the Well Design dialog. This will result in the spreadsheet being replaced by both the Plan
View and the Vertical Depth vs. Horizontal Distance charts, as illustrated below.
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Well Design mode dialog - chart display mode
Well design inputs can be modified by selecting the specific cell and entering a new value. By
adjusting segment inputs, you can create a wellbore profile that has the desired target location. If
you want to clear the current well design and start over, click the Clear button.
A hard-copy Well Design report is available and can be printed by selecting the Print button. This
report contains the tabular input data as well as the two corresponding charts. A sample of a Well
Design report is included in Appendix B.
Once you have finalized a wellbore design, click the OK button. Based on your specified inputs, a
directional profile spaced at 10 m intervals is generated and you are subsequently transferred back
into the main Wellbore Geometry window. To abort your design and return to the main window,
click the Cancel button.
Viewing Wellbore Geometry Information

Once you have input a directional survey or proposal, you can view its corresponding wellbore
profile information in the:
Survey spreadsheet;
Wellbore Geometry charts; and
Geometry Summary Information dialog.
Survey Spreadsheet
The survey spreadsheet contains both the input and calculated wellbore geometry data. Each
survey station is represented by a row in the spreadsheet, with the uppermost location positioned
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at the top of the spreadsheet. If necessary, you can use the horizontal and vertical scroll bars to
move about the spreadsheet to access the full range of data. The following parameters are
displayed in the spreadsheet columns from left to right:
Station: Survey station number.

Measured Depth*: Cumulative length along the wellbore.
Hole Angle*: Inclination (drift angle) of the wellbore segment.
Azimuth*: Direction (drift direction) of the wellbore segment.
Dogleg Severity (Overall): Three dimensional curvature of the wellbore segment.
Dogleg Severity (Vertical): Vertical section curvature of the wellbore segment.
Dogleg Severity (Plan): Plan view curvature of the wellbore segment.
Hole Angle Change: Rate of hole angle change of the wellbore segment.
Vertical Depth: Cumulative vertical depth of the wellbore.
Horizontal Distance: Cumulative horizontal displacement of the wellbore.
Latitude: Horizontal distance in the north (+) and south (-)direction.
Departure: Horizontal distance in the east (+) and west (-) direction.
Vertical Section: Horizontal distance projected on a vertical plane defined by the
wellbores closure (final) azimuth.
Note: The asterisked (*) parameters represent the measured directional survey data (inputs). All
other parameters are computed based on this survey data using the minimum curvature
method. If any of the calculated values appear to be in error, you should verify the survey
data that you have entered. Small errors in measured depth, hole angle or azimuth can
result in large errors in the calculated parameters.
PC-PUMP
creates a Wellbore Geometry Summary report that can be printed by selecting the
FilePrint menu command while in the main Wellbore Geometry window. This report includes
a tabular output of the data in the survey spreadsheet as well as the geometry summary
parameters. A sample of a Wellbore Geometry Summary report is included in Appendix B.
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Wellbore Geometry survey spreadsheet
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90
Wellbore Geometry Charts

You can view the directional well data displayed in the survey spreadsheet in graphical form using
the Wellbore Geometry charts. To access these charts, click the Charts button in the upper righthand portion of the main Wellbore Geometry window. The Wellbore Geometry Charts dialog
containing the following eight charts will be displayed:
Measured Depth vs Dogleg Severity;

Measured Depth vs Hole Angle;
Measured Depth vs Hole Angle Change;
Measured Depth vs Azimuth;
Plan View;
Vertical Section;
Measured Depth vs Vertical Depth; and
Wellbore Curvature Components.
Tabs on the bottom of the Wellbore Geometry Charts dialog allow you to move between the
different charts. You can print the chart that is currently active (i.e. being displayed) using the
FilePrint menu command.
Wellbore Geometry Charts dialog
Geometry Summary Information

In addition to the detailed information displayed in the survey spreadsheet, PC-PUMP calculates
several other parameters related to wellbore geometry. This summary information is displayed in a
dialog that you can access by clicking the Summary button in the upper right-hand portion of the
main Wellbore Geometry window.
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91
The following parameters are based on the survey data and summarize the basic well geometry:
Average Survey Interval: Average distance between survey stations.

Final Azimuth: Azimuth at the bottom of the well.
Final Hole Angle: Hole angle at the bottom of the well.
Horizontal Offset: Total horizontal distance of well from wellhead.
Total Measured Depth: Total length of well.
Total Vertical Depth: Total vertical depth of well.
Maximum Dogleg Severity: Maximum wellbore curvature.
Location: The depth at which the maximum dogleg severity occurs.
Wellbore Geometry Summary Information dialog
Exporting Wellbore Geometry Files

Wellbore geometry data is stored as part of PC-PUMPs standard file saving procedure (see Saving
PC-PUMP files section). However, in some cases you may want to store the directional information
separately. Wellbore geometry data can be exported to disk files using the WellboreExport
Wellbore menu command and selecting one of the available formats. PC-PUMP currently supports
the following export formats:
PC-PUMP Format: Exports files in a PC-PUMP format. Only the input parameters
(measured depth, hole angle and azimuth) are included in the exported file.
Copy/Paste: It is possible to copy data from PC-PUMP using Ctrl-c, and paste it into a
spreadsheet such as Microsoft Excel.
Text Format: Exports files in ASCII text format. Both input and calculated parameters
are included in the file. The first line contains the file description, and the second line
contains titles for the information contained in the rest of the table. Included in the
table are the measured depth, hole angle and azimuth values of successive survey
stations. An exported Text Format file is shown below.
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[PC-PUMP Version 2.0 Wellbore Information]

Comment
Start
Hole AngleAzimuth OverallDogVerticalDoPlanDoglegHoleAngle VerticalDe Horizontal Latitude
<No Comment>
0
0
0
0
0
0
0
0
0
0
<No Comment>
10
0
0
0
0
0
0
10
0
0
<No Comment>
20
0
0
0
0
0
0
20
0
0
<No Comment>
30
0
0
0
0
0
0
30
0
0
<No Comment>
40
0
0
0
0
0
0
40
0
0
<No Comment>
50
0
0
0
0
0
0
50
0
0
<No Comment>
60
0
0
0
0
0
0
60
0
0
<No Comment>
64.6
0
0
0
0
0
0
64.6
0
0
<No Comment>
74.6
1
0
3
3
0
3 74.5995 0.087264 0.087264
<No Comment>
84.6
2
0
3
3
0
3 84.5959 0.34903 0.34903
94.6
3
0
3
3
0
3 94.5863 0.785219 0.785219
<No Comment>
<No Comment>
104.6
4
0
3
3
0
3 104.568
1.3957
1.3957
<No Comment>
114.6
5
0
3
3
0
3 114.537 2.18028 2.18028
<No Comment>
124.6
6
0
3
3
0
3
124.49 3.13872 3.13872
<No Comment>
134.6
7
0
3
3
0
3 134.426 4.27074 4.27074
<No Comment>
144.6
8
0
3
3
0
3
144.34 5.57599 5.57599
<No Comment>
154.6
9
0
3
3
0
3
154.23 7.05406 7.05406
<No Comment>
159.6
9.5
0
3
3
0
3 159.165 7.85777 7.85777
<No Comment>
169.6 11.1667
2 5.11378
5 1.07273
5 169.003 9.65093 9.65087
<No Comment>
179.6 12.8333
4 5.15254
5 1.24444
5 178.784 11.7275 11.7266
<No Comment>
189.6
14.5
6 5.19636
5 1.41498
5 188.501 14.0842 14.0797
<No Comment>
199.6 16.1667
8 5.24498
5 1.58424
5 198.144 16.7173 16.7036
Departure VerticalSec
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0 0.087264
0 0.34903
0 0.785219
0
1.3957
0 2.18028
0 3.13872
0 4.27074
0 5.57599
0 7.05406
0 7.85777
0.033796 9.65087
0.145069 11.7266
0.353414 14.0797
0.67805 16.7036
Full Data export format
Exiting Wellbore Geometry
Once you have selected a wellbore geometry, use the WindowSystem Configuration menu
command to move back to the System Configuration module. If you want to close the Wellbore
Geometry window before moving back to this module, use the close box on the menu bar. Note
that when you return to the System Configuration window after inputting a wellbore profile, its
summary parameters will appear in the edit box in the lower left-hand corner of the screen.
Should you decide not to specify a wellbore geometry (i.e. assume a vertical well), use the
EditClear menu command to first clear all of the spreadsheet data entries. You can then return
to the System Configuration module using either of the methods listed above.
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94
Selecting Equipment
PC pumping systems consist of a series of components in addition to the downhole pump.
Depending on the pumping application and the type of drive system in use, these elements can be
configured in a variety of ways. There are also many different types (i.e. manufacturers and
models) of each system component available.
Equipment selection is accomplished through several windows and dialogs in which you configure
individual system components. In most cases, this is done by choosing the desired equipment
from various selection lists. These lists are generated from PC-PUMPs extensive equipment database
and contain all of the specifications necessary for the subsequent computations. Note that the user
cannot enter or modify the equipment database information. However, the user may create
custom databases for pumps, surface brakes, and downhole drive equipment (described in this
section of the User Guide). Occasionally, equipment selection requires you to input additional
product specifications. For example, in the case of an electric motor for a surface drive system,
you must specify the motor power rating, number of poles, nominal efficiency and power factor,
and supply frequency and voltage.
PC-PUMP requires the specification of a minimum equipment set before any analyses can be
performed. All tubulars, the rod string (surface drive systems only), and the PC pump must be
properly selected before any assessments can be performed. Selection of system drive equipment
will enable several more related output windows in the Analysis module.
Specifying the pump seating and mid-perforation locations first (see the start of the System
Configuration section in this User Guide) usually makes it easier to arrange the other components.
Subsequently, it is recommended (although not necessary) that you select equipment in the
following order:
A. Surface Drive Systems
(1) Pump;
(2) Casing, tubing and tail joints;
(3) Rod string; and
(4) Surface drive equipment.
B. Downhole Drive Systems
(1) Pump;
(2) Casing, tubing and shroud;
(3) Downhole drive equipment.
In the following sub-sections, you will be shown how to select each of these major system
components for surface and downhole drive PCP systems.
Pumps
The key component in any artificial lift pumping system is the bottomhole pump. It strongly
influences the operation and performance of the system, and consequently has a significant impact
on all of the other system components. For PC pumping systems, there are numerous
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considerations related to pump selection. The most important of these include: required
pumping capacity; required lift; temperature and fluid compatibility issues; casing size limitations;
sand handling capabilities; pump inflow behavior; and torque and power limitations. To address
these issues, manufacturers offer a large number of different pump models that collectively cover
a wide range of specifications.
Within the Pump Selection section of PC-PUMP, you can view specifications of commercially
available PC pumps and then select pumps for use in evaluations. In addition, you can input and
analyse pump test information as well as use it to determine performance characteristics for
subsequent assessments. You can also create new pumps that can be added to your own custom
pump database by inputting relevant specifications.
To access the pump selection section of PC-PUMP, click the Pump button near the lower left-hand
side of the System Configuration window. This will bring up the Pump Selection window which is
shown below.
Main Pump Selection window
The main Pump Selection window allows you to select pumps, view their specifications and, if
desired, assign corresponding pump tests. Pump selection is accomplished through several list
boxes at the top of the window. Specifications are displayed on the left-hand side of the screen
and shown in graphical format on the right-hand side of the screen. An area in the lower left-hand
corner of the window allows you to assign pump characteristics either through static inputs or by
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association with a pump test. The menu bar for the main Pump Selection window is shown
below. The Pump Options menu allows you to print the Pump Selection Summary report and
provides access to the Custom Pump, Pump Test, Swell, and Variable Efficiency dialogs. The
Window menu allows you to move between the main PC-PUMP windows.
Pump Selection menu bar
The pump selection area appears at the top of the window. The first step is to choose a pump
vendor or custom pump database using the drop-down list box in the upper left-hand corner of
the window. Note that some vendors may be listed twice to accommodate both their new and old
pump model designations. Once a vendor or custom database is selected, the list box will then
display all of the pump models available from that vendor. If necessary, scroll bars will appear in
the list box to allow you to scroll through all of the models. To select specific pump models,
highlight their names and then click the Add button. The highlighted pumps will be added to
your list of currently selected pumps that are displayed in the list box at the top right corner of the
window. To remove pumps from your current selection, highlight them and then click the Delete
button. Note that your current selection is unlimited and can consist of pumps from several
different vendors or custom pump databases.
When you highlight one of the selected pumps, the window shows the corresponding
specifications including its nominal displacement, pressure rating and lift. In addition, the
scrollable list box to the left of the chart displays the rotor and stator connection type, pump
length, pump outside diameter, swept rotor angle and cavity inflow index. Descriptions of these
parameters follow:
PC-PUMP User Guide
Nominal Pump Displacement: Nominal pump displacement per revolution (RPM) per
day at zero differential pressure.
Pump Pressure Rating: Rated differential pump pressure.
Nominal Pump Lift: Rated pump lift in terms of equivalent vertical head of water.
Rotor Connection: Connection on the rotor head for attachment to the rod string.
(This will still be shown if you have selected a downhole drive system.).
Stator Connection: Connection on the top of the stator for attachment to the tubing
string.
Pump Length: Total length of the pump not including tag bar/stop bushing assemblies.
Pump Outside Diameter: Maximum outside diameter of the pump.
97
Swept Rotor Angle: Angle of the rotor helix. (At lower swept rotor angles, the rotor
applies more force along the pump axis than it does circumferentially, thus providing
more effective cleaning of solids from the cavities.) This is not available for multilobe
pumps.
Cavity Inflow Index: Velocity of fluid flow through the pump cavities per 100 m3/day
production. (This index is a measure of the ability of fluids to flow into the pump
intake, with lower values indicating potential for improved viscous fluid inflow.) This is
not available for multilobe pumps.
The main Pump Selection window also contains a performance chart that can be switched
between three different formats using the Chart Type option buttons. The first format (Fluid
Rate) shows nominal fluid rates as a function of pump speed for several volumetric pump
efficiencies. The second format (Shaft Power) displays shaft power as a function of pump
differential pressure for several pump speeds. These charts can be changed between low (0 to
300 RPM) and high (0 to 600 RPM) pump speeds using the Speed Range option buttons. The
third format shows torque as a function of pump differential pressure.
Pump bench tests are almost always completed to quantify the performance characteristics of new
and used pumps (see Technical Considerations-Pump Testing). Based on these empirical tests,
values are usually determined for pump efficiency and pump friction over a range of operating
conditions (speeds, pressures and temperatures). These parameters have a significant impact on
pump and overall system performance. When performing assessments with PC-PUMP, you have the
option of specifying static values for these parameters or inputting pump test information from
which they can be calculated dynamically based on the specified operating conditions.
To input or change the static values, use the edit boxes in the lower left-hand corner of the
window. Note that when a new pump is selected, these parameters are assigned values based on
the defaults you have set in the Preferences window. In order to have volumetric efficiency and
friction torque values assigned dynamically, you must choose a pump test using the drop-down list
box. All of the tests associated with the currently selected pump model will appear in this list box.
The process for inputting, processing, viewing and saving new pump test information is described
in the next section.
Once you have selected all the pump models that you want to analyse as well as any corresponding
pump tests, use the WindowSystem Configuration menu command to move back to the
System Configuration module. If you want to close the Pump Selection window and move back to
this module, use the close box on the menu bar. When you return to the System Configuration
window, the pumps that you selected will be available in the pump drop-down list box at the
bottom centre of the screen. In addition, whichever pump you had highlighted when you left the
Pump Selection window will be selected in this list box. The pumps nominal displacement and
pressure rating will also be displayed in the display box below the pump list box.
A filtering feature in the pump selection window allows the user to see a list of only those pumps
which meet certain criteria. There is a Filter button and check box in the window. When the
Filter button is clicked on, or when the check box is turned on, the following window will appear:
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Enter the desired range of displacement and pressure rating. For convenience, PC-PUMP will
remember the settings you input. If a pump seating depth has been entered and casing has been
specified down to the pump seating depth, you will also have the option of selecting the Fit
pump to specified casing diameter check box. After you click on OK, only those pumps which
meet the filter criteria will be displayed in the Pump Selection area of the window. If a pump
vendor does not have any pumps meeting the filter criteria in the PC-PUMP database, then the
vendor will not appear in the Pump Selection drop-down box. The filtering can be turned off by
turning off the check box, and then all the vendors and pumps will once again be available.
Note: Filtering does not affect any pumps which you have already selected. They will still be
selected, even if they dont match the filtering criteria.
Variable Efficiency
A progressing cavity pump does not operate at a constant volumetric efficiency when in operation
downhole. As the differential pressure across the pump increases, the volumetric efficiency
decreases, and as the speed increases, the volumetric efficiency increases. In versions of PC-PUMP
before V2.55, the volumetric efficiency was entered either as a constant value, or using a bench
test. The constant value assumes that the user can predict the downhole efficiency of the pump.
(This could involve some iterationfor example, the user can enter an efficiency, and adjust it on
subsequent runs until it matches what he would expect at the given speed and differential
pressure.) Bench test results are normally from tests in water for short periods of time. This
means that they may be less accurate for oil, especially after the elastomer has undergone swelling
after being in the well for a period of time.
In the pump selection window, you can select Variable Efficiency from the Pump menu. The
window below will open:
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Variable Efficiency Window
You can decide if you want the pumps volumetric efficiency to be varied by differential pressure
or speed, or both together. Which inputs are required depend on which mode is selected. If
differential pressure is selected, you need to enter efficiencies at zero pressure, rated pressure, and
at some point in between. If speed is selected, you need to enter the speed at which the entered
efficiency (or efficiencies, if differential pressure is also selected) is valid. Click on Calculate, and
the efficiency curve will appear on the Output Graph. If speed is selected, you have the option of
displaying an efficiency curve at a second speed.
An example is shown below:
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Variable Efficiency Window with Data
Once you have entered an efficiency curve, you have a choice of whether or not you wish to use it,
or instead simply choose a constant efficiency. To turn off the variable efficiency feature, use the
check box labelled Use variable efficiency definition. You can also turn off this feature in the
Analysis window by clicking on the button labelled Pump Model. The following window
appears:
Pump Characteristics Window, in the Analysis Window
By turning off the check box under Variable Efficiency, you can revert to a constant efficiency
value.
Inputting Pump Test Information

The Pump Test Information dialog is accessed from the main Pump Selection window using the
PumpPump Test Information menu command. Within this window, shown below, you can
input, process, view and save pump test information.
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Pump Test Information dialog - data display mode
At the top of the Pump Test Information dialog, the pump model shown will be the one that was
highlighted when you accessed the dialog from the main Pump Selection window. In the box
directly below the pump model, all of the pump tests associated with the selected pump model
and stored in your default pump test directory (as specified in Preferences-Paths) will be displayed.
To select a specific pump test, highlight its name. This will result in the dialog being updated to
show the corresponding pump test information.
To create a new pump test, click the New File button. This will bring up a dialog box into which
you must enter a pump test name. Although a file name is automatically created, you can modify
it within the lower edit box. After you have entered the new test name, click the OK button and
you will be returned to the Pump Test Information dialog along with a blank pump test
spreadsheet.
To enter pump test data, type the corresponding values directly into the spreadsheet. For each
test point, you only need to input the pump speed, differential pressure, total torque and
volumetric efficiency values. To change or correct any of the input data, select the specific cell and
enter a new value. The Clear button at the bottom of the dialog clears all of the data from the
spreadsheet.
Once you have entered the desired data into the spreadsheet, click the Calculate button on the
bottom of the screen to update the spreadsheet with additional calculated parameters. Note that
the data points are automatically sorted by increasing speed and differential pressure. If necessary,
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you can use the horizontal and vertical scroll bars to move about the spreadsheet in order to
access the full range of data. The following parameters are displayed in the pump test spreadsheet
columns from left to right:
Pump Speed*: Pump test speed.

Differential Pressure*: Pump differential pressure.
Total Torque*: Total measured pump torque.
Volumetric Efficiency*: Volumetric pump efficiency determined based on the nominal
pump displacement.
Fluid Rate: Fluid rate.
Fluid Slippage: Rate of fluid leakage across the rotor/stator seal lines.
Adjusted Volumetric Efficiency: Volumetric pump efficiency determined based on the
calculated actual pump displacement at zero differential pressure.
Hydraulic Torque: Torque required by the pump to produce the measured fluid rate
across the differential pressure.
Friction Torque: Pump torque used to overcome the mechanical rotor/stator friction as
well as hydraulic losses within the pump.
Effective Power: Quantity of power required to generate the hydraulic torque.
Actual Power: Total power required to rotate the pump.
Total Efficiency: Total mechanical efficiency of the pump.
Note: The asterisked (*) parameters above represent the input parameters. All other parameters
are computed based on this input data using the assumptions discussed in Technical
Considerations-Pump Testing. If any of the calculated values appear to be in error, you
should verify the data that you have entered.
In addition to the parameters calculated and displayed in the spreadsheet, PC-PUMP also outputs
several summary parameters in the list box below the spreadsheet. Included in this area are the
following parameters:
Actual Pump Displacement: Pump displacement calculated based on obtaining 100%
volumetric efficiency at zero differential pressure. If test data is input for multiple
speeds, the average displacement at zero differential pressure is displayed.
Average Friction Torque: Average friction torque at all test points.
Volumetric Efficiency at Pump Pressure Rating: Volumetric efficiency at the pump
pressure rating calculated based on the actual pump displacement. (Values displayed for
each different test speed.)
You can also examine pump test information graphically by toggling the display to the chart mode.
This will result in the data portion of the window being replaced by a chart area as illustrated
below. Using the drop-down list box, you can display the following charts:
PC-PUMP User Guide
Total Torque vs. Differential Pressure;
103
Measured Volumetric Efficiency vs. Differential Pressure;

Fluid Rate vs. Differential Pressure;
Fluid Slippage vs. Differential Pressure;
Adjusted Volumetric Efficiency vs. Differential Pressure;
Friction Torque vs. Differential Pressure;
Total Power vs. Differential Pressure;
Mechanical Efficiency vs. Differential Pressure;
Fluid Rate vs. Pump Speed; and
Efficiencies vs. Pump Speed (at Target Pressure).
Pump Test Information dialog - chart display mode
The Pump Test Information dialog also permits you to calculate performance characteristics at a
target pump speed and differential pressure. Simply enter the target conditions into the two edit
boxes below the spreadsheet and click the Calculate button. A new data point that represents
your target conditions will be added at the bottom of the spreadsheet. In addition, most of the
charts will also contain an additional data series that corresponds to the target conditions. Use
caution when specifying the target condition inputs: values that are too far away from the test data
range, may result in unreliable extrapolations.
a Pump Test Summary report that can be printed by selecting the Print button at
the bottom of the dialog while in data display mode. This report includes a tabular output of the
information in the spreadsheet as well as the summary parameters. A sample of a Pump Test
Summary report is included in Appendix B. When in chart display mode, you can print the active
PC-PUMP creates
PC-PUMP User Guide
104
chart (i.e. the one currently being displayed) by clicking the Print button at the bottom of the
dialog.
Once you have finished inputting or making modifications to a pump test, click the Update
button to ensure that all of your changes are saved. Then click the OK button on the bottom of
the screen to confirm your pump test selection and to return to the main Pump Selection window.
Your pump test will now be associated with the currently selected pump and its summary
parameters will be displayed in the pump characteristics list box in the Pump Selection window.
You also have the option of aborting the selection of a pump test and returning to the main Pump
Selection window by clicking the Cancel button.
Adding Custom Pumps

