XROD

Advanced Design and Simulation

of Rod Pumping Systems
for Deviated and Ver tical Wells

3075 E. Imperial Hwy Suite 125

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

E-mail Addresses:
Product Manager: Kevin Lo, kevin@gotheta.com
Software Support: support@gotheta.com
Sales: Christy Kukula, christy@gotheta.com
 Theta Oilfield Services, Inc., 2014.
All Rights Reserved. This manual may not be reproduced in whole or in part without the written per-
mission of Theta Oilfield Services, Inc.

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

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

Printed in the United States of America

Fourth Edition, April 2014
 XROD| iii

Contents
Technical Support . . . . . . . . . . . . . . . . v
System Requirements . . . . . . . . . . . . . . v

1 Introduction 1
1.1 Program Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Advanced Capabilities and Program Limitations. . . . . . . . . . . . . . . 3
1.3 Help System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 XROD CD and Software Sentinel. . . . . . . . . . . . . . . . . . . . . . . 3

2 Software Installation 5
2.1 XROD Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Questions About Installation . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Installing the Software Sentinel. . . . . . . . . . . . . . . . . . . . . . . 5

3 Starting and Setting Up XROD 7

3.1 Starting XROD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Exiting XROD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Setting up XROD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.1 General setup options . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.2 Defaults and Limits . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.3 Output Options. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.4 Pumping Unit Options . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.5 Rod Grade Options. . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3.6 Cost Database. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3.7 Batch Mode Options . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.8 AI Mode Preferences . . . . . . . . . . . . . . . . . . . . . . . . 22

4 Running XROD 25
4.1 XRODs User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1.1 XRODs Help System . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Entering Rod Pumping System Data into XROD, AI mode. . . . . . . . . . . 27
4.3 Entering Rod Pumping System Data into XROD, non-AI mode. . . . . . . . . 29
4.3.1 Entering Well Information Data . . . . . . . . . . . . . . . . . . . . 30
4.3.2 Entering Production Information. . . . . . . . . . . . . . . . . . . 32
4.3.3 Entering Pump and Tubing Information Data. . . . . . . . . . . . . . 33
4.3.4 Entering Rod String Data. . . . . . . . . . . . . . . . . . . . . . . 36
iv | Table of Contents

4.3.5 Entering Pumping Unit Data. . . . . . . . . . . . . . . . . . . . . 40

4.3.6 Entering Motor Information and Energy Cost . . . . . . . . . . . . . . 48

5 Changing, Loading and Saving Data 51

5.1 Visual Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2 Storing Data Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3 Running and Viewing the Output. . . . . . . . . . . . . . . . . . . . . 52
5.3.1 Saving the output . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.3.2 Running in Batch Mode. . . . . . . . . . . . . . . . . . . . . . . 55
5.4 Loading Data from Disk. . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.4.1 Viewing Previously Saved Output . . . . . . . . . . . . . . . . . . . 59
5.5 Manipulating Input Windows. . . . . . . . . . . . . . . . . . . . . . . 59

6 Rod Pump System Design 61

6.1 Understanding XRODs Output . . . . . . . . . . . . . . . . . . . . . . . 62
6.1.1 Dynamometer and Permissible Load Plots . . . . . . . . . . . . . . . 62
6.1.2 Torque Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.1.3 IPR Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.1.4 Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2 Rod Pump System Design Guidelines . . . . . . . . . . . . . . . . . . . . 70
6.2.1 Shallow, High Rate Well Simulation . . . . . . . . . . . . . . . . . . 71
6.2.2 Selecting the Target Production . . . . . . . . . . . . . . . . . . . 71
6.2.3 Avoiding Rod Compression . . . . . . . . . . . . . . . . . . . . . . 71
6.2.4 Minimizing Power Consumption. . . . . . . . . . . . . . . . . . . 72
6.2.5 Reducing Gearbox Torque . . . . . . . . . . . . . . . . . . . . . . 72
6.2.6 Using XROD for Correct Equipment Sizing. . . . . . . . . . . . . . . 72
6.2.7 Using XROD for Diagnostic Analysis. . . . . . . . . . . . . . . . . . 73
 XROD| v

Technical Support
Technical Support for XROD is provided by
phone and e-mail to customers with a current An-
nual Technical Support Agreement.
The first year of technical support is provided free
with the initial purchase of a license.
Support for customers with an expired agreement
is billed at $100/hour with a one-hour minimum
per incident.
Please include the Serial Number from your Senti-
nel when contacting support.

