XDIAG

E xper t Diagnostic Analysis

of Rod Pumping Systems

Theta Oilfield Services, Inc.

1901 E. Lambert Rd. Suite 108
La Habra, CA 90631 USA
Telephone #: (562) 694-3297
Fax #: (562) 694-8641
www.gotheta.com or www.xspoc.com

Email Addresses:
Terry Treiberg - Vice President: terry@gotheta.com
Software Support: support@gotheta.com
Orders: Christy Kukula - Off. Manager: christy@gotheta.com
 Theta Oilfield Services, Inc., 2010.
All Rights Reserved. This manual may not be reproduced in whole or in part without the written per-
mission of Theta Oilfield Services, Inc.

RODSTAR, RODSTAR-D, RODSTAR-V, RODDIAG, XDIAG, CBALANCE, and XTOOLS are

trademarks of Theta Oilfield Services, Inc..

Printed in the United States of America

First Edition, November 2010
 XDIAG| iii

Contents
Customer Support . . . . . . . . . . . . . . . . . . . . v
System Requirements. . . . . . . . . . . . . . . . . . . v
Introduction. . . . . . . . . . . . . . . . . . . . . . . v
Program Features. . . . . . . . . . . . . . . . . . . . vi

1 Software Installation 1
1.1 XDIAG Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Questions about Installation . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Installing the Software Sentinel. . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Starting and Setting Up XDIAG . . . . . . . . . . . . . . . . . . . . . . . 2
1.4.1 Starting XDIAG . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4.2 The XDIAG Window. . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4.3 Selecting a Printer. . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.4 Setting up XDIAG. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.5 How the Automatic Batch Run Works . . . . . . . . . . . . . . . . . 17

2 Running XDIAG 19
2.1 XDIAGs User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1.1 Using the Keyboard. . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1.2 XDIAGs Help System. . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Entering Rod Pumping System Data . . . . . . . . . . . . . . . . . . . . 21
2.2.1 Entering Well Information Data . . . . . . . . . . . . . . . . . . . . 23
2.2.2 Entering Production Information. . . . . . . . . . . . . . . . . . . 25
2.2.3 Entering Pump and Tubing Information. . . . . . . . . . . . . . . . 26
2.2.4 Entering Rod String Information. . . . . . . . . . . . . . . . . . . 28
2.2.5 Entering Pumping Unit Data. . . . . . . . . . . . . . . . . . . . . 29
2.2.6 Entering Motor Information. . . . . . . . . . . . . . . . . . . . . 32
2.3 Storing Cases/Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4 Running XDIAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.4.1 Dynamometer Animation. . . . . . . . . . . . . . . . . . . . . . 34
2.4.2 Setting Horizontal and Vertical Lines . . . . . . . . . . . . . . . . . 35
2.4.3 Exporting the Balanced Maximum Counterbalance Moment or Structural
Unbalance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5 Printing the Output Report. . . . . . . . . . . . . . . . . . . . . . . . 37
2.6 Loading Data from Disk. . . . . . . . . . . . . . . . . . . . . . . . . . 37
iv | Table of Contents

2.6.1 Recent Files Feature. . . . . . . . . . . . . . . . . . . . . . . . 39

3 Expert Diagnostic Analysis 41

3.1 Explanation of XDIAGs Output . . . . . . . . . . . . . . . . . . . . . . . 41
3.2 Diagnosis of System Problems. . . . . . . . . . . . . . . . . . . . . . . 54
3.2.1 Recording Dynamometer Card in the Field . . . . . . . . . . . . . . . 54
3.2.2 Downhole Pump Dynamometer Card Interpretation. . . . . . . . . . 58
3.2.3 Avoiding Rod Compression . . . . . . . . . . . . . . . . . . . . . . 60
3.2.4 Gearbox Torque and Unit Balancing . . . . . . . . . . . . . . . . . . 60
3.2.5 Using XDIAG with RODSTAR-V or XROD. . . . . . . . . . . . . . . . 61
3.2.6 Setting Lines on Downhole Pump Cards. . . . . . . . . . . . . . . . 62
 XDIAG| v

Customer Support bad pumps

overloaded rods

If you have any questions or problems using XDI- overloaded gearboxes

AG, please call Theta Oilfield Services at (562) out of balance units
694-3297 or send an email to support@gotheta.
the cause of low system efficiency
com.
tubing leaks

Before calling Theta Oilfield Services, be ready to excessive rod-tubing friction due to paraffin
explain the problem or what kind of information or scale
you need. If you get an error while running XDI- incorrect pump spacing that may cause the
AG, try to reproduce it and make note of the steps pump to hit up or hit down
you took and the data you entered that caused the
etc.
error. Make sure youre at your computer when you
call.
XDIAG is the only program of its kind to detect
and correct input data errors caused by:
System Requirements
a load cell that is not calibrated properly
which may cause a load shift or load span
Minimum Re- Recommend-
quirements ed an incorrect fluid level measurement
Computer Pro- 1 GHz 1.6 GHz or an incorrect stroke length
cessor: faster
a phase shift of the surface positions in the
Operating Windows
dynamometer data
System: 2000 / XP /
Vista / 7 non-kinematic surface positions in the dyna-
Computer 256 MB 512 MB or mometer data
Memory: more a dynamometer file with data that is out of
Screen Resolu- 800 x 600 1024 x 768 order
tion: pixels pixels or higher
Available Hard 30 MB
Disk Space: In general, XDIAG is a tool that can help you
improve efficiency, reduce maintenance and lifting
costs, and determine common problems with any
Introduction part of the pumping system. Also, XDIAG can
help you balance pumping units, check system en-
ergy consumption, calculate additional production
XDIAG is a powerful yet easy-to-use rod pump-
(if you have IPR data) and if your prime mover is
ing system expert diagnostic analysis tool. XDIAG
correctly sized.
uses advanced expert system and pattern recogni-
tion techniques to detect problems with existing
rod pumping systems such as: The XDIAG user interface is very easy to use,
extremely flexible, and fast. With a single click of
vi | Introduction
the mouse you can access any input screen at any-
time. You can change an input by simply clicking
on it, and when you have a question, simply press
F1 for context sensitive help for any input item.
With XDIAG you can take advantage of standard
Windows features such as being able to copy the
dynamometer or torque plots to the clipboard and
then paste then in any other Windows document.
XDIAG is a diagnostic tool for existing wells. It
relies on input of actual dynamometer data for
its calculations. Please keep in mind that you can
only use XDIAG to find problems with existing rod
pumping systems. XDIAG is not a design program
and so, you should not use it to make predictive runs.
To design rod pumping systems or to evaluate
the effect of changes on system performance you
must use RODSTAR-V/D or XROD computer
programs developed by Theta Oilfield Services.
RODSTAR-V/D and XROD accurately predict
system performance, loading, efficiency, power
consumption, and the expected surface dynamom-
eter card for any rod pumping system. Also, since
RODSTAR-V/D and XROD can read XDIAG
files, it saves you time because you do not reen-
ter well data into RODSTAR-V/D or XROD.
RODSTAR-V/D and XROD can also overlay
the measured dynamometer card for easier history
matching and troubleshooting.
XDIAG uses the wave equation to model the
behavior of the rod string and exact kinematic
models to simulate pumping motion. With XDI-
AG you can analyze the performance of any rod
pumping system regardless of depth, rod material,
or pumping unit geometry, including long stroke
units like the Rotaflex.
XDIAG works with XBAL so you can enter the
existing counterbalance for your unit. You can ei-
ther use the toolbar function to copy and paste
the calculated existing counterbalance (maximum
counterbalance moment for crank balanced units
and structural unbalance for beam balanced units)
or you can open the XBAL file from the pumping
unit information window in XDIAG to import the
value. After you run XDIAG, you can enter the
maximum counterbalance moment or structural
unbalance back into XBAL to find out where to
move the counterweights in order to balance the
pumping unit.
Program Features
XDIAG is a very powerful software program that
combines expert system and pattern recognition
technology with wave equation diagnostic model-
ing. XDIAG uses exact pumping unit kinematics
which allows it to analyze rod pumping systems
with any pumping unit geometry. XDIAG deter-
mines the condition of the pump and calculates
fluid level, pump intake pressure, and net pump
displacement from the downhole pump card shape.
XDIAG will recall information you entered for a
new case if you exit the program in the middle of
entering the data. When you open XDIAG again,
it will prompt you if you would like to recall the
last case you were entering before it closed. This
works the same way if the program or the comput-
er crashes. If you click yes at the prompt, you will
be returned to the data entry window you were
using before you exited XDIAG, with all the data
you had already entered in place.
XDIAG contains data for all common rod-pump-
ing equipment: pumping unit types and sizes, rod
grades and sizes, tubing sizes etc. Also, XDIAG
will warn you of possible problems you can run
into in the field such as the need of slimhole
couplings or a thin wall pump, what rods fit the
tubing size you selected, etc.
XDIAG allows you to take maximum advantage
of centralized pump off control systems. It can
 XDIAG| vii

analyze hundreds of wells in a 24 hour period, and dynamometer files.

can create spreadsheet files that present results in
Start analyzing wells with new dynamometer
an organized way. XDIAG has many capabilities
data at any time with in a 24 hour period.
including the following:
Save a concise summary of all runs in an Excel
spreadsheet.
Determines pump condition using built in
expert knowledge and pattern recognition
techniques. The best way to take advantage of XDIAG diag-
nostic capabilities is to use Thetas XSPOC soft-
Detects and corrects input data errors such as
ware which uses XDIAG to automatically analyze
a load cell that reads too low or too high or an
all wells with rod pump controllers that communi-
incorrect fluid level.
cate with radio. For more information on XSPOC,
Lists recommendations for fixing downhole visit www.gotheta.com.
problems, for balancing the unit, etc.
Scores the well based on full pump conditions.
XDIAG can model all common pumping unit
This allows you to evaluate the design when
geometries. Also, it allows you to enter your own
any problems with the well are corrected. This
pumping unit dimensions in case your pumping
avoids the problem of fixing, for example, the
unit is not in the programs database. Advanced er-
rod string design if the pumping unit would be
ror trapping and warning messages prevent errors
overloaded with a full/pumped off pump.
and make you aware of special requirements neces-
Prints an expert analysis report that is similar sary for proper system operation.
to a report written by a human expert, and
plots surface and downhole dynamometer cards
and gearbox torque plots. Also, it can print
single page output that includes all the quanti- Advanced Capabilities
ties calculated by the program, including the
dynamometer and torque plots.
and Program Limitations
Calculates gross pump stroke, pump volumet-
ric efficiency, overall system efficiency, peak XDIAG has many advanced features that allow
torque and gearbox loading for existing and you to accurately calculate system performance for
balanced conditions, and the counterbalance any well depth, production rate, or pump condi-
you need to balance the unit. Also, it shows tion. Also, you can analyze wells that produce
the difference between balancing the unit heavy crude or other conditions with increased
for minimum gearbox torque and minimum friction (for deviated wells use XDIAG-D). By cal-
energy usage. culating the minimum stress at the bottom of each
rod section, XDIAG shows if the rods experience
From the downhole pump it automatically compression during operation. This is especially
calculates fluid load, fluid level, pump intake important for fiberglass rods that must never be in
pressure, net stroke, fluid production from net compression.
stroke, and pump fillage.
When using XDIAG with a centralized pump
off control system you can set it up to do the XDIAG accurately calculates electricity consump-
following: tion and the monthly energy bill. The results are
very accurate because it uses actual motor curves
Automatically load an analyze cases with new for these calculations. This provides you with data
viii | Introduction

you can use in economic calculations.

XDIAG assumes that the friction between the
rods and tubing is equally distributed along the
length of the rod string. It also assumes the tubing
is full of fluid and the rods are made of homoge-
neous material.
XDIAG does not consider the effect of pumping
unit moments of inertia on net gearbox torque.
This results in a conservative calculation for net
gearbox torque and gearbox loading. If your system
is equipped with an ultra high slip motor, this will
affect the shape of the measured dynamometer
card by lowering the peak polished rod load and
raising the minimum polished rod load. Since
XDIAG uses this actual dynamometer card for its
calculations, the effect of the ultra high slip prime
mover is partially accounted for. So, the results
are close to actual results. Also, XDIAG uses the
actual motor efficiency curves to calculate energy
consumption and monthly energy bill very accu-
rately.
Artificial Lift Glossary and
Help System
XDIAG takes full advantage of Microsoft Win-
dows to bring you context sensitive help and even
an electronic Artificial Lift Glossary. This glossary
is full of definitions for many specialized terms.
This is a very powerful help system that allows
you to run the program without a manual. You
can access the Artificial Lift Glossary at any time
by clicking on the Help tab on the menu bar at
the top of XDIAGs main window. You may find
faster concise help by hitting F1 in the input field
you have a question with. This will open the help
window to the topic on the input field in question
and can help you with your problem with one push
of a button.

When scoring your well, XDIAG only considers

the worst case scenario which is a full pump with
the fluid level at the pump. XDIAG cannot score
the current condition of the well. The reason for
this is the well could become pumped off in the fu-
ture, if it isnt already. If the design is not overload-
ed and the fluid level is not at the pump, there is a
risk that when the well is pumped off the rods or
pumping unit will become overloaded and encoun-
ter a failure. This works the same way for pump
problems or tubing leaks. If the score was based on
these conditions the equipment (pump, plunger,
rod string design, etc.) could receive a good score.
Then when the problems are fixed the system could
run into problems because the conditions changed
when the equipment was fixe

1 Software Installation
Before you install the program, make sure you
have the hardware and software you need to run
XDIAG for Windows.
1.1 XDIAG Installation
XDIAG is installed from the Theta Software Suite
installation CD that you received. Load the CD
into your PC and the installation program should
load automatically. After the Welcome screen
you will have options for whether you are using
a Network or Standalone license. After selecting
the proper choice, the next screen will prompt you
for the programs to install. That screen also has a
button that lets you display and print the detailed
Installation Guide for your specific installation.
After installing the program, put your original CD
away in a safe place. If the Software Installation
Suite CD becomes damaged or lost, please call
Theta Oilfield Services, Inc. at (562) 694-3297 for
a replacement.
1.2 Questions about
Installation
The following are some answers to questions you
may have about installing XDIAG for Windows.
Do I need to delete earlier versions of XDIAG
XDIAG| 1
before I install?
No. When updating versions of XDIAG, the pro-
gram defaults to install to the C:\Program Files\
Theta\XDIAG directory. If your previous copy
of XDIAG is in another directory, you can specify
to install over it. It will not replace any of you case
files, just the previous version of the program.
The installation defaults to setting C:\THETA
as the common folder for your case files. Using a
common folder is a good idea since several of the
Theta Oilfield Services applications that you might
have can all share the same case files.
Although a new version of XDIAG can read files
created with previous versions, a previous version
may not be able to read files created with the latest
version of the software.
What happens to files I have created with previ-
ous versions of XDIAG?
Nothing. When you install or reinstall XDIAG,
only program files are replaced. The latest ver-
sion of XDIAG can open older XDIAG files. The
saved output will not be available for viewing. This
is because changes in the new version of XDIAG
might change the output report of the older files.
This is due to additions to the pattern recognition
database that could improve the results of the older
XDIAG files.
2 | Software Installation
If the latest version might get better results that
the previous version, does that mean the calcula-
tions from the previous version are incorrect?
No. This is simply the nature of advancement of
technology. We do the best we can with what we
have. If the pattern recognition database improves
and changes the results, the changes will be slight
changes. Do to the differences we require that you
rerun cases to obtain output when updating to a
new version of XDIAG.
1.3 Installing the
Software Sentinel
Your XDIAG license is validated and protected
by a security bitlock called a Sentinel. For stand-
alone installations, this is either a USB key or a
Parallel Port key that is attached to your PC. For
Network Licenses, the key is attached only to the
Network License Server. See the Detailed Instal-
lation Guide that is available for printing from the
Software Installation Suite CD for more informa-
tion. XDIAG communicates with the sentinel
and although the program can be copied, it will
not operate without a sentinel supplied by Theta
Oilfield Services, Inc..
If the sentinel is not installed correctly, the pro-
gram will warn you that the sentinel does not ap-
pear to be connected. If this occurs, make sure the
sentinel is properly installed and the connection is
not loose. If the sentinel is properly installed but is
not working, it may have been damaged. Frequent
plugging and unplugging, and static electricity can
damage the sentinel. If you think your sentinel is
damaged, contact Theta Oilfield Services Inc. to
determine if you need a replacement. Do not dis-
card the damaged sentinel. Even if it is damaged,
you must return the sentinel to Theta Oilfield
Services Inc. before a replacement sentinel can be
sent out to you. When XDIAG first starts, it reads
and displays the serial number of your sentinel on
the opening screen. You will also find the sentinel
serial number in the About XDIAG window. To
open the About XDIAG window simply click
the About command on the Help tab of the
menu bar.
Theta Oilfield Services, Inc. uses Sentinel Super-
Pro for software protection. If you use software
sentinels from vendors, you may be able to cascade
Sentinels as long as the LPT1 port has only one
Sentinel C on it. If you have one or more Sen-
tinel PRO and one Sentinel C, then plug the
Sentinel C at the end of the Sentinel PROs or
SuperPros. USB type Sentinels can be plugged
into any available USB port or hub on the PC.
1.4 Starting and Setting
Up XDIAG
1.4.1 Starting XDIAG
You can start XDIAG by double clicking the icon
on your desktop. You may also click the XDIAG
icon in the Start menu under All Programs/Theta
Software/ XDIAG.
1.4.2 The XDIAG Window
The following figure shows the main XDIAG
window that appears when you start the program.
XDIAG behaves like any other standard Windows
program. You can use the mouse to move and
size windows, select text, choose commands from
menus and dialog boxes, and complete almost any
other task in XDIAG aside from typing text.
The following is an explanation of each part of
XDIAGs main window.