The Custom Pump dialog which appears below allows you to create new (single lobe) pump
models that can be added to your own custom databases. These pumps can subsequently be
selected and used in the same manner as any of the pumps included in the manufacturers
equipment database.
Custom Pump dialog
At the top of the Custom Pump dialog, a drop-down list box allows you to select a custom pump
database. This database can contain one or more custom pump models whose names appear in
the list box below. When you highlight a particular pump model, its specifications will be
displayed in the Custom Pump dialog.
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To create new custom databases, click the New File button to bring up a dialog box into which
you enter a name for your custom pump database. Although a corresponding file name is
automatically created, you can rename it within the lower input box. After you have entered the
new database name, click the OK button and you will be returned to the Custom Pump dialog
with a blank database. Note that if you ever want to remove a database, you can do so by
highlighting its name and clicking the Delete File button.
Once a database has been selected, new custom pump models can be created. Each time you
create a new model, enter its name and associated specifications into the series of edit boxes.
Click the Add button to add the new model to the active database. It is important to ensure that
the values you input correspond to the units of measurement that are currently selected. The
following specifications are required for custom pumps:
Rotor Head Connection: Connection on the rotor head for attachment to the rod string
(e.g. 25.4 mm API Pin).
Stator Connection: Connection on the top of the stator for attachment to the tubing
string (e.g. 73.0 mm EUE Box).
Pump Length: Total length of the pump not including tag bar/stop bushing assemblies.
Pump Outside Diameter: Maximum outside diameter of the pump (see geometry
diagram below).
Minor Rotor Diameter: Nominal diameter of the rotor (see geometry diagram below).
Pump Eccentricity: Eccentricity of the pump (see geometry diagram below).
Rotor Pitch: Pitch length of the rotor helix (see geometry diagram below).
Minor Rotor Diameter
Crest-to-Crest Rotor Diameter
Pump Outside Diameter
Rotor Pitch
2 X Pump Eccentricity
Stator Pitch
PC pump geometry (single lobe)
After you have entered values for all of the specifications, click the Calculate button on the righthand side of the screen. The following parameters will be calculated and displayed in the bottom
portion of the screen:
Calculated Pump Displacement: Pump displacement calculated on the basis of its

fundamental geometric parameters (minor rotor diameter, pump eccentricity and rotor
pitch).
Swept Rotor Angle: Pitch angle of the rotor helix.
Cavity Inflow Index: Velocity of fluid flow through the pump cavities per 100 m3/D
production.
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To check the accuracy of your pump specifications, compare the nominal pump displacement
with the calculated pump displacement and ensure the values closely match. To change or correct
any of the inputs, select their edit box and enter a new value. If you want to clear all of the input
specifications, use the Clear button on the right-hand side of the dialog. To remove a pump from
a database, select it by highlighting its name and then click the Delete button.
After you have finished inputting or making modifications to a custom pump, click the Update
button to save your changes. When you want to return to the main Pump Selection window, click
the OK button. All of the new custom pump databases and their corresponding pump models
will now be available for selection and use throughout PC-PUMP.
Notice: The custom pump module in PC-PUMP is not currently structured to support multi-lobe
pump designs. However, if you need to incorporate a custom multi-lobe pump into
your database, call PC-PUMP Technical Support for information on how this can be
achieved.
Stator Swell Model

In most cases, the common pump sizing practices used in the industry are based on selecting a
rotor/stator combination that meets predetermined criteria in a pump bench test. While sizing
guidelines developed by operators and pump suppliers do take into account expected downhole
conditions, laboratory tests are often conducted to better assess elastomer swell and chemical
compatibility. Results of these laboratory tests are usually presented in terms of % swell of the
elastomer samples, and need to be translated into the expected interference fit, to help in pump
sizing.
PC-PUMP includes an auxiliary tool to allow you to estimate how the interference fit of a single lobe
pump will be affected by elastomer swell. This tool can be accessed from PC-PUMPs Pump
Selection window, by selecting Swell from the Pump Options menu. You must input the pump
geometric characteristics (minor rotor diameter and eccentricityplease see page 105 of the User
Guide for a description of these geometric parameters), the stator elastomer OD (which is the
inside diameter of the tubing housing the pump is molded in), and the expected swell % of the
elastomer. Note that while the nominal values of the rotor and stator minor diameters are the
same, you can enter different values for these, to account for rotor over- or under-sizing.
Some of the inputs relating to pump geometry are proprietary to the pump companies. PC-PUMP
will therefore not provide these parameters from the pump database for use in the Swell program.
The only exception to this is when a custom pump is being used, because these numbers are
already accessible to the user.
After entering the required input, click on the Calculate button. The swollen shape of the stator
elastomer and the estimated interference fit are shown in the example window below.
The figure shows a quarter of a cross section of the pump. The outside circumference of the
elastomer is shown in green, the shape of the undeformed cavity (i.e. at 0% swell) in blue, the
shape of the cavity after the elastomer has swollen in red, and the rotor at the centre position in
magenta.
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There are two output values given. The Maximum Interference is the radial interference between
the rotor and the swollen stator elastomer when the rotor is at the centre of the cavity (note that
the diametric interference value would be twice). This maximum interference equals the distance
between the red line and the magenta line at the middle of the graph (0 on the horizontal axis).
The end interference is the distance the rotor must deform the swollen stator at the end of the
cavity, i.e. when the rotor is at the most eccentric position.
Note that the swollen shape of the stator is calculated for a stator free to expand without the
presence of the rotor.
Stator Swell Model Window
You can enter the input values in either inches or millimeters. The default setting depends on your
PC-PUMP settings. Output values are displayed in the same units as the input value.
There are limits to your input values, which should be in the following ranges:
Swell: 0% - 6%
Poissons Ratio: 0.45 - 0.49
D + 4 e : 0.70 0.97
OD
D : 2 10
e
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where D is stator minor diameter, e is eccentricity and OD is the outer diameter of the elastomer
(i.e. the inner diameter of the stator barrel). These limits are based on tests that were performed
during the development of the simplified swell model used within PC-PUMP. Corrections have been
applied to make the simplified swell model agree with more complex FEA models, and these
corrections would be invalid outside the above ranges.
Tubulars
The selection of tubulars in PC-PUMP varies slightly depending on the type of drive system in use.
For both surface and downhole drive PCP systems, you must specify casing and tubing strings.
For surface drive systems, you have the option of adding a tail joint below the pump. If you are
modeling a downhole drive system, you can add a motor shroud to redirect flow past the motor
(this is required if the pump is to be landed below the perforations). Tubulars are selected within
their own separate equipment dialog. You may access the tubulars specification window by
clicking the associated button on the left-hand side of the System Configuration window.
Surface Drive Systems
The Casing/Tubing/Injection Selection dialog shown below will appear when selecting tubulars
for surface drive PCP systems.
Casing/Tubing/Injection Selection dialog - Casing mode
Tabs on the bottom of the dialog allow you to toggle the window between the Casing,
Tubing/Tail Joint, and Injection Tubing modes. These components are selected by choosing a
size and weight and then adding a specified length. Multiple sizes and weights can be combined to
form each casing, tubing/tail joint, and injection tubing string.
To specify casing information, access the Casing mode by clicking its corresponding tab. From
the drop-down list box on the bottom of the screen, select a casing size and weight based on its
outside diameter and nominal weight (e.g. 244.5 mm x 53.57 kg/m). Next, enter the length you
want to add into the length edit box. Note that a default length is entered by PC-PUMPthis can be
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edited if you wish. Once you have verified your selection, click the Add button to add this
segment to the casing string. If required, repeat this process for several casing types thus
assembling a casing string from the bottom of the well, up to the wellhead. To remove unwanted
casing segments, highlight the corresponding row and then click the Delete button. The Clear
button can also be used to simultaneously clear all of the segments.
To specify tubing and tail joint information, click the Tubing/Tail Joint tab to open the proper
screen. Depending on what you want to specify, select either the tubing or tail joint type. In a
manner similar to the casing selection, choose a size and weight, enter a length (again, a default
length is given) and click the Add button to add the segment. This process can be repeated
several times to construct the required tubing and tail joint strings. Tubing segments are added
from the pump upwards to surface, while tail joints will be added downward from the pump.
Note that the coupling outside diameter displayed when any tubing size is selected corresponds to
API standard couplings for upset tubing. This information is used for cable clearance calculations
in downhole drive analyses.
Casing/Tubing/Tail Joint Selection dialog - Tubing/Tail Joint mode
Once you have finished configuring the casing, tubing and tail joints, click the OK button to
confirm your inputs and return to the System Configuration window. Any selections you have made
will be displayed in two tables in the lower portion of this window.
Injection tubing selection will be described later.
To abort your selection and return to the System Configuration window, click the Cancel button.
Diluent Injection
In some areas, operators inject diluent downhole in order to reduce flow losses, and thereby
reduce loading on the pump and other equipment. The capability to calculate the effect of this
diluent addition has now been added to PC-PUMP (in single-phase mode only).
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C-FER acknowledges SINCOR for contributing to the development of the diluent injection
feature in PC-PUMP.
Equipment Configuration
The check box to the left of the button labelled Injection in the System Configuration window
activates the diluent injection feature. If the diluent injection feature is activated, you must specify
the injection equipment. Do this by clicking on the Injection button. This opens the
Casing/Tubing/Tail Joint/Injection Tubing window. You can also open this window by clicking
on the Tubing/Tail Joint or Casing buttons and then switching to the Injection Tubing tab.
There are five essential things you must specify in the injection tubing window:
Injection depth: the measured depth at which the diluent injection occurs. It is
recommended that you enter this before anything else in this window.
Injection tubing size(s) and length(s): tubing size can be selected from a database, or
inputted manually
Injection location: diluent can be injected either into the casing or tubing
Nozzle diameter: inner diameter of the injection nozzle
Injection nozzle coefficient: flow coefficient of the nozzle
You have the choice of selecting injection tubing from a database, or you can enter a custom size.
To select a tubing size from the database, select Database in the Type drop-down box, and
then select the size of tubing from the Size and Grade drop-down. Injection tubing sizes are
listed by OD and ID, rather than OD and weight as in the production tubing database. Once you
select a tubing type, the default coupling size appears in the box next to the drop-down. You can
edit this if it is not correct for your particular tubing. If you choose to enter a custom size, select
Custom in the Type drop-down, and then enter the tubing ID and the coupling OD in the
appropriate boxes. (If you are using continuous tubing, or non-upset tubing, enter the tubing OD
instead of the coupling OD.) Specify a length of tubing and click Add, ensuring it appears on
the spreadsheet in the window.
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As with production tubing, tail joints, and casing, you can enter an injection tubing string that is
made up of different sizes of tubing. The injection string is constructed from surface towards the
injection depth. Also note that PC-PUMP will extend tubing to surface if you do not specify enough
tubing, or ignore tubing above surface if you specify too much tubing.
The nozzle diameter is the size of the orifice in the injection nozzle at the bottom of the diluent
injection tubing string. If no nozzle is to be used, enter the ID of the injection tubing. Specify in
the Injection Location drop-down whether the diluent is injected into the tubing or casingif
you want to inject into a tail joint, select Tubing.
You must also specify the injection nozzle coefficient. This is used, in conjunction with the nozzle
size, to calculate the pressure drop across the nozzle at the bottom of the injection tubing. The
relationship used to calculate the pressure loss across the injection nozzle is:
P =
k Q2
2 A2
Where:
Q is flow rate, m/s
is density, kg/m
k is the nozzle coefficient

A is the nozzle area, m
P is the pressure loss, Pa
A higher value of k will lead to a higher pressure loss. Some formulations for pressure drop across
a nozzle use a Cd2 coefficient instead, where an increasing value of Cd leads to a lower pressure
drop. If this is the form you prefer, the conversion to k is:
k=
1
C d2
Because the Cd coefficient is less than one, according to this equation, the value of k should be
greater than 1.0 PC-PUMP will allow you to enter a smaller value of k, however.
The SPE textbook Applied Drilling Engineering66 lists the following relationship for nozzle
flow losses:
P =
8.311 10 5 Q 2
C d2 A 2
Where:
Q is flow rate, GPM
is density, lb/gal
Cd is the nozzle coefficient
A is the nozzle area, in
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P is the pressure loss, psi

This relationship is identical to that listed, but in Imperial units.
Restrictions
Note that there are presently several restrictions on the use of the diluent injection feature in
PC-PUMP:
It can only be used in single-phase mode.

If injection is into the casing, the injection depth must be between the mid-perforations
depth and the pump seating depth or tail joint intake depth, if applicable (regardless of
whether the perforations are above or below the pump/tail joint intake).
If injection is into the tubing, the injection depth must fall either on the tubing or the tail
joint. It must not be between the top and bottom of the pump; it cannot be below the
pump if there is no tail joint, and if there is a tail joint, it cannot be below the tail joint
intake.
The injection tubing must fit into the casing along with the production tubing (the
coupling OD of the production and injection tubing, when added together, must be less
than the casing drift diameter.
Advanced viscosity (of the production fluid) with non-Newtonian effects is not
permitted with diluent injection.
The diluent injection feature is not available for downhole drive configurations.
Downhole Drive Systems

If a downhole drive system is being modelled, the method for selecting casing and tubing is the
same as in the case of a surface drive unit (see preceding subsection). However, while tail joints
may not be used with downhole drive systems, a shroud may be selected to redirect the flow past
the motor for cooling purposes. This is required if any part of the downhole equipment is below
the perforations, and is optional otherwise. To select a shroud, click the Tubing/Shroud tab and
pick Shroud as the type. Enter the shroud inside and outside diameters and click Add. In
PC-PUMP, it is always assumed that the shroud extends from the pump intake to the bottom of the
motor. When selecting a shroud, both the outside and inside diameters must be specified.
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Casing/Tubing/Shroud Selection dialog - Tubing/Shroud mode
Tubing coupling diameter information is used for ensuring that there is adequate clearance for
electric motor cable in downhole drive analyses. The coupling outside diameter displayed when
any tubing size is selected corresponds to API standard couplings for upset tubing. If you are
using another type of tubing connection, you may override the coupling diameter value by clicking
in the Coupling O.D. box and typing in the appropriate value before you click the Add button.
Rod Strings (Surface Drive Only)

Specification of rod strings is achieved through a process where the rod string is constructed in a
segmented manner from the pump rotor upwards to surface. The rod string can be constructed
using any combination of standard sucker rods with couplings, centralizers and rod guides as well
as continuous rod and hollow rod.
Rod strings are configured within the Rod String Selection dialog shown below. To access this
dialog, click the Rod button on the left-hand side of the System Configuration window.
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Rod String Selection dialog
The pump rotor is always the last segment and is automatically placed at the bottom of the rod
string, i.e. at the pump intake depth (as specified in the System Configuration window). The rod string
is constructed by specifying a rod configuration through a series of drop-down list boxes, then
adding either a specified number of segments or a length to the top of the rod string. By repeating
this process, various rod string configurations can be assembled from the pump intake upwards to
surface, to form the desired rod string configuration.
To construct a rod string of standard, continuous, or hollow rod, use the following procedure:
PC-PUMP User Guide
1.
From the rod type drop-down list box, choose standard, continuous or hollow rods.
2.
Choose a rod manufacturer from the Brand list box. There is an API option for
selecting a generic rod conforming to API standards. There is also a mod. API option for
selecting rods which meet API standards except with different sized pin connections.
3.
Select a rod size and grade from those in the corresponding list box. This box is also used for
selecting non-standard pin connection sizes.
4.
If API or mod. API rods are chosen, you can specify the material yield strength of the
selected rod. The default value is the API minimum yield strength for the specified rod grade
(e.g. API grade D minimum strength = 586 MPa). You cannot edit the yield stress provided
for specific manufacturers rods.
5.
Select a Coupling or Centralizer type from those available in the associated list box. Only
products that match the selected rod type and size will be displayed in the list. For
continuous rod and hollow rod, this is not applicable.
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6.
Choose a rod length from those listed within the length list box. You also have the option of
entering any length between 1 and 25 m (3 and 82 ft.).
7.
The next step, selection of rod guides, is optional and applies only to standard rods. By
default, the rod guide list box will display No Guides. If you wish to add rod guides, select
a particular type from those available in the drop-down list box. In addition, specify in the
adjacent list box the number of guides per sucker rod. Note that the list box contains a rod
guide optimization option, which is discussed in detail in the next sub-section.
8.
Once you have selected a configuration, add either a specified number of rods or a length of
rods. To accommodate this, the edit box next to the Add button can be toggled between
rods and length (m or ft). Change it to the desired setting, input a value and click the Add
button to add your selection to the rod string. Alternatively, to automatically add the
currently selected rod all the way to surface, you can click the Fill to Surface button.
9.
Repeat this process as often as necessary, choosing as many different segment configurations
as needed. It is good practice, however, to have the final rod string extend all the way to
surface (0 mKB, unless a Kelly Bushing offset is specified).
Your current rod string configuration is always displayed in the spreadsheet in the central portion
of the Rod String Selection window. Each rod segment occupies a row in this table where its rod
number, type, size & grade, length, coupling type, rod guide configuration and top and bottom
locations are displayed. Segments are listed from the top to the bottom of the well and scroll bars
allow you to access all of the information.
Several features have been included to assist you in modifying the rod string configuration. You
can remove segments by highlighting their corresponding rows in the spreadsheet and then
clicking the Delete button. Highlighted rows can be replaced by selecting a new configuration
and clicking the Replace button. Additional rod segments can also be added at a particular point
in the selected string by using the Insert button. To insert a rod segment, specify the new rod,
connection and rod guide characteristics and the number of rods to be added. Select the row in
the table below the insertion location, and click the Insert button. To clear the entire rod string,
use the Clear button.
After you have finished selecting a rod string, click the OK button in the bottom right-hand
corner of the screen to confirm your inputs and return to the System Configuration window. Within
this window, the rod string table displays a summary of your current configuration. Identical rods
are grouped together for convenient display. For each rod grouping, the top and bottom location,
number of rods and individual configuration are displayed. The active PC pump will always
appear at the bottom of this rod string table.
Rod Guide Optimization

When employing rod guides, you must decide on the number of guides to use on each rod. The
key criteria on which this decision is normally based is the rod/tubing contact loading. Because
this loading tends to vary along the length of a well (due to changes in well curvature and rod axial
load), the optimal number of rod guides also typically varies along the length of the rod string. For
example, the vertical section near the top of a well may not require any guides, whereas 3 or more
guides may be necessary to mitigate wear problems in the build section of the well.
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PC-PUMPs Rod Guide Optimization mode can help you select the most appropriate distribution of
rod guides for a particular set of well and operating conditions. This feature is activated by
selecting Optimize in the Number of Guides edit box (see Step 5 above). Selection of this option
will bring up the dialog box shown below.
Rod Guide Optimization dialog
Within this box you specify the maximum allowable contact load per guide (note that the units can
be toggled between N and lbf). In addition, you also input the minimum and maximum number
of guides per rod. After you have specified these parameters, click the OK button to return to the
Rod String Selection window.
When you add rod segments with this option activated, the rod guide configuration in the
spreadsheet will initially appear in the format OPT: ? x <Rod Guide Type>. However, after
you have performed a calculation in the Analysis module, the ? will be replaced with the optimized
number of rod guides. Further information on Rod Guide Optimization mode is provided in
Section C of the User Guide.
Drive Equipment
PC-PUMP is capable of modeling and analysing both surface drive and downhole drive PCP systems.
The drive equipment selection procedure varies depending on the type of drive in use.
Surface Drive Equipment

In a conventional PC pumping system, surface drive equipment transmits power from the prime
mover to the rod string. This equipment almost always incorporates some gear reduction that
permits the prime mover to operate at a higher speed and lower torque than the pump. Drive
equipment can be arranged in a variety of configurations and can be comprised of several different
components as shown in the schematic below.
Prime
Mover
Hydraulics
Belts
Hydraulics
Drivehead
Belts
Rod String
Typical surface drive equipment configurations
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provides you with the option of including drive equipment in your assessments. To
consider surface equipment, you must specify certain components within PC-PUMP's Drive
Equipment Selection dialog. This portion of the program is accessed by clicking the Drive
Equipment button on the left-hand side of the main System Configuration window. If you wish to
ignore drive equipment, just bypass this window. However, when you do not specify a drive
equipment configuration, some of the output in the Analysis module will not be available.
PC-PUMP
When you first enter the Drive Equipment Selection dialog, most of the screen will be greyed out.
In order to choose equipment, toggle the Surface Equipment Active check box at the top of the
Drivehead screen so that a check mark appears in it.
The tabs on the bottom of the screen can then be used to move between the following four major
surface drive equipment components:
Drivehead;
Belts;
Hydraulics; and
Prime Mover.
Selection of each of these components is described in the following sections. It is recommended

that you configure equipment starting at the drivehead and proceed toward the prime mover.
Although you must specify both a drivehead and a prime mover, belts and hydraulics are optional
components. Once you have finalized your selection, click the OK button to return back to the
System Configuration window. A summary of the chosen drive equipment will be displayed in a list
box near the top of this window.
To abort any changes made to the drive equipment configuration and return to the System
Configuration window, click the Cancel button.
Drivehead
The Drivehead portion of the Drive Equipment dialog is shown below. From the appropriate list
box, select a vendor. Once a vendor is selected, the adjacent list box will display all of that
vendors available drivehead models. After you choose a model, the screen will be updated with
specifications for the selected drivehead.
Descriptions of these specifications follow:
Type: Vertical or right angle input shaft, internal bearing box or gear box, and hollow or
solid shaft.
Comments: Additional comments provided by the vendor.
Wellhead Connection: Standard connection on the drivehead for attachment to the
wellhead.
Main Shaft Size: Standard main shaft size (polish rod size for hollow shaft driveheads).
Maximum Main Shaft Torque: Maximum allowable torque that can be handled by the
main drive shaft.
Thrust Bearing Rating (ISO): Dynamic load rating (ISO designation) for the thrust
bearing.
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Maximum Structural Load: Maximum axial load that can be carried by the drivehead
frame.
Maximum Power: Maximum power that can be handled by the drivehead.
Maximum Speed (at Polish Rod): Maximum continuous rotational speed of the polish
rod.
Gearbox - Reduction: Gear reduction in the gearbox (greyed out if a gearbox is not
present).
Gearbox - AGMA Gear Torque: Maximum gear torque based on the American Gear
Manufacturers Association ratings (greyed out if a gearbox is not present).
Drive Equipment Selection - Drivehead
Belts
The Belts portion of the Drive Equipment dialog is shown below. Because belts are an optional
component, to configure them you must enable the Active check box at the top of the screen.
After doing so, the following parameters can be input in the corresponding edit boxes:
PC-PUMP User Guide
Reduction Ratio: The total reduction ratio (ratio of the speed of the small gear/sheave
to the speed of the large gear/sheave) generated by the belt and sheave system. This can
be entered directly if Specify Reduction is chosen, or it can be calculated by entering
the sizes of the two sheaves if Calculate Reduction is chosen.
Power Transmission Efficiency: Power transmission efficiency of the belt and sheaves
system. This value typically ranges between 90% and 98% for the V-belts commonly
employed in PC pumping systems.
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Drive Equipment Selection - Belts
Hydraulics
Hydraulics are sometimes incorporated in PC pumping systems to increase the turndown ratio
and allow variable speed control. These systems consist of a hydraulic pump attached to the
output shaft of the prime mover, various intermediate valves and plumbing, a fluid reservoir and
filtration system and a hydraulic motor attached to either a belt and sheaves assembly or the
drivehead input shaft.
Hydraulics are considered an optional component of a surface drive system in PC-PUMP. To
include them in a drive equipment configuration, click the Active box at the top of the screen.
This will allow you to select hydraulic motor and pump models from their corresponding dropdown list boxes. After you choose a component, its specifications will be displayed in the dialog.
The hydraulic motor specifications are as follows:
Displacement: The volume of fluid required to produce one revolution of the hydraulic
motor.
Torque Output: The torque output of the hydraulic motor as a function of operating
pressure.
Maximum Pressure: The maximum peak and continuous operating pressures of the
hydraulic motor.
Continuous Operating Speed: The minimum and maximum continuous operating
speeds of the hydraulic motor.
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Similarly, the hydraulic pump specifications are as follows:
Full Displacement: The maximum volume of fluid that can be displaced with each
revolution of the hydraulic pump.
Maximum Pressure: The maximum peak and continuous operating pressures of the
hydraulic pump.
Continuous Operating Speed: The minimum and maximum continuous operating
speeds of the hydraulic pump.
Drive Equipment Selection - hydraulics
Prime Mover
The prime mover provides the energy to drive the rod string and pump. The amount of power
required from the prime mover is dependent on the power demand at the polish rod and the
transmission efficiency of the drive equipment. The two types of prime movers used in PC
pumping systems are electric motors and internal combustion engines. Electric motors are the
most common type of prime mover, being employed in over 90% of the installations. These
motors are usually of the three-phase, squirrel cage rotor, induction type.
The Prime Mover portion of the Drive Equipment dialog is shown below. Currently, PC-PUMP
only supports electric motors as a prime mover. Electric motors are specified by entering the
following specifications:
PC-PUMP User Guide
Motor Power Rating: Rated power output when operated at the rated supply frequency
and voltage conditions.
121
Motor Poles: Number of motor poles (typically two, four or six).