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

E-Mail Support:
support@gotheta.com

System Requirements
Processor: 1.6 GHz or higher
Operating System: Windows XP/Vista/7/8
Memory: 1 GB of RAM or higher
Hard Disk Space: 150 MB available disk space
Display: 1024 x 768 or higher

1 Introduction
XROD is a powerful, easy-to-use rod pumping
system simulator and Artificial Intelligence (AI)
design tool. With XROD you can design new rod
pumping installations faster than ever before, or
make changes to existing rod pumping systems
by running the program in non-AI mode. It is a
tool that you can use to compare pumping units,
pumping speeds, plunger sizes, rods, motor types,
etc. You can evaluate the effect of pump fillage,
fluid level, or an out-of-balance unit. Also, you can
study the effect of prime mover speed variation,
stuffing box friction, etc. XROD also allows you to
combine sophisticated rod pumping system model-
ing with inflow performance data for even more
powerful capabilities. The artificial intelligence
(AI) technology in XROD allows you to get great
system designs in seconds with minimum input
data.
In the non-AI Mode, XROD behaves the same as
RODSTAR (but with some additional capabili-
ties).
XROD is very easy to use, flexible, customizable,
and fast. With a single click of 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 ! for context
sensitive help for any input item. You can also take
advantage of standard Windows features such as
being able to copy the dynamometer, torque plots,
or IPR plots to the clipboard and then paste them
in any other Windows document.
By taking advantage of the programs powerful
AI mode, you can save a lot of time and come up
with better answers as compared to RODSTAR in
vertical mode. This makes it possible to optimize
rod string designs, find out the pumping speed
and plunger size you need for a target production,
XROD| 1
etc. in seconds instead of hours. XROD in the AI
mode makes it possible to get these answers even
with little rod pumping expertise.
The advantage of XRODs AI mode over ROD-
STAR in vertical mode is the built in expertise
which substantially minimizes the user input
required. After setting up the program one time
with some basic preferences for rods and pumping
unit types to consider, you can simply enter a depth
and production goal. XROD will utilize your
preferences and find the best system design for the
well including the pumpjack size, stroke length,
plunger diameter, rod string design, pumping
speed, motor size, etc., all done using a batch pro-
cess which also generates a summary spreadsheet
with all the best designs listed for each pumping
unit type.
1.1 Program Features
XROD remembers the information you type when
you start a case from scratch. You can exit XROD
while in the middle of entering data for a new case,
and XROD will save the data you have entered.
This works the same way if your system crashes.
The next time you start XROD, the program will
ask you if you want to resume entering data. If so,
you will be returned to the data entry window you
were using when you left XROD, with all the data
you had entered already in place. XROD contains
data for all common pumps, rod sizes, rod grades,
pumping units, tubing sizes, etc. Also, it knows
when you need slim hole couplings or a thin wall
pump, what rods fit in the tubing size you selected,
the maximum recommended pumping speed for
any system design, etc. When running XROD
in AI mode, the program will design all of these
parameters for you.
2 |Introduction
XROD can read well files created with ROD-
DIAG, XDIAG (Theta Oilfield Services,
Inc.s diagnostic computer programs) and CBAL-
ANCE or XBAL (Theta Oilfield Services,
Inc.s pumping unit balancing programs). XROD
can read all the data contained in a RODDIAG
or XDIAG file, including the measured dyna-
mometer card. This allows you to redesign pump-
ing systems without having to reenter system
data. XROD can display and print the measured
dynamometer card overlaid on the same plot as
the predicted surface dynamometer card (in the
non-AI mode). This feature has many uses that
include finding the correct rod-tubing friction, or
determining whether the load cell used to record
the dynamometer card may be out of calibration.
XROD will not read XROD files unless it is in the
AI Mode. The program switches from RODSTAR
(non-AI mode) to XROD using the AI button
on the toolbar and XROD files are not compatible
with RODSTAR. If you attempt to open ROD-
STAR files while in AI mode XROD will prompt
you to switch to non-AI mode in order to work
with these files, and vice versa.
By being able to read CBALANCE/XBAL files,
XROD can get the existing maximum counter-
balance moment based on the existing position of
the counterweights. This eliminates the need for a
field measurement of counterbalance effect. Also,
you can enter the calculated balanced maximum
counterbalance moment back into CBALANCE/
XBAL to find out how to balance the pumping
unit in one step.
XROD can simulate any pumping system and can
accurately predict its performance. For a system
you specify or ask the program to design for you
in the AI mode, the program predicts the sur-
face and downhole dynamometer cards. Also, it
calculates the peak gearbox torque and gearbox
loading, structure loading, rod loading, pump
stroke, minimum required pump length, plunger
length, pump spacing, expected production rate,
the counterbalance needed to balance the unit, the
prime mover size, overall system efficiency, daily
energy consumption, monthly electricity bill, and
other useful information. Also, XROD, in non-AI
mode, allows you to enter inflow performance data
so that you can easily design a pumping system for
any pump intake pump intake pressure, calculate
the expected production rate, pump intake pressure
and pump condition for any rod pumping system,
find out the maximum production rate you can get,
and more.
Also, in contrast to the conventional trial and
error system design, with XROD you can simply
enter the pump depth and a target production and
the program simultaneously recommends the best
system designs for each pumping unit type you
selected in Setup. It calculates strokes per minute,
plunger size, rod string design, motor size, etc. It
recommends the best pumping unit size you need
for each manufacturer based on the target produc-
tion you entered. Or, you can enter IPR data and
have XROD calculate the target production and
design the system for that target production.
XROD comes with a large pumping unit database
so that you can easily select and compare pumping
units without having to get the unit dimensions
yourself. XROD can model any pumping unit
geometry including long stroke units such as the
Rotaflex. Also, you can enter your own pumping
unit data in case your unit is not in the programs
database. Advanced error trapping and warning
messages help prevent errors and make you aware
of special requirements necessary for proper system
operation.
It is important to remember that XROD was cre-
ated with the idea of reducing the required input
to the bare minimum of pump depth and target
production when in the AI mode. The program
will design the whole system for you from this
information and for each pumping unit type you
selected in the AI Mode Preferences in Setup. In
order to input any other data you must click the
AI button to exit AI mode. When you do this,
XROD will behave like RODSTAR and it will
require the same input data as RODSTAR.
 XROD| 3