The control-menu box is in the upper-left corner
of each window. The control menu is most use-
ful if you use the keyboard. You can use the con-
trol menu commands to resize, move, maximize,
minimize, and close windows. Also, you can use it
to switch to other applications. These are the same
functions that are commonly performed with the
mouse. Double clicking on the control menu box
closes XDIAG.
The title bar shows the name of the application.
If more than one window is open, the title bar
for each active window is a different intensity the
other title bars.
The menu bar lists the available menus. A menu
contains a list of commands, or actions, you can
carry out with XDIAG.
XDIAG| 3
The toolbar gives you quick access to the menu
commands using your mouse. When you first load
XDIAG, only some of the toolbar buttons are
active. When you enter data or read a file from
disk, then the buttons will activate. This helps you
move through each input window and enter the
necessary data to run XDIAG. The following is an
explanation of each toolbar button as they appear
from left to right.
New file Click on this button to refresh
XDIAG to begin entering data for a new case.
Any unsaved data will be lost.
Open file Click on this button to read
a Theta software file. This includes XDIAG,
RODDIAG, RODSTAR-V, and RODSTAR-D.
XROD files saved in the non-AI mode format are
4 | Software Installation
similar to RODSTAR-V files and can be opened
in XDIAG. RODSTAR-V and RODSTAR-D
files will not contain dynamometer data. You must
open the dynamometer file after loading one of
these files types. Opening RODSTAR file types
makes it easier for you to input all the data for an
existing well without the need to enter the data for
each input window manually.
Save data to disk Click this button to save
the current case to an XDG file. If you run the
case the results will be saved in the file and the
next time you open the file you can open the re-
sults without running it.
Setup Click here to open XDIAGs Setup
window. The details of the Setup feature will be
explained in the next section.
Well information Click this button to open
the Well Information Window. In this window,
enter general information about the well such as
name, watercut, pressures, pump depth, etc.
Production information Click this button
to open the Production Information Window. In
this window, enter the pumping speed and gross
production. You can also choose to enter fluid
level, pump intake pressure, no fluid level, or IPR
information.
Pump and tubing information Click this
button to open the Pump and Tubing Information
Window. In this window, enter specific informa-
tion about the pump and tubing such as the pump
plunger size, tubing size, anchor depth, etc.
Rod string Click this button to open the
Rod String Information Window. In this window,
enter the rod string information which includes
service factor, and the rod grade, rod diameter, and
length of each taper in the rod string.
Pumping unit Click this button to open
the Pumping Unit Information Window. In this
window, select the pumping unit, stroke length,
and direction of rotation. You can also enter the
counterbalance information.
Motor Click this button to open the Motor
Information Window. In this window, select the
type of motor, size of the motor and motor set-
tings.
Previous window Click this button to open
the previous input window. The data entry win-
dows go in order from left to right on the toolbar.
If you are entering data for the pumping unit,
clicking this button will change your focus to the
Rod String Information Window (it will open the
window if it isnt already open).
Next window - Click this button to open the
next input window. The data entry windows go in
order from left to right on the toolbar. If you are
entering data for the pumping unit, clicking this
button will change your focus to the Motor Infor-
mation Window (it will open the window if it isnt
already open).
Run Click this button to run XDIAGs
expert diagnostic calculations.
View output Click this button to view the
output results. This button is only active if there
are output results to display. Older files with saved
output will not show output results when open-
ing in a newer version of XDIAG. This is because
improvements in the pattern recognition database
may generate better results. You must re-run these
cases for output results.
Email Click this button to send an email
to our technical support team. This function will
allow you to address the problem and attach up to
three files to the email without opening your email
client.

Print Click this button to send the output
results to your default printer. You can only print if
there is an output report available.
Export counterbalance to XBAL After
running a case, click this button to export the
balanced counterbalance moment (crank balanced
units) to the Theta clipboard. This makes the
value available to import into XBAL and balance
your unit in just a few clicks. If XDIAG calculated
a counterbalance moment to balance for minimum
energy as well as minimum torque you will be
prompted to chose one of the two to export. For
beam balanced units, this function will export the
structural unbalance required to balance the unit.
Start automatic analysis mode Click this
button to start XDIAGs automatic analysis mode.
XDIAG will run in the background and will start
analyzing wells at the time of the day you specified
in Setup.
XDIAG| 5
Help Click this button at anytime to get
context sensitive help. You may also press the F1
key to get context sensitive help.
Visual input Click this
button to open the Visual Input Window. This
window make it easy to change a parameter of the
case by clicking on the part of the well you wish
to change a parameter in. Click the rod string to
change a value that pertains to the rod string.
Alphabetical list Click this button to open
the alphabetical list of input parameters. Click on
an item in the list to open the input window where
the input field for the parameter is located.
The Status Bar is located at the bottom of the
main window. It shows useful messages during
data entry or when running XDIAG.
6 | Software Installation
The Getting Started window appears in the middle
of the main XDIAG window when you open
XDIAG. This window shows the most common
toolbar icons you need to know to begin using
XDIAG. This is especially useful for new users.
1.4.3 Selecting a Printer
XDIAG allows you to select any printer installed
on your system. Simply click on File on the menu
bar, and then click on Print Setup to see a list
of installed printers as the following figure shows.
To select a printer, simply click on the printer
name in the list.
1.4.4 Setting up XDIAG
Click on the Setup button on the toolbar (fourth
button from the left) to open XDIAGs setup win-
dow. You can also open the setup window by click-
ing Tools on the menu bar and clicking XDIAG
Setup. This window allows you to specify informa-
tion and choose options that usually do not change
with each run. The following describes each Setup
tab in the order they are presented in XDIAG.
General
Click on the General tab to specify measurement
units and also to select whether to have XDIAG
display the visual input window by default.
For measurement units you can select English,
Canadian, or Metric/SI. English units are mainly
used in the USA and South America. If you select
this option XDIAG will ask for pump depth in
feet, production rate in BFPD, plunger and rod
diameters in inches, etc. The Canadian option
provides you with the common mix of English
and Metric units used in Canada. The Metric/SI

option will change the input units to Metric units.
In any measurement unit setting you can press the
F2 key to convert from English to Metric and vice
versa. This works for numeric input fields only.
When you press F2 to convert units, the back-
ground of the input field changes color (from cyan
to green).
Batch Mode
Click the Batch Mode tab to adjust the batch run
capabilities. This affects the manual and automatic
batch mode runs. The top portion of this window
allows you to select whether you want XDIAG to
print results of each case it runs in batch, to create
a summary spreadsheet file, to run the cases using
your setup options or the setup options saved on
the file, or to rerun cases that contain saved output.
The middle section of the window contains options
for spreadsheet file formats. The bottom section
contains options for the automatic batch mode.
General batch mode options
If you check the Make printouts check box,
XDIAG will print the output report for each case
in the batch.
If you check the Create spreadsheet file check
box, XDIAG will summarize the results of all the
files you run in batch in a, Excel spreadsheet (xls
file format).
If you check the View spreadsheet file check box,
XDIAG will open Excel and display the spread-
sheet created in the batch run.
If you check the Dont re-run cases with saved
output checkbox, XDIAG will skip case files
that have saved output from previous runs. When
you run XDIAG in batch mode, XDIAG resaves
the files, which saves the output results into the
XDG files. This feature is useful if you would like
XDIAG| 7
to create spreadsheet files using different spread-
sheet formats. XDIAG will not rerun each case
and this speeds up the process of creating multiple
spreadsheets for a given batch run. For example,
let us assume there are two users (John and Paul)
who use XDIAG and they each have their pre-
ferred spreadsheet formats. John can run 20 cases
in batch mode and create a spreadsheet that sum-
marizes the batch run as he prefers. Since John ran
the cases, the 20 XDG files contain recent results
saved to the files. When Paul runs the same cases
in batch, he checks the Dont re-run cases with
saved output option to save time. XDIAG will
compile the spreadsheet without re-running each
case and this will execute quickly because XDIAG
only has to extract the saved results to create the
spreadsheet file.
If you check the Update file with Setups infor-
mation, the batch mode runs will use the setup
options in setup, not the setup information in the
files. These setup options will replace the options
in the files because batch mode runs resaves the
files. If you check the Update the Setup with
files information the setup will be updated with
the information on the files that are in the batch
mode run. We recommend saving a file with your
preferred setup information in case you use this
feature and change your settings and you wish to
change them back. You can simply use that file to
change setup to your preferred settings
Spreadsheet batch mode options
This section displays a list of the spreadsheet for-
mats you created. If you have not created any for-
mats then the only format available is the Default
format. Click on the + button to create a new
spreadsheet format. Select and existing format and
click the pencil icon to modify the format. Select
an existing format and click on the X button to
delete the format from the list. The following im-
age shows the window you will see when creating
or modifying a spreadsheet format.
8 | Software Installation
On the left side of this window is a list of variables
in the order they will appear in the spreadsheet.
On the right side you see an alphabetical list of
all other variables that are available and can be
added to the spreadsheet. You can drag and drop
the variables from one list to the other or you can
use the command buttons located between the two
lists. To add a value to the spreadsheet you must
highlight a variable from each list, and then click
either Add Before or Add After. Clicking Add
Before button will add the available variable to the
spreadsheet list right above the highlighted vari-
able on the left. Clicking the Add After button
will add the available variable to the spreadsheet
list right below the highlighted variable on the
left. You can also change the order of the variable
already in the spreadsheet list by using the Move
Up and Move Down buttons. Highlight the vari-
able on the left and click the Move Up or Move
Down button to move it up or down in the list. To
include the rod string design in the spreadsheet,
simply check the Include rod string in spread-
sheet checkbox. To name the spreadsheet format,
enter the name in the input box on the bottom
right of the window labeled Name of Format.
Automatic batch mode options
In this section of the batch mode options win-
dow you can set the time at which you would like
XDIAG to make the batch run and specify the di-
rectories of the files XDIAG will use in the batch
run. The three directories you need to specify
are for the XDIAG files, dynamometer files, and
where to save the Excel files. Details about how
the automatic batch mode works are in the next
section (1.4.5).
Defaults
The Defaults allows you to initialize inputs for
new cases such as electricity cost, plunger size, ser-
vice factor, run time, etc. This Setup page, shown
in the following figure, shows a list box containing
all the defaults you can set. As you select the de-
faults item from the list the input field will change
accordingly. The following is a list of the default
items you can set using this feature:
1. Casing pressure
2. Company name
3. Electricity cost
4. Folder for Open/Save files
5. Folder for XBAL/CBALANCE files
6. Folder for T1 Dynamometer files
7. Folder for Lufkin Automation Dynamometer
files

8. Folder for Import files
9. Folder for PDF files
10. Include buoyancy effects
11. IPR correlation
12. Most common pumping unit type
13. Motor type
14. Oil gravity
15. Plunger size
16. Pump type
17. Pumping speed
18. Rod-tubing friction
19. Run time
20. Second company name
21. Second company telephone number
22. Steel rod service factor
23. Stuffing box friction
24. Tubing pressure
25. Tubing size
26. User name
27. Water cut
XDIAG| 9
28. Water specific gravity
Output Options
This Setup option gives you more control over
what appears on XDIAGs output report. You can
select exactly which parts of the output will be
displayed and available to print. You can choose
from the expert diagnostic report, scoring page,
one-page calculations report, inflow performance
(IPR) chart, and separate dynamometer and torque
plots. You can also remove the dynamometer cards
and torque plots from the one-page calculations
report. To help you visualize exactly what will be
displayed, XDIAG shows a miniature representa-
tion of each page you have chosen. The preview
changes dynamically as you select the pages you
would like in the report.
Pumping Unit Options
Customize Pumping Unit List
The Customize Pumping Unit List tab, under
Pumping Unit Options, allows you to customize
the list of pumping units that XDIAG displays
on the Pumping Unit Information Window. This
makes it easier to locate your pumping unit. For
10 | Software Installation

example, if you only have 12 different sizes of your custom list, highlight it by clicking it in the
Lufkin Conventional units, 10 different sizes of list box and observe the Name/API and Other
Mark II units, and 14 different sizes of Ameri- fields on the bottom of the screen. These fields may
can Conventional units, you can set up XDIAG contain additional information about the pumping
to show only these units when you are selecting unit to correctly identify the pumping unit. This is
a pumping unit. The following explains how to especially useful for manufacturers (for example:
customize the pumping unit list. American Conventional) who have more than one
unit with the same designation but different crank
types. In such a case, the Other field shows the
1. From the Setup Window, click the Pumping crank type of other information that helps identify
Unit List tab under Pumping Unit Options the pumping unit.
tab.
2. Click the arrow on the Manufacturer drop-
This is not the only way to customize the pumping
down and select the manufacturer list you
unit database. As discussed in the next chapter,
would like to customize. All units that are not
you can also select a unit you want to add to the
already in the custom list will appear in the list
customized pumping unit list by first selecting it
box on the right of the window.
from the full database and then checking the Use
3. Add units to the custom list by dragging them custom pumping unit list check box. When you
from the available list on the right to the cus- check the check box XDIAG will ask if you would
tom list on the left. You can also select the unit like to add the selected unit to your custom unit
in the available list and click the Add button to database. Click yes to add the unit to your custom
add the unit to the custom list or select the unit database.
in the custom list and click the Remove button
to remove it from the custom list.
Measured Pumping Unit List
4. After you add your units to the custom unit list
click OK to save your changes. XDIAG allows you to enter data for pumping
units that are not in XDIAGs main database. If
you have the dimensions you need for these units,
To make sure you select the correct unit to add to you can enter them here to use them in XDIAG

(once you entered them in XDIAG they can be
transferred to other Theta programs such as ROD-
STAR and XROD: when you save an XDIAG file
with a measured pumping unit then open that file
in another program, you will be asked if you would
like to add that measured unit to the programs
measured pumping unit list). The following ex-
plains how to add a measured unit to XDIAG.
1. Click on the Setup icon on the toolbar, and
click on the Pumping Unit Options tab then
click on Measured Pumping Unit List tab.
2. To enter data for a new pumping unit click the
+ button.
3. Enter the pumping unit data for your pumping
unit.
4. To save your pumping unit to the measured
database, click OK.
The measured pumping unit will be under Mea-
sured Pumping Units when selecting the manu-
facturer on the Pumping Unit Information Win-
XDIAG| 11
dow.
If you need help with the input window click the
help button. To get help with a pumping unit
dimension hit the F1 key while the cursor is in the
input field. The help topic for that input field will
open automatically.
To modify the data of a measured unit, select the
pumping unit and click the pencil icon. To delete
a unit from the measured unit database, select the
unit and click the X button.
Measured Pumping Unit Dimensions
The data you must enter consists of geometric
dimensions as defined in the API 11E publication.
You can get these dimensions from the pump-
ing unit manufacturer or measure them yourself.
For old units without an API designation on their
nameplate, you may be able to put together an
equivalent API designation. Look at the gearbox
nameplate for the gearbox rating. Measure the
12 | Software Installation

stroke length, and try to decipher additional infor- B = Beam balanced geometry
mation from the units nameplate for the structure
M = Mark II geometry
rating and structural unbalance. If the nameplate
is legible then write down the units serial number A = Air-balanced geometry
or order number. If the units manufacturer is still R = Rotaflex or long stoke geometry
in business, you may be able to get the data you
need from them using the serial number or order LP = Low profile belted geometry
number. For help in locating dimensional data for H = Hydraulic geometry
pumping units not in the database call Theta Oil-
field Services Inc.
Structural unbalance
Structural unbalance is a term used for pumping
XDIAG allows you to enter data for Conventional,
units with a walking beam. It is defined in the
Mark II, Air-balanced, Enhanced Geometry,
API 11E as the force needed at the polished rod
long stroke, Hydraulic, and Low Profile Belted
(parallel to the polished rod) to hold the walking
units. When you enter your own pumping unit
beam in the horizontal position while the pitman
dimensions, XDIAG calculates and displays the
arms are disconnected from the crank pins. This
stroke length based on the dimensions you enter.
force is positive when the force is acting down and
For all pumping unit types you must first enter
negative when acting up. See the figure for a visual
the name of the manufacturer, the unit name or
representation of structural unbalance.
model number, the gearbox rating in thousands
of inch pounds (excluding hydraulic units), the
structure rating in hundreds of pounds, and the Structural unbalance for conventional units can be
maximum stroke length in inches. From these either positive or negative. Mark II units always
numbers XDIAG puts together the API pumping have a negative structural unbalance because their
unit designation. The API pumping unit designa- geometry places the saddle bearing on the back of
tion is a standard way of describing the size and the walking beam. This eliminates the possibility
capacity of the pumping units. The hydraulic units of balancing the walking beam on the saddle bear-
are given a unit designation because there is not ing. The walking beam will always want to rotate
gearbox rating. The following is an example of an to that the horsehead rests on the ground. The
API designation: structural unbalance will be filled in with the value
that is in the database. You can manually change it
if you would like. When you enter a custom unit in
C-228-246-100
Setup, if you do not know the structural unbalance
for the unit you are analyzing then enter zero. In
The C means this is a conventional unit. The most cases the structural unbalance will not affect
228 describes the gearbox rating (228,000 the results significantly.
in-lbs). The 246 describes the structure rat-
ing (24,600 lbs). This means to avoid overloading
the unit the maximum polished rod load cannot
exceed 24,600 lbs. The 100 describes the stroke
length (100 inches). Other unit types have the fol-
lowing designation:

C = Conventional or Enhanced Geometry

 XDIAG| 13

Definition of crank offset angle

The crank offset angle (or crank phase angle) is the
angle between the crank pin bearing and the coun-
terweight arm. The figure shows the crank offset
angle is defined.