Motor Slip: The difference between the actual operating speed and the motors
synchronous speed at the operating frequency. The accuracy of this value determines
the accuracy of the relationship between motor speed and frequency. Induction motors
used in PC pumping applications typically have values of slip less than or equal to 5% at
rated load. Note that PC-PUMP will not adjust the amount of slip when it adjusts
frequency. If a large change in frequency is required, you may need to manually re-enter
a more accurate value.
Motor Efficiency (Nominal): Nominal efficiency at full load under the rated supply
frequency and voltage conditions. In the range of motor power ratings utilized in PC
pumping applications, nominal efficiencies typically range between 90% and 95%.
Motor Power Factor (Nominal): Nominal power factor (ratio of active to apparent
power) at full load under the rated supply frequency and voltage conditions. Nominal
power factors typically range from 0.8 to 0.9 for induction motors utilized in PC
pumping applications.
Supply Frequency: The frequency at which electrical power is supplied in your area.
(Note: This parameter is initially assigned a value based on the default set in the
Preferences dialog.)
Supply Voltage: The voltage at which electrical power is supplied in your area. (Note:
This parameter is initially assigned a value based on the default set in the Preferences
dialog.)
Energy Cost: Electrical energy rate. (Note: This parameter is initially assigned a value
based on the default set in the Preferences dialog.)
After you have entered all of the specifications, the motor operating speed (at supply frequency)
and the motor full load current will be calculated and displayed.
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Drive Equipment Selection - Prime Mover
When performing assessments in PC-PUMPs Analysis module (see Section C), the pump speed can
be specified directly or indirectly through the fluid rate input. However, in most cases the selected
drive equipment configuration will not match this speed at the rated conditions. As a result, the
drive equipment specifications must be adjusted to match the pump speed. Option buttons
located in the bottom of the Prime Mover portion of the Drive Equipment Selection dialog allow
you to control the way in which the pump speed is matched to the drive equipment. The
following options are available for matching the pump speed:
Adjusting Prime Mover Speed: The prime mover speed will be adjusted to match the
pump speed. In the case of an electric motor, this will be done by modifying the
operating frequency (to replicate an electronic speed control system).
Adjusting Belt Reduction Ratio / Hydraulic Pump Displacement: The belt reduction
ratio or hydraulics will be adjusted to match the pump speed. If there are no hydraulics,
the belt reduction ratio will be adjusted (the reduction ratio you specified will be
overridden). However, if the drive equipment contains hydraulics, they will be adjusted
instead. (In practice, this is done by altering the swash-plate on the hydraulic pump to
vary its displacement.)
Downhole Drive Equipment

In a downhole drive PC pumping system, the drive equipment consists of a submersible electric
motor, a drive assembly that connects the motor to the PC pump, and the cable, which supplies
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the motor with electricity from surface. The drive assembly is typically made up of a number of
components and serves to isolate the motor from the well fluids, react the pump thrust load,
provide a gear reduction between the motor and pump, and absorb the eccentric motion of the
pump rotor. To activate the downhole drive equipment specification window, click the Drive
Equipment button in the System Configuration window.
Drive Assembly
The Drive Assembly portion of the Drive Equipment Selection dialog is shown below. To select
a drive assembly, start by choosing a manufacturer from the appropriate list box. The adjacent list
box will display all of that manufacturers available drive assemblies. After a model is chosen, the
screen will be updated with specifications for the selected drive assembly.
Type: The manufacturers description of the type of drive assembly. This will describe
the different components in the assembly.
Comments: Additional comments relating to this assembly, provided by the
manufacturer.
Outside Diameter: The maximum outside diameter of the drive assembly.
Length: The length of the drive assembly.
Pump Connection: The type of connection to the pump.
Power Requirement: The amount of power required to turn the drive assembly when
the system is in motion. This is the amount of power lost between the motor output
and the pump. Note that if this information is not available from the manufacturer, a
value of zero will be displayed and used in the calculations.
Gear Reduction: The gearbox reduction within the drive assembly, if any.
Maximum Torque: The maximum recommended operating torque on the low speed
side of the gear reduction.
Maximum Power: The maximum recommended output power of the drive assembly.
Maximum Speed: The maximum recommended continuous running speed of the drive
assembly on the low speed side of the gear reduction.
Maximum Thrust Load: The highest continuous operating axial load that can be carried
by the thrust bearings within the assembly.
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Drive Equipment Selection - Drive Assembly
The Clear button on the right side of the dialog will remove the selected drive assembly. By
clicking on the Custom Drive Assembly button, you may create drive assemblies for later use in
system analyses.
Adding a Custom Drive Assembly
The Custom Assembly dialog (shown below) allows you to create new drive assembly models that
can be added to your own custom databases. These drive assemblies can subsequently be selected
and used in the same manner as any of the assemblies included in the manufacturers equipment
database.
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Custom Assembly dialog
At the top of the Custom Assembly dialog, a drop-down list box allows you to select a custom
drive assembly database. This database can contain one or more models whose names appear in
the list box below. When you highlight a particular drive assembly, its specifications will be
displayed in the Custom Drive Assembly dialog.
To create a new database, click the New File button to bring up a dialog box and enter a custom
assembly database name. Although a corresponding file name is automatically created, you can
rename it within the lower edit box. After you have entered the new database name, click the OK
button and you will be returned to the Custom Drive Assembly dialog with a blank database.
Note that if you ever want to remove a database, you can do so by highlighting its name and
clicking the Delete File button.
Once a database has been selected, new custom drive assembly models can be created. Each time
you create a new model, enter its name and associated specifications into the series of edit boxes.
Click the Add button to add the new model to the active database. It is important to ensure the
values you input correspond to the units of measurement that are currently selected. The
following specifications are required for custom drive assemblies:
Type: A description of the type of drive assembly. This should describe the different
components in the assembly.
Comments: Additional comments relating to this assembly. These will appear in the
Drive Equipment Specification window when the assembly is selected.
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Outside Diameter: The maximum outside diameter of the drive assembly.

Length: The length of the drive assembly.
Pump Connection: The type of connection to the pump.
Power Requirement: The amount of power required to turn the drive assembly when
the system is in motion. This is the amount of power lost between the motor output
and the pump. Note that if this information is not available, a value of zero will be
displayed and used in the calculations.
Gear Reduction: The gearbox reduction within the drive assembly, if any.
Maximum Torque: The maximum recommended operating torque on the low speed
side of the gear reduction.
Maximum Power: The maximum recommended output power of the drive assembly.
Maximum Speed: The maximum recommended continuous running speed of the drive
assembly on the low speed side of the gear reduction.
Maximum Thrust Load: The highest continuous operating axial load that can be carried
by the thrust bearings within the assembly.
If you want to clear all of the input specifications, use the Clear button on the right hand side of
the dialog. To remove a drive assembly from the database, select it by highlighting its name and
then click the Delete button.
After you have finished inputting or making modifications to a custom drive assembly, click the
Update button to save your changes. When you want to return to the Drive Assembly portion of
the Drive Equipment Selection dialog, click the OK button. All of the new custom drive assembly
databases and their corresponding models will now be available for selection and use throughout
PC-PUMP.
Motor
The Motor portion of the Downhole Equipment dialog is shown below. To select a motor,
choose a manufacturer from the list box on the upper left side of the dialog. Once a manufacturer
is selected, the adjacent list box will display all motors in the PC-PUMP equipment database available
from the selected manufacturer. After you choose a model, the screen will be updated with
specifications for the selected motor. Alternatively, you may click on the Custom Motor button
to enter the specifications for motors not in the equipment database supplied with PC-PUMP.
Descriptions of motor specifications follow:
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Outside Diameter: The maximum outside diameter of the motor.

Length: The length of the motor.
Power Rating: The power rating of the motor when it operates at the nameplate
frequency and voltage.
Nameplate Voltage: The voltage at which the motor is designed to operate.
Nameplate Current: The current drawn by the motor when operating at nameplate
power, voltage and frequency.
Nameplate Frequency: The electrical frequency at which the motor is designed to
operate.
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Maximum Winding Temperature: The maximum recommended temperature that the

motor windings can withstand in continuous operation.
Number of Poles: The number of electrical poles in the motor (typically two, four or
six).
Supply Frequency: The frequency at which electrical power is supplied in your area.
(This value is set in the PC-PUMP defaults window.)
Synchronous speed at Supply Freq.: The speed at which the motor will theoretically
operate with no applied load, when the voltage is applied at the supply frequency.
Drive Equipment Selection Motor
Motor operating performance can be specified at the bottom of the Motor Selection window in
one of three ways. You have the choice of using the manufacturers motor performance curves,
specifying motor test curves, or using static performance values. You may select the desired
method to calculate motor performance using the option buttons in this window.
Choosing No curves (static) allows you to enter constant values for motor operating
parameters, regardless of the motor operating point. The values which must be specified are:
Efficiency: The efficiency at which the motor is assumed to be operating, expressed as a

percentage (0-100%). Note that electric submersible motors typically have lower
efficiencies than surface drive motors.
Power Factor: The power factor at which the motor is assumed to operate, expressed as
a decimal fraction (0-1.00).
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Slip: The difference between the actual operating speed and the motors synchronous
speed at the operating frequency, expressed in RPM.
Temperature Rise: The difference between the temperature of the surface of the motor
and the maximum temperature of the windings.
Many motors in the PC-PUMP database have manufacturer-supplied performance curves. When
available, this is the recommended method of modeling motor performance. If you would like to
enter data from a motor test, click the Motor Test button and follow the instructions in the
subsection below.
If you have chosen to use manufacturers curves or a test to model motor performance, you can
view the curves by clicking the Charts button on the right hand side of the dialog. User-specified
motor test data can always be viewed in this way. However, motor performance data may be
considered by the manufacturer to be proprietary and, while the relationships will be used to
evaluate the motor performance during analysis, manufacturers motor curves will not always be
accessible for graphical display.
The Clear button will remove the motor selection.
Inputting Motor Test Information
Motor test data is entered in a similar manner as pump test information. The Motor Test
Information dialog is shown below.
Motor Test Information dialog
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The motor model that was active in the Motor Specification window will appear in the Motor
Model box at the top of the dialog. Below this, any existing tests associated with this model of
motor will be displayed. Files containing motor test information are stored by default in the
TEST subdirectory of the PCPV25 installation directory. To select a specific motor test, click on
the test name using the mouse. This will update the dialog box with the corresponding motor test
information.
To create a new motor test, click the New File button. PC-PUMP will display a dialog box for the
motor test name. Although a corresponding file name is automatically created in the lower edit
box, it can be modified by typing over the default name. After entering the name of the new test,
click the OK button to return to the Motor Test Information dialog along with a blank motor test.
You can enter motor test data by typing the corresponding values directly into the spreadsheet.
For each test point you must enter the Motor Load (as a percentage of rated load), Efficiency,
Power Factor, Motor Speed and Temperature Rise. To correct a value, simply select the specific
cell and enter a new value. The Clear button at the bottom of the dialog clears all of the data
from the spreadsheet. The power supply frequency at which the test was done must be entered in
the corresponding edit box below the spreadsheet. This should be as close as possible to the
frequency at which the motor will be operated.
Once you have entered the motor test data into the spreadsheet and have specified the frequency
value, click the Calculate button on the bottom of the screen. This will arrange the specified data
points in order of increasing motor load. You can examine the test data graphically by toggling
the display to chart mode. This will result in the data portion of the window being replaced by a
chart. Using the drop-down list box, you can display the following charts:
Speed vs Percent Rated load

Efficiency vs Percent Rated Load
Power Factor vs Percent Rated Load
Temperature Rise vs Percent Rated Load
After inputting or making modifications to a motor test, always click the Update button to ensure
that your changes are saved. PC-PUMP fits a curve through the specified data points for use in the
primary calculation routines. Because of the complexity of motor performance curves and the
variability in motor performance characteristics, it is recommended that you check that the curves
generated from the motor test data are accurate before using them in an actual analysis.
creates a Motor Test Summary report that can be printed using the Print button at the
bottom of the dialog while in data display mode. This report includes a tabular output of the
information in the spreadsheet. When in chart display mode, you can print the active chart (i.e. the
one currently being displayed) by clicking the Print Button at the bottom of the dialog. When you
are satisfied with your motor test selection, click the OK button to return to the Motor portion of
the Downhole Equipment window. You also have the option of aborting the selection of a motor
test and returning to the Motor portion of the Downhole Equipment window by clicking the
Cancel button.
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Adding a Custom Motor

The Custom Motor dialog (shown below) allows you to create new motor models that can be
added to your own custom databases. These motors can subsequently be selected and used in the
same manner as any of the motors included in the manufacturers equipment database.
Custom Motor dialog
At the top of the Custom Motor dialog, a drop-down list box allows you to select a custom motor
database. This database can contain one or more custom motor models whose names appear in
the list box below. When you highlight a particular motor model, its specifications will be
displayed in the Custom Motor dialog.
To create a new database, click the New File button to bring up a dialog box and enter a custom
motor database name. Although a corresponding file name is automatically created, you can
rename it within the lower edit box. After you have entered the new database name, click the OK
button and you will be returned to the Custom Motor dialog with a blank database. Note that if
you ever want to remove a database, you can do so by highlighting its name and clicking the
Delete File button.
Once a database has been selected, new custom motor models can be created. Each time you
create a new model, enter its name and associated specifications into the series of edit boxes.
Click the Add button to add the new model to the active database. It is important to ensure the
values you input correspond to the units of measurement that are currently selected. The
following specifications are required for custom motors:
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Outside Diameter: The maximum outside diameter of the motor.

Length: The overall length of the motor.
Number of poles: The number of electrical poles in the motor, normally two, four or
six.
Power Rating: The full-load shaft power the motor produces at the nameplate
frequency.
Max. Winding Temp.: The maximum recommended temperature of the motors
windings.
Nameplate Frequency: The design frequency of the motor.
Nameplate Voltage: The design operating voltage of the motor at the nameplate
frequency.
Nameplate Current: The current the motor will draw when operating at nameplate
frequency and rated power.
Comments: Any additional comments about the custom motor.
If you want to clear all of the input specifications, use the Clear button on the right hand side of
the dialog. To remove a motor from the database, select it by highlighting its name and then click
the Delete button.
If performance curves are available for the custom motor, click on the Specify Motor Curves
button. This opens the Motor Test Information window, which allows you to enter motor
performance curves that may be used when the custom motor is selected for an analysis. (See the
previous section for step-by-step instructions on how to specify motor performance curve data.)
After you have finished inputting or making modifications to a custom motor and have added a
motor performance curve, click the Update button in the Custom Motor window to save your
changes. When you want to return to the Motor Specification portion of the Downhole
Equipment dialog, click the OK button. All of the new custom motor databases and their
corresponding motor models will now be available for selection and use throughout PC-PUMP.
Cable
The Power Transmission Cable portion of the Downhole Equipment Selection dialog is shown
below. To select a cable, choose a manufacturer from the list box on the upper left side of the
dialog. Once a manufacturer is selected, the adjacent list box will display all of the manufacturers
available cable models. After you choose a model, the screen will be updated with specifications
for the selected cable. Alternatively, you may click on the Custom Cable button to enter the
specifications for a cable which is not in the PC-PUMP database.
Type: Flat or round cable

Comments: Additional comments related to this cable, provided by the manufacturer.
Conductor Size: The American Wire Gauge (AWG) of the cable.
The maximum conductor temperature
Maximum Conductor Temperature:
recommended by the manufacturer.
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Thickness: The cable thickness in the direction of the tubing radius when banded to the
tubing. This cable dimension is used to verify consistency with the casing drift diameter
to avoid problems during installation of the downhole drive system.
Drive Equipment Selection Cable
The graphical display on the window can be changed using the buttons below the chart. You can
view either a resistance chart (voltage loss vs. current at a number of conductor temperatures) or a
conductor temperature chart (conductor temperature vs. current at a number of ambient
temperatures).
Adding Custom Cables
The Custom Cable dialog shown below allows you to create new cable models that can be added
to your own custom databases. These cables can subsequently be selected and used in the same
manner as any of the cables included in the manufacturers equipment database.
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Custom Cable dialog
At the top of the Custom Cable dialog, a drop-down list box allows you to select a custom cable
database. Each database may contain one or more custom cable models. Once a database is
selected, the names of these models will appear in the list box below the database name.
Highlighting a particular cable model will display the specifications of the selected model.
To create a new database, click the New File button to bring up a dialog box and enter a name
for the custom cable database. Although a corresponding file name is automatically created, you
can rename it within the lower edit box. After you have entered the new database name, click the
OK button and you will be returned to the Custom Cable dialog with a blank database. Note that
if you ever want to remove a database, you can do so by highlighting its name and clicking the
Delete File button.
Once a database has been selected, new custom cable models can be created. To create a new
model, enter its name and associated specifications into the series of edit boxes. Click the Add
button to add the new model to the active database. It is important to ensure the values you input
correspond to the units of measurement that are currently selected. The following specifications
are required for custom cables:
Size: The cables AWG gauge.

Thickness: This cable dimension is used to verify consistency with the casing drift
diameter to avoid problems during installation of the downhole drive system.
Max. Conductor Temp.: The maximum temperature for the conductor recommended
by the manufacturer.
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Cable Type: Flat or round.

Comments: Any additional comments about the cable.
Click the Specify Ampacity Curves button to enter the performance curves for the cable. This is
described further in the subsection below.
If you want to clear all of the cable inputs, use the Clear button on the right hand side of the
dialog. To remove a cable from the database, select it by highlighting its name and then click the
Delete button.
Once you have finished inputting or making modifications to a custom cable, click the Update
button to save your changes. When you want to return to the Cable section of the Drive
Equipment Selection dialog, click the OK button. All of the new custom cable databases and their
corresponding cable models will now be available for selection and use throughout PC-PUMP.
Custom Cable Ampacity Curve Input
There are two sets of curves that must be specified to describe power transmission cable
performance in PC-PUMP. Both the cable voltage drop and cable conductor temperature curves
may be defined in the Cable Ampacity Curve Input window.
The upper section of the window is used to describe the cable voltage drop as a function of line
current. To input this information, simply enter the current and associated voltage drop data in
the appropriate columns in the spreadsheet. The associated reference temperature should also be
entered in the Reference Conductor Temperature edit box. Note that PC-PUMP will perform a
linear regression on the data you provide to model the voltage drop relationship, and will force the
curve fit to result in a voltage drop of zero if there is no current. Specify as many data points as
possible to make the cable performance relationship more accurate.
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Cable Ampacity Curve Input dialog
The Cable Conductor Temperature section on the lower half of the window describes the heating
performance of the cable. Using the spreadsheet, enter conductor temperatures corresponding to
given currents and ambient temperatures. Once again, it is recommended that you enter a
number of data points as PC-PUMP will perform curve-fitting operations on the data you have input.
Once you have finished specifying the cable performance data, click the Calculate button at the
bottom of the screen. This calculates the electrical resistance and the thermal resistance of the
cable and displays these values at the bottom of the screen along with the reference temperature.
Clicking the OK button will save this data and return you to the Custom Cable dialog. Click the
Cancel button to return to the Custom Cable dialog without saving the data.
Working With Equipment Cases

PC-PUMP has been designed to allow you to work with a number of different equipment
configurations simultaneously. This feature is useful for performing comparative analyses of two
or more equipment configurations, and for modeling both surface and downhole drive systems
for the same application. To utilize this capability, you must first set up the different equipment
cases within the programs System Configuration module. Note that PC-PUMP does not conduct
comparative analyses between surface and downhole drive equipment cases.
When you first start PC-PUMP, your active equipment case is assigned a default name according to
the type of drive system you are modeling. If you are working with a surface drive system the case
name will be Untitled Surface, while the downhole drive case will be called Untitled
Downhole.
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Equipment cases can be modified using the buttons and edit boxes located in the upper righthand corner of the System Configuration window. The Add and Delete buttons perform relatively
simple operations within the active drive type. The Case Manager button allows you more
flexibility in examining and manipulating the equipment cases you are working with for both
surface and downhole drive systems. Note that cases shown in the System Configuration window
correspond to the active drive type only. If you are in surface drive mode you must toggle the
drive type button to see downhole drive equipment cases.
Adding and Deleting Cases
When you click the Add button on the System Configuration window, the current system
configuration is duplicated into a new case. This new equipment case can then be configured in
any manner you want. Note, however, that any changes you make in the System Configuration
window only apply to the currently active case. You can switch between existing equipment cases
by selecting their names from the list shown on the window. Equipment cases can be renamed by
first making them active and then entering a new name in the top of the edit box. If you want to
remove an equipment case, make it active and then click the Delete button.
Equipment case setup box
The following steps are recommended for setting up different equipment cases:
1.
Follow the sequence defined previously, and select all of the equipment which is common to
the different cases;
2.
Within the System Configuration window, duplicate the case you are working with as many times
as required and assign appropriate names to the new cases;
3.
Select each case individually, and either add or change the selected equipment to the sizes or
types of equipment which make the highlighted case unique; and
4.
Verify that the proper equipment has been selected for each case by sequentially activating
them and checking the summary information shown in the System Configuration window.
Note that while each equipment case must include a single assigned pump, multiple pumps may
also be chosen within the Pump Selection window for completing pump comparison analyses.
When more than one pump has been selected, the pump model which is highlighted prior to
closing the Pump Selection window will be assigned to the active equipment case. The pump
section in the System Configuration window displays the summary information for the pump
assigned to the active equipment case. You may change the pump assigned to a particular case
within the System Configuration window by clicking on the pump model list and selecting another
pump from among the models chosen previously.
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Using the Case Manager

The Case Manager dialog can be activated by clicking on the associated button on the System
Configuration window. This utility displays all equipment cases of both drive types in the active data
file and allows you to easily duplicate, create, and delete cases as well as transform cases from one
drive type to another. The Case Manager dialog is shown below.
Case Manager dialog
When the Case Manager is opened, you will also notice that one case appears highlighted. This is
the active equipment case. When the Case Manager is closed, specifications for the active case will
be displayed in the System Configuration window. Almost all operations in the Case Manager will
involve this highlighted case. To highlight a case, click directly on the case name.
Adding and deleting cases using the Case Manager is very simple. To duplicate or delete the
highlighted case, click the Duplicate or Delete buttons in the center of the dialog. (These
buttons perform the same operation as the corresponding buttons on the System Configuration
window.) The Move button moves the selected case from one drive type to the other, without
leaving a copy of the case behind.
You may create a new surface drive or downhole drive case by clicking on the New Surface Case
or New Downhole Case button on the appropriate side of the window. Cases may be renamed
by highlighting the existing case name and typing the new name in the text field at the top of the
list of cases.
There may be instances when you would like to perform an analysis with a different drive type
using equipment you currently have selected. Specifications in PC-PUMP which are common to
surface drive and downhole drive PCP systems include the pump seating and mid-perforation
depths and the pump, tubing, and casing selections. The Case Manager can be used to copy these
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specifications. Simply highlight the case you would like to copy and click the Copy button to
create a comparable case for the other drive type. You may wish to rename the new case to
indicate that it corresponds to the case just copied. After copying the equipment case you will
likely have to add components that are not common to the two systems before any analyses can
be performed. Note that the wellbore geometry and all analysis inputs (fluid properties and
operating conditions) are common to all configurations in the same data file.
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SECTION C: ANALYZING THE SYSTEM
Section C: Analysing the System

Once you have configured the system by specifying a wellbore geometry and selecting equipment, you
are ready to begin analysing the system. The Analysis module is your principal tool for this purpose. In
this portion of the program, you specify fluid properties and operating conditions, perform calculations
and examine the results.
Getting Around Analysis

Analysis is the second of the two primary modules in PC-PUMP. After you finish inputting
information into the System Configuration module, you can move to the Analysis module by clicking
the large Analysis button located at the right-hand corner of the System Configuration window. This
will bring up the Analysis window, which provides you with access to all of the other windows and
dialogs in this module.
There are two sections to the Analysis window which can be accessed using the tabs at the bottom
of the screen. The Analysis Inputs screen allows you to input fluid properties and operating
conditions and commence the system analysis. The Analysis Outputs screen allows you to view a
summary of key results and provides access to detailed output screens.
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Analysis windows
The process that you typically follow for a PC-PUMP analysis is:
From the Analysis Inputs screen, choose fluid property and operating condition modes
and specify the corresponding inputs;
Select an equipment case and pump;
Choose and configure a calculation mode and initiate the calculation process; and
Examine the output results in the Analysis Outputs screen.
The upper left-hand portion of the Analysis Inputs window is used for specifying fluid properties,
while the upper right area is for specifying operating conditions. The Drive Location, Equipment
and Calculation areas and the Pump Model button are on the lower right of the screen below the
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operating conditions input area. The large Configuration button in the lower left-hand corner of
the window returns you to the System Configuration module.
Printing Analysis Reports
PC-PUMP creates an Analysis Summary report that can be printed by selecting the FilePrint menu
command while in either section of the Analysis window. This report includes an equipment
summary as well as a listing of the fluid properties and operating conditions, summary output
parameters and output messages. Samples of Analysis Summary reports for surface and
downhole systems are included in Appendix B. You can also print to PDF files.
Saving and Restoring Data Files

PC-PUMP allows
you to save and restore your assessments in the form of data files. A single saved
file contains all of the input information including wellbore profiles, equipment specifications, fluid
properties and operating conditions.
To save a data file, simply select the File Save menu command and enter a filename. If the file
has been previously saved, PC-PUMP uses that file name. File Save As can be used to store an
existing file under a new name, or in a format which can be read by older versions of PC-PUMP.
The default extension .pcp is recommended.
Note that data files cannot be restored from within the Analysis module. You will have to return
to the System Configuration window and follow the instructions provided in the previous section.
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Specifying Analysis Inputs

PC-PUMP has numerous process paths that make it highly versatile in terms of the assessments it can
perform. In specifying analysis inputs, you control the type of computational path that is
executed. Evaluations can range from relatively simple to very complex.
In PC-PUMPs most basic mode, you only need to specify single-phase Newtonian fluid properties
(i.e. tubing and casing fluid densities, gas gravity, fluid viscosity and sand and water cuts) and
standard operating conditions (i.e. fluid rate, fluid level, and tubing and casing head pressures).
However, through various switches you can enable advanced viscosity, multiphase flow, inflow
performance, and motor heating calculations. Naturally, these options require additional input
data. The diagram below summarizes the various analysis input configurations and their
associated input parameters.