1.2 Advanced Capabilities and help for any input field by simply pressing the !
key. Also, you can search help for any other item.
Program Limitations
XROD has many advanced features that enable
you to accurately predict system performance for
any rod pumping system. It can simulate wells of
1.4 XROD CD and Software
any depth including very deep or shallow wells.
XROD, like RODSTAR can model fluid inertia
Sentinel
effects that are present in wells that pump incom- The XROD program installation CD contains
pressible fluids with larger than 2.00 plungers many compressed files that the installation pro-
from depths of less than 4000 feet. gram copies to the hard disk of your computer.
Some of these are useful to know about. These are
By calculating the minimum stress at the bottom located in the same folder where you elected to
of each rod section, XROD shows whether the install XROD. The default is C:\Program Files\
rods are in compression or not. This is vital for Theta\RODSTAR or C:\Program Files\Theta\
fiberglass rods which must never be in compression XROD.
to avoid premature failures. This is also important
for steel rods since excessive compression can cause
buckling failures. File Name: Explanation:
XROD can model the effect of prime mover speed XRODV.EXE The program file for
variation and pumping unit inertia and can ac- XROD. It is the file
curately calculate electricity consumption and the that your Desktop Icon
runs when you double-
monthly energy bill. Because XROD uses actual click it.
motor efficiency curves, the results are very ac-
RODSTAR.CDB Contains the costs for
curate. You can use this capability to compare the both rods and pumping
energy consumption of systems with different rod units. Once you create
designs, plunger sizes, or pumping unit types. this file by entering rod
and pumping unit cost
XRODs Inflow Performance Relationship (IPR) data, you can provide
capabilities allow you to select the IPR relationship copies to other users in
you want XROD to use (Vogel or Fetkovich), you your company.
can enter one to ten test points, and can integrate CUSTOM32.PUD This file contains the
IPR and rod pumping system models to predict measured pumping
the maximum production rate possible, the fluid unit information you
level and pump condition for a given pumping entered in Setup. Once
you create this file, you
speed, or the target production for any fluid level can distribute copies
or pump intake pressure you want. to other users in your
company.
Because of all these features, XROD has virtually
no limitations and is the most advanced and easiest
to use program of its kind.

1.3 Help System

XROD takes full advantage of Microsoft Win-
dows to bring you state-of-the-art context-sensitive
4 |Introduction

Files ending in .PUD The programs pumping

unit database. When
updates are announced
on our Website for new
pumping units that
have been added, you
can download a zipped
file that contains addi-
tional PUD files to add
to your folder.
Files beginning with Several files are in-
demo_ cluded that are example
cases to demonstrate
the program functions.
During installation,
there are copies of these
files placed in the folder
used when opening
case files.
Files ending in .RST Case files saved by
RODSTAR release
prior to 3.0.
Files ending in .RSVX Case files saved by
RODSTAR in vertical
mode.
Files ending in .XRVX Case files saved by
XROD in AI mode.
Files ending in .RDG Case files saved by
RODDIAG.
Files ending in .XDG Case files saved by
XDIAG.
Files ending in .CBL Case files saved by
CBALANCE
SENTINEL.INI For installations using
a Network license, this
file is located in the
program folder on the
client PC and has the
name or IP address of
the license server being
used.