XDIAG requires a positive crank offset angle for

Mark II units and a negative one for enhanced ge-
ometry units such as Torqmaster, Lufkin Reverse
Mark, or American Producer II. For conventional
units the crank offset angle is zero. For belted low
profile units the crank offset is typically entered as
zero. This is because XDIAG analyzes the units
beginning at the bottom of the stroke. Belted low
profile units are typically designed in such a way
that at the bottom of the stroke the counterweight
arm is directly vertical pointed upwards. With this
orientation, entering a zero for crank offset angle
will result in correct calculations.
Conventional and enhanced pumping unit data
For conventional and enhanced units you must en-
ter unit dimensions R, A, C, I, P, and K in inches,
the structural unbalance in pounds, and the crank
offset angle in degrees. The crank offset angle is
negative for enhanced geometry units. The follow-
ing explains each dimension with respect to the
pumping unit.

R Radius of the crank for each crank hole

The following explains the rest of the required unit measured from the center of the slow-speed
geometry to add units to XDIAG for each unit shaft to the center of the crank-pin in inches.
type.
A Distance from the centerline of the saddle
bearing to the centerline of the polished rod in
14 | Software Installation
inches.
C Distance from the centerline of the saddle
bearing to the centerline of the equalizer bear-
ing in inches.
I Horizontal distance from the centerline
of the saddle bearing to the centerline of the
crankshaft (slow-speed shaft) in inches.
P Effective length of the pitman arm (from
the center of the equalizer bearing to the center
of the crank-pin bearing) in inches.
K Distance from the center of the crankshaft
to the center of the saddle bearing in inches.
Some manufactures will supply G and H di-
mensions instead of the K dimension.
H Height from the center of the saddle bear-
ing to the bottom of the base beams in inches.
G Height from the center of the crankshaft
to the bottom of the base beams in inches.
You can find the K dimension using the G, H, and
I dimensions in the following equation:
Beam balanced pumping unit data
Beam balanced units require the same dimensions
as conventional units. The major difference be-
tween beam balanced units and conventional units
is beam balanced units carry the counterweights
on the walking beam instead of the cranks, hence
the name beam balanced. This requires the units
to have elongated walking beams. The E dimen-
sion is the distance from the back end of the beam
to the center of the equalizer bearing. This di-
mension is not required to enter a beam balanced
unit to XDIAG. XDIAG does require the crank
maximum counterbalance moment (in thousands
of inch pounds). This allows XDIAG to accurately
calculate the required counterbalance while taking
into account the counterbalance obtained from the
cranks.
Mark II pumping unit data
Mark II unit entry also requires pumping unit
dimensions R, A, C, I, P, and K in inches, the
structural unbalance in pounds, and the crank
offset angle in degrees. The crank offset angle for
Mark II units is positive. The following explains
each dimension with respect to the pumping unit.
R Radius of the crank for each crank hole
measured from the center of the slow-speed
shaft to the center of the crank-pin in inches.
A Distance from the center of the Sampson
Post bearing to the centerline of the polished
rod in inches.
C Distance from the centerline of the Samp-
son Post bearing to the center of the equalizer
bearing (or cross yoke) in inches.
I Horizontal distance between the centerline
of the Sampson Post bearing and the centerline
of the crankshaft (slow-speed shaft) in inches.
P Effective length of the pitman in inches
(measured from the center of the equalizer
bearing or cross yoke to the center of the
crank-pin bearing).
K Distance from the center of the crankshaft
to the center of the Sampson Post bearing in
inches.
 XDIAG| 15

inches.
M Geometry constant in inches squared. M
is the distance from the Sampson Post bearing
to the air tank bearing (distance X) multiplied
by the area of the piston in the air cylinder
divided by the A dimension.

Ap refers to the area of the air cylinder piston in
square inches.
S Pressure in the air cylinder required to off-
set the weight of the walking beam, horsehead,
equalizer, pitman arms, etc. in psig.
V0 Minimum air volume in the air tank be-
tween the plunger and cylinder at the bottom
Air-balanced pumping unit data of the stroke in cubic inches.
Air-balanced unit entry also requires pumping
unit dimensions R, A, C, I, P, and K in inches. In
addition, you must enter pumping unit dimensions Long stroke pumping unit data
M, S, and V0. The figure displays most of the data Long stroke pumping unit entry requires the
required for entering air-balanced units. The fol- sprocket diameter (dimension D), the centerline
lowing explains each dimension with respect to the distance between the top and bottom sprockets
pumping unit. (dimension C), the pitman arm length (dimension
P) if one exists, and the top drum diameter ratio
(usually 1).
R Radius of the crank for each crank hole
measured from the center of the slow-speed
shaft to the center of the crank-pin in inches.
A Distance from the center of the Sampson
Post bearing to the centerline of the polished
rod in inches.
C Distance from the centerline of the Samp-
son Post bearing to the center of the equalizer
bearing in inches.
I Horizontal distance between the centerline
of the Sampson Post bearing and the centerline
of the crankshaft (slow-speed shaft) in inches.
P Effective length of the pitman in inches
(measured from the center of the equalizer
bearing to the center of the crank-pin bearing).
K Distance from the center of the crankshaft
to the center of the Sampson Post bearing in
16 | Software Installation

pumping unit.
You can use this geometry to model other non-
beam unit types with long slow strokes. You can
R Radius of the crank for each crank hole
do this by entering data that will produce the
measured from the center of the slow-speed
required stroke length. The stroke length can be
shaft to the center of the crank-pin in inches.
calculated using the following equation:
D Diameter of the drum in inches.
I Horizontal distance between the centerline
Stroke = C + D
of the drum and the centerline of the crank-
shaft (slow-speed shaft) in inches.
For example, to simulate a long stroke unit with K Distance from the center of the crankshaft
a stroke length of 200 inches, you can enter a to the top of the drum in inches.
sprocket diameter (D) of 20 inches and a center-
H Height from the center of the drum to
line distance of 180 inches. This technique can be
the bottom of the base beams in inches.
used as long as the units upstroke and downstroke
velocities are approximately equal. G Height from the center of the crankshaft
to the bottom of the base beams in inches.

Hydraulic pumping unit data

You can find the K dimension using the D, G, H,
Hydraulic pumping unit entry only requires the
and I dimensions in the following equation:
structural rating and the maximum stroke length.
All calculations pertaining to the gearbox are not
performed on hydraulic units. Hydraulic unit types
allow you to adjust the stroke length when you
select the unit in the pumping unit information
window. For example, if you select a unit with a
maximum stroke length of 200 inches but the unit
had been adjusted to a 165 inch stroke, you can XDIAG analyzes units beginning with the pol-
enter 165 inches when running the case so that ished rod at the bottom of the stroke. This orienta-
XDIAG will analyze the actual conditions. tion usually has the counterweight in the vertical
position perpendicular to the base. If this is correct
then the crank offset angle (Theta) is 0. If at the
The unit designation generated for hydraulic units bottom of the stroke the counterweights are not
is not an API standard. The unit designation is in the vertical position then Theta is not equal to
created the same way as other unit types but omit- zero.
ting the gearbox rating. For hydraulic unit with
a maximum stroke length of 200 inches and a
structural rating of 25,000 lbs the unit designation Customize Rod Grades
is H-250-200. You can enter custom rod grades for steel rods
only. To enter a rod grade that is not in XDIAGs
database do the following:
Belted low profile pumping unit data
Belted low profile unit entry requires pumping unit
dimensions R, D, I, and K in inches. The follow- 5. Click on the Custom Rod Grades tab on the
ing explains the dimensions with respect to the Setup window.

6. To add a new sucker rod or sinker bar click
on the + button. This opens a new window
where you enter the following information
about the rod, rod grade or manufacturer
name, minimum tensile strength in psi for
English or kPa for Metric data entry, and stress
analysis method. Also, there is a check box on
the bottom of the window to identify the rod
as a sinker bar. This changes the available rod
diameters of the custom rod grade. XDIAG
follows the API 11B for rod sizes.
7. When you are done entering the information
for the rod, click on the OK button to save the
custom rod.
After you enter one or more custom rod grades,
you can modify or delete any of them by clicking
on the rod name and them clicking on the appro-
priate option. Once you enter a rod grade to your
custom list, it will appear on the same list as the
rest of the rod grades that are built into XDIAG.
Expert Diagnosis
This Setup option allows you to specify expert
input data corrections to be performed by XDAIG.
For example, to have XDIAG correct load shifts of
3% or larger, enter a 3 in the input field after you
check the check box labeled Correct load shift
of at least. This is a powerful option that allows
XDIAG to correct bad data so that you can get
an accurate analysis without having to re-measure
the dynamometer card. Also, you can select to
have XDIAG correct a load span shift, an entered
fluid level, a measured stroke length that does not
XDIAG| 17
match the calculated stroke length, and correct
out of order dynamometer data. You can allow the
friction to be entered for each case, allow XDIAG
to calculate friction if there is a traveling or stand-
ing valve leak detected and set a friction limit. You
can also set a target pump intake pressure. If you
enter IPR data, XDIAG can use your target pump
intake pressure to calculate additional possible
production capacity.
1.4.5 How the Automatic Batch Run
Works
Before XDIAG can run in automatic batch mode,
you must specify the directories and the time you
want to start analyzing the wells. XDIAG will
first look at the XDIAG data directory for data
files for each well (.xdg files). Then, it will look at
the dynamometer file directory for dynamometer
files that are newer than the XDIAG files. If a
new dynamometer file exists in this directory with
the same name as the XDIAG file, then XDIAG
will analyze the well. For example, if you have an
XDIAG file named ABC101.xdg in the XDIAG
directory which was saved on December 5, 2009,
and a dynamometer file named ABC101.dyn in
the dynamometer file directory which was saved
on December 9, 2009 then XDIAG will analyze
the well.
The automatic batch mode option is primarily for
use with a centralized pump off control system that
can generate the dynamometer files needed. How-
ever, as explained in the next chapter, this is not
the only batch mode available in XDIAG. If you
18 | Software Installation

do not use centralized pump off control systems or

if you want to create new XDIAG files yourself,
you can still run XDIAG in batch mode. Simply
select to load more than one file from the file menu
(you can select multiple files by highlighting all the
files in the batch when opening a file). The next
chapter will explain this method in more detail.
 XDIAG| 19

2 Running XDIAG

To start XDIAG, double click the XDIAG icon An item followed by an ellipsis () opens a
on your desktop. After a few seconds you will first dialog box or another window. For example,
see XDIAGs introductory window then XDIAGs click File and then click Open.
main window. When XDIAG first loads, only a
few of the toolbar buttons are active. This feature
helps guide you through the input windows to be The Visual Input Window and Other Ways to
sure all the required values are entered. The ac- Change Data
tive icons include the following: new case, open
The following figure shows XDIAGs Visual Input
file, setup, email, automatic batch mode, and help.
If you have not set up XDIAG then do so before
you begin entering data for a new case (see Chap-
ter 1 section 1.4.4 for information on setting up
XDIAG). To enter data for a new case, click the
first icon on the toolbar (New) or click File on the
menu bar and then click New.

2.1 XDIAGs User Interface

XDIAG has a user friendly interface that simpli-
fies and speeds up data entry. The program uses
standard Windows features along with other
unique features designed to make entering and
changing data as easy as possible. Windows fea-
tures utilized by XDIAG include the following:
menu bar with drop down menus, control box at
the top right of the main window, and the ability
to resize and move windows.

When selecting an item from the menu, visual

clues tell you what will happen next.

An item followed by no markings starts an

action. For example, click File and then click
New.
20 | Running XDIAG
Window that makes it easy to locate an input
item you wish to change. When you have entered
all the required data for a new case, or you have
loaded a case from disk, the Visual Input Window
will appear if you have it set to open by default.
See the General tab in XDIAGs Setup Window.
The Visual Input Window shows an image of a
conventional pumping unit system. As you move
our mouse over the picture, tool tips appear nam-
ing the various parts of the system. Whenever a
tool tip is showing, right-click the mouse to see
a popup list box of the input variables associated
with that part of the system. Left-clicking opens
the data entry window associated with the part of
the system you clicked.
Another way to change data is to click the Alpha-
betical List button at the bottom of the Visual
Input Window or on the tool bar. This button will
open a list of all input parameters in alphabetical
order. Double-click an item in the list or select the
item and clock the OK button to open the input
window associated with that item.
2.1.1 Using the Keyboard
Most of the functions you can access with the
mouse, you can also access with the keyboard. For
example, to open a file using the mouse, click the
Open File button on the toolbar. Using the key-
board, first open the File menu, and then select
Open to open a file from disk. The quickest way to
perform these steps is to use XDIAGs accelerator
keys or shortcuts.
Accelerator Keys
To use accelerator keys to access menus, first press
ALT to activate the menu bar, the press the ap-
propriate accelerator key. The accelerator key is
underlined in the word on the menu. For example,
if you press ALT then the F key, the File menu
will open. You can also use the arrow keys to
select a function after you activate the menu bar by
pressing ALT. For example, follow this sequence
to open a file using accelerator keys and the arrow
keys: ALT, F, down arrow, and Enter. To close an
open menu drop down, press the ESC key. You
can also move to other menu drop down while you
have on open by pressing the left or right arrow.
For example, if you pressed ALT then the F key,
press the right arrow to move to and open the Edit
menu drop down.
Shortcut Keys
Shortcut keys give you the fastest access to impor-
tant functions. A shortcut can be a single keystroke
or keystroke combination (usually two keys). For
example, you can use the shortcut key combina-
tions for such features as Cut, Copy, Paste, Open
File, Save File, etc. There are also keystrokes for
insertion point movement and moving from input
box to input box in XDIAGs input windows.
For example, to switch between XDIAG and
the Program Manager, press ALT + TAB. This
keystroke takes you to the Program Manager but
does not quit XDIAG. XDIAG is still running
and may be partially visible on the desktop. At this
point, you could start another application or return
to XDIAG by pressing ALT + TAB until you
cycle back to XDIAG in the Program Manager.
Following is a list of the most common keystrokes
for XDIAG.
ALT Activates the menu bar. Arrow keys or
accelerator keys select menus and items. The
down arrow will open the selected menu.
ALT + F4 Quits XDIAG and other applica-
tions. Also, closes dialog boxes and specialized
windows.
CTRL + F4 Closes the active window.
ALT + Space bar Opens the application
Control menu.