Fluid Property Windows
Inputs:
Fluid Prop.
Single-Phase
Tubing fluid density

Casing fluid density
Advanced Density
Specific gas gravity

Bottomhole temperature
Temperature gradient
Fluid viscosity
Advanced Viscosity
Advanced Density
Oil API gravity

Water specific gravity
Sand specific gravity
Tubing density factor
Casing density factor
Water fraction
Sand cut
Multiphase
Inputs:
Oper. Cond.
Standard
Fluid rate or pump speed

Fluid level
Tubing head pressure
Casing head pressure
Water fraction
Advanced Viscosity
Viscosity vs
temperature data
Viscosity vs shear
rate data
Inputs:
Fluid Prop.
Operating Condition Windows
Inputs:
Oper. Cond.
Advanced
IPR Data
Oil API gravity

Specific gas gravity
Water salinity
Producing GOR
Bottomhole temperature
Temperature gradient
Free gas separation (@ intake)
Fluid rate or pump speed or

producing pressure
Tubing head pressure
Casing head pressure
Water fraction
Model type
Reservoir pressure
Bubble point pressure
Test data
IPR Data - Undefined
input configurations
Analysis
Fluid properties and operating conditions are specified within the Analysis Inputs window. Fluid
property inputs can be switched between single-phase and multiphase flow by clicking the
associated option buttons at the top of the fluid properties inputs section on the left side of the
window. Operating conditions are specified on the right side of the window. Options for
operating conditions include the use of an inflow performance relationship (IPR) and the
execution of motor heating analyses (downhole drive systems only). The specification of fluid
properties and operating conditions is described in detail within the following sections.
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Analysis Inputs window
Fluid Properties
Fluid flow and the different methods typically used to model various flow conditions were
described earlier in this Guide in the Technical Considerations-Fluid Flow section. PC-PUMP has the
ability to simulate either single-phase or multiphase fluid flow. In a particular assessment, the type
of flow modelled is determined by the corresponding fluid properties mode that you select.
The selection of single-phase or multiphase fluid properties can have a significant impact on the
computed results. In general, if there is a significant, measurable quantity of gas, it is advisable to
use the multiphase mode.
To select the desired type of fluid flow, click on the button located adjacent to the appropriate
flow mode. The fluid properties that you must input depend on the selected mode. The two fluid
property modes are described in detail below.
Single-Phase
When specifying single-phase fluid properties, you have the option of either directly specifying
fluid density in the casing and tubing or specifying the composition of the fluid to calculate values
for these densities. The latter option may be activated by clicking the check box labelled "Specify
Fluid Composition". The required input values change depending on whether or not this box is
checked.
If the "Specify Fluid Composition" box is not checked, the following inputs are required:
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Water Cut: The water volume percentage derived from a BS&W (basic sediment and
water) analysis. Note that if a sand cut is specified, the water cut is not necessarily equal
to the percentage of the liquid portion of the produced fluids that is water. For more
details on how PC-PUMP uses the water cut, see the section on Technical ConsiderationsFluid Flow.
Sand Cut: The sand volume percentage derived from a BS&W (basic sediment and
water) analysis. For more details on how PC-PUMP uses the sand cut, see the section on
Technical Considerations-Fluid Flow.
Fluid Density-Tubing: The absolute density of the fluid in the tubing, taking into
account water, solids and gas content.
Fluid Density-Casing: The absolute density of the fluid in the casing, taking into account
water, solids and gas content.
Gas Specific Gravity: Specific gravity of produced gas relative to air at standard
conditions. (Note: this parameter is initially assigned a value based on the default set in
the Preferences window.)
Fluid Viscosity: This value can be specified either in the input box as the overall mixture
viscosity or through the Advanced Viscosity option. Use of the Advanced Viscosity
option is described in the subsection to follow. This is an absolute (or dynamic)
viscosity, measured in centipoises, and not a kinematic viscosity, which would be
measured in centistokes.
Consider Torque from Viscous Flow in Pump: This option is available in all the fluid
property modes. It is described below in the section Viscous Torque.
Fluid Properties Single phase input, Fluid Composition feature not active
If the Specify Fluid Composition box is checked, the following inputs are required:
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Oil API gravity: The API gravity of the produced oil (after being separated from water,
gas and solids content).
Water Specific Gravity: Specific gravity of the produced water relative to pure water at
standard conditions. Due to brine content, produced water normally has a specific
gravity slightly greater than 1.0. (Note: this parameter is initially assigned a value based
on the default set in the Preferences window.)
Sand Specific Gravity: Specific gravity of the produced sand grains relative to pure water
at standard conditions. This is based on the density of solid sand. (Note: this
parameter is initially assigned a value based on the default set in the Preferences
window.)
Water Cut: The water volume percentage derived from a BS&W (basic sediment and
water) analysis. Note that if a sand cut is specified, the water cut is not necessarily equal
to the percentage of the liquid portion of the produced fluids that is water. For more
details on how PC-PUMP uses the water cut, see the Technical Considerations-Fluid Flow
section.
Sand Cut: The sand volume percentage derived from a BS&W (basic sediment and
water) analysis. For more details on how PC-PUMP uses the sand cut, see the Technical
Considerations-Fluid Flow section.
Tubing Density Factor: A factor which is multiplied by the calculated composite density
to arrive at a density of fluid in the tubing. (For example, to account for gas, a factor less
than 1.0 would be used; if no correction needs to be made, use 1.0.)
Casing Density Factor: A factor which is multiplied by the calculated composite density
to arrive at a density of fluid in the casing.
Fluid Density - Tubing: This value is calculated based on the above values and is the
composite density of the fluid in the tubing.
Fluid Density -Casing: This value is calculated based on the above values and is the
composite density of the fluid in the casing.
Gas Specific Gravity: Specific gravity (relative to air at standard conditions) of gas in the
casing/tubing annulus above the fluid level. (Note: this parameter is initially assigned a
value based on the default set in the Preferences window.)
Fluid Viscosity: Absolute (or Dynamic) fluid viscosity (in centipoises) can be specified
either in the input box as the overall mixture viscosity or through the Advanced
Viscosity option. Use of the Advanced Viscosity option is described below.
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Fluid Properties Single phase input, Fluid Composition feature active
Multiphase
If the Multiphase option button is selected, you must enter the following inputs:
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Oil API Gravity: API gravity of the produced oil.

Water Specific Gravity: Specific gravity (relative to pure water at standard conditions) of
the produced water. Due to brine content, produced water normally has a specific
gravity slightly greater than 1.0. (Note: This parameter is initially assigned a value based
on the default set in the Preferences dialog.)
Gas Specific Gravity: Specific gravity (relative to air at standard conditions) of the
produced gas. (Note: This parameter is initially assigned a value based on the default set
in the Preferences dialog.)
BS&W Content: The percentage of the produced fluid that is water and sand. If you
have specified a composite IPR, this value will be calculated and the input box will be
greyed-out.
Producing GOR: The producing gas/oil ratio, measured at standard conditions (15C
and atmospheric pressure). This must consider the total quantity of gas produced up the
casing and tubing.
Producing GLR: The producing gas/liquid ratio, measured at standard conditions
(15C and atmospheric pressure). This parameter is used when there is no oil, for
example in the dewatering of gas or coal bed methane wells. (Note: This parameter is
made available by clicking on the Producing GOR button.)
Free Gas Separation: Percentage of free gas at either the pump or tail joint intake which
is separated and diverted up the casing/tubing annulus. This value is used to determine
the annular and tubing gas rates. (Note: This parameter is initially assigned a value based
on the default set in the Preferences dialog.)
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Fluid Properties - Multiphase input
In multiphase mode you have the option of selecting different correlations for various fluid
properties, as was described in Part 2 of this User Guide. You can adjust the correlations for a
specific case by clicking on the Multiphase Correlations button in the Fluid Properties section of
the Analysis Inputs window. This button opens a window very similar to the tab in the
Preferences dialog. Changing the correlations in this window, however, does not change the
defaults, but only affects the current case. You can revert to the default correlations by clicking on
the Defaults button in this window.
Advanced Viscosity
If you wish to model the viscosity of the produced fluid as a function of temperature, shear rate,
or BS&W (water and sand) content, you should use the Advanced Viscosity Option. To access the
Advanced Fluid Viscosity Window, activate the mode by clicking on the associated check box and
click the Advanced Viscosity Effects button.
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Advanced Viscosity Data Display
This dialog can be switched between data and chart display modes with the option buttons at the
top of the window. In data mode, you can define the effects of temperature, non-Newtonian
properties, and produced water on fluid viscosity. If you are performing a single-phase flow
calculation, you may use any combination of temperature, shear rate and water cut effects. The
software will directly apply the advanced viscosity relationships you specify to obtain the mixture
viscosity. If you are performing a multiphase flow analysis, only temperature dependency can be
modelled. In this case, the program considers the specified values to be dead oil viscosities and
will utilize a correlation to obtain the downhole (live) oil viscosity28.
Temperature Effects
Crude oil viscosity is typically dependent on temperature. Depending on the overall magnitude of
viscosity, this dependency may influence the design of a PC pumping system. PC-PUMP allows you
to define relationships between oil viscosity and temperature. To activate this feature, click the
Temperature Effects check box. Enter the dead oil viscosity at a range of temperatures into the
corresponding spreadsheet. At least two data points are required to define the relationship. (In
multi-phase flow, the program adjusts the dead oil viscosity to account for solution gas content to
obtain the live-oil viscosity.) Once you have finalized your input, click the Calculate button to
obtain the best-fit mathematical relationship between viscosity and temperature. The two
calculated correlation coefficients will be displayed below the spreadsheet. The relationship can be
viewed graphically by switching to chart display mode and selecting the Viscosity vs. Temperature
chart from the drop-down list box. An example of chart display mode in the Advanced Fluid
Viscosity dialog is shown below.
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Advanced Viscosity Chart Display
Non-Newtonian (Shear Thinning) Effects

Most petroleum fluids tend to be non-Newtonian, exhibiting pseudoplastic (shear thinning)
behaviour. This behaviour can have a considerable impact on fluid flow behaviour. PC-PUMPs
flow algorithms have the ability to model non-Newtonian fluids. Further information on this
topic can be found in Technical Considerations-Fluid Flow: Single Phase. The Non-Newtonian
Effects option can be enabled using the associated check box in the Advanced Viscosity window
if single-phase fluid properties are in use. Enter the oil viscosity at a number of shear rates into the
corresponding spreadsheet. A minimum of two data points must be specified. Once you have
finished inputting the data, click the Calculate button. This will determine and display the
consistency (K) and flow behavior (n), indexes for a power law fluid model that best fits the input
data. The non-Newtonian fluid relationship can be viewed by selecting the Viscosity vs. Shear
Rate chart from the drop-down list box.
Note: When Temperature and Non-Newtonian effects are selected simultaneously, the
temperature data forms the base curve while the flow behavior index is used to adjust for shear
rate effects.
BS&W Effects
Water content will also affect the viscosity of the produced fluid. To incorporate the effects of
produced water on fluid viscosity into your analysis, select the BS&W Effects check box.
You must first define the viscosity of the oil itself. If you have selected Temperature Effects or
Non-Newtonian Effects, the oil viscosity will automatically be calculated from the selected
correlation(s). Otherwise, you must specify the oil viscosity in the corresponding input box.
Within PC-PUMP, you have the option of calculating the oil/water mixture viscosity by using one of
the following three methods:
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1.
Weighted average of the oil viscosity and water viscosity. In this case, the program varies the
mixture viscosity between the oil and water viscosities as a linear function of the BS&W
content (sum of the sand and water cuts). No input parameters are required for this method.
2.
Default emulsion correlation. This correlation assumes that the mixture viscosity increases
with BS&W content to a maximum value 8.67 times the oil viscosity at a BS&W content of
60%. At BS&W contents above 60%, it is assumed that the emulsion is inverted and the
mixture viscosity is equal to the water viscosity. No further input parameters are required for
this method.
3.
Custom emulsion correlation. This correlation is similar to the default emulsion correlation.
It allows the user to specify the maximum viscosity and the BS&W content at which the
emulsion becomes inverted. You must specify both the maximum viscosity factor, which is a
multiplication factor applied to the viscosity of the oil to define the maximum mixture
viscosity, and the inversion point, which defines the BS&W content at which the mixture
viscosity drops to the water viscosity.
Use the toggle buttons to choose one of the viscosity correlations. After you have made your
choice, click Calculate. You may view the effects of BS&W content on viscosity by selecting
appropriate charts from the drop-down list box. To print the Advanced Viscosity chart that is
currently displayed, click the Print button at the bottom of the dialog.
Once you finished configuring the Advanced Viscosity options, return to the Analysis window by
clicking the OK button. As long as Advanced Viscosity is active (i.e. the check box is enabled),
fluid viscosity will be determined based on the criteria that you have defined. Note that if
Temperature Effects are active, ensure that you have entered the appropriate bottomhole
temperature, temperature gradient and/or flowing wellhead temperature inputs.
Fluid Thermal Properties

If you select the Consider Heat Generated by Pump Friction option, or are modeling a
downhole drive system and have chosen to perform a motor heating analysis (see the next section
on Operating Conditions) then you must describe fluid heat transfer properties before the
calculation may proceed. Clicking on the Specify Fluid Thermal Properties button brings up
the dialog box shown below.
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Fluid Thermal Properties dialog
The values required for heat transfer calculations are the specific heat capacity (Cp) and thermal
conductivity (K) of the produced fluids. (The K value is only required for the downhole drive
motor heating analysis.) Heat transfer calculations in multiphase flow also use the specific heat
capacity of the gas, which is specified in the Preferences window. This gas property will generally
have little effect on the overall (mass-weighted) mixture heat capacity as liquids will normally
constitute the bulk of the mass flow rate.
There are three ways in which you may specify the specific heat capacity and thermal conductivity
values in PC-PUMP.
1. You may directly specify bulk thermal properties for the produced fluids by activating the
User Specified option on the specification window and entering values for Cp and K.
If you are using the single-phase flow mode and have specified the fluid composition or if you are
using multiphase flow, you may have PC-PUMP calculate mixture thermal properties using oil and
BS&W fractions in the produced fluids. PC-PUMP calculates mixture values as linear functions of the
component volume and mass fractions for the thermal conductivity and specific heat capacity,
respectively. In this case, you may:
2.
Specify the thermal properties for the oil and BS&W components and have PC-PUMP calculate
values for the mixture based on the composition. This option is activated by clicking on the
Derived from Fluid Composition option and choosing User-Input Values.
3.
Use the PC-PUMP default thermal properties values for oil and water. These can be activated
by clicking on the Derived from Fluid Composition option and choosing Default
Values.
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Diluent Injection
You will specify the diluent type and flow rate in PC-PUMPs Analysis Window. There is a button
for this below the Advanced Viscosity button:
Click on the Diluent Injection Effects button to open the Diluent Specification window:
You must specify diluent density, flow rate and viscosity. You have the option of specifying an
advanced viscosity for diluent. This works in the same way as the advanced viscosity for the
produced fluids but you can only specify a viscosity/temperature relationship for the diluent.
PC-PUMP uses the following equation to combine the viscosity of the produced fluids with the
viscosity of the diluent:
log mix = (1 DF ) log prod + DF log diluent
Where DF is the diluent fraction of the combined fluids (by volume). If you are using the
BS&W effects option in the advanced viscosity window (for the produced fluids), PC-PUMP will
mix the diluent and oil together first, using the above equation, and then calculate the overall
mixture viscosity by blending the oil/diluent mix with the water using the method you select in the
advanced viscosity window.
Viscous Torque
PCPs in applications where large volumes of viscous fluids are pumped have reportedly
experienced a larger torque than was predicted by previous versions of PC-PUMP. The increase in
torque is due to flow losses within the pump. Users of PC-PUMP V2.6 now have the option of
considering this viscous torque. To turn on this feature, simply click on the check box located
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immediately below the Advanced Viscosity button in the fluid properties section of the Analysis
Input window.
PC-PUMP will print an output message when this option is used. The calculation performed in
PC-PUMP is based on a model developed from limited amounts of laboratory and field data available
to C-FER. Therefore, caution is recommended when performing analyses with this feature turned
on. This feature cannot be used with multilobe pumps.
The estimated viscous torque is reported in the Output Messages, Energy Flow window, and in
the Torque Breakdown tab of the Rod Loads/Deflection charts.
Operating Conditions
Operating condition inputs in the Analysis Inputs window include the fluid rate, pump speed, fluid
level (or producing pressure), tubing and casing head pressures, well temperature profile, and
motor operating frequency (for downhole drive cases only). These inputs are described in detail
below:
Fluid Rate (Surface): Total surface fluid rate at standard conditions. This rate includes
the oil, water, and sand components of the produced fluid.
Volumetric Efficiency: Volumetric pump efficiency. Normally this is simply a static
value which is set in the pump selection process. However, the program can be directed
to determine volumetric efficiencies dynamically based on pump test information. This
mode is activated by clicking on the Pump Model button located in the lower right area
of the Analysis Inputs window. This opens a Pump Characteristics dialog which lists the
static friction and volumetric efficiency values and contains a Pump Test Data toggle
switch for all available pumps. If you activate the Test mode and there is a pump test
available for the currently selected pump, the word "test" appears in the volumetric
efficiency box on the Analysis Inputs window. However, if Test mode is selected and
there is no pump test specified for the current pump, the corresponding static
volumetric efficiency is displayed in the box and used in any calculations.
Pump Speed: Rotational speed of the PC pump.
Motor Operating Frequency (downhole drive module only): The frequency of the
electrical power supplied to the downhole electric motor. This frequency may differ
from the power supply frequency. Downhole motors are normally controlled by a
variable speed drive (VSD), which allows speed control by converting input power from
the supply frequency to the desired motor operating frequency.
Fluid Level: Distance from surface to the top of the annular fluid column. To specify
this value with respect to measured depth (mKB or ftKB), vertical depth (Vm or Vft) or
joints of fluid (jts), toggle the unit button to the right of the fluid level value to the
desired units. Note that PC-PUMP assumes that one joint of fluid is equivalent to a
measured length of 9.6 m.
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Bottomhole Pressure: Pressure at the mid-perforation location during production.

Tubing Head Pressure: Tubing head pressure.
Casing Head Pressure: Casing head pressure.
Bottomhole Temperature: Fluid temperature at the mid-perforation location.
Temperature Gradient: The reduction in tubing fluid temperature per unit vertical
depth as it travels to surface.
Flowing Wellhead Temperature: Temperature of fluid flowing through wellhead. This
parameter should not be entered manually when the Consider Heat generate by Pump
Friction or Perform Motor Heating Analysis options are turned on.
Some operating conditions are interdependent, and by specifying one you define another. For
example, consider fluid rate and pump speed: For a given pump displacement and volumetric
efficiency, either parameter can be calculated based on the value input for the other. To address
interdependent parameters, PC-PUMP uses special toggle buttons that can be switched between
several alternative combinations of parameters to designate the input and calculated parameters.
Calculated parameters cannot be entered manually and hence their edit boxes will be greyed out.
You can click on the toggle buttons until the arrow points away from the one value you wish to
specify and towards the other values, which will be calculated.
The operating conditions you need to specify will be dependent on whether or not an inflow
performance relationship (IPR) is available. The IPR defines a direct relationship between the
produced fluid rate and the bottomhole pressure (see Technical Considerations Inflow
Performance). An IPR correlation can be activated by marking the IPR check box. (See the next
section for a description of how to specify an IPR.) If an IPR is not selected, you will see two
toggle buttons alongside the operating conditions inputs. You must enter the fluid rate, pump
speed, or motor operating frequency (downhole drive only), and the fluid level or bottomhole
pressure. If an IPR is active, only one toggle button will appear beside the inputs. In this case you
must enter one of the fluid rate, pump speed, motor frequency (downhole drive only), fluid level
or bottomhole pressure.
Warning: Extra care must be taken when using the multiphase fluid properties option when an
IPR is not active. The pump intake pressure calculated in PC-PUMP is affected by the casing head
pressure and fluid level and by the amount of free gas which is separated and diverted up the
casing/tubing annulus. This effect may make comparative analyses somewhat complicated. For
instance, in order for the producing pressure to remain constant in several analysis cases with the
same free gas separation efficiency, flow rate, and casing head pressure but different pump seating
depths, the fluid level in the annulus must change accordingly. This is because the amount of free
gas in the casing/tubing annulus changes with different pump seating depths, which affects the
annulus pressure gradient and consequently the pump intake pressure. Therefore, for the results
to be meaningful, you must select the input conditions carefully when performing analyses using
these options.
Motor heating analyses are used to calculate the temperature of the motor when a downhole drive
is used. In some cases, particularly with low flow rates or high viscosity fluids, the motor can
overheat. PC-PUMP can help you predict if there is potential for a motor overheating problem to
occur.
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There are several temperatures of importance if a motor heating analysis is performed. These
include the ambient fluid temperature around the motor, the motor housing surface temperature,
and the motor winding temperature. Heat is transferred by conduction from the motor windings
to the motor housing surface, and then by convection to the produced fluid as it flows past the
motor. PC-PUMP calculates the motor housing surface temperature and the temperature increase of
the produced fluid past the motor using the appropriate fluid thermal properties. The key motor
design parameter is the temperature of the windings, since excessive winding temperatures may
shorten motor life significantly. Motor manufacturers may provide information on temperature
increase of the windings in relation to the housing temperature as part of the motor performance
curves included in the PC-PUMP equipment database. This temperature difference between the
motor windings and motor housing surface is a function of motor power loading. It is suggested
that you contact the motor manufacturer to confirm your design if this information or the
maximum acceptable motor winding temperature is not available from the PC-PUMP motor
database.
If you choose to perform a motor heating analysis, ensure the appropriate check box is selected
under Inputs Operating Conditions. If this option is selected, you must enter thermal properties
of the fluid using the associated button on the left side of the window. Results can be viewed in
the Motor dialog of the Drive Equipment Output window.
Heat Generation by Friction
Friction within the pump generates heat. In steady state operation, this heat is all absorbed by the
fluids passing through (and past) the pump; this will tend to increase the temperature of the fluid.
This can affect the performance of the system if there is multiphase flow, or if you have selected
the option to adjust the viscosity of the fluid with temperature.
PC-PUMP gives the user the option of whether or not to consider this extra heat in the calculation.
This option is turned on using the check box in the Operating Conditions area of the Analysis
Inputs window, shown below:
When this option is turned on, the program requires that you enter the specific heat of the fluid.
This is described in the Fluid Properties section above.
Inflow Performance Relationships
PC-PUMP allows you to perform system analyses using inflow performance relationships (IPR) that
define the correlation between the fluid flow rate and the producing (bottomhole) pressure.
General information on this topic is contained elsewhere in this User Guide under Technical
Considerations-Inflow Performance.
To access the IPR Data dialog shown below, ensure that the IPR check box is active and click on
the associated button at the bottom of the operating conditions input area. To select an IPR type,
enable its corresponding option button. PC-PUMP supports the following five common IPR types:
Straight Line (PI);

Straight Line (with Data Point);
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Vogel;
Backpressure (Fetkovich);
Quadratic (Jones, Blout and Glaze); and
Composite.
Once you have chosen an IPR type, enter the corresponding test data. The parameters that must
be specified depend on the IPR type selected and are defined as follows:
Static Reservoir Pressure: Static reservoir pressure.