The XROD program is protected and cannot run

without a software sentinel supplied by Theta
Oilfield Services, Inc.. See Chapter 2 for details on
how to install the software sentinel.

2 Software Installation
Before you install the program, make sure you
have the hardware and software you need to run
XROD
2.1 XROD Installation
XROD is installed from the Theta Software Suite
installation CD that you received or from the
installation file you download from our web site.
Load the CD onto your PC and the installation
program should load automatically. Or, if you
downloaded a stand-alone installation file, double
click on its name. After the Welcome screen you
will have three options for whether you are using
a Network or Standalone license and whether you
have a USB Sentinel or a Parallel Port Sentinel.
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 spe-
cific 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.
2.2 Questions About Installation
The following are some answers to questions you
may have about installing XROD.
Do I need to delete earlier versions of XROD
before I install?
No. When updating versions of XROD, the pro-
gram defaults to install to the C:\Program Files\
XROD| 5
Theta\XROD directory. If your previous copy of
XROD is in another directory, you can specify to
install over it. It will not replace any of your case
files, just the old 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 Enterprise applications that you might have
can all share the same case files.
Although a new version of XROD can read files
created with older versions, an older version of
XROD cannot read files created with a new ver-
sion of the software.
What happens to files I have created with older
versions of XROD?
Nothing. When you install or reinstall XROD,
only program files are replaced. The latest version
of XROD saves files in the XML file format but
can read files created with older versions of XROD
as well.
What happens to the Setup Settings from previ-
ous versions?
If the previous version is not very old (before the
new setup options were developed) then your set-
tings will be preserved.
2.3 Installing the Software
Sentinel
Your XROD 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
6 | Software Installation

Network License Server. See the Detailed Instal-

lation Guide that is available for printing from the
Software Installation Suite CD.
Theta Oilfield Services, Inc. uses SafeNet sentinels
for software protection. USB type sentinels can be
plugged into any available USB port or hub on the
PC. Only one sentinel is needed to support mul-
tiple products on a standalone PC or on a network
server.
XROD communicates with the sentinel and al-
though the program can be copied, it will not op-
erate 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 in 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 this occurs, contact Theta
Oilfield Services Inc. to determine if you need a
replacement. Do not discard the damaged sentinel.
Even if it is damaged, you must return it to Theta
Oilfield Services, Inc. before a replacement can be
sent out. When XROD first starts, it reads and
displays the serial number of your sentinel on the
opening screen.
 XROD| 7

3 Starting and Setting Up XROD

3.1 Starting XROD 4. Choose the OK button.

The XROD installation program will put an Icon After you do the above steps then to load and run
on your Desktop and an entry in your Start Pro- a RODSTAR file from the File Manager, simply
grams for access to XROD. To start the program, double click on it.
simply double-click on its icon. XROD has a getting-started window, shown in
You can also start XROD from the File Manager Figure 3.1, that appears whenever you start the
by double clicking on XRODV.EXE. Also, the program. The window shows the most common
Windows File Manager allows you to associate toolbar icons you need to know to begin using
files with applications. When you associate a file XROD.
with an application, you open the file and start the
application at the same time.
For example, to associate RODSTAR files (with 3.2 Exiting XROD
an .RSVX file name extension) with XRODV.
To exit XROD, double click on its Control-menu
EXE, do the following:
box (upper left hand corner) or select File and then
1. From the File manager, go to a directory that Exit. Another way to exit XROD is to press A+
contains XROD files and double-click on one
of these files. $. Before exiting XROD make sure you have
stored your data to disk (XROD asks you if you
2. If the file is not
already associated
with XROD windows
will let you know and
ask you to select the
program from a list.
Make sure this option
is selected and click
on the OK button.
3. Click on Browse, go
to the directory where
XRODV.EXE resides
(typically, it will be
in C:\Program Files\
Theta Enterprises\
XROD, and double
click on it.
Figure 3.1 - The Getting Started Window
8 | Starting and Setting Up XROD
Figure 3.2 - XRODs main window
want to save the data when you exit, if you have
changed your data since the last time you saved it).
Otherwise it will be lost.
The XROD Window
Figure 3.2 shows the XROD window that appears
when you start the program. XROD behaves like
any other standard Windows program. You can use
the mouse to move and size windows, move and
restore icons, select text, choose commands from
menus, and dialog boxes, and complete almost any
other task in XROD aside from typing text.
Following is an explanation of the parts of the
XROD window as shown in Figure 3.2.
The control-menu box is in the upper-left corner
of each window. The control menu is most useful
if you use the keyboard. You can use the control
menu commands to resize, move, maximize, mini-
mize, and close windows. Also, you can use it to
switch to other applications. (If you use a mouse,
you can perform these tasks by clicking and drag-
ging.) Double-clicking on the control menu box
closes XROD.
The title bar shows the name of the application and
the name of the file currently in memory. If more
than one window is open, the title bar for each
active window (the one that you are working with)
is a different color or intensity than 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 XROD. For example, click on the
Help menu to see a list of helpful choices.
The Minimize button reduces XROD to an icon.
After you minimize XROD, you can reopen it by
 XROD| 9