ALT + - Opens input window Control
menu. Input windows include the Well In-
formation Window, Production Information
Window, Pump and Tubing Information
Window, etc.
Enter Initiates the selected action.
ESC Cancels dialog boxes, menus, etc.
ALT + ESC Cycles through open applica-
tions and icons.
ALT + TAB Cycles through open applica-
tions.
CTRL + F6 Cycles through open input
windows.
Home Moves cursor to the beginning of the
input field or text box.
End Moves the cursor to the end of the input
field or text box.
F2 Switches the measurement system from
English to Metric and vice versa for the current
input field.
F1 opens the context sensitive help. The help
system will open to the topic related to the
input field that the cursor currently occupies. remain in your preferred orientation.
2.1.2 XDIAGs Help System
XDIAG has a powerful help system that provides
context sensitive help for every single input item.
Also, it allows you to easily locate help on any sub-
ject relating to system simulation and diagnostics.
It even includes a complete artificial lift glossary
that provides instant access to definitions for hun-
dreds of artificial lift terms.
Click on the help drop down on the menu bar to
see the following options:
Contents Start page for navigating through
the help system.
XDIAG| 21
Index Allows you to search for topics by
keyword.
Search Allows you to search topic content for
specific words or phrases.
About XDIAG Displays information about
your version of XDIAG.
Click on the About XDIAG option in the help
menu dropdown to find XDIAGs version number.
To see information about your system click the
System Info button on the About XDIAG
window. You can view information such as Win-
dows version, operating mode, free system memo-
ry, and free resources.
Click on Contents to see a list of items XDIAG
can provide help with. For example, to get help
with the toolbar, click on Toolbar Options.
XDIAG displays a picture of the toolbar. Click on
an item in the image for information on that item.
To exit help, click on the control-menu box X or
press ALT + F4. Help saves the window viewing
position and size so that when you return it will
Click on Help and then click on Glossary to see
an alphabetical listing of artificial lift terms. To see
the definition of any of the terms in the glossary,
click on the term.
2.2 Entering Rod
Pumping System Data
When entering data in XDIAGs input windows,
it helps to know the following:
The insert mode is on by default. To toggle the
insert mode on and off press the Insert button.
22 | Running XDIAG
To replace the contents of an input box, double
click the input field to select all of the content
in it and enter the new data to overwrite the
old information.
If an input window contains information that
is made up of more than one word, double click
any word to select it. You can know type a new
word to replace that word only.
To enter rod system data into XDIAG for the
first time, click on the first toolbar icon or go to
the menu bar and click File then click New. This
opens the Well Information Window as the next
figure shows. This window acts like a standard
window and can be moved and resized.
XDIAGs input windows use the following color
scheme to help with data entry:
Yellow Denotes a required data input field.
You must fill in the yellow input fields before
you can move on to the next input window.
Cyan Denotes the active input field. If you
press the F2 key to change the measurement
units, this color changes to green.
You can move around an input window by clicking
input fields with the mouse are using the TAB key.
As you press the TAB key, the cursor will jump
forward to the next input field. You can also move
backward through the input fields by pressing
Shift + TAB. Completed input fields will change
from yellow to white.
You can get context sensitive help for any input
field by pressing the F1 key. Use the context sensi-

tive help as often as possible because the help sys-
tem contains important information that will allow
you to make better use of XDIAG (this includes
assumptions and limitations built into XDIAG).
2.2.1 Entering Well Information Data
Company name
If you entered a accompany name in Setup, it ap-
pears in the Company name field. You eliminate
the need to enter your company name each time
you create a new case by utilizing the defaults fea-
ture in Setup. See section 1.1.4 of this manual for
information about the Setup feature of XDIAG.
Well name
The well name is required because XDIAG uses it
to create the default file name when you save the
case to disk
Date
The date defaults to the current date on your com-
puter. If you load a file and you would like to insert
XDIAG| 23
the current date that is on your computer, click the
Today button next to the date input field to over-
write the old date. If the date on your computer is
incorrect you can manually enter the date.
Comment
You can type up to 100 characters in the comment
field. The comment field allows you to enter obser-
vations or other useful information about the well.
Source of Dynamometer Data
The source of the dynamometer data drop down
list allows you to select either a Theta dynamom-
eter file (.DYN), a Lufkin Automation dyna-
mometer file (.DAT), a Dynostar file to extract a
dynamometer card from it (.DNS), or Automatic
Batch Mode where it will locate the dynamometer
files when it runs. To change the source of dyna-
mometer data, select one of the options above. If
you select a file type you will be asked if you would
like read in a new file. If you click yes you will see
a dialog box to find and open the dynamometer
file. You can also read in a new file without chang-
ing the source of the file by clicking the Read new
24 | Running XDIAG
file button. After you load a dynamometer file
XDIAG will generate a miniature plot of the card
shape. If you use an Echometer dynamometer sys-
tem, select the Theta dynamometer file because
the Echometer system files are saved in the Theta
format. You can also read a card directly from a
Dynostar file by selecting Import from Dynostar
File. You dont have to export the card to a .DYN
file first. XDIAG has the ability to extract a spe-
cific dynamometer card from a Dynostar file. You
can open a Lufkin Automation Dynamometer file
which has a .DAT extension by selecting Lufkin
Automation Dynamometer File.
Options
You can manage the dynamometer input data
using the Options button on the Well Informa-
tion Window. These options include adjusting the
load cell measurement, detecting and correcting
non-kinematic surface positions, and detecting
and correcting phase-shifted surface positions.
You can set the options to use the configuration
in Setup (Expert Diagnosis tab) or select one of
the available options. You can have XDIAG us
the calculated kinematic positions instead of the
measured positions on the dynamometer card and
you can manually adjust the position shift and top
of stroke. A position phase shift refers to a problem
with the position measurements in the dynamom-
eter card. If the position recordings have a lag time
then there is a shift as the card is generated. Ad-
justing position phase adds or subtracts an amount
of time which will correct the problem caused by
the lag when recording the surface card. There can
also be a shift in the card if the top of the stroke
was incorrectly set when the card was recorded.
Some dynamometer recording equipment requires
the user to press a button when the unit is at the
top of the stroke. If this is done incorrectly, the
adjustment input field can correct the top of stroke
shift by adding or subtracting a few inches from
the points in the dynamometer card. You can also
set XDIAG to not correct or detect such problems.
Run time
The run time you enter allows XDIAG to ac-
curately calculate the production rate and daily
energy consumption. If the well is operating
throughout the day then the default 24hrs/day ap-
plies. Adjusting the run time is generally done for
wells that use pump off controllers.
Pump depth
Pump depth is used to calculate fluid loads and
check the rod string depth entered in the Rod
String Information Window. If there is a discrep-
ancy, you will be informed after you enter the rod
string information.
Tubing and Casing Pressure
The tubing and casing pressures are used in the
IPR calculations. The rest of the required informa-
tion for IPR calculations are found in the Produc-
tion Information Window.
Stuffing box friction
The default stuffing box friction is 100 pounds.
This friction can be adjusted for tight stuffing box-
es. The best way to estimate the stuffing box fric-
tion of you well is by performing a history match
using a predictive program such as RODSTAR.
Fluid Properties
The water cut percentage, along with the oil API
gravity, is used to calculate a default specific
gravity for the produced fluid. This affects the
weight of the fluid on the plunger when running
XDIAGs diagnostic calculations. These values are
also used to calculate lifting costs per barrel of oil
and to calculate specific gravity of the fluid in the
casing-tubing annulus. The fluid specific gravity
can be entered manually or XDIAG can use the
water cut percentage, water specific gravity, and

the oil API gravity to calculate the fluid specific
gravity. This fluid specific calculation is accurate
when the produced fluid is liquid. If free gas occurs
in the well then you should enter a fluid specific
gravity that is less than the calculated fluid specific
gravity. Performing a history match is the best way
to adjust the fluid specific gravity.
XDIAG assumes that the tubing-casing annulus
is full of oil. It calculates the specific gravity of the
oil from the API gravity you enter. If you do not
agree with this assumption then change the oil
API gravity to correspond to the specific gravity
you would like simulate in XDIAG. For example,
if you want to simulate water in the casing-tubing
annulus instead of oil, then enter an API gravity of
10.
2.2.2 Entering Production Information
Fluid level
Please not that when you enter a measured fluid
level and you do not select to have XDIAG to
correct the fluid level in Setup, XDIAG uses the
entered fluid level in its calculations because it
assumes that the entered value is accurate. If you
want XDIAG to use the fluid level that it calcu-
lates from the downhole pump card lines then do
not enter a fluid level.
Pump intake pressure
Use this production input if the pump intake
XDIAG| 25
pressure has been measured for the well. XDIAG
allows pump intake pressures that are 14.7 psi
greater than the casing pressure. If the wellbore
contains a packer, you must enter a low casing
pressure to be able to enter a pump intake pressure
lower than the measured casing pressure.
Pumping speed (SPM) and Gross production
XDIAG uses these two variables to detect prob-
lems with the well. If the calculates production
from the entered SPM does not match the entered
production rate then XDIAG knows that some-
thing may be wrong with the well. Along with the
pattern recognition system, XDIAG can inform
you of problems with the well that could reduce
the production rate.
Inflow Performance Data
The Production Information Window gives you
the capability to calculate additional production
rates if you reduce the pump intake pressure. Click
the IPR Data button to expand the window to
enter inflow performance data.
Required data includes calculation method (cor-
relation), depth from surface to middle of perfora-
tions, static bottom-hole pressure, and bubble point
pressure. You can also enter up to 10 test points.
The pressure that corresponds to the production
test points can either pump intake pressure or
flowing bottom-hole pressure (in the middle of the
perforations). If you do not know the value of the
26 | Running XDIAG
bubbling point pressure, but you know you are pro-
ducing below the bubble point pressure, then leave
the bubble point pressure field blank and check the
Producing below bubble point check box. After
you enter the last IPR input item, click on the Up-
date prod button to allow XDIAG to calculate the
maximum oil, water, and fluid production rates.
You can also see the IPR plot by clicking the IPR
Plot button. When the IPR plot is displayed,
you can move the horizontal line that you see
on the plot with the mouse to see the calculated
production rate for any bottom-hole pressure. You
can print the IPR plot by clicking the Print button
at the bottom of the IPR plot window. Click the
Close button to return to the IPR input window.
2.2.3 Entering Pump and Tubing
Information
Tubing size
Select the tubing size of your well from the drop
down list. The inner and outer diameters of the
tubing size will be displayed to the right of the
drop down. You can select other in the drop down
to input custom tubing dimensions. The tubing in-
ner and outer diameter fields become activated and
you can enter these measurements for your custom
tubing size.
Tubing anchor
You can check the tubing anchor checkbox to enter
the tubing anchor depth. XDIAG used this input

as part of the calculation to determine the stretch
of free tubing.
Include buoyancy effects
Use this checkbox to include the force of the fluid
on the rods when calculating the rod string stress
loading.
For steel rods we recommend always excluding
buoyancy effects. If the bottom minimum stress
of bottom sucker rod section is in compression
(without buoyancy effects), you must add enough
sinker bars to make this number positive to avoid
buckling problems. For example, if you are using
a three-tapered rod string with 1, 7/8, and on better for most cases to allow XDIAG to calculate
the bottom, check the bottom minimum stress on
the rods. If this number is negative, add sinker
bars or sinker rods to make this number positive.
The bottom of the sinker bar section will always
be negative (due to the resistance on the plunger as
it moves down on the downstroke). This is normal
and is not a problem.
For fiberglass & steel rod strings, also do not
include buoyancy effects when analyzing the steel
section of the taper. Run the case again with buoy-
ancy effects to check if the fiberglass rods are in
compression.
XDIAG| 27
Rod-tubing friction coefficient
You can enter your own rod-tubing friction fac-
tor in this field. If you do not know what to enter
have XDIAG calculate the rod-tubing friction
coefficient for you. The rod-tubing friction number
primarily affects the calculated downhole pump
card shape and the gross pump stroke.
If you are analyzing a well with high friction,
you may want to use a higher rod-tubing friction
coefficient to get a more accurate downhole pump
card and sucker rod stress analysis. However, it is
the friction coefficient for you; if you use a friction
factor that is too large, you may get a distorted
downhole pump card shape.
Even if the actual friction between rods and tubing
is much larger than the calculated friction coef-
ficient, the calculated downhole pump card shape
will be easy to diagnose. You can remove frictional
loads from the actual fluid load on the pump
plunger by setting horizontal lines on the calcu-
lated downhole pump card. This is explained later
in this chapter (setting lines).
28 | Running XDIAG
Plunger size and pump type
XDIAG will use the pump type to inform you if
the pump with the selected plunger size will not fit
into the tubing of the well. Insert pumps fit inside
the tubing, tubing pumps attach to the tubing and
are connected with an on-off tool, and large bore
pumps are thin walled to allow for even larger
plungers. You can select the plunger size from the
drop-down list or select other and enter a custom
plunger size in the input field next to the drop-
down.
2.2.4 Entering Rod String Information
XDIAG can analyze steel (including continuous
rods) and fiberglass rods, by performing the appro-
priate stress analysis calculations depending on the
type of rods you specify.
Number of tapers or segments
Click the button with the pound or number XDIAG will warn you if the selected rod sizes will
symbol to select the number of rod tapers in the
string. Once you select the number of tapers, the
empty rows will be created so that you can add the
required information for each taper. You can enter
up to 10 rod tapers.
Rod grade
This field is populated with a drop down which
contains all rod data (including custom rod data
entered in Setup). The rods are separated by type
(steel, fiberglass, continuous, and sinker bars).
Rod size
The rod sizes follow production information (API
and manufacturer information for available rod
diameters). There is also a custom rod diameter
feature. Select Other from the drop-down and you
can enter the rod diameter in the Actual diameter
field. After you select a rod diameter for the top
taper, simply click the diameter fields for the rest
of the tapers and XDIAG will automatically select
the next size down to create a common string
design. When proceeding to the next input screen,
not fit the selected tubing size or if they require
slim-hole couplings.

Actual diameter
This field shows the actual diameter of the rod
taper as a decimal. The actual diameter may differ
from the selected rod diameter depending on the
manufactures specifications.
Length
Enter the length of the rod taper in this input field.
Once you enter the length for each taper above the
last, XDIAG will automatically enter a rod taper
length for the last taper to match the rod string
length to the pump depth. You can change this en-
try if you wish. XDIAG will run if the rod string
is no less than 50ft from the pump depth. XDIAG
will not run if the rod string is longer than the
pump depth. There are two displays on the bot-
tom section of the window which show the pump
depth and the rod string length. This makes it easy
to enter the correct length and run XDIAG.
Steel rod service factor
The steel rod service factor is used to adjust the rod
loading calculations. The service factor enables you
to degrade the stress rating of your rods based on
corrosive conditions or other reasons that lead to
premature rod failures. A service factor between
.8 and .9 is recommended in most cases. For wells
that produce large amounts of H2S you may want
to use a service factor of 0.75 or even 0.7. The
smaller the service factor you enter, the stronger
(larger diameter or higher stress rating) the rods
must be to avoid becoming overloaded. The default
service factor in the program is 0.9. If you enter
this service factor it means that you do not want to
exceed 90% of the calculated maximum allowable
stress.
Adding and removing rod sections
XDIAG allows you to add and remove rod sec-
tions from anywhere in the rod string. For exam-
ple, if you want to remove a rod section, first click
XDIAG| 29
the rod section and then click the remove button.
When you select a rod section, XDIAG outlines
the section with a light blue rectangle.
To add a rod section, click a rod section and then
click the add button. XDIAG automatically creates
a new slot for the new section, moves the other
sections below the new section, and increases the
number of rod sections by one.
2.2.5 Entering Pumping Unit Data
This input screen handles all pumping unit data
entry. You can select a pumping unit from the
database that comes built into XDIAG by using
the drop down or entering the pumping unit ID
and you can select a pumping unit from the list
of measured units that you entered into XDIAG
yourself through Setup. Once you select a pump-
ing unit, you can enter/select all other associated
information.
Manufacturer
This drop-down contains all of the available
pumping unit manufacturers. If you entered a
measured unit using Setup, you can find your cus-
tom pumping unit entry by selecting the (Mea-
sured pumping units) option at the top of the
drop-down. Once you select a manufacturer you
can select the specific pumping unit from the list
box that is populated directly below the manufac-
turer drop-down. This list box shows the data that
you entered: manufacturer name, API designation,
Unit Name, and Other Info.
If your unit is not in the built in database and you
do not have the measurements to add the unit in
Setup, then use a unit that is close to it. As long as
you use the same unit geometry and you select a
unit with the same stroke length and gearbox rat-
ing, the results should be very close to the results
30 | Running XDIAG
using the actual unit.
If after you enter a pumping unit ID XDIAG
displays The pumping unit ID you entered is not
valid this means that the ID you entered is not
recognized. This can happen for two reasons:
You entered the wrong ID such as CL901
instead of CL91.
You have erased the pumping unit file by ac-
cident or it has been changed, or the pumping
unit files are not in the same directory as the
XDIAG.EXE file.
Unit ID
Each pumping unit in the built in database is
assigned a unit ID. This feature makes it easy to
jump to common pumping units with a short ID
entry. If you are maintaining lists of pumping units
in your field for analysis, add the pumping unit ID
to the lists. Using the pumping unit ID makes it
easy to select the pumping unit without the need
to first select the manufacturer then finding the
exact unit.
Use custom pumping unit list checkbox
Check this checkbox to filter the pumping unit
database. Only units that you assign to be in the
custom pumping unit list will be displayed in the
list box once this checkbox is checked. For in-
formation on how to add pumping units to the
custom pumping unit list see section 1.4.4 of this
manual under Pumping Unit Options. To auto-
matically add units to the custom pumping units,