Bubble Point Pressure: Bubble point pressure. The specified value must be either equal
to (i.e. saturated reservoir) or less than (i.e. undersaturated reservoir) the static reservoir
pressure.
Test Points #1 & #2 - Producing Pressure: Producing bottomhole pressure (at midperforations) for the corresponding test point. (Note: Test Point #2 only needs to be
specified for multiple point IPRs).
Test Points #1 & #2 - Fluid Rate: Surface fluid rate for the corresponding test point.
(Note: Test Point #2 only needs to be specified for multiple point IPRs).
Test Point #1 BS&W Content: Volumetric percentage of basic sediment and water in
the produced fluid measured at surface. (Note: This input is only specified for a
Composite IPR).
Once you have entered your test data, click the Calculate button to update the IPR chart on the
right-hand side of the dialog. This chart shows producing bottomhole pressure as a function of
fluid rate and extends from zero flow rate (producing pressure = static reservoir pressure) to the
maximum flow rate (producing pressure = zero). If the Composite IPR type is selected, the chart
will contain separate curves for oil and BS&W rates as well as the BS&W content. Test point data
is also always displayed on the IPR chart.
The IPR Data dialog allows you to calculate a producing pressure at a target fluid rate or vice
versa. To do this, select the desired target condition (i.e. either pressure or rate) by enabling its
option button. Enter the target value into its corresponding edit box and click the Calculate
button. The other value is calculated and the target data point is displayed on the IPR chart.
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IPR Data dialog
To obtain a hard-copy of the IPR chart, click the Print button at the bottom of the dialog. Once
you have finalized your IPR relationship, click the OK button on the bottom of the screen to
return to the Analysis window. To abort specifying an IPR relationship and return to the Analysis
window, click the Cancel button.
Note: For entry and display convenience, the units for all of the parameters within the IPR dialog
can all be toggled between SI and Imperial. The units shown on the chart depend on the
status of the units on the target conditions.
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Performing Calculations
Now that you have configured a system and specified analysis inputs, you are ready to perform
calculations using the following procedure:
select an active equipment case and pump model;

choose and configure a calculation mode; and
initiate the calculation process.
The calculation procedure is controlled from the lower right-hand portion of the Analysis Inputs
window shown below.
Calculation control area of PC-PUMP
First, select a drive location, either surface or downhole, using the option buttons. Then, use the
drop-down list boxes and Pump Model button in the Selection area to select an active equipment
case and pump model from those available. Note that if you have only defined equipment cases
for one location in the System Configuration module, you must select that drive location for the
analysis.
The next step is to choose one of the calculation modes by enabling its corresponding button. In
PC-PUMP, the following four different calculation modes are available:
Standard: used to perform the fundamental calculation for the current scenario
Equipment Comparison: used to compare results of different equipment cases
Pump Comparison: used to compare results using different pumps
Batch Comparison: used to get results over a range of operating conditions
Once a calculation mode has been chosen, the Calculate button can be activated. In Standard
mode, this immediately initiates the calculation process. However, if one of the other three modes
is selected, a dialog box is first displayed in which more specific options can be selected to
configure the calculation process. After these options are set, clicking the Continue button
initiates the calculation process. For all modes, a status bar displays the progression of the
calculation. Depending on the mode selected, a specific window may be automatically opened at
the conclusion of the calculation process. Each of PC-PUMP's calculation modes is described in
detail in the following sections.
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Standard
PC-PUMP's fundamental calculation mode has been denoted Standard. When this mode is
enabled, an equipment case and a PC pump need to be selected before you click the Calculate
button. The progress bar shown below may appear instantaneously; the computational time,
however, should be relatively short. At the conclusion of the calculation, the Analysis window will
be updated to reflect the results of the analysis for the active pump, equipment case, and fluid
properties/operating conditions.
Calculation progress bar
Equipment Comparison
The Equipment Comparison calculation mode allows you to directly compare different equipment
configurations using the same analysis inputs. To utilize this mode, at least two configurations
should be set up as equipment cases within the System Configuration module. To initiate the
Equipment Comparison calculations, click on the Calculate button. This will bring up the
Equipment Comparison Configuration dialog shown below.
Equipment Comparison Configuration dialog
All of the equipment cases that have been defined are shown in the list box on the left-hand side
of the Configuration dialog. Note that only the equipment cases for the active drive location are
shown. PC-PUMP does not allow you to simultaneously run equipment comparisons between
surface and downhole drive cases. To select specific cases for analysis, highlight their names and
then click the Add button. The highlighted cases are added to your current selection list displayed
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on the right-hand side of the screen. If desired, all of the defined equipment cases can be selected
simultaneously using the Select All button. If you want to remove cases from your current
selection, highlight them and then click the Delete button. Once you have finalized your
selection, click the Continue button on the bottom of the dialog to start the computational
process. Selecting the Cancel button returns you back to the Analysis window without
performing any calculations.
Calculation time will be contingent on the number of equipment cases selected, the level of
calculation complexity and the processing speed of your computer. A progress bar displays the
status of the calculation. Should you wish to abort the calculation process, click the Cancel
button on the progress bar. When all of the calculations are complete, a Comparison Table
output window is displayed. This table is discussed elsewhere in this User Guide under Examining
Results.
Pump Comparison
The Pump Comparison calculation mode allows you to simultaneously evaluate numerous
different PC pump models using the same analysis inputs. Before you can use this mode, the
pump models you want to evaluate must be selected within the System Configuration module.
The first step in performing Pump Comparison calculations is to select an equipment case for use
in the assessment. With the exception of the pump, the equipment associated with this case forms
the standard system configuration for the pump comparison assessment. Once the desired
equipment case has been selected, click the Calculate button to bring up the Pump Comparison
Configuration dialog shown below.
Pump Comparison Configuration dialog
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All of the selected pumps are shown in the Available Pumps list box on the left-hand side of the
configuration dialog. If necessary, scroll bars appear in the list box to allow you to access each of
the pumps. To select specific pumps for analysis, highlight their names and then click the Add
button. The highlighted pumps will be added to Selected Pumps list box on the right-hand side of
the screen. If desired, you can select all of the available pumps simultaneously using the Select All
button. To remove pumps from your current selection, highlight them and then click the Delete
button.
Within the Pump Comparison calculation mode, the program provides the ability to exclude any
pumps from the analysis that would operate at an undesirable speed or pressure loading. This is
accomplished through the use of filtering criteria that are specified in a series of edit boxes located
in the central portion of the Pump Comparison Configuration dialog. For both pump speed and
pressure rating, you can specify minimum and maximum acceptable values. Initially, the
minimum and maximum values for speed will be set to 0 and 2000 RPM, respectively, while the
minimum maximum values for pressure will be 0 and 100% of rated pressure, respectively (i.e.
essentially no filtering). You can modify these criteria to suit your requirements by typing the
desired values into the appropriate edit boxes.
Once you have finalized configuring the pump comparison dialog, click the Continue button on
the bottom of the dialog to start the computational process. Selecting the Cancel button returns
you back to the Analysis window without performing any calculations.
Calculation time is contingent on the number of pumps selected, the level of calculation
complexity and the processing speed of your computer. A progress bar displays the status of the
calculation. Should you wish to abort the calculation process, click the Cancel button on the
progress bar. When all of the calculations are complete, a Comparison Table output window is
displayed. This output window is described later in this User Guide under Examining Results.
Batch Comparison
When evaluating PC pumping systems, it is often desirable to perform assessments for a range of
operating conditions (e.g. fluid rates, fluid levels). This type of analysis can be done most
effectively using PC-PUMP's Batch Comparison calculation mode. The first step in this process is to
select an equipment case and a PC pump. Next, click the Calculate button to bring up the Batch
Comparison Configuration dialog shown below.
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Batch Comparison Configuration dialog
Batch Comparison calculation mode allows you the option of varying one of the following key
operating parameters:
API Gravity: Available in multiphase mode or single phase mode with Specify Fluid
Composition option turned on.
Bottomhole Pressure;
BS&W: Available in multiphase mode only.
Casing and Tubing Head Pressure: Either the tubing and casing head pressures can be
varied together, or one of them can be varied individually. When varied together, the
two pressures are considered to be equal at all steps in the comparison.
Casing Head Pressure;
Density: Available only in single phase mode with Specify Fluid Composition option
turned off.
Diluent Rate: Available when diluent injection is being used.
Diluent Viscosity: Available when diluent injection is being used.
Fluid Level;
Fluid Rate;
Free Gas Separation: Available in multiphase mode only, with Calculate Free Gas
Separation option turned off.
GOR: Available in multiphase mode only.
GLR: Available in multiphase mode only.
Motor Operating Frequency: Available in downhole drive mode only.
Pump Speed;
Tubing Head Pressure;
Viscosity: Available in single phase mode only, with Advanced Viscosity option turned
off.
Water Cut: Available in single phase mode only.
You choose the parameter you want to vary from the drop-down list box at the top of the Batch
Comparison Configuration dialog. Once a batch parameter has been selected, the values for
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which evaluations will be completed need to be defined. This can be done either automatically or
manually. To define values automatically, enable the Automatic Values toggle button and then
specify a starting value, ending value and increment. To define values manually, enable the
Manual Values toggle button and then type the desired values into the single column spreadsheet.
Once the input is finalized, click the Continue button on the bottom of the dialog to start the
computational process. Selecting the Cancel button returns you back to the Analysis window
without performing any calculations.
Calculation time is contingent on the number of batch values selected, the level of calculation
complexity and the processing speed of your computer. A progress bar displays the status of the
calculation. Should you wish to abort the calculation process, click the Cancel button on the
progress bar. When all of the calculations are complete, the Comparison Graphs output window
will be displayed. This output window is described in the next section of the User Guide.
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Examining Results
When you perform calculations using PC-PUMP, a whole array of results are generated. To use
PC-PUMP effectively, it is important that you are familiar with the type of information that is
available and the best ways to examine it. You should also recognize that some results are
contingent upon the specification of certain inputs (e.g. in order to get rod/tubing contact loads for
surface drive systems you must input a wellbore geometry). PC-PUMP results can be classified into
three main types of output:
summary output conditions;

output messages; and
output windows.
In many cases, the summary output conditions and the output messages provide you with all the
information you need. However, in certain situations - such as troubleshooting field applications,
you may need to utilize the more comprehensive information contained in the output windows to
complete a more detailed review. The remainder of this section guides you through all of the
results that can be generated by PC-PUMP. For convenience, it has been divided into parts
corresponding to the three main output types.
Results are presented in the Analysis Outputs window, which is shown below. This window appears
automatically after initiating a calculation in Analysis Inputs. Once a calculation has been
performed, you can toggle between these two windows by clicking the tabs at the bottom of the
screen. Important: any changes in the Analysis Inputs window will only be reflected in the results
if you click on the Calculate button.
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Analysis Outputs window
On the left side of the Analysis Outputs window, fluid properties and operating conditions are
summarized. You can use the bars to the right of each of the summary boxes to scroll through
the lists if necessary. Parameters that are displayed include the fluid properties and operating
conditions that were specified or calculated as a result. For example, if you specified the fluid flow
rate in Analysis Inputs, the corresponding pump speed will be displayed in the operating conditions
box. The active drive type, pump and equipment case are listed below the summary boxes on the
lower left side of the window. Buttons in the centre of the window allow you to access the
detailed output windows, which are described later in this Users Guide. As mentioned above, not
all of the output windows may be applicable to any given case; buttons which are not applicable
will be greyed-out. On the right side of the window are summary output parameters and a display
area for output messages. Note that you can return to the System Configuration window by clicking
on the Configuration button on the bottom left side of the screen.
Summary Output Parameters

When evaluating PC pumping systems, there are certain parameters that are commonly used to
measure system performance. For convenience, the most important of these parameters are
displayed prominently on the right-hand side of the Analysis Outputs window. Some of these are
always available, but others are only applicable to either surface or downhole drive systems and are
only shown when appropriate. Summary output parameters are listed below.
The following parameters are applicable to both surface drive and downhole drive systems:
Pump Intake Pressure: Pressure at the inlet to the pump.
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Pump Discharge Pressure: Pressure at the pump discharge.

Hydrostatic Head: Total differential head between the fluid columns in the tubing and
annulus, expressed as a pressure.
Flow Losses: Cumulative flow losses, expressed as a pressure, through the entire flow
path (casing, tail joint or shroud, and tubing).
Pump Pressure Loading: Pressure loading of the pump as a percentage of its rated
pressure capacity.
System Input Power: Electrical power required to operate the system. This parameter is
only shown if drive equipment has been included in the analysis.
Energy Costs: Energy cost per day based on active power consumption. This parameter
is only shown if drive equipment has been included in the analysis. Note that the unit
power cost can be assigned in the Preferences-Defaults window or in the Drive
Equipment window.
Efficiency: A drop-down list box allows you to switch between three efficiency values:
1. Pump Volumetric Efficiency: the ratio of the actual well total flow rate at the pump
intake to the flow rate calculated based on the nominal displacement and
speed of the pump. This is either specified as a static value in the pump
selection process or calculated using pump test information and the operating
conditions of the current analysis.
2.
System Mechanical/Electrical Efficiency: derived from the mechanical or electrical

efficiencies of each individual system component, and represents the portion
of the total system input power that is used to overcome the hydraulic
component of the pump torque at the pumps operating speed.
3.
Overall System Efficiency: the percentage of the total system input power that
contributes to increasing the pressure of the produced fluids (and any
associated gas) across the pump. This is equivalent to the System
Mechanical/Electrical Efficiency multiplied by the Pump Volumetric
Efficiency.
These parameters are specific to surface drive systems:
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Max. Rod Torque: Maximum torque that occurs in the rod string.
Max. Axial Rod Load: Maximum axial load that occurs in the rod string.
Max. Effective Rod Stress: Maximum rod string effective stress in terms of a percentage
of the rod yield strength.
Max. EDF: Maximum elastic design factor in the rod string. The EDF is the ratio of
the effective stress in the rod to its material yield strength. (See Rod String Loading in
Part 2: Background.)
Max. DDF: Maximum deformation design factor in the rod string. The DDF is the
ratio of the operating rod torque to the maximum allowable rod torque (defined by the
deformation-based method - see Rod String Loading in Part 2: Background.)
Max. Contact Loads: Maximum contact load between the rod string and the tubing. A
drop-down list box allows you to switch this value between the maximum loads
associated with the coupling/centralizers, rod guides and continuous rod. (Note: these
values will be zero in the case of a perfectly vertical well.)
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Prime Mover Output Power: The shaft power output of the prime mover in the surface
drive equipment.
These parameters are specific to downhole drive systems:
Pump Torque: The amount of torque required to operate the pump at the given
conditions.
Pump Axial Load: The axial load transmitted by the pump to the downhole drive
assembly.
Cable Conductor Temp.: The calculated maximum temperature of the conductor in the
electrical cable.
Motor Winding Temp.: The calculated maximum temperature of the motor windings.
Motor Output Power: The shaft power output of the downhole electric motor.
Output Messages
There are many considerations that you may wish to address when evaluating PC pumping
systems. To highlight possible problem areas, PC-PUMP tests the analysis results against some
common design criteria. Whenever a problem is detected during the calculation process, a
message is written to an output messages file. In turn, the information in this file is displayed in
the output messages text box located at the bottom of the Analysis Outputs window. Scroll bars in
this text box allow all of the output messages to be viewed.
Output messages text box

PC-PUMP displays three different types of output messages.
These are:
Notes that indicate adjustments or assumptions made during the analysis

Warnings that indicate potential problems with the current system design
Errors in the calculation that were not serious enough to prevent completion of the
calculation but that could indicate that there is some aspect of the design that will not
work properly.
Output Windows
The summary output parameters in the Analysis Outputs window provide a general overview of the
analysis results. However, in many instances you may want to examine specific analysis outputs in
more detail. In the central portion of the Analysis Outputs window, a vertical row of buttons allows
you to access the following output windows which contain additional detailed information:
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Energy Flow: Diagram that traces the energy flow through the system from the prime
mover to the pump and a table which provides a breakdown of the energy consumed by
the various system components.
Drive Equipment: Specifications related to the operating conditions of either the
surface drive or downhole drive equipment. Tabs allow you to view separate windows
for the different components of the system. This window is only available if drive
equipment was specified in the System Configuration window.
Rod Loads/Defl.: Charts which display rod string loading and deflection results.
Rod/Tubing Cont.: Charts that display rod/tubing contact loads.
Basic Fluid Flow: Charts that display basic fluid flow information (e.g. pressure,
temperature and viscosity profiles).
Multiphase Flow: Charts that display multiphase flow information (e.g. liquid holdup,
flow regime).
Key Locations: Table that displays important parameters for several key locations (e.g.
pump intake, surface).
Comparison Tables: Tabular output from all the scenarios (i.e. equipment cases,
pumps or batch values) run in the comparison calculation modes.
Comparison Charts: Charts that allow you to examine the batch comparison output
results graphically as a function of the varying parameter.
Rod/Tubing Wear: Supplementary analysis window in which you input additional
data in order to assess rod string and tubing wear for surface drive systems.
Rod Fatigue: Supplementary analysis window in which you input additional data in
order to assess rod string fatigue for surface drive systems.
Backspin: Supplementary analysis window in which you input additional data in
order to evaluate rod string backspin behavior for surface drive systems.
Sand Settling: A tool to determine if the velocity in the tubing is sufficient to carry
entrained sand to surface.
Not every output window listed above will be available for every analysis you perform. Numerical
markers on the output window descriptions indicate the following limitations:
Only accessible for surface drive cases.

Only accessible for downhole drive cases.
Only available for multiphase flow conditions
Only available if a well geometry is specified
Only available in the comparison calculation modes.
Only available in batch comparison calculation mode.
Only available if surface equipment has been specified.
These output windows facilitate supplementary analysis that is not completed in the standard
calculation routines. These analyses require additional input data.
The following sub-sections review each of the output windows in detail:
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Energy Flow
The Energy Flow window can be accessed by clicking the Energy Flow button in the Analysis
Outputs window. It traces the utilization of power through the individual PC pumping system
components. The Energy Flow window clearly shows where power is being consumed within the
overall system. If the results show that a particular component has an unacceptable efficiency, you
may want to reconsider its use. For example, when surface drive hydraulics operate outside of
their designed speed and pressure range, they experience dramatic reductions in efficiency.
The Energy Flow output window is divided into two sections: Electrical/Mechanical Power Train
and Hydraulic Power Train. The electrical/mechanical power train breakdown (upper half of the
window) isolates the power consumption of each component of the system, and is specific to the
type of drive system in use (surface or downhole). The power input and output of each
component is shown along with the associated power loss and resulting mechanical and/or
electrical efficiency.
The hydraulic power train (lower half of the window) provides a detailed breakdown of the power
consumed by the progressing cavity pump. This includes the effective torque and power
associated with each of the components contributing to the differential pressure acting on the
pump, along with the pump friction torque. Contributing pressures include the hydrostatic head,
wellhead pressure differential, and flow losses. Both the hydrostatic head and wellhead pressures
are displayed in terms of the net pump differential pressure that they create. When added to the
flow losses, they generate the total pressure load in the pump.
Energy Flow - Surface Drive Systems
The Energy Flow window for surface drive systems is shown below. The upper half of the
window describes the flow of energy from the prime mover through auxiliary surface equipment
and the rod string to the pump. Components not applicable to the selected equipment
configuration are greyed-out on the screen. With the exception of the rod string, each of the
surface drive system power train components is self explanatory. Rod String (Mech.) represents
the frictional losses that occur due to mechanical contact between the rotating rod string and
stationary tubing. Rod String (viscous) represents the frictional losses due to viscous interaction
between the rotating rod string and the fluid in the tubing.
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Energy Flow window Surface drive systems
Energy Flow - Downhole Drive Systems

The Energy Flow window for downhole drive systems appears as shown below. The upper half
of the window describes the flow of energy from the power transmission cable through the motor
and drive assembly to the pump. This window allows you to determine if any of the components
are performing inefficiently, to assist with system optimization. For example, an undersized cable
can cause a large voltage drop and dissipate more power than necessary.
Energy Flow window Downhole drive systems
Drive Equipment
The Drive Equipment window provides a detailed breakdown of the performance of each
component of the drive system and addresses key concerns for equipment selection. Like the
Energy Flow window, the appearance of the Drive Equipment window changes depending on
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whether a surface drive or downhole drive system is active. The window can be accessed by
clicking on the Drive Equipment button. Once you are in the Drive Equipment window, tabs at
the bottom of the screen allow you to move between screens showing detailed outputs for each
component of the selected drive system.
Drive Equipment - Surface Drive
The drive equipment window for surface drive systems displays results for the drivehead, belts (if
selected), hydraulics (if selected) and prime mover. By examining the results presented for each
components loading conditions relative to the manufacturers ratings, you can determine if the
surface equipment components are sized appropriately. Additionally, by moving from component
to component, the transmission of speed, torque and power can be traced from the drivehead
back to the prime mover. Note that if a component has not been selected as part of the current
equipment configuration, all of its specifications will be displayed as zero.
A Drive Equipment Summary report can be printed by selecting the FilePrint menu command.
This report includes all of the information displayed in the individual component windows. A
sample of this report is included in Appendix B.
Drivehead
The Drivehead portion of the Drive Equipment output window is shown below. At the top of
the screen the drivehead model, type, gearbox reduction (if applicable) and transmission efficiency
are displayed. Below these, the following operating conditions are listed:
Speed: Drivehead output speed (i.e. the polish rod speed) and input speed.
Torque: Drivehead output torque (i.e. the polish rod torque) and input torque.
Power: Drivehead output power (i.e. the polish rod power) and input power.
Thrust Bearing L10 Life: Length of time (in years) that 90% of the thrust bearings will
operate before the first evidence of fatigue develops. Within a large sample size, the
median bearing life is somewhere between four and five times the L10 life.
Main Shaft Torque Loading: Main shaft torque loading as a percentage of its maximum
allowable limit.
Structural Loading: Structural loading of the drivehead frame as a percentage of its
maximum capacity.
Power Output: Drivehead power output as a percentage of rated maximum.
Output Speed: Output speed of the drivehead as a percentage of its rated maximum
continuous rotational speed.
Gearbox Torque: Gearbox torque as a percentage of its AGMA rating (greyed out if a
gearbox is not included).
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Drive Equipment output window - Drivehead
Belts
The Drive Equipment output window for Belts is show below. Since belts are an optional
component, their specifications may be greyed out to indicate their absence in the current
equipment configuration. The reduction ratio and transmission efficiency of the belt and sheaves
system is displayed at the top of the screen. If the Adjusting Belt Reduction Ratio option for
speed matching was selected, then the reduction ratio is likely to be different from the value
originally specified during equipment selection (because the surface equipment speed will have
been matched to the pump speed by changing the belt reduction ratio). In the lower portion of
the screen, values for the following operating conditions are listed:
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Speed: Output and input speed of the belt and sheaves system.
Torque: Output and input torque of the belt and sheaves system.
Power: Output and input power of the belt and sheaves system.
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Drive Equipment output window - Belts
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Hydraulics
The Hydraulics portion of the Drive Equipment output window is shown below.
Drive Equipment output window - Hydraulics
Since hydraulics are an optional input, the parameters on the screen may be greyed out indicating
that hydraulics are not present in the current equipment configuration. Information for the
hydraulic motor and pump are displayed on the left-hand and right-hand sides of the screen,
respectively.
The hydraulic motor specifications listed are:
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Model: Hydraulic motor manufacturer and model.

Displacement: Volume of fluid required to produce one revolution of the hydraulic
motor.
Total Efficiency: Overall operating efficiency of the hydraulic motor.
Flow Rate: Hydraulic motor input and output flow rates.
Power: Hydraulic motor input and output power.
Output Speed: Output shaft speed generated by the hydraulic motor.
Output Torque: Output shaft torque generated by the hydraulic motor.
Operating Pressure: Hydraulic motor operating pressure.
Pressure Load: Hydraulic motor operating pressure as a percentage of its maximum
continuous rating.
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Operating Speed: Hydraulic motor output speed as a percentage of its rated maximum
continuous operating speed.
Output Power: Hydraulic motor output power as a percentage of its rated maximum
power.
The hydraulic pump specifications listed are:
Model: Hydraulic pump manufacturer and model.