double clicking on the XROD icon at the bottom

of your screen.
The Maximize button causes the XROD window
to fill the entire screen. After you maximize the
XROD window, the maximize button shows a
double box and is called the restore button. Click-
ing on the restore button re-sizes the XROD win-
dow to the size it was before you maximized it.
Figure 3.3 - Tool Tip Example
Using the mouse you can resize XRODs main
windows. When you resize XRODs window to a
New file - This is the first button on the toolbar
size smaller than required to display all informa-
and shows a picture of a blank page. Click on this
tion, it will display vertical or horizontal scroll bars
button to start entering data for a new case.
as necessary. You can use these scroll bars with the
mouse to view unseen portions of entry windows Open file - This is the second button on the toolbar
that do not fit in the allotted space. and shows the standard open file icon used by most
Windows programs. Click on this button to read a
The Close button causes XROD to exit. Its easier
RODSTAR, XROD, RODDIAG, or XDIAG file
to click the Close button once than to select Exit
that was previously stored on disk.
from the File menu.
Save file - This is the third item on the toolbar and
The Status bar shows useful messages during data
shows a picture of a diskette. Click here to save
entry, when you load a case from disk or when you
the data in memory to disk. If this is the first time
point to a toolbar icon. The status bar is located at
you are saving this case, XROD asks for a new
the bottom of the main window.
file name. After you save a file, or after you load
The toolbar gives you quick access to menu com- a file from disk and make changes to it, click on
mands using your mouse. When you first load this button to quick-save the data under the same
XROD, only some of the buttons on the toolbar file name. To save it under a different file name
are active. When you enter data or read a file from click on File on the menu bar and then select Save
disk, then the print button and all the buttons that As....
correspond to input windows become active. If you
Setup - This is the fourth item on the toolbar.
load a file that contains output then the report icon
Click here to see XRODs Setup window. This
also activates. Otherwise, if the file contains only
allows you to specify inputs and preferences that
input then the report icon remains inactive until
normally do not change often such as: your com-
you run the case. For a quick reminder of what
pany name, electricity cost, units of measure,
each toolbar button does, simply place the mouse
standard sucker rod length, custom sucker grades,
pointer on it. A small message box called a tool
measured pumping unit data, pumping unit and
tip appears that tells you what the toolbar icon
sucker rod cost, batch run options, printed report
does (see Figure 3.3). Also, the status bar shows
options, and custom summary spreadsheet formats.
more information about the same tool bar item.
Well information - This is the fifth item on the
Following is a more detailed explanation of each
toolbar and shows a picture of a file cabinet. Click
button on the toolbar from left to right:
here to open the well information window. When