select a unit then check the custom pumping unit
list checkbox. XDIAG will ask you if you would
like to add the selected unit to the custom pump-
ing unit database.
Crank rotation
Select the crank rotation using this drop-down.
XDIAG will default to a recommended crank
rotation that should give the least gearbox loading.
If the unit is one-directional then this feature will
be disabled.
Crankhole
Select the crank hole using this drop-down. The
measured stroke length is displayed next to the
crankhole number. When you select a crankhole,
the calculated stroke length is displayed below the
drop-down. The crankhole numbers are labeled by
number beginning with the closest to the slow-
speed shaft. This is because some pumping units
have optional cranks that have extra crankholes
(such as 4 instead of 3 or 5 instead of 4). This
extra crankhole is always the farthest crankhole
from the slow-speed shaft. If the crankhole on
the end of the crank (farthest from the slow-speed
shaft) is identified as crankhole number 1, the
same pumping unit using crankhole number 1 can
have a different stroke lengths depending on which
crank is on the unit. By identifying the crankhole
closest to the slow-speed shaft as crankhole num-
ber 1 we can avoid this confusion.
Structural unbalance
Structural unbalance is a term used for pumping
units with a walking beam. It is defined in the
API 11E as the force needed at the polished rod
(parallel to the polished rod) to hold the walking
beam in the horizontal position while the pitman
arms are disconnected from the crank pins. This
force is positive when the force is acting down and
negative when acting up. See the figure for a visual
representation of structural unbalance. Structural
XDIAG| 31
unbalance for conventional units can be either
positive or negative. Mark II units always have a
negative structural unbalance because their geom-
etry places the saddle bearing on the back of the
walking beam. This eliminates the possibility of
balancing the walking beam on the saddle bearing.
The walking beam will always want to rotate to
that the horsehead rests on the ground. The struc-
tural unbalance will be filled in with the value that
is in the database. You can manually change it if
you would like. When you enter a custom unit in
Setup, if you do not know the structural unbalance
for the unit you are analyzing then enter zero. In
most cases the structural unbalance will not affect
the results significantly.
Counterbalance options
There are several options available for entering the
counterbalance information. Counterbalance infor-
mation used in XDIAG changes depending on the
type of unit you are analyzing. Conventional units
are balanced using a counterbalance moment about
the slow speed shaft. Air-balanced units are coun-
terbalanced using tank pressure. Beam balanced
units are balanced by the structural unbalance.
Long-stroke units are balanced by counterbalance
weight. If you do not know the existing counter-
balance XDIAG will only run the gearbox calcula-
tions using the balanced conditions.
For crank balanced units you can enter the existing
maximum counterbalance moment, counterbalance
effect (moment and angle), import the CBE from
the dynamometer file (if it is in the file), or use
XBAL to import the existing counterbalance.
For air-balanced units you can enter the existing
tank pressure at the bottom of the stroke, counter-
balance effect, or import the CBE from the dyna-
mometer file (if it is in the file).
For long-stroke and hydraulic units you can enter
32 | Running XDIAG
the counterbalance weight, counterbalance effect,
or import the CBE from the dynamometer file (if
it is in the file).
2.2.6 Entering Motor Information
XDIAG contains the most common electric mo-
tors which allow XDIAG to calculate the lifting
cost and warn you of problems that might occur
such as small motor size.
Electricity cost
XDIAG uses the electricity cost to calculated lift-
ing cost. XDIAG uses the instantaneous efficiency
at many different points throughout the stroke to
find electricity consumption. These electricity con-
sumption values are then used with the electricity
cost to calculate the cost to lift the fluid.
Power meter type
Select detent if you are given no credit for generat-
ed power. Select non-detent if you are given credit
for generated power. This variable is used to adjust
the lifting cost calculation. The generated power
will lower the lifting cost if the power meter type
is non-detent.
Motor type
Select the motor type from the drop-down list.
The most common electric motors are available.
The available motor sizes are populated after a mo-
tor size is selected.
Motor size
Once the motor type is selected, the available
motor sizes are populated in this drop-down list.
XDIAG will inform you if the motor size may be
too small or too big for the well.
Motor setting
Motors such as the Sargent Econo-PacII have
different motor settings. If you select one of these
motors then the motor setting drop-down will ap-
pear. Select the appropriate motor setting from the
drop-down list.
2.3 Storing Cases/Files
After you finish entering data, you can save the
data to disk by clicking on the quicksave button
on the toolbar (diskette icon), or by selecting File
from the menu bar and then choosing Save As...
This opens a standard Windows dialog box used
for storing files. XDIAG will use the first non-
blank characters from the Well Name input from
the first input window as a default file name. The
XDIAG file extension is .XDG. We suggest
saving a new file if you change something in the
case so that you can recover previous input data.
If you wish to save over the previous file (use the
same name) simply click the quicksave icon on the
toolbar to save over the file.
XDIAGs Permanent Memory Feature
Like all software developed by Theta Oilfield
Services, XDIAG has a unique feature that saves

the data you enter automatically as you fill in each
input field. You will never lose data if XDIAG or
your machine shuts off unintentionally due to a
computer crash or loss of power. This works even
if you exit the program without saving your data.
If any of these scenarios occur, the next time you
open XDIAG you will be prompted with the
following message: The previous XDIAG for
Windows session ended while data was still being
entered. Do you want to continue entering data?
Click Yes and XDIAG will start from where you
left off from the last time you ran the program.
XDIAG| 33
2.4 Running XDIAG
The run button on the toolbar will be activated
after you enter all the required data to perform
diagnostic calculations. Click on the run button to
run XDIAGs diagnostic calculations and receive
a complete report. You can also click Run on the
menu bar to run XDIAG. If XDIAG detects any
problems with the input data you will be prompted
after clicking the Run button.
XDIAG will automatically display the output re-
port after the calculations are complete. The pages
34 | Running XDIAG
of the report that are displayed can be managed in
Setup. See section 1.4.4 in this manual to set up
XDIAG.
When the results window opens, you can jump to
different plots by use of the buttons on the bottom
of the window. You can open the dynamometer
plot, torque plot, IPR plot (if IPR data was en-
tered) and you can return to the output report by
clicking the Report button.
2.4.1 Dynamometer Animation
When the dynamometer plots are displayed (af-
ter clicking the Dynamometer button) you can
animate the surface and downhole dynamometer
cards to see the stroke at the surface and the pump
simultaneously. Click on the play button to see
the actual pumping speed at the surface and at the
pump. A dot on each card indicates the movement
at the surface and at the pump. You can observe
the delay between the surface and downhole cards
as the stroke is translated through the rod string.
This animation helps you to understand the dy-
namics of the pumping system with respect to
stretch of the rods, the speed of the plunger versus
the speed of the polished rod, and the load fluctua-
tions of the pump plunger. This feature allows you
to learn and understand more about how the rod
pumping systems work. You will be able to see
different operating characteristics such as under-
travel, overtravel, compressive wave reflections of
the sinker bars when you have fluid pound with

fiberglass rods, plunger speed versus polished rod
speed during fluid pound, effect of overtravel or
undertravel on plunger speed, etc. This animation
may reveal reasons for the surface card shape with
respect to the downhole card shape. The controls
at the bottom of the window allow you to play,
stop, or move forward through each time step
one frame at a time.
Exporting Dynamometer Card Files
You may use XDIAG to export surface dynamom-
eter card files. XDIAG saves these files in the
Theta dynamometer file type. There must be data
in memory before using this option. If you export a
file before running XDIAG, the dynamometer file
will be a copy of the imported dynamometer file.
After running XDIAG, when you export a dyna-
mometer file, you will be asked if you would like to
export a modified dynamometer card if any correc-
tions were made to the card by XDIAG. The files
exported by XDIAG have a DYN file extension
(for example, ABC#1.DYN).
XDIAG| 35
2.4.2 Setting Horizontal and Vertical
Lines
The purpose of setting horizontal lines on the
calculated downhole pump dynamometer card is
to calculate fluid load, pump intake pressure, and
fluid level. The purpose of setting vertical lines
on the downhole pump card is to calculate net
stroke and production through the pump. Chapter
3 explains the theory behind line setting and the
limitations of this method of calculating fluid level
and pump intake pressure. This section discusses
the mechanics of setting the lines once the down-
hole pump card is calculated.
First, please note that you do not have to set lines
yourself. XDIAG has the expertise necessary to
decide when and where to set lines. In some
cases XDIAG will not set lines because it is dif-
ficult to determine where to set the lines. Although
XDIAG sets these lines for you, you may still set
36 | Running XDIAG
the lines yourself if you wish.
To set lines manually, click on the Set Lines
button at the bottom of the Output Report Win-
dow. This will open a window which displays the
downhole dynamometer card with horizontal and
vertical lines.
To move a line, move the cursor over the line. The
cursor will change shape. Click and hold the left
mouse button then drag the line to the desired
location. While the line is selected it changes from
red to orange. When the line is at the desired
location, release the left mouse button. When you
release a line it will become red again. As you
change the distance between the horizontal lines,
you can see the fluid over the pump, fluid level,
and pump intake pressure values dynamically
change at the bottom of the window.
Follow the same procedure to move the vertical
lines to calculate net pump stroke and production
through the pump. As you change the distance
between the vertical lines, you see the net pump
stroke and production values dynamically change
at the bottom of the window.
To go back to the line settings made by XDIAG
just click the XDIAG settings button under the
horizontal line header or vertical line header on
the bottom right of the window. If you need help
setting lines or if you have questions regarding
how and why line setting works, press the F1 key
for context sensitive help on the setting lines. After
you finish setting lines on the downhole pump
card, click on the OK button to go back the Out-
put Report Window.
Please note that even though XDIAG allows you
to change the line settings, the program does not
necessarily use the numbers calculated from your
line settings. If your line settings make sense then
XDIAG will use the values calculated from your
line settings. However, on the calculated results
page of the output report, in the section labeled
Tubing, pump and plunger calculations, your line
settings will be reflected in these calculates results
regardless of whether or XDIAG uses them or not.
2.4.3 Exporting the Balanced Maximum
Counterbalance Moment or Structural
Unbalance
After XDIAG runs, it calculates the balanced
maximum counterbalance moment to balance the
unit with the existing conditions (structural unbal-
ance for beam balanced units). Simple enter the
counterbalance data into XBAL and XBAL will
calculate where to move the counterweights or to
add/remove counterweights to balance the unit.
Please note that this will balance the unit for the
current conditions. If there is a problem with the
well, you should fix the problems before attempt-
ing to balance the unit.
Crank balanced units
After XDIAG runs, it calculates the max. CB mo-
ment needed to balance the unit for either mini-
mum torque or minimum energy consumption. For
more information see the Torque Analysis section
in Chapter 3.
XDIAG works with XBAL to make data ex-
change very easy. To transfer a balanced max CB
moment from XDIAG to XBAL, click on the
XBAL button on the XDIAG toolbar. It shows
an arrow and XBAL on it indicating that it sends
information to XBAL. If XDIAG calculated a
balanced max CB moment for minimum torque
only, clicking the XBAL button will send that
value to the Theta Clipboard with no other ac-
tion required. If XDIAG calculated a balanced
max CB moment for minimum energy along with
one for minimum torque, you will be prompted

as to which value you would like to send to the
Theta Clipboard.
The Theta Clipboard is a separate file that stores
the exported data to be retrieved by Theta soft-
ware. It is a single file which means that every
time you export a value, the previous value will be
overwritten. These values will be saved in this file
even after XDIAG is closed.
Beam balanced units
The same procedure for crank balanced units
applies. XDIAG will use structural unbalance
instead of maximum counterbalance moment to
balance the unit. This allows XBAL to calculate
the amount of counterweight and the position on
the beam to balance the unit.
2.5 Printing the Output
Report
To print XDIAGs output, click on the printer icon
located on the toolbar. To change what the pro-
gram prints, open Setup from the toolbar and then
click on the Output Options tab. Select the out-
put pages you want generated then click OK. Now
that you defined the pages in the report, when
XDIAG prints the report you will have printed the
desired pages.
XDIAG| 37
Once you define the output pages
you want in the report, XDIAG
will continue to generate this re-
port until you change the settings
again.
When using the print button on
the toolbar, XDIAG will automat-
ically print to your default printer.
If you would like to send the report
to a different printer, click the print button on the
top right of the Output Results Window. This will
open a standard Windows printing dialog box. You
can then access the printer properties and select
the printer like most Windows programs.
2.6 Loading Data from
Disk
After you enter and store your input data, you can
easily modify it by loading it back in memory. You
may need to do this if you want to analyze a new
dynamometer card or make an equipment change
on the same well.
To load a previously saved file, click on the open
file button on the toolbar. Or, you can click on File
on the menu bar and then on Open. A standard
Windows open file dialog box will open. Select
the file you wish to load by double clicking on it or
selecting the file and clicking the Open button.
If there is data in memory from a current case you
are building, XDIAG will warn you that loading
a file will erase the current data in memory. This
alert will help you to avoid accidental loss of input
data so you will have a chance to save it.
XDIAG can read all Theta Oilfield Services Inc.
38 | Running XDIAG
file types (RODSTAR-V/D, RODDIAG, and
XDIAG). By default, the open file dialog box
shows the XDIAG files when it opens. To load
a different file type, such as a RODDIAG file,
click on the drop-down list labeled Files of type
and select the file type (.rdg for RODDIAG files).
This applies a filter to the list of files you see so
only RODDIAG files are displayed. To load one
of these files, double click the file or select the file
and click the Open button. If the file you are look-
ing for is not in the list you can change the direc-
tory like other standard Windows programs.
When you open predictive program file types, the
loaded data will not contain any dynamometer
card data. You will have to load a dynamometer
card if you chose to use a RODSTAR file to run
XDIAG. Being able to open RODSTAR file types
is a quick way to enter the required well data that
is shared between the programs. This eliminates
the need to re-enter the well name, pump depth,
run time, etc.
To locate a file, you can click on the scroll bar
next to the file list, or you can press the Page Up
or Page Down keys to quickly move through the
list. To move to the beginning or the end of the
list, press the Home key or End key respectively.
If the current directory contains many files, it
may be faster to press the first few characters of
the file name to find the file you are looking for.
For example, if you are looking for a well named
 XDIAG| 39

PR100.xdg then enter PR1 and the dialog box

will jump to the file that begins with PR1. It may
be equally beneficial to simply use the first letter of
the file name.

2.6.1 Recent Files Feature

XDIAG has a feature that makes it easy to re-

load a file you recently worked with. Instead of
clicking on Open icon on the toolbar, click on the
arrow next to it to open a list of recent files used in
XDIAG. You can also click on the File menu and
click Recent Files to open the recent files list. This
list is made up of the last 20 files ran and or saved
with XDIAG. Click on a file in the list to load the
file.
 XDIAG| 41

3 Expert Diagnostic Analysis

XDIAG is a sophisticated diagnostic tool that

combines expert knowledge and pattern recogni-
Also, XDIAG can calculate fluid level, pump
tion with state of the art wave equation and pump-
intake pressure, net stroke, and fluid rate through
ing unit kinematic models. You can use XDIAG
the pump. For wells with packers, or foamy fluid
to quickly analyze the performance of existing
in the annulus, XDIAG may be the only way to
rod pumping systems. XDIAG can simulate any
get a pump intake pressure. If you have IPR data,
pumping unit geometry and gives accurate diag-
XDIAG can even calculate additional production
nostic results regardless of pump depth, rod string
potential based on your target pump intake pres-
type, or production rate. You must make sure that
sure. Combining these calculations with XDIAGs
your input data is accurate to get accurate results
scoring capability and expert diagnostic analy-
from XDIAG. However, because of its sophisticat-
sis report and you can use XDIAG to optimize
ed input data error detection features, XDIAG can
the well. The following sections explain how to
even detect and correct common input data errors
use XDIAG as a diagnostic tool of common rod
such as incorrect load cell calibration, incorrectly
pumping problems. As you become more familiar
measured fluid level, wrong stroke length, etc.
with XDIAG you will discover many different
ways of using the program to help you identify
XDIAG automates the expert diagnostic analysis problems with your rod pumping wells.
of large numbers of rod pumping systems whether
they are connected to centralized pump off control
systems or not. XDIAG has unique features that
have been specifically designed to allow you to ef- 3.1 Explanation of
fectively use the results of the program. The capa-
bility of XDIAG to run in batch mode, creating
XDIAGs Output
summary spreadsheet files, makes it easy to man-
age the information XDIAG provides to you about To maximize the benefit of using XDIAG, it is
your wells. important to understand its output. After XDIAG
runs, it displays the expert diagnostic report
(including a scoring page to show the areas of the
XDIAG can help you detect almost all surface and
system that need improvement) along with the
downhole system problems which include the fol-
predicted surface and downhole dynamometer
lowing: incorrectly sized prime mover, overloaded
card plots, torque plots, and IPR plots. The expert
gearbox, overloaded pumping unit or rod string,
report created by XDIAG simulates the report a
worn traveling or standing valve, incomplete pump
human expert may write about the rod pumping
fillage, low pump efficiency, undertravel, pump
system. In many cases, the expert report is the only
hitting up or down, etc. Also, because XDIAG
part of the output you may want to read. How-
can accurately calculate the prime mover energy
ever, XDIAG provides you with a calculations
consumption, you can use it to help you identify
page that summarizes all the important system
costly or unprofitable wells.
42 | Expert Diagnostic Analysis

parameters. Following is a detailed explanation of
XDIAGs output.
Dynamometer and permissible load plots
These plots show the surface and downhole dy-
namometer card plots, and the permissible load
diagram. XDIAG uses a permissible load dia-
gram that shows if the gearbox or structure of
the pumping unit is overloaded or if the mini-
mum polished rod load is negative. This is differ-
ent than the traditional permissible load diagram
which only shows whether the gearbox is overload-
ed. This extended permissible load diagram can be
made up of several curved lines only, a combina-
tion of curved and straight lines, or straight lines
only. If the upstroke part of the predicted surface
dynamometer card cuts into the curved line of the
permissible load diagram, this indicates that the
gearbox torque is overloaded at that point. If the
dynamometer card cuts into the straight line sec-
tion of the permissible load, this indicates that the
structure of the pumping unit is overloaded be-
cause the polished to load is larger than the struc-
ture rating of the unit.
For the exact numbers of peak net gearbox torque
and gearbox loading, look at the torque analysis
section of the output results page. The permissible
load diagram corresponds to existing conditions if
you entered a counterbalance moment. If you do
not enter existing counterbalance information then
the permissible load diagram corresponds to the
balanced condition.
Note: The above discussion about XDIAGs
permissible load diagram refers to beam pumping
units and low profile belted units. The permissible
load diagram for long stroke units such as Rotaflex