Full Displacement: Maximum volume of fluid that can be displaced with each
revolution of the hydraulic pump.
Total Efficiency: Overall operating efficiency of the hydraulic pump.
Flow Rate: Input and output flow rates generated by the hydraulic pump.
Power: Hydraulic pump input and output power.
Input Speed: Speed of the hydraulic pump input shaft.
Input Torque: Torque required on the hydraulic pump input shaft.
Operating Pressure: Hydraulic pump operating (discharge) pressure.
Pressure Load: Hydraulic pump operating pressure as a percentage of its maximum
continuous rating.
Operating Speed: Hydraulic pump input speed as a percentage of its rated maximum
continuous operating speed.
Actual Displacement: Actual displacement of the hydraulic pump as a percentage of its
full displacement. If the Adjusting Hydraulic Pump Displacement option for speed
matching was selected, then the actual displacement may not be 100%. The surface
equipment speed is matched to the downhole pump speed by varying the hydraulic
pump displacement (in practice this would be achieved through adjustment of its swashplate).
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Prime Mover
The Prime Mover portion of the Drive Equipment output window is shown below. The window
only displays information for electric motors, since they are currently the only type of prime
mover supported by PC-PUMP.
Drive Equipment output window - prime mover
At the top of the screen, the motor power rating, synchronous speed (at supply frequency),
nominal efficiency and nominal power factor are displayed. The following operating parameters
are listed in the lower portion of the window for the electric motor:
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Output Speed: Operating speed of the electric motor.

Output Torque: Torque delivered by the electric motor.
Output Power: Power output of the electric motor.
Operating Frequency: Frequency of the motor input power. If the Adjusting Prime
Mover Speed option for speed matching was selected, then the operating frequency
may be different than the supply frequency. The surface equipment speed is matched to
the pump speed by varying the motor operating frequency to replicate an electronic
speed control system.
Voltage Draw: Voltage drawn by the motor during operation. If the motor is operating
at supply frequency or higher, then this value is equal to the supply voltage. However, if
the operating frequency is less than the supply frequency, then the voltage draw is
decreased to maintain a constant Volts/Hertz ratio to simulate variable speed control
systems operating at below supply frequency.
Current Draw: Current drawn by the motor during operation.
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Power Input: Power drawn by the motor during operation. The left-hand value (kW or
hp) is the active power while the right-hand value (kVA) is the apparent power.
Energy Cost: Energy cost per day based on active power consumption. Note that the
unit power cost can be assigned in the Preferences-Defaults window.
Motor Loading: Loading of the electric motor as a percentage of its power rating.
Drive Equipment - Downhole Drive

The downhole equipment version of the Drive Equipment window has three tabs at the bottom
of the screen which allow you to move between screens showing detailed analysis results for the
drive assembly, downhole motor and power transmission cable.
Drive Assembly
The Drive Assembly portion of the window shows the manufacturer and model of drive assembly
that was selected, along with its gear reduction. It displays the input and output speed, power and
torque from the drive assembly and the calculated mechanical efficiency. The thrust loading,
torque loading, power loading and speed are shown as a percentage of the associated rated
capacities of the drive assembly.
Drive Equipment Output window Drive Assembly
Motor
The Motor portion of the Drive Equipment window summarizes the equipment that was selected
and provides results that describe the operating conditions and performance of the motor.
The window displays a summary of the specifications of the selected motor including the
manufacturer, model, power rating, number of poles, and nameplate frequency. Performance
parameters that are displayed on the window include:
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Operating Frequency: The electrical frequency at which the motor operates. This
frequency may differ from the power supply frequency. Downhole motors are normally
controlled by a variable speed drive (VSD), which allows pump speed control by
converting power from the supply frequency to the desired motor operating frequency.
Output Power: The shaft power provided to the system by the motor.
Operating Voltage: The voltage at which the motor operates.
Current Draw: The amount of current required by the motor.
Operating Speed: The speed at which the motor output shaft rotates.
Efficiency: The overall mechanical efficiency of the motor.
Power Factor: The ratio of active to apparent power drawn by the motor.
Slip: The difference between the operating speed of the motor and the synchronous
speed at the operating frequency.
Motor Loading: The ratio of the actual motor output power to the motors rated power
at the operating frequency. This value is scaled with frequency, so that the motor rated
power will not be the nameplate power if the operating frequency is not equal to the
nameplate frequency.
Motor Skin Temperature: The maximum temperature at the outside surface of the
motor.
Motor Winding Temperature: The maximum temperature of the windings inside the
motor. The winding temperature depends on temperature rise at operating conditions,
and may not be available from manufacturers for all motors.
Winding Temperature Rating: The motor manufacturers maximum allowable winding
temperature specification.
Flow Velocity Past Motor: The average velocity of the flow in the annulus between the
motor and the casing or shroud.
Drive Equipment Output window Motor
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Cable
The cable output window displays a summary of the specifications of the selected cable including
the manufacturer, model, and type (round/flat). The following analysis results are presented in the
window:
Conductor Temperature: The maximum calculated temperature of the cable conductor.

Allowable Conductor Temperature: The cable manufacturers maximum allowable
conductor temperature specification.
Voltage Loss in Cable: The voltage drop in the cable corresponding to the current draw
and conductor temperature.
Motor Voltage: The operating voltage of the motor.
Current Draw: The current passing through the cable to the motor.
Surface Voltage: The voltage at surface.
Power Input at Surface: The total power drawn by the system.
Total Energy Cost: The daily cost of the energy drawn by the system. Note that the
unit power cost can be assigned in the Preferences-Defaults window.
Drive Equipment Output window Cable
Rod Loading/Deflection (Surface Drive Systems)
The Rod Loading/Deflection output window can be accessed by clicking the Rod Loads/Defl.
button. The tabs on the bottom of the window allow you to move between the following ten
charts:
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Torque and Axial Load - Displays the torque and axial load profiles along the length of the rod
string. The peak polish rod torque and tension values are also listed.
Effective Stress - Displays the effective rod stress profile along the length of the rod string.
Values are expressed in both conventional stress units (i.e. MPa or ksi) and as a percentage of the
rod yield strength.
Elastic Based Design - Compares the operating torque to the torque needed to yield the rod
material along the length of the rod string. Note that the torque at yield strength values have been
determined using combined loading methods which take into consideration the operating axial
load.
Deformation Based Design - Compares the operating torque to the maximum allowable torque
as specified by a 0.2% plastic strain of the material given the operating axial load and effective rod
curvature. This deformation-based load limit should not be used as a design limit. It should be
taken only as an indication of the maximum torque the rod string could withstand before
encountering excessive plastic deformation.
Torque Loading Compares the operating torque to the manufacturers torque limit. The
torque ratings do not include any effects of axial load. Different manufacturers may provide
torque ratings based on different levels of axial load and different safety factors. Currently, there is
no standardized method for determining the torque rating for a sucker rod.
Design Factors - Displays elastic and deformation design factors over the length of the rod
string. The elastic design factor (EDF) is the ratio of the effective stress (from the applied
torsional and axial loading) to the yield stress for the rod material. The deformation design factor
(DDF) is the ratio of the operating torque to the torque at the deformation-based combined
loading limit. Additional information on rod string loading is contained in the User Guide under
Technical Considerations-Rod String Loading.
Torque Breakdown (Incremental) - Displays the rod/tubing contact and viscous loading
contributions of each rod string element (i.e. individual sucker rod or continuous rod segment).
Contact load contributions result from mechanical friction between the rod string and tubing.
Viscous contributions result from interaction between the rotating rod string and viscous fluid in
the tubing. The graph also shows the pump hydraulic and friction torque values. The hydraulic
component is the torque required to displace the fluid across the differential pump pressure. The
friction component is the torque required to overcome friction within the pump.
Torque Breakdown (Cumulative) Displays the torque breakdown data as above, but on a
cumulative basis downhole.
Deflection and Rotation - Displays the cumulative axial deflection and rotation along the length
of the rod string under operating conditions. Total deflection and rotation values are also included
on the chart. Note that the axial deflection values include both rod weight and operating load
extensions but do not include any changes due to thermal effects.
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Space-Out - Displays information useful for determining rod string space-out requirements for
system installation. Curves on the chart show rod deflection due to rod weight; rod deflection due
to operating loads, rod extension due to thermal effects (see note below), and total rod deflection.
Also listed are values that correspond to the maximum deflections for each of these curves as well
as a minimum space-out value, which is the total deflection resulting from operational loading and
thermal effects.
Note: If the tubing is anchored, temperature changes will cause the rod string to lengthen relative
to the constrained tubing. When you click the Space-Out tab, the Thermal Effects dialog
shown below first appears before the chart is displayed. If you want to consider the
effects of thermal expansion on space-out requirements, enable the check box, enter a
space-out temperature (i.e. the average temperature of the rods within the wellbore during
space-out) and click the OK button to view the space-out chart. If you do not want to
consider thermal effects, just click the OK button.
Thermal Effects dialog
The active Rod Loading/Deflection chart can be printed by selecting the FilePrint menu
command.
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Rod Loading/Deflection output window charts
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Rod/Tubing Contact (Surface Drive Systems)
The Rod/Tubing Contact output window is accessed by clicking the Rod/Tubing Contact
button. Tabs at the bottom of the window allow you to view the following five charts:
Rod/Tubing Contact Loads - Displays the contact loads for each rod string element (i.e.
individual sucker rod or continuous rod segment). Different data symbols are used for
couplings/centralizers, rod guides and continuous rod. The contact loads for couplings,
centralizers and rod guides are expressed as point loads per connection. In the case of continuous
rod, the contact loads are expressed as a linearly distributed load in the specified force per distance
units. Note that the charts will only display data for rod components included in the specified
equipment configuration.
Rod/Tubing Distributed Contact Loads - Displays contact loads for each rod string element
expressed as a distributed load. This chart is intended to facilitate contact loading comparisons
between conventional sucker rods and continuous rod. Distributed contact loads for couplings,
centralizers and rod guides are determined by proportioning their point contact loads along their
load bearing (i.e. contacting) length. Different symbols are used to differentiate the results for
couplings/centralizers, rod guides and continuous rod.
Rod/Tubing Contact Load Component Breakdown - Displays a breakdown of the loading

components contributing to the distributed contact load along the wellbore. These loading
components include weight, vertical curvature and plan curvature. The weight component is due
to the contact produced by gravitational effects acting on the rod string. The vertical and plan
view curvature components reflect the contact loads generated by the combination of rod tension
and wellbore curvature in the respective planes.
Rod/Tubing Contact Locations - Graphically illustrates the location of the rod contact within
the tubing. The contact location is displayed as azimuth values ranging from 0 to 360. Looking
up through the tubing from the pump to surface, the high side of the hole is assigned a contact
location of 0. The contact location then increases in a clockwise direction around the
circumference of the tubing (i.e. low side of the hole = 180). This graph is useful in determining
whether high contact loads are occurring on the low side of the wellbore. This condition can be
quite detrimental from a wear perspective if the well is producing abrasive fluids.
Rod Guide Loading and Spacing - Displays for each sucker rod, the average rod guide contact
load and number of guides per rod. This chart is helpful if you are utilizing the Rod Guide
Optimization mode and want to view the optimized configuration.
The active Rod/Tubing Contact chart can be printed using the FilePrint command.
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Rod/Tubing Contact output window charts
Basic Fluid Flow
The Basic Fluid Flow output window can be accessed by clicking the Basic Fluid Flow button.
The tabs at the bottom of the window allow you to move among the following four charts:
Pressure Profiles - Display the pressure profiles in the casing, tubing and tail joints or shrouds.
Locations of the mid-perforations and downhole equipment are also labelled on the chart.
Tubing Pressure Components - Displays the pressure profile in the tubing, as well as a
breakdown of the flow loss and hydrostatic head components. The hydrostatic component is due
to the weight of the fluid column. The flow loss component is due to frictional pressure losses as
the fluid moves through the tubing. Tubing head pressure results in an offset at surface.
Combined, these components generate the total pressure profile in the tubing.
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Tubing Flow Losses - Displays flow loss components for pre-set lengths of production tubing.
For surface drive cases, flow loss is shown for every rod string element (i.e. individual sucker rod
or continuous rod segment). For each rod segment, different data symbols show the pressure
losses attributed to the rod body, couplings/centralizers and rod guides. In the case of multiphase
flow, only a single flow loss representing the entire element is shown. For downhole drive cases,
tubing flow loss is shown per joint of tubing.
Temperature and Viscosity Profiles - Displays the fluid viscosity profile along the length of the
tubing and the temperature profiles in the casing and tubing. For multiphase flow, the viscosity
displayed corresponds to the mixture viscosity determined based on no-slip conditions (i.e. gas and
liquid moving at the same velocity).
The active Basic Fluid Flow chart can be printed by selecting the FilePrint menu command.
Basic Fluid Flow output window charts
Multiphase Flow
Once you have completed an analysis using multiphase fluid properties, the Multiphase Flow
output window can be accessed by clicking the Multiphase Flow button. The tabs at the bottom
of the window allow you to move between the following four charts:
In-Situ Flow Rates - Displays the in-situ gas, water and oil rates through the tubing and tail joint
or shroud. The location of the pump is marked to illustrate the crossover between the tubing and
tail joint or shroud.
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Produced Gas - Displays the free gas percentage, the solution gas/oil ratio (GOR) and the
solution gas/water ratio (GWR) throughout the tubing string and tail joint or shroud. Note that
the free gas percentage is based on the ratio of free gas flow to total flow (i.e. as opposed to the
percentage volume occupied in the tubing, tail joint, or shroud). Also included on the chart are
the producing gas/oil ratio, tubing gas/oil ratio and casing gas rate values.
Solution Gas - Displays the GOR and GWR throughout the tubing string and tail joint or
shroud. This data is also available in the Produced Gas tab, but is better scaled for viewing in this
tab.
Flow Pattern - Displays the flow pattern types throughout the tubing string and tail joint or
shroud. Types of flow patterns include: single-phase liquid, bubble, dispersed bubble, slug and
annular. The flow pattern may progress from single-phase liquid to bubble or dispersed bubble to
slug as the fluid moves from the pump discharge to surface. Additional information on flow
pattern types is included elsewhere in the User Guide under Technical Considerations-Fluid Flow:
Multiphase.
Liquid Holdup - Displays two-phase and no-slip liquid holdup throughout the tubing string and
tail joint or shroud. The two-phase liquid holdup is the volume fraction of liquid in the tubing or
tail joint during two-phase flow. The no-slip holdup, sometimes called input liquid content, is the
volume fraction of liquid in the tubing or tail joint that would exist if the gas and liquid flowed at
the same velocity (i.e. no slippage). Holdup values vary from zero for single-phase gas flow to one
for single-phase liquid flow. Note that when significant gas production occurs, the two-phase
holdup will be higher than the no-slip holdup indicating gas slippage past the liquid.
The Multiphase Flow chart which is currently displayed can be printed by selecting the
FilePrint menu command.
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Multiphase Flow output window charts
Key Locations
The Key Locations output window shown below can be accessed by clicking the Key Locations
button.
Key Locations output window
This window contains a table with each row corresponding to one key location in the prescribed
well:
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Flowline at Standard Conditions of 101.7 kPa (14.7 psi) & 15.6C (60F);
Wellhead at Tubing Head Pressure;
Pump Discharge;
Pump Intake;
Tail Joint Intake (for surface drive cases only, and only if tail joint is specified);
Bottom of Motor (for downhole drive cases only)
Ventline at Standard Conditions of 101.7 kPa (14.7 psi) & 15.6C (60F);
Wellhead at Casing Head Pressure;
Casing Gas/Liquid Interface (Fluid Level); and
Mid-Perforations.
The table summarizes the calculated values for the following key parameters (rates and properties
are given at in situ pressure and temperature) at each key location:
Measured Depth;
Vertical Depth;
Fluid Temperature
Fluid Viscosity;
Pressure;
Total Fluid Rate;
Oil Rate;
BS&W (basic sediment and water) Rate;
Free Gas Rate;
Free Gas Percent;
Solution GOR; and
Solution GWR.
When diluent injection is used, some more information is given, as shown in the example below:
In this case, the injection was into the tubing at 600 mKB. This is reflected in the viscosity and
diluent flow rate from this point (which has a row in the Tubing section of the table) up to surface.
The difference between the pressure in the tubing at this point (9112 kPa), and the pressure in the
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injection string at this point (9132 kPa, as shown in the bottom line of the table) is the pressure
loss calculated through the injection nozzle. The injection tubing pressure is shown at the
wellhead. In some cases this may be a negative number, which would mean that the specified
diluent flow rate would be able to be injected by gravity alone.
Notes:
1.
When a key location appears twice in the table, the values in the top part apply to the
tubing stream (after gas separation) and the values in the bottom part apply to the casing
stream (before gas separation).
2.
Some of these parameters may not be applicable to all locations (e.g. oil and BS&W rate
are not applicable at the ventline). Similarly, several of the parameters do not apply in
single-phase mode (e.g. free gas rate, free gas percent, solution GOR). In such cases, an
N/A value will be displayed in the table.
Comparison Tables
If you have performed a calculation in any of the three comparison modes, the Comparison
Tables output window shown below provides a tabular display of the results for each of the
scenarios run. Although this window can be accessed by clicking the Comparison Tables
button, it will be displayed automatically following equipment and pump comparison calculations.
The upper portion of the Comparison Tables output window contains a large table with the
results presented in each row corresponding to an individual scenario and the columns containing
numerous operating parameters. Scroll bars allow you to examine all of the information in the
table. In the lower portion of the window, a summary of the system configuration for the
currently active scenario is displayed. The active scenario can be changed by highlighting the row
of interest in the table and then clicking the Update button.
Comparison Tables output window
The following parameters are included in the Comparison Table output window:
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Equipment Case;
Pump Model;
Nominal Displacement (only included in pump comparison mode);
Pressure Rating (only included in pump comparison mode);
Pump Speed;
Volumetric Efficiency;
Flow Rate;
Fluid Level;
Producing Pressure;
Motor Operating Frequency ;
Energy Costs ;
Prime Mover Output Power ;
Motor Output Power ;
System Input Power ;
Polish Rod Power;
Pump Intake Pressure;
Pump Discharge Pressure;
Pump Pressure Loading;
Net Hydrostatic Head;
Flow Losses;
Maximum Rod Torque;
Maximum Axial Rod Load;
Maximum Effective Rod Stress;
EDF (Elastic Design Factor) ;
DDF (Deformation Design Factor) ;
Maximum Contact - Continuous Rod ;
Maximum Contact - Connection ;
Maximum Contact - Rod Guide ;
Rod Torque Loading ;
Free Gas Separation ;
Multiphase Flow Apparent Volumetric Efficiency ;
Free Gas as Pump Intake ;
Drivehead Thrust Bearing L10 Life ;
Drivehead Main Shaft Torque Loading ;
Drivehead Structural Loading ;
Drivehead Power Output ;
Drivehead Speed ;
Drivehead Gearbox Torque ;
Motor Loading ;
Pump Torque;
Pump Axial Load;
Cable Voltage Drop ;
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Cable Conductor Temperature ;

Motor Winding Temperature ;
Flow Velocity Past Motor ;
System Mechanical/Electrical Efficiency ;
Overall System Efficiency; and
Comments.
All of these parameters have been defined previously within this section. The markers on the
above parameters denote the following limitations:
Displayed as N/A if surface drive equipment has not been specified for surface drive
systems.
Displayed as N/A if a wellbore geometry has not been specified.
Applicable to surface drive cases only.
Applicable to downhole drive cases only.
Applicable to multiphase flow cases only.
The comparison table can be printed by selecting the FilePrint menu command.
Comparison Charts
If you have completed an analysis in Batch Comparison calculation mode, the Comparison Charts
output window shown below provides a graphical display of the effect of changes in the batch
parameter have on numerous other system parameters. Although this window can be accessed by
clicking the Comparison Charts button, it is displayed automatically following a Batch
Comparison calculation.
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Comparison Charts output window
The Comparison Chart window contains a series of different charts with the specified range of
values of the batch parameter displayed on the x-axis. Tabs on the bottom of the screen allow the
y-axis to be changed among the following parameters:
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Volumetric Efficiency;
Fluid Rate;
Pump Speed;
Fluid Level;
Producing Pressure;
Motor Operating Frequency ;
Energy Costs ;
Prime Mover Output Power ;
Motor Output Power ;
System Input Power ;
Polish Rod Power;
Pump Intake Pressure;
Pump Discharge Pressure;
Pump Pressure Loading;
Net Hydrostatic Head;
Flow Losses;
Rod Torque Loading ;
Free Gas Separation ;
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Multiphase Flow Apparent Volumetric Efficiency ;

Free Gas as Pump Intake ;
Drivehead Thrust Bearing L10 Life ;
Drivehead Main Shaft Torque Loading ;
Drivehead Structural Loading ;
Drivehead Power Output ;
Drivehead Speed ;
Drivehead Gearbox Torque ;
Motor Loading ;
Maximum Rod Torque;
Maximum Axial Rod Load;
Maximum Effective Rod Stress;
EDF (Elastic Design Factor) ;
DDF (Deformation Design Factor) ;
Maximum Contact - Continuous Rod ;
Maximum Contact - Connection ;
Maximum Contact - Rod Guide ;
Drive Assembly Thrust Loading ;
Drive Assembly Torque Loading ;
Drive Assembly Power ;
Drive Assembly Speed ;
Downhole Motor Loading ;
Downhole Motor Skin Temperature ;
Downhole Motor Winding Temperature ;
Downhole Cable Conductor Temperature ;
Pump Torque;
Pump Axial Load;
Cable Voltage Drop ;
Cable Conductor Temperature ;
Motor Winding Temperature ;
Flow Velocity Past Motor ;
Diluent Rate;
Diluent Viscosity;
Gas Oil Ratio ;
Gas Liquid Ratio ;
BS&W ;
Water Cut ;
System Mechanical/Electrical Efficiency ; and
Overall System Efficiency .
These parameters have been defined previously within this section. The markers on the above
parameters denote the following limitations:
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Displayed as N/A if surface drive equipment has not been specified for surface drive
systems.
Displayed as N/A if a wellbore geometry has not been specified.
Applicable to surface drive cases only.
Applicable to downhole drive cases only.
Applicable to multiphase flow cases only.
Applicable to single phase flow cases only.
The currently displayed comparison chart can be printed by selecting the FilePrint menu
command.
Comparison Table and Chart Filtering