Figure 3.4 - XRODs toolbar when in non-AI mode

10 | Starting and Setting Up XROD
you first load XROD this icon (and the next five
icons) is inactive until you enter well information
data or until you load a file from disk. The file
information window contains data such as pump
depth, run time, pump condition, tubing and cas-
ing pressures, fluid gravity, etc.
Production information - This is the sixth item on
the toolbar and shows a picture of a barrel. Click
here to open the production information window
that has data for items such as fluid level, pump
intake pressure, target production, IPR data, etc.
Pump and tubing information - This is the seventh
item on the toolbar and shows a picture of a down-
hole pump . Click here to see data for tubing size,
pump type and size, tubing anchor depth, rod-tub-
ing friction, and fluid inertia effects.
Rod string information - This is item eight on the
toolbar and shows a picture of a sucker rod. Click
here to open the rod string information window.
This is where you specify what kind of rod string
you want XROD to design for you. Also, you can
enter your own rod string design, specify the ser-
vice factor you want to use, etc.
Pumping unit information - Click here to open
the pumping unit information window that has
data for pumping unit type, crank rotation, stroke
length, structural unbalance and counterbalance
data.
Motor information - This icon shows a picture of
a motor. Click here to open the motor information
window that has data for electricity cost, power
meter type, motor type and size, moments of iner-
tia and whether to include motor speed variation.
Previous window - This icon shows an arrow
pointing to the left. Click it to go back to the pre-
vious input window.
Next window - This shows an arrow pointing to
the right. Click here to advance to the next win-
dow when entering data for the first time or when
you are changing data.
AI Mode - Click on this icon to change between
AI and non-AI (RODSTAR) modes.
Run - This item follows the arrow icon on the
toolbar and shows a picture of surface and down-
hole dynamometer plots. Click here to run XROD
after entering all your data or after you change an
input.
Report - This item follows the run icon on the
toolbar and shows a picture of a printed page.
Click here to view the output in memory. This
allows you to view the output saved in a file you
just loaded from disk, or to return to the output
screen. If this button is inactive (dimmed) it means
that there is no output report in memory. To make
it active, run the case, or load a case with saved
output.
E-mail Icon - Click on this icon to e-mail one or
more cases to Theta Oilfield Services, in case you
have questions.
Print - This button follows the Report button on
the toolbar and shows a picture of a printer. Click
it to send the output to the printer.
If you have entered data for a case, but havent run
the calculations yet, you can get a printout of your
input data by itself. You get the same one-page
output, except that only the input data appears on
the page.
The Print command on the File menu allows
you to select exactly which parts of the output you
want printed. For more information, see section
3.3.4, Output Options under Setup.
Export CBM - This item is second from last on the
toolbar and shows a picture of a crank and coun-
terweight. This button becomes active after XROD
runs or after you load a file with saved output.
Click it to place the maximum counterbalance mo-
ment for balanced conditions on the clipboard for
use in CBALANCE or XBAL.
Automatic Batch - This enables the batch mode set-
ting. If not set up it will redirect you to the setup
option for this feature.
Help - This is the last item on the toolbar and
shows a picture of a question mark. Click this but-
ton at any time to get help.
 XROD| 11

Visual Input - This al-

lows you to select what
system variable you
want to change using a
visual depiction of a rod
pumping system. Right
click to select a specific
item to change and then

left-click on the specific

item.
Alphabetical List - This
shows an alphabeti-
cal list of all the input
parameters. Selecting
any of these parameters
and clicking ok will
bring up the window in
which you can modify
this input. Figure 3.5 - XRODs Setup window

The measured pumping unit data you enter is saved

3.3 Setting up in the CUSTOM32.PUD file in the program
directory; the cost data you enter for rods and
XROD pumping units is saved the RODSTAR.CDB file
Click on the Setup button on the toolbar to open in the program directory. XROD stores all other
XRODs Setup window. Another way to access information you enter in Setup in the registry.
Setup is to open the
Tools menu and then
select XROD Setup.
This window which is
shown in Figure 3.5
allows you to enter
items that do not
normally change from
run to run. Also, Setup
allows you to customize
XROD by entering your
company name, default
electricity cost, custom
rod grades, measured
pumping units, rod
and pumping unit cost
data, and a lot more. Figure 3.6 - Help for XRODs setup
12 | Starting and Setting Up XROD

It is recommended to save
a file with your personal
settings because you have
the option to convert your
settings to the settings
saved on a file. If you wish
to duplicate a run, one of
your colleagues created,
you can use the settings
from the file. To restore
your settings you can load
your saved file and follow
the prompts to load the
settings from your saved
file.
You can access the help
menu for helpful tips when
setting up XROD. This
menu contains three tabs
to navigate the help topics
and a fourth tab for help Figure 3.7 - Setting up default quantities for XROD
with terms (Glossary).
For context sensitive
help simply press the F1
key while in the field in
question. The help menu
will automatically open up
to the help topic pertaining
to that field. You can
manually search the topic
using the Contents tab or
use the search tab to input
a specific term and search
for help topics related
to that term. Figure 3.6
shows the help feature for
the XROD Setup window.

3.3.1 General setup options

Measurement Units
For measurement units you
can select English, Cana-
dian, or Metric/SI. Eng- Figure 3.8 - Selecting output options
 XROD| 13

lish units are mainly used in the USA and South Pump efficiency
America. If you select this option XROD will ask Pump fillage
for pump depth in feet, production rate in BFPD,
plunger and rod diameters in inches, etc. The Pump load adjustment
Canadian option provides you with the common Run time
mix of English and Metric units used in Canada.
The Metric/SI option will cause XROD to use Standard steel sucker rod length
Metric/SI units for most inputs. Regardless of the Steel rod service factor
units you select, you can press @ while entering Stuffing box friction
numeric data to convert from one system of units
Tubing pressure
to the other. When you press @ to convert units,
the background of the input field box changes User name
color from light blue to light green. Water cut
Water specific gravity