units will have straight line segments that cor-
respond to the gearbox loading or the structural
loading. Hydraulic units do not have gearboxes so
the permissible load diagram corresponds to the
structural loading. Please look at the structure
loading and gearbox loading value and percentage
for the exact percent unit loading.
In addition to showing whether the gearbox is
overloaded, the permissible load diagram also
shows how well the pumping unit matches the
load requirements of your system. If the predicted
polished rod dynamometer card fits nicely in the
permissible load envelope, this indicates a good
agreement between the pumping unit and the rest
of the system. However, if the predicted surface
dynamometer card shows a trend that is opposite
that the permissible load diagram, this indicates
that design changes are necessary to avoid over-
loading the pumping unit and to better match it
XDIAG| 43
to the of the system. If the permissible load has
a trend that is opposite than the predicted dyna-
mometer card, it may indicate that the pumping
unit you selected is not the best geometry for this
application.
Torque plots
When you click on the Torque button on the
bottom of the output report window, XDIAG
displays the net gearbox torque plots for existing
and balanced conditions. If you entered an existing
maximum counterbalance moment (crank balanced
units) or structural unbalance (beam balanced
unit), you may have a torque plot with as many as
three curves: one for existing conditions, one for
balanced conditions for minimum torque, and one
for balanced conditions for minimum energy con-
sumption. XDIAG will not display the balancing
information for minimum energy if the lifting cost
44 | Expert Diagnostic Analysis
is close to the lifting cost when balanced for mini-
mum torque. If balancing the unit for minimum
energy will reduce lifting costs by 1% or more the
balancing calculations for minimum energy will be
displayed.
The torque plot will also be displayed on bottom of
the calculations page by default. You can change
this as well as other displayed pages by going to
Setup.
IPR plots
When you click on the IPR Plot button, XDIAG
displays the IPR plot for the well as the figure
shows. Also, if you entered IPR data, the report
shows a table of calculated production rates versus
pressures.
Set lines
Click this button to go to the line setting window
where you can change the placement of the vertical
and horizontal lines used to calculate fluid level,
net pump stroke, and net pump displacement.
More details about this feature can be found in
section 2.4.2 of this manual.
Report
Click the Report button to go back to the default

output report display. The first part of the out-
put report is the Expert Diagnostic Report Page
which has four sections. The Downhole Equip-
ment Analysis section shows the condition of the
pump and the fluid level determined by XDIAG.
The Rod String Analysis section shows if any of
the rod sections of the rod string are overloaded
and by how much. The Surface Equipment Analy-
sis section shows if the gearbox or pumping unit
structure is overloaded. The balancing recommen-
dations are also in this section. The Input Data
Analysis section shoes possible input data errors
that were detected by XDIAG and any input data
corrections that are made (such as load cell drift
correction).
The next page in the output report is the Scoring
Page. XDIAG looks at six vital components of the
XDIAG| 45
well to determine if it is a good design. Because
XDIAG is a diagnostic tool, the data entered into
XDIAG is rarely of an optimized well. The fluid
level may be high or pump may be in poor condi-
tion. Scoring a well with these conditions will
yield incorrect scores. This is because the fluid load
may be reduced due to the high fluid level. Imag-
ine a well received a good score then the operator
changed the speed of the unit to pump off the
well. The structural loading will increase as the
fluid level drops and there is a possibility of fail-
ure due to the increased fluid load. If the operator
based his decisions on the scoring of the well with
a high fluid level, he may be unaware of this po-
tential problem. For this reason XDIAG scores the
well for the worst case scenario (full pump with
the fluid level at the pump). The score given to the
well is for the optimized condition, balanced and
pumped off with a full pump in good condition.
46 | Expert Diagnostic Analysis
The sections scored are as follows:
Balanced Gearbox Loading
Maximum Rod Loading
Structural Loading
System Efficiency
Bottom Minimum Stress
Minimum Polished Rod Loading
Each section will receive reduced scores if they
are over loaded or under loaded except for System
Efficiency. System Efficiency will only receive a
reduced score if it is low. Reduced scores are given
to sections that are under loaded because these
areas can be optimized to reduce initial costs of the
well. You may be able to use a smaller pump jack
or rods which will save money when ordering these
components for the well. Each section will display
an explanation of the score and how to improve it.
After the Scoring Page, XDIAG shows all the
parameters it uses for the calculated results and the
results. Following is a detailed explanation of the
Input Data and Calculated Results Page.
Input Data
Along the left side of the Input Data and Calculat-
ed Results Page you will see the input data for your
well. The data is separated into sections to make it
easy to read. The top section contains the generic
information about the well (run time, SPM, sur-
face stroke, fluid level, tubing and casing pressures,
gross production, and stuffing box friction). As you
move down the page you will see more detailed
 XDIAG| 47

information. The following list shows the detailed Minimal tensile strength
sections and the input data in each section:
Fluid Properties
Calculated Results
Watercut
Along the right side of the page you will see the
Water specific gravity calculated results for your well. These values are
Oil API gravity separated into sections to make it easy to read. The
top section contains generic information about the
Fluid specific gravity well (peak and minimum polished rod load, min/
Motor and power meter peak polished rod load ratio, system efficiency,
buoyant rod weight, maximum rod loading, pol-
Power meter type ished rod HP, permissible load HP, polished rod/
Electricity cost permissible load HP ratio, unit structure loading,
and gearbox loading). As you move down the page
Motor type
you will see more detailed information.
Motor size
Pumping unit
The following list shows the detailed sections and
API designation the calculated data in each section:
Crank hole number Required prime mover size for existing condi-
Calculated stroke length tions

Crank rotation Nema D motor

Maximum CB moment (existing) Single/double cycle engine

Structural unbalance Multicylinder engine

Crank offset angle Torque analysis and electricity consumption

(listed for existing, minimum torque, and
The dynamometer file information is in the minimum energy balancing when applicable)
bottom part of this section
Peak gearbox torque
Tubing and Pump information
Gearbox loading
Tubing outer and inner diameter
Maximum counterbalance moment (struc-
Plunger size tural unbalance for beam balanced units)
Tubing anchor depth Counterbalance effect
Rod-tubing friction Daily electricity use
Pump type Monthly electric bill
Pump depth Electricity cost per bbl of fluid
Rod string (listed for each rod segment) Electricity cost per bbl of oil
Rod diameter Tubing, pump, and plunger calculations
API rod grade Tubing movement
Rod segment length Gross pump stroke
48 | Expert Diagnostic Analysis

Gross pump displacement Top minimum stress

Apparent net stroke Bottom minimum stress
Effective net stroke Stress calculation method
Net stroke displacement
Fluid load on the pump The following is a detailed explanation of calcu-
Fluid level lated results.

Pump intake pressure

Pump volume efficiency General calculations
Pump fillage Peak and minimum polished rod loads

Estimated pump friction These values are single polished rod loads. The
peak polished rod load is the maximum load ex-
Rod string stress analysis (listed for each rod perienced by the polished rod while the minimum
segment) polished rod load is the least amount of load expe-
Stress load % rience by the polished rod. The ratio of these values
is also displayed as MPRL/PPRL. This value is
Top maximum stress

used to understand how aggressively the rods are
oscillating. Some companies use this value as a fac-
tor when determining if their design will run for
an extended period of time without a problem.
Polished rod horsepower
The polished rod horsepower is the power required
at the polished rod to run the pump. This value is
affected by parameters such as pump depth, fluid
level, plunger size, pump condition, rod-tubing
friction, etc. It is proportional to the area of the
measured polished rod dynamometer card.
Permissible load horsepower
The permissible load horsepower is the area
bounded by the upper permissible load line, lim-
ited by the structural rating of the pumping unit,
and the lower permissible load line, limited by zero
minimum load. It can be described as the capac-
ity of the pumping unit as the area between these
lines makes up the recommended operational
range of the systems surface dynamometer card for
the given conditions.
PRHP/PLHP
The ratio of the polished rod horsepower divided
by the permissible load horsepower is another value
used to evaluate the design. The ratio of the per-
missible load horsepower divided by the polished
rod horsepower should be as large as possible with-
out overloading the pumping unit. If we were to
use all of the available capacity of a pumping unit,
the ratio would be equal to 1. This is not possible
so it is our goal to maximize this value. For exam-
ple, one case has a polished rod horsepower of 28.9
and a permissible load horsepower of 75.5. The
ratio comes out to 0.38 which means the system
is only using 38% of the pumping units capacity.
Another system has a polished rod horsepower of
26 and a permissible load horsepower of 44.5. This
system is using 58% of the pumping units capac-
ity. This ratio gives you another way to compare
XDIAG| 49
system designs.
System efficiency
The system efficiency is calculated using instanta-
neous efficiencies which are calculated throughout
the stroke. These instantaneous efficiencies are
used to calculate an overall efficiency which is the
amount of energy supplied to the motor which is
usable and lifts fluid.
Buoyant rod weight
The buoyant rod weight is the weight of the rods
in fluid. The fluid creates a force on the rods which
make them seem lighter than normal. When run-
ning cases with fiberglass rods it is important to
include buoyancy forces because fiberglass cannot
be in compression. This will allow you to avoid
this hazard. When running cases with steel it is
important to run without buoyant forces because
you need to design the rod string so that it will not
buckle. It has been proven that buoyant forces to
not cause buckling. Removing buoyant forces al-
lows you to look at the linear forces that may cause
buckling.
Unit structure loading
This value is the percent loading on the structure
of the pump jack. This number shows whether
the measured peak polished rod load exceeds the
structural rating of the unit. It must be less than
100% to avoid pumping unit structural damage or
failure. If this number is too small (less than70%)
then it shows that the unit structure may be too
strong for this application.
Gearbox loading
This shows how much the gearbox is loaded as
a percent. It is recommended that the gearbox is
loaded between 70% and 95%. For more detailed
information on the gearbox loading and torque
calculations, see the Torque Analysis and Gearbox
50 | Expert Diagnostic Analysis
Torque Plots sections of this output report page.
Max. rod loading
This value is the largest percent loading of all rod
segments. This gives you an idea of how your rod
string design is handling the well at a quick glance.
More detailed information on the rod string can
be found in the Rod String Analysis section of this
output report page.
Required prime mover size for existing
conditions
This value calculated the required power needed to
run the pump with the existing conditions. Ex-
isting conditions refers to the way the pump is
operating which includes leaks, high fluid levels, or
other production problems. This does not include
the balancing of the unit. This allows XDIAG to
show you the required prime mover size required if
the unit is balanced for minimum energy or mini-
mum torque.
Torque analysis
Peak gearbox torque
This is the maximum required gearbox torque to
operate the pump for the current downhole condi-
tions. This value is reflected by the peaks in the
Gearbox Torque Plots.
Gearbox loading
This shows how much the gearbox is loaded as
a percent. It is recommended that the gearbox is
loaded between 70% and 95%. To see more de-
tailed information about how the gearbox is oper-
ating you can look at the Gearbox Torque Plots or
the Permissible Load Diagram which is overlayed
onto the dynamometer card plots.
Cyclic loading factor
The cyclic load factor shows how smooth the
gearbox torque changes throughout the stroke. The
smaller this value is, the less the gearbox torque
fluctuates. The cyclic loading factor is also related
to the thermal losses in the motor. A small cyclic
loading factor will result in lower thermal losses in
the motor and therefore higher system efficiency.
Counterbalance information
If you enter a maximum counterbalance moment
or counterbalance effect, the program calculates
the above values for both existing and balanced
conditions. If you did not enter an existing coun-
terbalance moment XDIAG will calculate these
values for balanced conditions only. The same
applies for beam balanced units with a difference
in the balancing method. XDIAG calculates the
required structural unbalance to balance beam
balanced units. This value will replace the maxi-
mum counterbalance moment in the output report.
Air-balanced units will show tank pressure in place
of both the maximum counterbalance moment
and counterbalance effect on the output report.
Longstroke units (like the Rotaflex) will show
counterbalance weight which will also replace both
the maximum counterbalance moment and coun-
terbalance effect.
Daily electricity use
The daily electricity use is calculated as Kilowatt-
hours per day. Using the prime mover size and
instantaneous system efficiency throughout the
stroke, XDIAG can accurately calculate the
amount of electricity required to operate the sys-
tem over a 24 hour period.
Monthly electric bill
Using the daily electricity use and the cost of
electricity you enter, XDIAG calculates the cost of
operating the well for one month.

Electricity cost per barrel of fluid or oil
This value is calculated using the production rate
and the cost of electricity to show you the cost
of electricity to lift a barrel of fluid or oil. Other
costs such as payroll and maintenance come into
play when calculating the total cost to lift the fluid
from the well. XDIAG can only calculate the
lifting cost for electricity per barrel with the data
entered in each case.
How to read additional columns for torque and
energy consumption calculations
For balanced conditions, XDIAG may show one
or two different columns of all Torque analysis
and Electricity Consumption calculations: one for
balancing the unit to minimize torque and one for
balancing the unit to minimize energy consump-
tion. XDIAG will not run balancing calculations
to minimize energy if the difference in lifting costs
between balancing to minimize torque and energy
is less than 1%. This is because balancing the unit
for minimum energy will cause higher peak loads
on the gearbox. The savings in lifting costs must
justify the added wear on the gearbox.
You can use the XBAL program developed by
Theta Oilfield Services to find out where to move
the counterweights for crank balanced and beam
balanced units. Clicking the XBAL button on the
toolbar will record the balancing information to
use in XBAL. If both balanced columns are dis-
played (for minimum torque and minimum energy)
you will be prompted as to which value you would
like to use when you click the XBAL button on
the XDIAG toolbar. You can also use the maxi-
mum counterbalance moment or counterbalance
effect in conjunction with manufacturer charts to
figure out where to position counterweights to bal-
ance the units. However, the easiest way to balance
units is with the XBAL program.
XDIAG| 51
Tubing, pump, and plunger calculations
Tubing movement
The only calculation in this section which pertains
to the tubing of the well is tubing movement.
This will give you an idea of the effectiveness of
the tubing anchor. If there is no tubing anchor on
your well, this value might indicate the need for
a tubing anchor. Tubing movement reduces the
efficiency of the well because the pumping unit
is lifting the tubing along with the plunger for a
small distance. During the time the tubing is be-
ing lifted the plunger is not producing fluid.
Gross pump stroke
The gross pump stroke is the total distance trav-
eled by plunger from the bottom to the top of the
stroke. This value shows the total travel of the
plunger.
Gross pump displacement
This value is the maximum amount of produc-
tion possible given the gross pump stroke calcu-
lated. If the pump us full and the pump produces
fluid throughout the stroke it would produce the
amount of fluid shown here.
Apparent net stroke
The apparent net stroke is the stroke calculated
where the fluid load is transferred from the travel-
ing valve to the standing valve. Understanding the
mechanics of the pump, some may assume that
this stroke can be used when calculating the pro-
duction of the well. This is incorrect because if the
fluid load isnt very large and the well is producing
gas, the transfer of the fluid load from the traveling
valve to the standing valve may occur while some
of the fluid in the pump is gas. This is because
the gas pressure may be able to open the traveling
valve before it is compressed into liquid.
52 | Expert Diagnostic Analysis

Effective net stroke amount of produced liquid.