The comparison tables and charts have the ability to display a large amount of information
about different cases. However, there are such a large number of columns (in the tables) or
tabs (in the charts) that it can sometimes be difficult to find specific information.
When either the comparison table or charts window is open, you will see a menu heading Filter
in the main windows menu bar. Under this menu is an item: Change Filter Options. When
this is selected, the following window appears.
Column Filter Window
For each column in the table (or tab in a chart), you have two check boxes: Show and
Filter. If the show option is turned off, the column (or tab) will not be displayed. In this
way, you can determine which information you wish to have displayed. The filter option is
available only if Show is turned on. What this option does is show the column (or tab)
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only if it contains some real data. If the entire column (or tab) contains N/A, it will not be
displayed if the Filter option is turned on.
The Show All/None and Filter All/None buttons at the bottom allow you to change all
the options at once. Note that you must have at least one column/tab shown.
The options for charts and tables are independent of one anotherchanging the options for
one does not affect the other.
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Rod/Tubing Wear (Surface Drive Systems)
The rod/tubing wear analysis module can be accessed by clicking on the Rod/Tubing Wear
button. Note that the wear calculations are completed in a special module outside the main
calculation loop.
Upon opening the wear analysis module you will see the Input/Output Data window. The table at
the top of the window displays the rod string segments that were selected for the current analysis.
The wear analysis allows different wear rate characteristics to be assigned to each rod segment
which appears in this table. By clicking on the table, scroll bars will appear to allow you to view all
of the information. The bottom portion of the window includes inputs for assigning wear
coefficients and operating conditions, a display area for key outputs from the wear analyses and a
set of tabs along the bottom to access the analysis results presented.
Wear analysis Input/Output Data window
The following inputs are necessary for the wear analysis:
Sand Cut: the volumetric percentage of sand in the produced fluid. Note that the wear
correlation used in PC-PUMP has been benchmarked against field results to sand cuts of
15%. Care should be taken in using sand cuts above this level.
Target time: the period of operation over which you would like to examine the wear
state at the most severely worn point in the tubing string.
Wear Coefficients: coefficients which describe the characteristic behavior of the material
in contact with the production tubing. These coefficients are used with the empirical
wear formula shown on the right side of the window which was developed through a C-
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FER study on rod/tubing wear50. Note the empirical wear data suggested that wear
rates were linearly related to rod/tubing contact loads and exponentially related to sand
cut.
Although the program accurately calculates the curvature-induced contact loads and
corresponding wear rates based on the well geometry, equipment, and operating conditions
specified, you may find the predicted wear profiles do not match field observations. This may be
due to the presence of curvature reversals along directional wellbores which cause localized
increases in the contact loads. The Hole Angle Change chart in the Wellbore Geometry module
can be used to verify if curvature reversals exist. Note that in many cases the survey data available
may not accurately portray the overall magnitude or variation in the curvature along the wellbore.
In addition, the sand cut along the low side of a directional or slant well will likely be much higher
than the average cut measured at surface. This effect should be considered in cases where the
rod/tubing contact occurs on the low side as well. The Rod/Tubing Contact Location chart in
the Rod/Tubing Contact output reports indicates the location of the rod contact within the
tubing. It is recommended that sensitivity analyses be completed if you are investigating wearrelated problems experienced in the field.
The wear coefficients must be specified for each type of rod string element that could come into
contact with the tubing including rod connectors (couplings/centralizers), rod guides, or the
surface of continuous rod string. Three wear coefficient input options are available: Steel
Defaults, Urethane Defaults, and Custom Inputs. The steel and urethane defaults were
established through the C-FER wear study. PC-PUMP automatically assigns either the steel or
urethane coefficients to each section of rod in the well. To assign different coefficients, you must
first highlight the spreadsheet row containing the contacting element. Then select the appropriate
set of wear coefficients and click on the Assign button. If all of the contacting elements use the
same set of wear coefficients, select the appropriate coefficients and click the Assign All button.
Clicking on the Charts button will display a set of curves which show the calculated wear rates as
a function of localized and distributed contact loads and different sand cuts for the selected set of
wear coefficients.
Contact loading charts
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Once the analysis conditions and wear coefficients have been selected, click the Calculate button
to complete the wear analysis calculation. Results of the analysis are displayed on the following
table and charts:
Input/Output Data - The maximum tubing wear rate and the corresponding location along the
wellbore are displayed at the bottom of the window. The maximum tubing wear that would occur
within the period defined by the specified target time is also shown.
Tubing Wear Profile #1 - Shows the tubing wear rate in mm of wall loss per million revolutions at each
segment of the rod string.
Tubing Wear Profile #2 - Shows the tubing wear rate as a percentage of the nominal tubing thickness per
year at each segment of the rod string.
Tubing Wear vs. Time - Shows the cumulative tubing wear as a function of time at the most
severe wear location along the wellbore.
Rod/Tubing Wear output window charts
If you wish to complete comparative wear assessments with different types or segments of rod
string components, you must return to the Rod String Selection window and make the desired
equipment changes there. Once the rod string changes have been made, return to the Analysis
window, click the Calculate button, and then open the Rod/Tubing Wear window. Note that
the Rod String Specifications table will be updated with the new equipment selection although the
wear coefficients assigned previously will be retained for any rod segments which have not
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changed. Any new segments will have zero values for the wear coefficients and must be assigned
the appropriate values (as described above) before proceeding with the new wear analysis.
A summary of the wear analysis can be printed by selecting the FilePrint menu command from
the Input/Output Data Sheet. Each of the output window charts can be printed in the same way.
Rod Fatigue (Surface Drive Systems)
The rod string fatigue module can be accessed by clicking the Rod Fatigue button. Note that
fatigue calculations are conducted separately from the primary calculation loop.
You will initially see the Input/Output Data window. The following five parameters must be
entered before the fatigue calculation can proceed:
Rod Ultimate Strength: The ultimate tensile strength of the rod material. The default
value of this input corresponds to the ultimate strength of the rod grade selected when
the rod string was specified.
Surface Finish Type: The surface finish of the sucker or continuous rod. The choices
available include as-forged, hot rolled, machined, and cold drawn. Most sucker rods are
hot rolled (the default value), although specific rod manufacturers may use different
fabrication techniques for special rods. Note that the drop-down list box lists the
surface finish types in order of decreasing susceptibility to fatigue damage.
Torque Amplitude: Half of the total amount of fluctuation observed or expected in the
operating torque magnitude.
Axial Load Amplitude: Half of the total amount of fluctuation observed or expected in
the operating axial load magnitude.
Fluctuation Period: The average duration of each torque and axial load fluctuation.
Bending
Axial Load
Torque
Torque
Amplitude
Axial Load
Amplitude
Torque and Axial Load

Period
Bending
Amplitude
0
Bending
Period
Time
Definition of fatigue loading parameters
If you do not anticipate alternating torque or axial load conditions in your application, you may still
want to conduct a fatigue analysis as alternating bending loads may be generated due to wellbore
curvature. Once the input parameters have been specified, click the Calculate button to conduct
the fatigue analysis.
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Fatigue analysis Input/Output Data window
Results of the fatigue analysis are displayed on the following table and charts:
Input/Output Data - Results of the base case analysis corresponding to the input conditions
specified are shown in terms of the minimum rod fatigue life and the corresponding location in
the rod string most susceptible to a fatigue failure. The Elastic Design Factor (EDF) and
Deformation Design Factor (DDF) (see descriptions in Rod Loading/Deflection section) at this
location are also listed. The lower section of the screen displays the minimum fatigue life of the
rod string predicted for several different operating conditions. You can switch the table display to
show results for a range of either torque or axial load amplitude variations by clicking on the
appropriate box in the lower left-hand corner of the window. The spreadsheet text will vary in
color according to the severity of the rod loading. Black text indicates that the EDF and DDF are
both less than one, blue text indicates that the EDF is greater than one and the DDF is less than
one, and red text indicates that both the EDF and DDF are greater than one.
Measured Depth vs. Life - Displays the fatigue life for the specified loading scenario at each
point in the rod string. The text box on the chart summarizes the "base case" alternating load
input conditions. All points at which the predicted fatigue life is "infinite" are plotted along the
top axis of the chart.
Alternating Torque vs. Life - Displays the predicted minimum fatigue life of the rod string at a
number of alternating torque amplitudes and fluctuation periods given a single axial load
fluctuation amplitude.
Alternating Axial Load vs. Life - Displays the predicted minimum fatigue life of the rod string
for several different load fluctuation periods as a function of the amplitude of the alternating axial
load at one alternating torque amplitude.
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Fatigue output window charts
A summary of the fatigue analysis Input/Output Data sheet can be printed by selecting the
FilePrint menu command. The three output window charts can be printed in the same way.
Backspin Analysis (Surface Drive Systems)
The backspin analysis module can be accessed by clicking on the Backspin button. The backspin
calculation is conducted independently of the main calculation loop and will only function if you
have already completed the primary analysis.
The backspin module consists of separate Specifications and Analysis windows. Tabs located at the
bottom of the screen are used to switch between the two windows. When you open the Backspin
Analysis window, you will start at the Specifications tab.
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Backspin Specifications window
The following values must be entered prior to performing a backspin calculation:
Electric Motor Power Rating: The rated power of the electric motor.
Electric Motor Poles: The number of poles on the electric motor.
Electric Motor Inertia: The mass moment of inertia of the electric motor.
Sheave Diameter: The outside diameter of the driver and driven sheaves.
Sheave Inertia: The mass moment of inertia of each sheave about its axis of rotation.
Bearing/Gear Box Reduction: The reduction ratio of the bearing or gear box (if
applicable).
Bearing/Gear Box Inertia: The mass moment of inertia of the gear box.
Surface Equipment Friction: The total dynamic friction of the surface equipment
between the polish rod and the prime mover, expressed in terms of polish rod torque.
Pump Friction: The friction torque of the pump.
Pump Volumetric Efficiency: static value for the volumetric efficiency of the pump
under normal operating conditions.
Fluid Density: Average density of the fluid in the production tubing.
Fluid Viscosity: Average viscosity of the fluid in the production tubing.
Clicking on the Refresh Specifications button updates the motor, drivehead, pump and fluid
specifications (except inertia values) to the values corresponding to the equipment/operating case
which is currently selected in the Analysis window.
If you do not know the motor, sheave, and bearing/gear box inertia values for the selected
equipment, the program is equipped with a set of default values that should serve as reasonable
estimates. The default sheave inertia values are based on typical inertia values for the respective
sheave sizes. Default motor inertia values are assigned based on the number of poles and the
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horsepower inputs specified. Bearing/gear box inertia defaults vary with the reduction ratio. The
default values can be assigned by clicking on the Inertia Defaults button.
Clicking on the Brake Specifications button opens the Brake Specifications window shown in the
figure below, which allows you to input data defining the characteristics of the brake equipment in
the surface drive.
Brake Specifications window
Brake information is stored in a separate data file so that the same file can be used with multiple
simulations without having to specify the information each time. Upon entering the window, click
the New File button if you wish to create a new brake file. Alternately, you may choose an
existing brake file from the Brake File pull down menu. If you are creating a new brake file, you
will be prompted to input a file description and file name. Note that a default file name will be
automatically created based on the description entered. This name can be changed by typing in a
new file name with a .bks file extension.
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Each brake file may contain the specifications for several different brake models. To add a new
model, type a name in the Brake Model input box and click the Add button on the right side of the
window. You can toggle between brake models by selecting the model names. The brake model
inputs can also be used to specify multiple tests for the same brake model. Note that the brake
model which is active when the Brake Specifications window is closed (by clicking the OK button)
will be used in subsequent braking simulations.
The following parameters must be specified in the Brake Specifications window:
PC-PUMP User Guide
Braking Location: Placement of the brake within the surface equipment system. The
brake may act at the polish rod, gear pinion, or prime mover. Specifying the position
accurately is very important since the applied braking toque will be strongly affected by
the speed ratios corresponding to gearboxes or belts and sheaves included in the drive
system. If the Polish Rod option is selected, the brake torque will be based on the
rotational speed of the polish rod. By selecting Gear Pinion, the gearbox speed ratio
will be taken into account and the rotational speed of the gearbox input shaft will be
used to calculate the brake torque. The Prime Mover option will apply brake torque
based on the electric motor speed.
Braking Characteristics: Data which defines the torque response of the brake as a
function of speed and temperature. The input table will accommodate the entry of
values for up to 15 different speeds and 10 brake temperatures. The backspin
calculation uses linear interpolation/extrapolation of this data to determine the
magnitude of the applied brake torque at each time-step of the simulation. Brake torque
must be specified at a minimum of two speeds at each brake temperature. If only one
brake temperature is specified, the torque response will be independent of temperature.
When entering the characteristics of brakes with non-linear torque/speed/temperature
relationships, it is important to ensure that the brake response will be accurately
represented by the linear interpolation/extrapolation of the data input. Although the
program will extrapolate the brake response over the full range of speeds/temperatures
associated with the calculated backspin response, the errors associated with
extrapolations well beyond the established brake characteristics can be significant.
Therefore, it is important to obtain brake data covering the full range of the predicted
response from the equipment manufacturer. Note that some brake systems can be
adjusted so they will continue to apply a resistive torque when the polish rod backspin
speed is zero, while other brakes will not apply any torque until the brake activation
speed is reached (see below).
Brake Activation Speed: The threshold rotational speed at which the brake begins to
apply resistive torque to inhibit the backspin of the PCP system (e.g. centrifugal spring
brake). If the brake activates as soon as the system begins to backspin, this value should
be left at zero.
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Dissipation Characteristics: The rate of heat transfer from the brake to its surroundings.
Energy dissipation rates are specified as a function of differential temperatures (i.e. the
difference between the brake temperature and the ambient temperature) in the
corresponding table input area at the bottom of the window. The program uses linear
interpolation between the specified temperatures to calculate the energy dissipation rate
at each time-step of the simulation. Note that the program automatically specifies a zero
dissipation rate at a differential temperature of zero (i.e. no heat transfer when the brake
temperature is equal to the ambient temperature).
Brake Specific Heat Capacity: The amount of energy required to raise the temperature of
the brake by one degree. This value is used to calculate the increase in brake
temperature due to the braking action during the backspin. All braking energy is
assumed to go directly into heating the brake.
Maximum Brake Temperature: The maximum operating temperature for the brake
based on applicable safety requirements or the functional limits of the system
components.
Notes (optional): Any additional information you wish to input concerning the brake
model.
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Clicking on the Charts button will display the braking and heat dissipation data in graphical form
(shown below). The two charts can be printed by clicking on the Print button on the lower right
side of the chart window.
Brake Specifications charts
When you are satisfied with the braking data entries, you must click the Update button to save the
information in the brake file. Once this is done, click OK to return to the Specifications window.
You are now ready to tab over to the Analysis window (shown below) where the backspin analyses
are executed based on the conditions specified.
Backspin Analysis Window
Backspin Scenarios
PC-PUMP performs backspin calculations for two key shut-down scenarios: seized pump and normal
shutdown. The Seized Pump case models situations in which the rotor becomes stuck within the
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stator and the strain energy stored in the rod string is released without any fluid drainage
occurring. The Normal Shutdown case models system stoppages under normal operating
conditions where the fluid within the tubing drains back into the wellbore causing the pump, rod
string, and drive to spin in reverse. Both cases are important and should be considered whenever
you are designing a new installation or changing the surface equipment and when production
conditions change significantly.
Seized Pump Scenario
Click on the seized pump toggle button at the top of the window to active the data inputs for this
backspin mode. The following values specific to the seized pump scenario must be specified
before the analysis can be executed:
Seized Pump Torque: The torque stored in the rod string when the backspin
commences, which will be governed by one of the following three conditions: (1) rod
torque corresponding to motor output torque; (2) maximum rod torque capacity; or (3)
torque corresponding to controller limits. Since the driving force in the seized pump
case is the strain energy stored in the rod string, higher torque values will generally lead
to higher peak sheave speeds.
Initial Brake Temperature: The brake temperature at backspin initiation.
Ambient Temperature: The air temperature at backspin initiation.
Torque Limits: Click on this button to activate the Torque Limits dialog box which
provides assistance in determining the maximum possible seized pump torque defined
by the selected rod string and electric motor. Note that the use of the Torque Limits
dialog box is not mandatory as the calculated torque limits are not used in the final
backspin calculation. A conservative estimate of the maximum torque the rod string will
withstand without breaking can be obtained by specifying the rod diameter and rod
material ultimate strength in the appropriate input boxes. Click the Calculate button to
display the maximum torque. Similarly, the maximum polish rod torque the electric
motor can produce at a given speed will be determined if you input the motor
horsepower rating and pump operating speed and then click Calculate. The lower of
the rod and motor torque values provides an indication of the peak torque that the
system would experience under a seized pump scenario. Note that the stall torque for
electric motors without a torque-limiting device is typically between two and three times
the full-load torque. Therefore, you may wish to be conservative in choosing the value
you specify for the seized pump torque.
Calculation: This input area allows you to specify additional conditions governing the
backspin analysis. For the seized pump scenario, there are two options that can be
selected. Normally, the backspin calculation will take into account the entire system
inertia. By checking the Driver Sheave/Electric Motor Disengaged (Broken Belts) option, the
motor inertia is ignored in the calculations, although the surface equipment friction will
still be included in the system analysis. Selecting the Brake Disengaged (No Braking Action)
option will remove the brake from the analysis, making the surface equipment friction
the only source of energy dissipation within the drive system. Note that you may select
either one or both of these options.
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Normal Shutdown Scenario

The inputs for the Normal Shutdown scenario are activated by clicking the Normal Shutdown
toggle button at the top of the window. The following parameters must be specified before the
normal shutdown scenario is analyzed:
Pump Speed: The speed at which the pump is operating when the system shuts down.
Fluid Level: The fluid level in the tubing/casing annulus (depth from surface) when the
system shuts down. The measurement units for this parameter can be toggled between
mKB, jts (joints), and Vm (vertical metres).
Initial Brake Temperature: The brake temperature at backspin initiation.
Ambient Temperature: The air temperature at backspin initiation.
Calculation: This input allows you to specify additional conditions governing the
backspin analysis. For the normal shutdown scenario, five options are available. The
first two, Driver Sheave/Electric Motor Disengaged (Broken Belts) and Brake Disengaged (No
Braking Action) are the same as described in the Seized Pump section above. The third,
Flowback to Reservoir Above Perforation Pressure of ### kPa requires you to specify a
flowback pressure at the perforations. If the fluid pressure at the perforations exceeds
this value, any additional fluid which drains from the tubing is assumed to flow back into
the reservoir. If the pressure is below the specified flowback pressure or if the option is
not selected, all of the fluid draining from the tubing is assumed to remain in the
casing/tubing annulus. The Ignore Flow Considerations During Backspin option will disregard
pressure losses in the fluid as it drains out of the tubing string. Similarly, Ignore
Rod/Tubing Friction During Backspin disregards any torsional loading effects associated
with contact between tubing and rod string components during backspin.
Backspin Analysis Execution

Clicking on the Calc. Target or Calc. Sensitivity buttons will commence the backspin
calculation for the active scenario. The Target calculation performs backspin analyses for the
specified seized torque value (Seized Pump case) or fluid level (Normal Shutdown case). The
Sensitivity calculation determines peak speed, backspin time and the peak and final brake
temperatures for a range of seized torque values (Seized Pump case) or fluid levels (Normal
Shutdown case).
Results of the backspin analysis are displayed on the Analysis sheet and in accompanying chart
format. Results presented on the Analysis sheet are as follows:
PC-PUMP User Guide
Peak Electric Motor Speed: The highest rotational speed reached by the electric motor
during the backspin response.
Peak Sheave Speeds: The highest rotational speed reached by each sheave during the
backspin period.
Peak Sheave Rim Velocities: The highest speed reached at the outside diameter of each
sheave during the backspin period.
Peak Rod String Speed: The highest polish rod speed predicted during the backspin
response.
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Backspin Time: The time period from backspin initiation to the point when the polish
rod stops moving. The toggle button allows the time to be displayed in seconds or
minutes.
Retained Torque: The magnitude of the torque remaining (if any) in the rod string after
the polish rod has stopped moving.
Backspin Revolutions: The cumulative number of polish rod revolutions over the entire
backspin period. (Normal Shutdown case only).
Backspin Fluid Drain: The volume of fluid which has drained from the production
tubing during the backspin period. (Normal Shutdown case only).
Final Fluid Levels (from surface): The fluid levels in the tubing and casing when the
polish rod has stopped moving. (Normal Shutdown case only).
Braking Energy: The total amount of energy dissipated by the brake.
Total Energy Dissipated: The total amount of energy dissipated by the system during
the backspin period, including braking energy and frictional losses.
Brake Temperatures: The peak and final temperatures of the brake.
Click on the Charts button to activate the following Backspin Analysis output charts:
Backspin Response - Displays the polish rod torque and speed and the total system energy as a
function of time. A numeric value for the total amount of energy dissipated is also displayed.
Fluid Level Response - Displays the casing and tubing fluid levels and the hydraulic torque
generated by the pump as a function of time. The retained (final) torque, the total volume of fluid
drained from the tubing, and the cumulative number of rod rotations during the backspin are also
displayed on the chart. (Normal Shutdown case only).
Braking Response - Displays the applied braking torque, the brake temperature, and the polish
rod speed as a function of time. The total amount of energy dissipated by the brake is also
displayed.
Sensitivity Analysis - Peak Speed - Displays the peak backspin speed as a function of seized
pump torque (Seized Pump case) or fluid level (Normal Shutdown case).
Sensitivity Analysis - Backspin Time & Brake Temperatures - Displays the backspin time
period and the peak and final temperatures of the brake as a function of seized pump torque
(Seized Pump case) or fluid level (Normal Shutdown case).
The currently active chart can be printed by selecting the FilePrint menu command.
PC-PUMP User Guide
214
Backspin Analysis output window charts
PC-PUMP User Guide
Sand Settling Velocity

When sand is produced by the well, the tubing flow velocity must be significantly larger than the
sand particles settling velocity to ensure that the sand can be carried successfully to surface by the
flow. PC-PUMP now has an auxiliary module to help you assess if these conditions are met. In the
Auxiliary Analysis section of the Analysis Outputs window the Sand Settling button gives you
access to a Sand Settling Calculator. The Sand Settling window is shown below:
Sand Settling Window
PC-PUMP uses the following equation to calculate the sand settling velocity:
v=
4 D g
3 f CD
Where:
v is the settling velocity (m/s)
is the difference in density between the particle and the fluid (kg/m)
D is the particle diameter (m)
PC-PUMP User Guide
216
g is 9.81 m/s
f is the density of the fluid (kg/m)
CD is the drag coefficient, a function of Reynolds number
The input data consists of the fluid density, fluid viscosity, sand particle density and sand particle
diameter. Note that this model was developed for single-phase flow only.
If you have just completed a single-phase calculation, PC-PUMP will automatically display the
available information. This is fluid density, sand density and fluid viscosity; you will still need to
enter particle diameter. If advanced viscosity is used, the lowest viscosity in the tubing string will
be passed by PC-PUMP to the sand settling program. (This ensures a conservative result.) Please
note that the fluid density passed by PC-PUMP will include the effect of any sand (calculated in the
Specify Fluid Composition mode), so you should adjust the value accordingly if you have a high
sand cut. Also, note that this model does not consider the interaction between sand particles, so
the results will be less accurate in high sand cuts.
PC-PUMP User Guide
4
Part
HELP/TROUBLESHOOTING
The previous sections of this User Guide described the layout and use of PC-PUMP. As you venture
beyond the scope of this Guide and use the program to evaluate your own applications, you may
occasionally encounter problems. This Help/Troubleshooting part of the User Guide may assist
you in resolving these problems. In addition, further troubleshooting information is available on
PC-PUMP
web
site
at
C-FERs
http://www.pc-pump.com.
Input Restrictions
PC-PUMP requires numerous inputs. In most cases, restrictions or limits are placed on these inputs
for one of the following reasons:
to avoid computational errors;

to prevent correlations from being used outside their valid range; and
to warn the user of incorrectly entered values.
PC-PUMP User Guide
218
PART 4: HELP/TROUBLESHOOTING
If you attempt to exit an edit box having entered a value which is outside of the valid range, the
Input Restriction Warning dialog shown below will be displayed.
Input Restriction Warning dialog
This dialog box displays a message which informs the user of the problem input parameter and its
valid entry range. To return back to the program, click the OK button. Then correct the invalid
input value before proceeding with further data input or the execution of a calculation. If you do
not correct the input, an error message will likely be generated during the calculation process.
The seven tables below list the valid range of values for input parameters in the different areas of
PC-PUMP.
Preferences:
PC-PUMP User Guide
Location
Input Parameter
Valid Range
Defaults
Defaults
Defaults
Defaults
Defaults
Defaults
Defaults
Defaults
Defaults
Defaults
Defaults
Pump Friction (Static)

Volumetric Efficiency (Static)
Gas Specific Gravity
Water Specific Gravity
Sand Specific Gravity
Tubing Roughness
Free Gas Separation
Supply Frequency
Supply Voltage
Power Cost
Gas Specific Heat
x 0 Nm
0% x 100%
0.55 x 1.20
1.00 x 2.00
2.00 x 4.00
0.001 mm x 2 mm
0% x 100%
x > 0 Hz
x>0V
x > 0 $/kWh
x > 0 kJ/kgK
219
Wellbore Geometry:
Location
Input Parameter
Valid Range
Well Design Mode