3.3.2 Defaults and Limits The program uses the standard steel sucker rod
length (typically 25 or 30 ft.) to calculate steel rod
The Defaults input window in Setup for XROD string section lengths that are evenly divisible by
is shown in Figure 3.7. Here, XROD allows you it. This works whenever XROD designs the rods
customize the default information used by the
program when you
begin entering data for
a new case. You can also
change the rod stress
loading limits used by
XROD in a steel or
fiberglass rod design,
so that XROD will use
larger rods rather than
exceed the loading lim-
its you specify.
Any of the following
items can be custom-
ized:
Casing pressure
Company name
Electricity cost
IPR correlation
Motor type
Oil gravity
Plunger size
Pump condition Figure 3.9 - Cover Page Editor Window
14 | Starting and Setting Up XROD
string (when XROD calculates a steel rod string
taper design, whether for a steel rod string, or a
tapered steel rod section beneath a fiberglass.) For
Corod rod strings, XROD ignores this number.
For fiberglass rods, the program uses the standard
length of 37.5 feet.
3.3.3 Output Options
XROD gives you full control over what is shown
on the printed output. Using the Output Options
tab in Setup, shown in Figure 3.8, you can select
the items you want included on the output. The
options you select here are the items printed by de-
fault when you select Print from the File menu,
or use the Print toolbar button. You can choose
from among the following:
Cover Page
This option prints a page showing all the company
data of the user and recipient of the results output.
To insert this information, select the defaults tab
Figure 3.10 - Cover Page
in the setup window. Second Company fields hold
this information. This page may also be edited
using the comments button on the well informa-
tion window. When clicking this button you will
find the input window for the cover page, refer to
Figure 3.9. This page is regenerated when viewing
the report so that you can run a case and edit the
cover page to comment on the results of the run.
The cover page window contains input fields for
your company information labeled My Company.
The recipient of the document is labeled Customer
Company. Special buttons have been created to
automatically insert comments from other parts of
the program which include Add Well Informa-
tion Comment, Add Rod String Information,
and Add Setup/Defaults Cover Page Comment.
An example of a completed cover page is shown in
Figure 3.10.
Input data and calculated results.
This option prints one page showing all the input
data and the results of the calculations, as well
as miniature predicted dynamometer and torque

plots.
Cost analysis.
This option prints both the rod string and the
pumping unit costs. You must already have entered
the costs into XRODs cost database (see section
3.3.6, Cost Database, on page 23 for more infor-
mation).
Inflow performance (IPR) chart.
Selecting this option gives you an additional page
with the IPR plots, the IPR data including the test
points, and a table of pressure versus production.
Dynamometer cards and Torque Plots
Selecting this option prints a separate single page
containing the predicted surface and downhole
dynamometer cards with the predicted permissible
load diagram. It also prints the net gearbox torque
plots for existing and balanced conditions on the
bottom half of the page. The dynamometer card
plot may also show the actual (measured) surface
dynamometer card (if you loaded a RODDIAG or
XDIAG case into XROD).
Overlay actual (measured) dynamometer unit sizes, you can setup XROD to show only
card.
If you load a RODDIAG or XDIAG case into
XROD in the non-AI mode, the program can plot
the surface dynamom-
eter card that was stored
in the RODDIAG or
XDIAG file on the same
plot as the predicted
dynamometer card.
3.3.4 Pumping Unit
Options
Under this item, there
are two sub-items,
Customize Pumping
Unit List, and Measured
Pumping Unit List. Let Figure 3.11 - Customizing the pumping unit database
XROD| 15
us take a look at each of these items:
Customize Pumping Unit List
This option allows you to customize the list of
units displayed by the program at the pumping
unit selection window (non-AI mode) when you
select the option Use custom pumping unit list.
Here you can select the pumping unit manufac-
turer and the pumping unit sizes you have for each
manufacturer in the field. After you customize the
pumping unit list, you can select pumping units
faster since the program will only show the units
you have in the field instead of displaying all the
pumping units in the pumping unit database. As
mentioned above, you need to select the option
Use custom pumping unit list in the pumping
unit input window to see the custom list.
Also, when running XROD in AI mode, you can
select the option to use the customized pumping
unit list only by selecting this option in the AI
Mode Preferences window in Setup. This saves you
time by minimizing the time and effort required
to select a pumping unit. For example, if you only
have 12 different sizes of Lufkin Conventional, 10
sizes of Mark II, and 14 American Conventional
these units in the pumping unit selection screen.
To customize XRODs pumping unit list, do the
following:
16 | Starting and Setting Up XROD