The effective net stroke is always equal to or small-
er than the affective net stroke. This is because it
Net stroke displacement
is the stroke that produces fluid, which omits the
part of the stroke that may have compressed gas. This value is calculated using the effective net
The following figure shows the relationship be- stroke and should be in closer agreement with the
tween apparent net stroke and effective net stroke. actual production of the well. It is the amount
The difference between the apparent and effective of production that this well should be producing
net strokes increases as the fluid load decrease. given the stroke at the pump and the strokes per
This is because the pressure of the compressed gas minute.
doesnt need to be as large to open the traveling
valve. A low pressure corresponds to a larger vol-
ume of gas when gas is present which reduces the

Fluid load on the pump
This value is calculated using the specific gravity
of the fluid, pump depth, and the fluid level. This
value is the load on the plunger cause by the fluid.
The horizontal lines set on the downhole card are
used to calculate the fluid load on the pump.
Fluid level
This value is displayed as fluid level from the sur-
face or fluid level over the pump. Adding these two accurate production data. So, before you decide to
values together will equal the pump depth. This
value is affected by the placement of the horizon-
tal lines. The horizontal lines that are set on the
downhole card are used to calculate the fluid load
on the pump which is used to calculate the fluid
level. As the fluid level get closer to the surface the
fluid load on the pump decreases. This is because
all the fluid in the casing annulus is pushing back
on the fluid in the tubing so the plunger has to
carry less of the load.
Pump intake pressure
The pump intake pressure is also calculated using
the fluid load. If you change the horizontal lines
on the downhole card you can see how the pump
intake pressure is related to the fluid load.
Pump volume efficiency
This value is calculated using the net stroke dis-
placement and the entered production rate. This
will tell you how well the pump is pumping fluid.
If this value is over 100% then the input data has
an error which implies that the pump is produc-
ing more fluid than the volume of the pump can
realistically pump given the stroke length. Pump
volume efficiencies from 85% to 95% are excellent.
High pump volume efficiencies suggest the pump
is in good mechanical condition and it pump little
to no free gas. Lower pump efficiencies indicate
the pump is in poor mechanical condition, or there
is incomplete pump fillage due to fluid pound or
gas interference. XDIAG tells you what is wrong
XDIAG| 53
with the pump by recognizing the calculated
downhole dynamometer card shape.
A tubing leak can cause a low pump volumetric
efficiency. Tubing leaks usually do not affect the
shape of the downhole pump card. The only clue
you may have that there is a tubing leak is a low
pump volumetric efficiency. This also reduces the
overall system efficiency. But to detect tubing leaks
from pump volumetric efficiency you must have
pull tubing thinking that you have a tubing leak,
pressure test the well to verify that leak exists.
Pump fillage
This value is calculated using the gross pump
stroke and the net pump stroke. This will tell you
if the pump is pumping free gas due to fluid pound
or gas interference.
Estimated pump friction
Rod string stress analysis
This section shows all of the calculated rod data for
each rod segment and displays the stress analysis
method used for each rod segment. It also shows
the maximum and minimum stresses at the top,
and the minimum stress at the bottom of each
rod section. For systems with fiberglass rods the
calculated bottom minimum stress shows whether
the fiberglass section is in compression. A negative
bottom minimum stress can cause fiberglass rods
to part prematurely. Also, to maximize rod life,
stress loading must be less than 100%. If XDIAG
shows a negative stress at the bottom of the fiber-
glass section, or if rod loading for any rod sec-
tion exceeds 100%, then the rod string should be
redesigned. Then, if the rods part you can replace
them with a new rod string design. This will help
maximize rod string life. However, keep in mind
that you must use a predictive computer program
such as RODSTAR or XROD to redesign the rod
string.
54 | Expert Diagnostic Analysis
For sinker bars XDIAG calculates stresses and
stress loading based on the elevator neck. XDIAG
is programmed with the latest API standards and
uses the appropriate elevator neck diameter for
each sinker bar size.
3.2 Diagnosis of System
Problems
Dynamometer and pump off control systems are
commonly used with wave equation diagnostic
programs, such as XDIAG, to help diagnose com-
mon pumping system problems. Diagnostic tech-
nology is based on a mathematical solution of the
wave equation. The one-dimensional damped wave
equation models the behavior of the rod string
and allows calculation of downhole loads at any
point in the rod string. The wave equation model
in XDIAG calculates the downhole dynamometer
card from the polished rod dynamometer card that
you enter. Downhole dynamometer cards are much
easier to interpret than surface cards because their
shape depends only on the condition of the pump
(for most wells).
Before running XDIAG you must record a quan-
titative dynamometer card and you must complete
an XDIAG data sheet. You can find copies of the
XDIAG data sheet in the back of this manual.
3.2.1 Recording Dynamometer Card in
the Field
You can find most pumping system problems from
a dynamometer card analysis with XDIAG. This
chapter describes practical, step by step procedures
of how to use a dynamometer system to get the
data you need to run XDIAG.
The dictionary defines the word dynamometer as
an instrument for measuring force. It comes from
two Greek words: Dynamis meaning force and
metron meaning a measuring device. Therefore,
dynamo-meter simply means force-meter. A
dynamometer records polished rod load (force) as
a function of polished rod position. This is com-
monly called the dynamometer card. Early
technology used equipment to draw an X-Y plot
(dynamometer card shape) on a piece of paper. A
common dynamometer system to date has a load
cell, a position transducer, and a recorder box.
Instead of plotting dynamometer cards on paper, as
the early style dynamometers do, current systems
store data on disk or in the computers memory.
The latest technology will send this information
wirelessly to a server where well information is
stored. These systems can monitor and control
wells. The recorded data can be analyzed automati-
cally and if the data shows a problem the well can
be shutoff automatically. XSPOC is automation
software that can do this.
To record a dynamometer card you must insert the
load cell between the polished rod clamp and car-
rier bar. The position transducer has a string that
clamps on the polished rod. The load cell contains
strain gauges. Strain gauges are devices that use
the change of electrical resistance of a wire to
measure load. The strain gauges inside of the load
cell contract when a load is applied to the load cell.
This increases the cross sectional area of the thin
wire. The change in area causes the change in re-
sistance to the flow of electricity though the strain
gauge. The electronic circuits in the dynamometer
box translate changes in resistance into polished
rod load.
The position transducer box contains a potenti-
ometer attached to a spring loaded pulley that
has string wrapped around it. As the polished rod
moves up and down, the string movement causes
the potentiometer to turn. The electronics of the

dynamometer system translate the number of times good unit brake is vital to ensure operator safety
the shaft of the potentiometer turns into polished especially when installing or removing the load
rod position.
Commonly Used Dynamometer Equip-
ment:
To record a dynamometer card you need a dyna-
mometer system with a set of polished rod load
and position transducers. In addition, you need the
following tools:
A set of two or three polished rod clamps for
the polished rod sizes in your field.
A wrench for the polished rod clamp bolts.
A load transducer leveling plate.
A Knock-off which is a piece of pipe one to
two feet long, cut in half lengthwise, with a
safety latch.
A stuffing box protector.
Protective gloves.
A strong chain that is 12-15 feet long.
A piece of pipe to give you leverage when
tightening the polished rod clamp.
An empty bucket.
Installing and Removing the Load and
Position Transducers
To record a dynamometer card, you need to install
the load and position transducers on the polished
rod. You must insert the load cell between the
permanent polished rod clamp and the carrier bar.
Clamp the position transducer string to the pol-
ished rod after you install the load cell. You must
be very careful when recording data in the field, to
avoid injury. The power switch must be off when
installing the transducers or making measurements
around the pumping unit. Also, dynamometer
measurements are not recommended on units that
do not have brakes in good working condition. A
XDIAG| 55
cell from the polished rod. If possible, well analysts
should work in teams of two for added safety.
Steps for Installing the Transducers
1. Stop the pumping unit close to the bottom of
the downstroke. Engage the units brake and
make sure that it holds.
2. If there is a polished rod liner, put the polished
rod clamp about 6 inches above the stuffing
box. Do not put the clamp on the polished sec-
tion of the polished rod since it will be in the
way when the unit starts to pump. Tighten the
clamp to hold the polished rod load without
slipping.
3. If you have a Hercules stuffing box (usually
red with bolts), insert the stuffing box protec-
tor (metal wedge) to support the load that may
otherwise damage the stuffing box bolts.
4. Lay out all cables on the ground and zero the
load and position transducers.
5. Turn the unit on and raise the polished rod
close to the top of the stroke. Then turn the
unit off and engage the brake.
6. Put the knock-off on top of the stuffing box
and secure it by closing the safety latch.
7. Restart the unit and turn the power off just be-
fore the polished rod clamp hits the top of the
knock-off. You need to get the clamp to rest on
the top of the knock-off as smoothly as possible
while trying to throw slack between the per-
manent polished rod clamp and the carrier bar.
If the pumping speed is high, you may need
to run the motor on and off every few mo-
ments. This is so that you can transfer the load
smoothly from the carrier bar to the knock-off.
When you created enough room to insert the
load transducer, turn the unit off and immedi-
ately set the brake. Make sure the brake is on
tightly enough to hold the polished rod load.
8. Load transducers are U-shaped and they usu-
56 | Expert Diagnostic Analysis
ally have three buttons that must be pressed
to record polished rod load. For accurate load
measurement, at least two of these buttons
must be pressed. If the carrier bar is so skinny
that only one button will be pressed, then in-
sert the load transducer with the buttons facing
upwards. If you put the leveling plate between
the carrier bar and the buttons you can be sure
at least two of the buttons will be pressed.
Otherwise, insert the load cell with the buttons
down and insert the safety pin to hold it in
place. Some load cells have this leveling plate
as part of the load cell itself to avoid having to
perform the above steps.
9. Narrow the distance between the carrier bar
and the load cell using the brake. When they
are about 2 inches apart, let off on the brake
and let the carrier bar come up fast. If the unit
cannot pick up the load, you need to turn the
motor on momentarily until you pick up the
polished rod load. Make sure there is some
space between the carrier bar and the top of
the knock-off. Apply the brake as soon as you
pick up the polished rod.
10. Remove the knock-off, put the bucket as close
to the well head as possible, and put the posi-
tion transducer on top of the bucket to keep it
clean. Attach the position transducer string to
the polished rod. Make sure the cables are not
tangled and then turn on the unit.
11. Wait for a few strokes until the well stabilizes
(which is when the dynamometer card shape
does not change from stroke to stroke). Then
record the dynamometer card, counterbalance
effect, and the traveling and standing valve
checks.
Steps for Removing the Transducers
1. To remove the load position transducer, stop
the unit at the beginning of the downstroke.
Insert the stuffing box protector (if needed),
place the knock-off on top of the stuffing box,
and set the safety latch on the knock-off.
2. Turn the unit on and off to get the carrier bar
to gently rest on the knock-off and to throw
slack between the carrier bar and the perma-
nent polished rod clamp. Then, turn the unit
off and set the brake tightly.
3. Remove the load cell safety pin and then
remove the load cell. Do this as quickly as pos-
sible to avoid hand injury if the pumping unit
brake does not hold.
4. Remove the position transducer clamp and
slowly release the brake until the carrier bar
picks up the polished rod load. Make sure
there is enough space to allow removal of the
knock-off. Then turn the power off and reset
the brake.
5. Remove the knock-off and the polished rod
clamp you installed, and restart the unit.
After you record the dynamometer card and while
the load and position transducers are still on the
polished rod, you can do traveling and standing
valve checks. These checks help you find out if the
pump barrel, plunger, or valves are worn.
Counterbalance Effect Measurement
To have XDIAG do a torque analysis that shows
the existing gearbox loading and unit balancing,
XDIAG needs information about the existing
counterbalance. One way to enter existing counter-
balance data in XDIAG is by entering a measured
counterbalance effect (CBE). XDIAG uses the
measured CBE to calculate the maximum counter-
balance moment and from this, the existing peak
gearbox torque, etc. An easier and more accurate
way is to use the XBAL computer program (please
contact Theta Oilfield Services for more informa-
tion).
The CBE is an indirect measurement of the unit
counterbalance. To measure the counterbalance ef-
fect you must stop the unit with the cranks as close
as possible to 90 or 270, then, with the brake off,

record the polished rod load at that position. You
must also record the corresponding counterweight
crank angle or record the point on the dynamom-
eter card plot when the counterbalance effect was
recorded (with respect to position). When you re-
cord the CBE as a point, you must record whether
the unit was in the upstroke or downstroke where
the CBE measurement was measured. You can
then read in the counterbalance effect from the dy-
namometer file. XDIAG uses the CBE measure-
ment to calculate the maximum counterbalance
moment.
If the unit is not perfectly balanced then the
cranks will not stop close to the horizontal posi-
tion. Instead, they tend to stop close to the 12
oclock or 6 oclock positions. In such cases, to
record an accurate counterbalance effect you must
chain off or prop up the polished rod.
If the unit is weight heavy then the unit has the
tendency to stop with the horse head at the top of
the stroke and the cranks at the 6 oclock position.
In this case you must chain off the unit using the
following steps:
1. Stop the unit as close to 90 or 270 as possible,
on the downstroke, and engage the brake. We
stop the unit on the downstroke so that when
we want to unchain the unit we simply turn it
on for a moment and it will create slack in the
chain.
2. With the pumping unit brake on, wrap a
strong chain around the polished rod clamp
and tie it down to the well head. Be sure to tie
the chain to a strong part of the well head to
avoid damaging it.
3. Release the brake and record the counterbal-
ance effect (the polished rod load at that point).
4. Turn the unit on for a moment then off to re-
lease tension in the chain. As you turn the unit
off, engage the brake to hold the unit in place.
XDIAG| 57
5. Remove the chain.
If the unit is rod heavy then the unit has the ten-
dency to stop with the horse head at the bottom of
the stroke and the cranks at the 12 oclock posi-
tion. In this case you must prop the polished rod
up using the following steps:
1. Stop the unit as close to 90 or 270 as possible,
on the upstroke, and engage the brake. We
stop the unit on the upstroke so that when we
want to remove the clamp we simply turn it on
for a moment and it will pick up the polished
rod load off of the clamp.
2. With the brake on, attach a clamp onto the
polished rod just above the stuffing box.
3. Slowly release the brake. When the clamp rests
on the stuffing box and the unit stop moving,
record the counterbalance effect load.
4. Turn the unit on for a moment then off to pick
up the polished rod load off of the clamp. As
you turn the unit off, engage the brake to hold
the unit in place.
5. Remove the clamp.
Stroke Length and Strokes per Minute
Accurate stroke length and strokes per minute
measurements are very important when analyz-
ing the performance of a pumping system. Still,
when using XDIAG you do not need to measure
the stroke length since the program calculates it
from pumping unit dimensions. You only need to
measure the stroke length for units that have been
altered from their original design, when analyzing
a hydraulic unit which has a variable stroke length,
or checking the accuracy of the pumping unit
dimensions that you measured.
To calculate stroke per minute (SPM) accurately,
use a stop watch and record the time it takes for
the pumping unit to cycle through several strokes
58 | Expert Diagnostic Analysis
(for example 10 strokes). Divide the number of
strokes by the time in minutes and you will calcu-
late strokes per minute. In the following example,
we timed a pumping unit which took 50 seconds to
complete 10 strokes.
Tip: When measuring the time for calculating
strokes per minute, use a point of reference in the
stroke to start your stop watch. For example, if you
start at the bottom of the stroke, then do the fol-
lowing:
1. Wait for the polished rod clamp to approach
the bottom of the stroke. Start the stop watch
just as the clamp stops moving downward and
reverses direction.
2. Wait for the clamp to move upward then
downward to the bottom of the stroke. When
the clamp is at the bottom of the stroke this
is stroke number one. Continue to count the
number of strokes in this way.
3. As you are completing the tenth stroke, stop
the stop watch as the clamp reaches the bottom
of the stroke and stops just before it reverses
direction.
4. Record the time and calculate the strokes per
minute as described above.
To run XDIAG you need a recorded dynamometer
card and an XDIAG data sheet. You must carry
XDIAG data sheets when collecting data in the
field to make sure you have the data you need to
run the program.
3.2.2 Downhole Pump Dynamometer
Card Interpretation
XDIAG combines expert knowledge and pattern
recognition with a wave equation sucker rod mod-
el, accurate calculations of gearbox torque, unit
balancing, power consumption, structure loading,
etc. With XDIAG you can answer practically all
questions about system performance quickly and
accurately.
However, because all wells are not the same, you
must be aware of the differences between different
types of rod pumping systems. Rod pumped wells
must be divided into two groups. The first group,
that we will call Group 1, includes wells that
are deeper than 4000 feet of are less than 4000
feet but have pump plungers that are 2.0 inches in
diameter or less. The second group, that we will
call Group 2, includes wells that are less than
4000 feet and have pump plungers larger than 2.0
inches. These two groups have unique character-
istics that you must be aware of to diagnose prob-
lems more accurately.
Characteristics of Group 1 Wells
Since this group includes all wells deeper than
4000 feet and all wells less than 4000 feet with
pump plungers with a diameter of 2.0 inches or
less, it represents the majority of rod pumped
wells. For group 1 wells, dynamometer card shape
depends on several factors including the follow-
ing: pump depth, rod string material and design,
pumping speed, pumping unit type, pump fillage,
prime mover type, etc. This makes surface dyna-
mometer card analysis very difficult. However, for
these wells downhole dynamometer card shape
depends only on the condition of the pump. For
example, the pump dynamometer card shape cor-
responding to fluid pound is the same regardless
of depth, pumping unit type, rod string, pumping
speed, etc. Verified downhole dynamometer card
shapes for Group 1 wells are available (see the