Well Design Mode
Initial Hole Angle

Initial Azimuth
0 x 90
0 x 360
Location
Input Parameter
Valid Range
Main
Main
Pump Selection
Pump Selection
Pump Selection: Pump Test Information
Pump Selection: Pump Test Information
Pump Selection: Custom Pump
Casing/Tubing/Tail Joint/Shroud Selection
Rod String Selection
Rod String Selection: Rod Guide Optimization
Surface Drive Equipment Selection: Belts
Surface Drive Equipment Selection: Belts
Surface Drive Equipment Selection: Prime Mover
Downhole Drive Equipment Selection: Motor
Custom Drive Assembly
Pump Seating
Mid-Perforations
Pump Friction (Static)
Volumetric Efficiency (Static)
Target Pump Speed
Target Differential Pressure
Nominal Pump Displacement
Pump Pressure Rating
Pump Length
Pump Outside Diameter
Minor Rotor Diameter
Pump Eccentricity
Rotor Pitch
Tubing/Casing/Tail Joint Length
Tubing Coupling Diameter
Shroud OD
Shroud ID
Length
No. Guides
Rods/Length
Maximum Contact Load
Minimum No. Rod Guides
Maximum No. Rod Guides
Reduction Ratio
Power Transmission Efficiency
Motor Power Rating
Motor Poles
Motor Efficiency (Nominal)
Motor Power Factor (Nominal)
Supply Frequency
Supply Voltage
Efficiency (static)
Power Factor (static)
Slip (static)
Temperature Rise (static)
Power Requirement
Max. Thrust Load
Max. Speed
Max. Power
Max. Torque
Length
Gear Reduction
x > 0 mKB
x > 0 mKB
x 0 Nm
0% x 100%
x > 0 RPM
x > 0 kPa
x > 0 m3/D/RPM
x > 0 kPa
x>0m
x > 0 mm
x > 0 mm
x > 0 mm
x > 0 mm
x>0m
x > tubing OD
x > 0 mm
0 mm < x < shroud OD
0.5 m x 25 m
1 x 10
X>0
x>0N
1 x 10
1 x 10
X>0
0% < x 100%
3 kW < x 125kW
2x8
0% < x 100%
0<x1
x > 0 Hz
x>0V
0% < x 100%
0< x 1
x 0 RPM
x 0 C
x > 0 kW
x > 0 kN
x > 0 RPM
x > 0 kW
x > 0 Nm
x>0m
x>0
System Configuration:
PC-PUMP User Guide
220
Location
Input Parameter
Valid Range

Custom Motor
Custom Motor
Custom Motor
Custom Motor
Custom Motor
Custom Motor
Custom Motor
Custom Motor
Custom Cable
Custom Cable
Custom Cable
Motor Test
Motor Test
Motor Test
Motor Test
Motor Test
Motor Test
Cable Ampacity Curve Input
Outside Diameter
Outside Diameter
Length
Number of Poles
Power Rating
Max. Winding Temp.
Nameplate Frequency
Nameplate Voltage
Nameplate Current
Size
Thickness
Max. Conductor Temp.
Motor Load
Efficiency
Power Factor
Motor Speed
Temperature Rise
Test Frequency
Reference Conductor Temperature
Current
Voltage Drop
Conductor Temperature
Ambient Temperature
x > 0 mm
x > 0 mm
x>0m
x>0
x > 0 kW
x > 0 C
x > 0 Hz
x>0V
x>0A
x>0
x > 0 mm
x > 0 C
x>0%
x>0%
x>0
x > 0 RPM
x > 0 C
x > 0 Hz
x > 0 C
x>0A
x>0V
x > 0 C
x > 0 C
Location
Input Parameter
Valid Range
Single-Phase
Single-Phase
Single-Phase
Single-Phase
Single-Phase
Single-Phase
Single-Phase w/Fluid Composition
Multiphase
Multiphase
Multiphase
Multiphase
Multiphase
Multiphase
Advanced Viscosity BS&W Effects
Advanced Viscosity Temperature Effects
Advanced Viscosity Temperature Effects
Advanced Viscosity Non-Newtonian Effects
Advanced Viscosity Non-Newtonian Effects
Fluid Density Tubing

Fluid Density Casing
Water Cut
Sand Cut
Fluid Viscosity
Oil API Gravity
Water Specific Gravity
Sand Specific Gravity
Tubing Density Factor
Casing Density Factor
Oil API Gravity
Water Salinity
Producing GOR
BS&W content
Free Gas Separation
Oil Viscosity
Max. Viscosity Factor
Inversion Fraction
Viscosity
Temperature
Viscosity
Shear Rate
Fluid Cp
Fluid K
x > 0 kg/m3
x > 0 kg/m3
0.55 x 1.20
0% x 100%
0% x 100%
x > 0 cp
0 x 150
1.00 x 2.00
2.00 x 4.00
0x2
0x2
15 x 150
0.55 x 1.20
0 ppm x 2.5e5 ppm
x > 0 m3/m3
0% x 100%
0% x 100%
x > 0 cp
x>1
0<x<1
x > 0 cp
x > -40C
x > 0 cp
x > 0 1/s
x > 0 kJ/kgK
x > 0 W/mK
Fluid Properties:
PC-PUMP User Guide
Location
Input Parameter
Valid Range

Oil Cp
Oil K
BS&W Cp
BS&W K
x > 0 kJ/kgK
x > 0 W/mK
x > 0 kJ/kgK
x > 0 W/mK
Location
Input Parameter
Valid Range
Inputs Operating Conditions

Fluid Rate
Pump Speed
Motor Operating Frequency
Fluid Level
Bottomhole Pressure
Tubing Head Pressure
Casing Head Pressure
Bottomhole Temperature
Temperature Gradient
x > 0 m3/D
x > 0 RPM
x > 0 Hz
x0m
x 0 kPa
x 0 kPa
x 0 kPa
-10C x 200C
x 0 C/100m
Location
Input Parameter
Valid Range
IPR Data
IPR Data
IPR Data
IPR Data
IPR Data
IPR Data
IPR Data
Static Reservoir Pressure

Bubble Point Pressure
Test Point Producing Pressure
Test Point Fluid Rate
Test Point BS&W Content
Target Producing Pressure
Target Fluid Rate
x > 0 kPa
x 0 kPa
x > 0 kPa
x > 0 m3/D
x > 100%
x 0 kPa
x 0 m3/D
Location
Input Parameter
Valid Range
Pump Comparison Configuration

Batch Comparison Configuration
Minimum Pump Speed

Maximum Pump Speed
Minimum Pump Pressure Rating
Maximum Pump Pressure Rating
Fluid Level
Fluid Rate
Bottomhole Pressure
Pump Speed
Motor Operating Frequency
x 0 RPM
x 2500 RPM
x 0 %Rtd
x 500 %Rtd
x0m
x > 0 m3/D
x 0 kPa
x > 0 RPM
x > 0 Hz
221
Operating Conditions:
IPR Data:
Calculation Modes:
Note that there are also some ranges which apply to calculated values within PC-PUMP. PC-PUMP will
normally not abort a calculation if one of these ranges is exceeded, but will print a warning
message in the Output Messages box in the Analysis Outputs window, as described in Part 3,
Section C of this manual.
PC-PUMP User Guide
APPENDICES
222
APPENDICES
Appendix A: Unit Conversions ........................245

Appendix B: Output Reports............................247
Appendix C: References.....................................265
PC-PUMP User Guide
APPENDIX A: UNIT CONVERSIONS
223
Appendix A: Unit Conversions

S.I.
S.I. to Imperial
multiply by
1.8 + 32*
1.8*
0.5486
Imperial to S.I.
multiply by
0.5556 - 17.8
0.5556
1.823
6230.6
1.605 10-4
6.29
0.03531
5.615
0.159
28.32
0.178
1.016
2.205
23.73
0.0624
0.984
0.454
0.0421
16.02
kilograms per metre (kg/m)

kilojoule (kJ)
kilojoules per Celsius degree
(kJ/C)
kilojoules per kilogram degree
Celsius (kJ/kgC)
0.672
0.9478
0.5266
1.488
1.055
1.899
0.2388
4.187
kilonewton (kN)
kilopascal (kPa)
kilowatt (kW)
megapascal (MPa)
0.2248
0.145
1.341
0.145
4.448
6.895
0.7457
6.895
metre (m)
metres per second (m/s)
millimetre (mm)
newton (N)
newtons per metre (N/m)
newtonmetre (Nm)
ohms per metre (/m)
ohms per thousand metres
(/1000m)
volts per thousand metres
(V/1000m)
watts per metreCelsius
degree(W/mC)
3.281
3.281
0.03937
0.2248
0.0685
0.7376
0.3048*
0.3048*
0.3048*
0.3048*
25.4*
4.448
14.59
1.356
3.281
3.281
Fahrenheit degree (F)

Fahrenheit degree differential (F)
Fahrenheit degrees per 100 feet
(F/100ft)
Fahrenheit degreefoot second per
British thermal unit (Ffts/BTU)
barrel (bbl)
thousand cubic feet (mcf)
standard cubic feet gas per stock
tank barrel oil (scf/STB)
degrees per 100 ft (/100ft)
pound-mass (lbm)
pound-massfoot squared (lbmft)
pounds-mass per cubic foot
(lbm/ft)
pounds-mass per foot (lb/ft)
British thermal unit (BTU)
British thermal units per
Fahrenheit degree (BTU/F)
British thermal units per poundmassFahrenheit degree
(BTU/lbmF)
thousand pound-force (kip)
pound-force per square inch (psi)
horsepower (hp)
thousand pound-force per square
inch (ksi)
foot (ft)
feet per second (ft/s)
inch (in)
pound-force (lbf)
pounds-force per foot (lbf/ft)
footpound-force
ohms per foot (/ft)
ohms per thousand feet (/1000ft)
0.3048*
3.281
volts per thousand feet (V/1000ft
1.605 10-4
6230.6
British thermal units per

footsecondFahrenheit degree
(BTU/ftsF)
Celsius degree (C)

Celsius degree differential (C)
Celsius degrees per 100 metres
(C/100m)
Celsius degreemetre per watt
(Cm/W)
cubic metre (m)
cubic metre (m)
standard cubic metres gas per
standard cubic metre oil (m/m)
degrees per 30 metres (/30m)
kilogram (kg)
kilogrammetre squared (kgm)
kilograms per cubic metre (kg/m)
*Conversion
Imperial
is Exact
PC-PUMP User Guide
APPENDIX B: OUTPUT REPORTS
224
Appendix B: Output Reports

This section shows examples of the hard-copy output reports available from PC-PUMP. (Where a
report is more than one page long, only the first page is shown below.) The individual output
reports summarize the information contained in the respective program windows. A report is
available for most windows in the program and they can be printed using the FilePrint pulldown menu command or by clicking on the Print button in the window (if available). While none
of the graphs that PC-PUMP can display are shown in this appendix, many of them can be printed.
PC-PUMP User Guide
225
System configuration output summary, surface drive version
PC-PUMP User Guide
226
System configuration output summary, downhole drive version
PC-PUMP User Guide
227
Wellbore design output summary
PC-PUMP User Guide
228
Wellbore geometry output summary
PC-PUMP User Guide
229
Pump test output summary
PC-PUMP User Guide
230
Analysis output summary, surface drive version
PC-PUMP User Guide
231
Analysis summary output, downhole drive version
PC-PUMP User Guide
232
Energy flow output summary, surface drive version
PC-PUMP User Guide
233
Energy flow output summary, downhole drive version
PC-PUMP User Guide
234
Surface equipment output summary
PC-PUMP User Guide
235
Downhole equipment output summary
PC-PUMP User Guide
236
Key locations output summary
PC-PUMP User Guide
237
Wear output summary
PC-PUMP User Guide
238
Fatigue output summary
PC-PUMP User Guide
239
Backspin output summary
PC-PUMP User Guide
240
Brake data output summary
PC-PUMP User Guide
APPENDIX C: REFERENCES
241
Appendix C: References
1.
Moineau, Ren Joseph Louis. 1932. Gear Mechanism. United States Patent 1,892,217. 4
pages, 11 figures. [Patent]
2.
Moineau, Ren Joseph Louis. 1937. Gear Mechanism. United States Patent 2,085,115. 3
claims, 3 figures. [Patent]
3.
Lea, J. F., Anderson, P. D., and D. G. Anderson. 1987. Optimization of Progressive

Cavity Pump Systems in the Development of the Clearwater Heavy Oil Reservoir.
38th Annual Technical Meeting of the Petroleum Society of CIM, Calgary, Alberta, June 710. pp. 25-58 Paper No. 87-38-03 [Conference]
4.
Dunn, L. J., Matthews, C. M. and Zahacy, T. A. 1994. Progressing Cavity Pumping

Systems: Design, Operation and Performance Optimization - Course Notes. Centre
for Frontier Engineering Research, September.
5.
Saveth, K. J. and S. T. Klein. 1989. The Progressing Cavity Pump: Principle and
Capabilities. SPE Production Operations Symposium, Oklahoma City.
6.
Gaymard, B., Chanton, E. and P. Puyo. 1988. The Progressing Cavity Pump in Europe:
Results and New Developments. 7th Offshore South East Asia Conference, Singapore,
February, 2-5. pp. 444-453. OSEA 88136 [Conference]
7.
Rahimian, S. Moyno Subsurface Progressing Cavity Pumps. Southwestern Petroleum

Short Course. pp. 421 - 426.
8.
Clegg, J. D., Bucaram, S. M. and Hein, Jr., N. W. 1993 Recommendations and

Comparisons for Selecting Artificial-Lift Methods. Journal of Petroleum Technology,
December. pp. 1128 - 1167.
9.
Craig, Jr., J. E. and Randall, B. V. 1976. Directional Survey Calculation. Petroleum

Engineer, March. pp. 38 - 54.
10. Wiggins, M. L., Russell, J. E., and Jennings, J. W. 1991. Analytical Development of Vogeltype Inflow Performance Relationships. Society of Petroleum Engineers, SPE 23580, 32.
11. Vogel, J. V. 1968. Inflow Performance Relationships for Solution-gas Drive Wells.
Journal of Petroleum Technology, 83 - 92.
12. Fetkovich, M. J. 1973. The Isochronal Testing of Oil Wells. Society of Petroleum
Engineers of AIME, SPE 4529, 1 - 15.
13. Wiggins, M. L. 1994. Generalized Inflow Performance Relationships for Three-Phase
Flow. SPE Reservoir Engineering, 181 - 182.
PC-PUMP User Guide
242
14. Zigrang, D. J., and Sylvester, N. D. 1985. A Review of Explicit Friction Factor
Equations. Transactions of the ASME Journal of Energy Resources Technology, 107, 280 283.
15. Metzner, A B. and Reed, J. C. 1955. Flow of Non-Newtonian Fluids - Correlation of the
Laminar, Transition, and Turbulent-Flow Regions. AIChE J., December, 1, no. 4. pp.
434 - 440.
16. Dodge, D. W. and Metzner, A. B. 1959. Turbulent Flow of Non-Newtonian Systems.
AIChE Journal, June, Vol. 5, No. 2. pp. 189 - 204.
17. Govier, G. W. and Aziz, K. 1972. The Flow of Complex Mixtures in Pipes. Litton
Educational Publishing, Inc.
18. White, F. M. 1986. Fluid Mechanics. McGraw-Hill, Inc.
19. Haciislamoglu, M., and Cartalos, U. 1994. Fluid Flow in a Skewed Annulus. Drilling
Technology ASME, PD-Vol. 56, 31 - 39.
20. Vazquez, M. and Beggs, H. D. 1980. Correlations for Fluid Physical Property
Prediction. J. Pet. Tech., June, 32. pp. 968 - 970.
21. Katz, D. L., et al. 1959. Handbook of Natural Gas Engineering. McGraw-Hill Book
Co., Inc., New York City, 129.
22. Osif, T. L. 1988. The Effects of Salt, Gas, Temperature, and Pressure on the
Compressibility of Water. SPE Res. Eng., February, 3, No. 1. pp. 175 - 181.
23. Sutton, R. P. 1985. Compressibility Factors for High-Molecular-Weight Reservoir
Gases. Paper SPE 14265 presented at the SPE 60th Annual Technical Conference and
Exhibition, Las Vegas, September 22-25.
24. Dranchuk, P. M., Purvis, R. A. and Robinson, D. B. 1974. Computer Calculation of
Natural Gas Compressibility Factors Using the Standing and Katz Correlation.
Institute of Petroleum Technical Series, NO. IP74-008.
25. Baker, O. and Swerdloff, W. 1956. Finding Surface Tension of Hydrocarbon Liquids.
Oil and Gas J., January 2.
26. Jennings, H. Y., Jr., and Newman, G. H. 1971. The Effect of Temperature and Pressure
on the Interfacial Tension of Water Against Methane-Normal Decan Mixtures.
Trans., AIME 251. pp. 171 - 175.
27. Ng, J.T.H. and Egobah, E.O. 1980. An Improved Temperature-Viscosity Correlation
for Crude Oil Systems. Paper 83-34-32 presented at the 34th Annual Technical Meeting of
the Petroleum Society of CIM, Banff, May 10-13.
28. Beggs, H. D. and Robinson, J. R. 1975. Estimating the Viscosity of Crude Oil Systems.
J. Pet. Tech., September, 27. pp. 1140 - 1141.
29. McCain, Jr., W. D. 1989. The Properties of Petroleum Fluids. PennWell Publishing
Company, Tulsa, Oklahoma.
PC-PUMP User Guide
243
30. Lee, Al. L., Gonzlaes, M. H. and Eakin, B. E. 1966. The Viscosity of Natural Gases.
Trans., AIME, 237. pp. 997 - 1000.
31. Taitel, Y., Bornea, D., and Dukler, A. E. 1980. Modelling Flow Pattern Transitions for
Steady Upward Gas-Liquid Flow in Vertical Tubes. A.I.Ch.E. Journal, 26, 3. pp. 345 354.
32. Barnea, D., Sholham, Ol, Taitel, Y., and Dukler, A. E. 1985. Gas-Liquid Flow in Inclined
Tubes - Flow Pattern Transitions for Upward Flow. Chemical Engineering Science, 40,
1. pp. 131 - 136.
33. Barnea, D. 1987. A Unified Model for Predicting Flow-Pattern Transitions for the
Whole Range of Pipe Inclinations. International Journal of Multiphase Flow, 13,1. pp. 1 12.
34. Poettmann, F. H., and Carpenter, P. G. 1952. The Mutliphase Flow of Gas, Oil, and
Water Through Vertical Flow Strings with Application to the Design of Gas-lift
Installations. Drilling and Production Practice. pp. 257 - 317.
35. Duns, F. H., and Ros, N. C. J. 1963. Vertical Flow of Gas and Liquid Mixtures in Wells.
Proc. 6th World Pet. Cong., Paper 22, Section II. pp. 451 - 465.
36. Hagedorn, A.R. and Brown, K.E. 1965. Experimental Study of Pressure Gradients
Occuring During Continuous Two-Phase Flow in Small Diameter Vertical Conduits.
Journal of Petroleum Technology. pp 475-484.
37. Beggs, H. D., and Brill, J. P. 1973. A Study of Two-Phase Flow in Inclined Pipes.
Journal of Petroleum Technology. pp. 607 - 617.
38. Orkiszewski, J. 1967. Predicting Two-Phase Pressure Drops in Vertical Pipe. Journal
of Petroleum Technology. pp. 829 - 838.
39. Aziz, K., Govier, G. W., and Fogarasi, M. 1972. Pressure Drop in Wells Producing Oil
and Gas. The Journal of Canadian Petroleum Technology. pp. 38 - 48.
40. Hasan, A. R., and Kabir, C. S. 1992. Two-Phase Flow in Vertical and Inclined Annulie.
International Journal of Multiphase Flow, 18, 2. pp. 279 - 293.
41. Ansari, A. M., Sylvester, N. D., Sholham, O., and Brill, J. P. 1990. A Comprehensive
Mechanistic Model for Upward Two-Phase Flow in Wellbores. 65th Annual Technical
Conference and Exhibition, SPE 20630. pp. 151 - 165.
42. Zabaras, G. J. 1994. Physical Modelling of Vertical Multiphase Flow - Prediction of
Pressure Gradients in Oil and Gas Wells. Offshore Technology Conference, OTC 7515.
pp. 85 - 96.
43. Pucknell, J. K., Mason, J. N. E., and Vervest, E. G. 1993. An Evaluation of Recent
Mechanistic Models of Multiphase Flow for Predicting Pressure Drops in Oil and
Gas Wells. Offshore European Conference, SPE 26682. pp. 109 - 1119.
44. Godbey, J. K., and Dimon, C. A. 1977. The Automatic Liquid Level Monitor for
Pumping Wells. J. Pet. Tech, August. pp. 1019-1024.
PC-PUMP User Guide
244
45. Clegg, J. D. 1963. Understanding and Combating Gas Interference in Pumping Wells.
Drilling and Production Practice - American Petroleum Institute. pp. 149 - 155.
46. Beggs, J.D. 1991. Production Optimization Using NODAL Analysis.
Publications, Tulsa, Oklahoma.
OGCI
47. Shigley, J.E. 1986. Mechanical Engineering Design. McGraw-Hill, pp. 227-281.
48. Bannantine, J.A. et al. 1990. Fundamentals of Metal Fatigue Analysis. Prentice Hall.
49. Matthews, C.M. and Dunn, L.J. 1991. Drilling and Production Practices to Mitigate
Sucker Rod/Tubing Wear-Related Failures in Directional Wells. SPE Annual
Technical Exhibition, Dallas, Texas, SPE 22852, October.
50. Dunn, L.J. and Zahacy, T.A. 1992. Elk Point Field Study, Phase II Final Report.
Project 85-1302, Confidential to C-FER members and Field Study Participants. Centre for
Frontier Engineering Research, February.
51. Specification for Sucker Rods. API Specification 11B.
Institute.
52. Specification for Casing and Tubing
Petroleum Institute.
1990.
American Petroleum
API Specification 5CT.
1990.
American
53. Dunn, L.J. et al. 1994. Well Monitoring Program, Final Report. Project 90-16,
Confidential to J.I.P. participants for Phase I of the PCP Study. Centre for Frontier
Engineering Research, May.
54. Skoczylas, P. and Alhanati, F.J.S. 1998. Flow Regime Effects on Downhole Motor
Cooling. SPE Gulf Coast Section ESP Workshop, Houston, Texas, April.
55. Powers, M.L. 1994. Depth Constraint of Electric Submersible Pumps.
Production and Facilities, SPE 24835, May.
SPE
56. Alhanati, F.J.S., Bottomhole Gas Separation Efficiency in Electrical Submersible Pump
Installations, PhD Thesis, University of Tulsa, 1993.
57. Beggs and Brill, Two Phase Flow in Pipes, 1994.
58. Bennison, T.G., Prediction of Heavy Oil Viscosity, Presented at IBC Heavy Oil Field
Development Conference, London, Dec. 2-4, 1998.
59. Brill, J.P. & Scott, S.L., LIQVIS function, Tulsa University Fluid Flow Projects FORTRAN
code, 1989.
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code, 1989.
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study participants, 1999.
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Heavy Oils, SPE 30316, 1995.
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Reservoir Engineering, SPE 18571, May 1991.
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Technical Considerations ............................................................................ 24

PC-PUMP User Guide

Rod String Loading ............................................................................................... 41

Windows User Interface............................................................................... 50

On-Line Help ............................................................................................... 72

Specifying a Wellbore Geometry ................................................................. 82

Selecting Equipment .................................................................................... 94

PC-PUMP User Guide

Working With Equipment Cases ................................................................ 135

SECTION C: ANALYSING THE SYSTEM........................................................... 140

Specifying Analysis Inputs ......................................................................... 144

Performing Calculations ........................................................................... 161

Examining Results ..................................................................................... 168

HELP/TROUBLESHOOTING .................................................................... 217

PC-PUMP User Guide

APPENDIX A: UNIT CONVERSIONS ................................................................ 223

PC-PUMP User Guide

Know the version of Microsoft Windows installed on your computer.

(780) 450-3700 (fax).

PC-PUMP User Guide

PC-PUMP User Guide

for information about software support and maintenance plans;

downhole geometric design of wellbores;

PC-PUMP User Guide

User Guide Layout

This part describes:

This part provides:

This part provides:

This part provides tables which define input restrictions.

The four appendices provide additional information as follows:

PC-PUMP User Guide

Intel Pentium-type processor that is 100% IBM compatible;

can run successfully with a variety of hardware configurations. However, some

To install PC-PUMP on your personal computer:

PC-PUMP User Guide

PC-PUMP User Guide

Click Next and the installation will proceed.

PC-PUMP User Guide

PC-PUMP User Guide

You will then be asked about the type of installation:

Confirm the installation location:

PC-PUMP User Guide

Click on Next to proceed.

PC-PUMP User Guide

PC-PUMP User Guide

Using Hardlock Feature Codes

PC-PUMP User Guide

PC-PUMP User Guide

Automatic Upgrade Checking

PC-PUMP User Guide

The user has several options:

PC-PUMP User Guide

PC-PUMP User Guide

PC-PUMP User Guide

Locate a USB port on your computer.

Connect the Hardlock to this port.

PC-PUMP User Guide

Parallel Port Hardlock

PC-PUMP User Guide

Progressing Cavity Pumping Systems