appendix for shapes of Group 1 downhole cards)
and several papers have been published on diag-
nostic techniques for these wells. XDIAG alone
is sufficient to diagnose pump problems accurately
for Group 1 wells. You can do this by comparing
the calculated downhole pump dynamometer card
shapes to shapes that correspond to known condi-
tions. The figures at the end of this manual show
several downhole pump card shapes that you can
use for this purpose.
Characteristics of Group 2 Wells
Compared to Group 1 wells, Group 2 wells ac-
count for few of todays rod pumped wells. Group
2 wells include all wells of less than 4000 feet
with pump plunger sizes larger than 2.0 inches. In
this group there are many high volume wells that
can cause large production losses when they are
down. Group 2 wells are separated from Group
1 wells because they are affected by large fluid in-
ertia forces. These forces are caused by large plung-
ers, fast pumping speeds, and low fluid compress-
ibility.
In deeper wells, rod loading is the main factor
limiting production rates. Therefore, to reduce
rod loading you must use a smaller pump plunger.
Also, in deeper wells (deeper than 4000 feet) the
rod string behaves more like a shock absorber,
stretching when the pump plunger load increases.
This effectively absorbs the shock of picking up
the fluid load on the upstroke and no dynamic
fluid forces appear on the downhole pump dyna-
mometer card. However, in the shallow high rate
Group 2 wells, fluid inertia is significant and
sometimes can more than double the load on the
pump plunger. Because the plungers in these wells
are large, they must pick up the fluid in the tub-
ing and accelerate it upward at rates that are much
higher than for deeper wells. Also, because of the
shallow depths of Group 2 wells, the rod string
is practically rigid and does not provide any shock
absorption. This results in significantly higher
loads than would be predicted by considering the
XDIAG| 59
dead fluid alone.
The fluid inertia effects on the pump depend on
plunger size, pumping speed, and fluid compress-
ibility. This makes diagnostic analysis of Group
2 wells very difficult. For Group 2 wells, both
surface and downhole dynamometer card shapes
depend on pump condition, pump depth, plunger
size, pumping speed, and the fluid compressibil-
ity. Therefore, unlike Group 1 wells, you cannot
identify the downhole pump condition by simply
comparing the calculated pump card shape to
known pump card shapes.
Up to now, the peculiar characteristics of Group
2 wells had not been well documented. Since the
downhole pump dynamometer card shape for any
given pump condition depends on so many factors,
conventional diagnostic techniques (such as those
used on Group 1 wells) are insufficient. Compar-
ison of calculated downhole pump dynamometer
cards for Group 2 wells with known downhole
card shapes developed for Group 1 wells can
result in incorrect conclusions. For example, the
downhole pump dynamometer card shape corre-
sponding to a full pump for a Group 2 well may
be similar to the shape for a severely worn pump
for Group 1 wells. This can cause unnecessary
pulling jobs and frustration due to misdiagnosis
of pump condition. To diagnose pump problems
correctly for Group 2 wells you need an ad-
ditional tool known as predictive wave equation
program. A predictive wave equation program can
model not only the behavior of the rod string but
also the fluid inertia effects. RODSTAR-V/D or
XROD (developed by Theta Oilfield Services) is
such a tool. Because RODSTAR-V/D and XROD
can model fluid inertia effects, they can accurately
simulate the behavior of Group 2 wells and can
predict the shape of both surface and downhole
dynamometer cards for a full pump. If the predict-
ed dynamometer card shape matches the measured
one, then you know that the pump is in good
mechanical condition.
60 | Expert Diagnostic Analysis
Also, XDIAG understands Group 2 wells and
recognizes strange downhole dynamometer card
shapes. Using its built-in experience with Group pumping unit with a slower downstroke polished
2 wells, XDIAG can accurately diagnose prob-
lems with these wells.
Downhole Dynamometer Card Shape
Analysis for Group 1 Wells
The figures at the end of this manual show a col-
lection of downhole dynamometer card shapes that
correspond to most pump operating conditions or
problems for Group 1 wells. Although XDIAG
interprets the downhole pump card shape for you,
it is still useful to know what these shapes are so
that you can figure out the pump condition. Keep
in mind that these shapes are only valid for Group
1 wells.
3.2.3 Avoiding Rod Compression
Because XDIAG calculates stresses at the bot-
tom of each rod section in the rod string, you
can use it to check for compression. This feature
is especially useful for fiberglass rods that must
never be in compression. Compression in fiberglass
rods will surely cause the rods to part. If you use
RODSTAR-V/D or XROD to design fiberglass
rod strings then you can prevent this problem from consumption will increase if you balance the unit
ever occurring. Rod compression is also detri-
mental to steel rods. Excessive rod compression
can cause buckling related failures. According to
research done by Norris Sucker Rods, you must
maintain a minimum load of +2000 pounds at
the top of the lowest sucker rod section to avoid
buckling problems. This load corresponds to a
minimum stress of 3300 psi doe 7/8 inch rods and point throughout the cycle or stroke changes with
4530 psi for inch rods. We recommend design-
ing a rod string with sinker bars so that the bottom tions the energy consumption can increase when
minimum stress of the lowest sucker rod segment
(just above the sinker bars) is between 300 and 600 the prime mover now spends more time in the less
psi.
If you detect rod compression, you can add more
sinker bars, reduce the pumping speed, or use a
rod velocity. These changes will reduce rod com-
pression. To find out how many sinker bars you
need to eliminate rod compression, use ROD-
STAR-V/D or XROD. With RODTAR-V/D or
XROD you can design a rod string with minimum
rod compression. You can even have the programs
design a rod string for you using its expert system
design capabilities. When you have RODSTAR-
V/D design a fiberglass rod string, you must be
sure to add enough sinker bars so that the fiber-
glass rods are not in compression. XROD can do
this for you automatically.
3.2.4 Gearbox Torque and Unit Balancing
Sometimes, using the largest available stroke
length may not be the best way to maximize
production since this can overload the gearbox.
You may be able to use the next smaller stroke and
speed up the unit to get the production rate you
want without overloading the gearbox. Another
way of reducing gearbox torque is by using a small-
er pump plunger and faster pumping speed. You
may use a lighter rod string by using high strength
or fiberglass rods which may decrease the gearbox
loading. Sometimes XDIAG will show that energy
for minimum torque. This is normal because mini-
mizing torque doesnt directly relate to minimizing
energy consumption. Balancing the unit for mini-
mum torque makes the peak torque on the up-
stroke equal to the peak torque on the downstroke
but also changes the torque throughout the cycle.
The instantaneous efficiency calculated for each
the changes in the torque values. In some applica-
you balance the unit for minimum torque because
efficient part of its performance curve.

3.2.5 Using XDIAG with RODSTAR-V or
XROD
XDIAG helps you find problems such as over-
loaded rods, worn pump, overloaded gearbox,
poor system efficiency, excessive fluid pound, etc.
Once you find a problem that requires redesign-
ing the system, you must predictive program such
as RODSTAR-V or XROD to help you evaluate
different changes to the system. For example, if
you find that the second section on the rod string
is overloaded you may want to redesign the rod
string to eliminate this problem. Possible solutions
include creating a balanced rod string design to
minimize rod loading, using stronger rods such
as Norris 97, Weatherford EL, or LTV HS, using
a smaller plunger size, etc. RODSTAR-V and
XROD can help you evaluate different solutions to
this problem. They allow you to predict the effect
of each change on system performance and load-
ing. RODSTAR-V and XROD do not depend
on input of a measured dynamometer card but
instead simulates the pumping system you specify.
RODSTAR-V and XROD predicts the surface
dynamometer card along with other important
parameters relating to system performance.
Although RODSTAR-V and XROD are primarily
design tools, they can be very powerful diagnostic
aids when used in conjunction with XDIAG. This
is due to the powerful overlay feature that allows
direct comparison of predicted versus measured
cards.
Using RODSTAR-Vs and XRODs
Dynamometer Overlay Feature
This feature can have many different uses. For
example, it can help you to verify whether the load
cell is out of calibration, if the fluid level you mea-
sured is accurate, etc. RODSTAR-V and XROD
can help you find these problems by comparing the
XDIAG| 61
shape and load range of the measured dynamom-
eter card versus the one predicted by the program.
Also, the predictive programs can help verify
downhole problems such as a worn pump, leaking
traveling or standing valves, deep rod parts, stuck
pump, etc. You can simulate a worn out pump or a
deep rod part by entering a fluid level at the sur-
face (zero feet from the surface). This will result in
a zero fluid load on the pump plunger.
RODSTAR-V and XROD cannot simulate a
traveling valve leak, a hole in the pump barrel,
or a sticking pump. But it can predict what the
dynamometer card should look like if there were
no problems. You can use this comparison of the
actual dynamometer card shape with the predicted
card shape and have confidence in XDIAGs
diagnosis of system problems. For example, if you
have a traveling of standing valve leak or a worn
out pump, then the pump will be doing less work
and the measured surface dynamometer card will
contain less area than the predicted surface dyna-
mometer card.
If the pump is sticking, or if there is more friction
that normal between rods and tubing (which may
be due to paraffin, scale, etc.) then the predicted
surface dynamometer card from RODSTAR-V or
XROD will be smaller than the measured dy-
namometer card. This is especially true for steel
rods. By entering a larger rod-tubing friction, you
can obtain a better match between the measured
and predicted dynamometer cards (cause this will
increase the predicted surface dynamometer cards
area) which can aid in improving future designs.
Note: Rod-tubing friction is especially important
for fiberglass rods. Higher friction than normal
may actually reduce the area of the predicted sur-
face dynamometer card because it causes the rods
to stretch and give a small stroke at the pump.
62 | Expert Diagnostic Analysis
3.2.6 Setting Lines on Downhole Pump
Cards
XDIAG automatically sets the horizontal and
vertical lines, unless the pump is not in good
condition, to calculate pump intake pressure, fluid
level, net pump stroke and production through the
pump. Also, XDIAG allows you to modify the
line settings after the run. To understand how to
set these lines it is necessary to discuss some of the
assumptions made when XDIAG does its calcula-
tions.
Setting Horizontal Lines:
To calculate the downhole dynamometer card
using the wave equation, XDIAG assumes an
average friction between rods and tubing. If you
were to enter the exact friction coefficient between
rods and tubing, then XDIAG would calculate a
downhole dynamometer card that shows exactly
how much fluid load the pump plunger carries
(assuming it is in good mechanical condition)/
For example, in a case with fluid pound, XDIAG
would calculates a downhole dynamometer card
similar to Figure 3.1. However, because rod-tubing
friction is different in each well, it is impossible to
know that friction coefficient to use. Fortunately,
it is not necessary to know the exact friction to get
useful results with XDIAG. When calculating a
downhole dynamometer card, it is better to under-
estimate rod-tubing friction than to over-estimate
it. If you enter a friction coefficient that is too
large, the wave equation model will remove more
load than it should from the calculated downhole
dynamometer card. This will distort the downhole
dynamometer card shape. This is why it is better to
use a friction coefficient that is lower than actual.
The default friction coefficient of 0.5 in XDIAG
is a safe number to use for most applications. The
only side effect of using a lower than actual fric-
tion coefficient is that the calculated downhole
dynamometer cards are fatter than actual. This
occurs because the wave equation removes only a
part of the frictional load. The remaining frictional
forces appear as extra load on the calculated down-
hole dynamometer card. For example, Figure 3.1
would look more like Figure 3.2 with the added
frictional forces. You can see how XDIAG didnt
remove all fractional loads from the calculated
downhole dynamometer card and it appears fat-
ter. However, you can still use this downhole card
to identify problems at the pump.
If all you want to do is to identify the pump condi-
tion, then the friction coefficient makes little dif-
ference. However, if you can separate the frictional
loads from the actual fluid load on the plunger,
you can calculate pump intake pressure and fluid
level from a downhole dynamometer card. You can
do this by setting two horizontal lines as shown
in Figure 3.2. The area above the top line and
below the bottom line represents frictional work
at the pump. The distance between the two hori-
zontal lines is the true fluid load on the plunger.
Once you know the fluid load, you can calculate
the pump intake pressure and the fluid level as
explained in Figure 3.3. The fluid load on the
pump plunger corresponds to the pressure differ-
ence across the pump plunger. If we assume that
the pressure in the pump barrel on the upstroke is
about the same as the pump intake pressure, then
you can use equation 1 in Figure 3.3 to calculate
the fluid load on the plunger. You can calculate the
pressure above the pump plunger using equation 2,
and the plunger area using equation 3. Then, you
can solve equation 1 for the pump intake pressure
as shown in equation 4.
The fluid load, Fo, is the distance in pounds
between the two horizontal lines you set on the
downhole dynamometer card. Because the pump
intake pressure is also a function of the fluid level
in the tubing-casing annulus, it also can be calcu-
lated using equation 5. Since we know the pump
intake pressure from equation 4, we can solve
equation 5 for fluid level over the pump as shown
 XDIAG| 63
64 | Expert Diagnostic Analysis

in equation 6. This is how XDIAG calculates the
fluid level from horizontal line settings. XDIAG
assumes that the casing fluid is oil and uses the oil
API gravity to calculate the casing fluid specific
gravity.
Using the above method you can calculate pump
intake pressure and fluid level even in wells with
packers or with foamy fluid over the pump. Shoot-
ing a fluid level with a fluid level sounder (echo
meter) will not give meaningful results in this case
because you do not know the gradient of the fluid
in the annulus. By setting horizontal lines on the
downhole pump dynamometer card you can get
more accurate results because pump intake pressure
affects plunger load. If you have foamy fluid over
the pump, XDIAGs calculation of fluid level will
not agree with the shot fluid level. This is because
using the above method, XDIAG calculates an
effective fluid level by assuming the annulus is
full of oil and not mixed with gas. This works
because when you have foam over the pump the
fluid level is meaningless since it does not tell you
if more production is possible. Fluid level is easier
to visualize than pump intake pressure. But, if you
have foam over the pump then pump intake pres-
sure is the only meaningful quantity you should
look at.
Setting Vertical Lines:
XDIAG separates the net stroke from gross pump
stroke with a set of vertical lines that it sets on the
calculated pump card. The gross pump stroke is
the total distance the plunger moves. Figure 3.2
shows the gross pump stroke on a downhole card
of a pumped off well. The net stroke is the portion
of the gross pump stroke during which the plunger
moves through fluid in the pump (on the down-
stroke). In other word, net stroke is the part of the
pump stroke that produces fluid. By setting vertical
lines, XDIAG estimates the amount of fluid going
through the pump. This also lets you estimate pos-
XDIAG| 65
sible production gains if you can increase the net
stroke. For example, if the pump card shows gas
interference, you can move the second vertical line
to the right to see how much more liquid produc-
tion you could get by using a gas anchor or by
lowering the pump intake below the perforations.
Tips for Setting Horizontal and Vertical
Lines:
To accurately set horizontal and vertical lines you
must have experience with dynamometer card
shape interpretation. Otherwise, it will be bet-
ter to let XDIAG set the lines for you. For hori-
zontal lines you must have an idea of how much
rod-tubing friction your well normally has. If we
assume that friction is about equal on the upstroke
and downstroke, then for a fluid pound case you
can draw the lines as shown in Figure 3.2. The
top horizontal line intersects the nose of the
dynamometer card. This splits the friction equally
between the upstroke and the downstroke. Then
you can set the bottom line so that it removes
about the same amount of friction as the top one
does (equal to half the thickness of the nose). It
is easier to set lines on the downhole pump cards
with fluid pound or gas interference because of the
nose in the card shape. Also, since the well pounds
fluid, the fluid level (from the surface) is close to
the pump intake.
Once you figure out where to place the lines when
the well is pounding fluid then you can use the
same horizontal line setting when the pump is full.
If the well does not pump off then shoot a fluid
level reading and record the dynamometer card at
the same time. Then, after XDIAG calculates the
downhole dynamometer card, set the horizontal
line so that the calculated fluid level matches the
fluid shot reading. Remove the same amount of
friction on the upstroke as the downstroke. From
now on, use the same horizontal line settings
whenever you analyze the same well. You should
66 | Expert Diagnostic Analysis

only set lines on a downhole pump dynamometer
cards that show a good mechanical pump condi-
tion. If the traveling valve or plunger is worn, it
cannot pick up the entire fluid load which means
setting horizontal lines will yield incorrect results.
Figure 3.4 and Figure 3.5 show example line set-
tings for many common pump card shapes. Use
the examples along with measured fluid levels and
see how XDIAG sets the lines to learn how to set
horizontal and vertical lines yourself.
Vertical line placement is easier than horizontal
line placement. When setting vertical lines you are
estimating the net pump stroke. The gross pump
stroke is the total plunger travel. The net stroke is
the portion of the gross pump stroke that produces
fluid. For fluid pound or full pump cases, you can
place vertical lines as shown in Figure 3.4 and
Figure 3.5. For gas interference cases the net pump
stroke should account for both gas expansion on
the upstroke and gas compression on the down-
stroke. For downhole pump cards that show severe
problems, XDIAG will not set the lines on the
downhole pump dynamometer card.
If the downhole pump card calculated by XDIAG
corresponds to a worn pump, stuck plunger, or any
other condition for which line placement is not
possible, do not set the lines yourself. Sometimes,
it is possible to set either vertical or horizontal lines
on these problematic wells but not both. XDIAG
provides you the flexibility to set either pair of
lines.
zontal lines will be in error. Often XDIAG may
detect possible input data errors in plunger size or
fluid specific gravity when setting horizontal lines.
For example, if you enter the wrong plunger size,
then the fluid level calculated from horizontal lines
may be too low or too high depending on whether
you entered a plunger that is larger or smaller than
actual.
When setting horizontal lines, XDIAG does not
let the calculated pump intake pressure go below
casing pressure. If plunger size or fluid specific
gravity is smaller than actual, you will not be able
to move the horizontal lines as far apart as they
should be. If you set the lines yourself and start
with the top line first, you will not be able to move
the bottom line close to the bottom of the dyna-
mometer card.
If the pump plunger size or specific gravity of the
produced fluid is larger than actual, you cannot
get a low enough pump intake pressure even if
you move the horizontal lines as far apart as they
can go. If you set the top line first, you will see a
higher than expected pump intake pressure even
after you move the bottom line all the way to the
bottom of the card.

Effect of Plunger Size and Fluid Specific

Gravity on Line Placement:

As Figure 3.3 shows, the fluid level calculation

from horizontal lines depends on plunger diameter
and fluid specific gravity. If you make a mistake
when entering either the plunger diameter or fluid
specific gravity, the calculations from the hori-
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