1. Click on the +
symbol on the left
of Pumping Unit
Options. Then,
click on Custom
pumping unit list.
This opens the
window shown in
Figure 3.11.
2. Drop down the
manufacturer list
by clicking on the
down arrow next to
Manufacturer:
3. Select a manufac- Figure 3.12 - Selecting a manufacturer
turer you want to
add to your custom drag it from the list on the left, and drop it
pumping unit list as shown in Figure 3.12. If in the list to the right. Or, you can click on a
this is a new manufacturer for the custom list, unit once and then click the Remove>> but-
all available pumping units will appear in the ton (in the middle of the screen). To make sure
window on the right side of the screen. you select the correct pumping unit, highlight
it (click on it once with the mouse) and the
4. You can select the units to include in the Name: and Other: fields on the bottom of the
custom pumping unit list using drag and drop. screen will show additional information about
To add a unit from the list of available units the pumping unit as shown in Figure 3.13.
to the custom database list, you simply drag This is especially useful for manufacturers (for
(click on it with the mouse and hold the left example, American conventional) who have
mouse button while moving it) the units you more than one unit with the same designation
want from the list on the right to the custom but different crank types. In such a case, the
list on the left. Or,
you can click on a
unit once to select
it, and then click on
the <<Add button
(in the middle of
the screen). The
program automati-
cally arranges the
units in the proper
order (largest stroke
length and largest
gearbox size first).
5. To remove a unit
from the custom-
ized list, simply Figure 3.13 - Customizing the pumping unit database
 XROD| 17

Other: field shows

the crank type of
the unit or other
information that
helps identify the
pumping unit type.
This is not the only
way to custom-
ize the pumping
unit database. As
discussed in the
section dealing with
the pumping unit
information screen,
you can also select
a unit you want to
add to the custom-
ized unit list by first
selecting it from
the full database
and then selecting
to use the custom
Figure 3.14 - Entering custom pumping unit information
pumping unit
list. At that point 1. Click on Measured Pumping Unit List.
XROD will ask you if you want to add this
unit to the custom pumping unit database. If 2. Click on the + symbol (on the left of the pen-
you do, then select Yes. cil symbol). This will open the window shown
in Figure 3.14.
6. After you are done customizing the pumping
unit list, click on 3. Enter the data in this window starting with the
OK.
Measured
Pumping Unit List
Here you can enter data
for pumping units that
are not in XRODs main
database. If you have the
dimensions you need
for these units you can
enter them here to make
them a permanent part
of your XROD software.
To enter dimensions for
a pumping unit, do the
following: Figure 3.15 - Custom pumping unit help
18 | Starting and Setting Up XROD

pumping unit manufacturer name. rod as shown in Figure 3.16.

4. Enter the pumping unit data for your pumping
unit.
5. When you are done entering data click on
OK.
If you need help with one of the items you have to
enter, press ! to get context sensitive help on that
item. For example, if you press ! when you are
in one of the pumping unit dimension input fields,
the program will show you an outline drawing of
the pumping unit with a visual explanation of the
pumping unit dimensions (see Figure 3.15). To get
more information on any of the dimensions you
see, simply click on it with the mouse. For ex-
ample, you can click on the P box to see detailed
help on the P dimension. Also, you can click on
the See Also hot button to get help for any other
pumping unit related item.
3. You can also specify that this is a sinker bar by
clicking on the Sinker bar option at the lower
left hand corner of this window.
4. Enter the rest of the information for the rod
you want to add and then click on the OK
button.
XROD allows you to select any of the available
stress analysis methods. Once you enter a special
rod grade to the program, it becomes part of the
programs equipment database and it works exactly
the same way as XRODs built-in rod grades.
For example, once you enter a special rod grade,
you can enter cost information for it, and you
can select it from the same rod grade menu that
XROD uses for the built-in rod grades.
The modify (Pencil Icon) and delete (X Icon)
options allow you to change or erase custom rod
grades you have already entered.

3.3.5 Rod Grade Options

Entering Custom Rod
Grades
To enter a rod grade that
is not in the programs
database, do the follow-
ing:
1. From the setup win-
dow, click on Cus-
tom Rod Grades.
2. To add a new rod
grade, click on the +
button (to the left of
the pencil icon). This
opens up a new win-
dow where you can
enter the name of the
rod you want to add,
the tensile strength,
and the stress analy-
sis method you want Figure 3.16 - Entering custom rod grade information
XROD to use for this
 XROD| 19

3.3.6 Cost Database

When you click on this
item in Setup, XROD
displays a window,
shown in Figure 3.17,
that allows you to enter
or change pumping unit
or rod string costs. To
enter or change pump-
ing unit costs select
Pumping unit costs
This makes the window
change by showing a
drop-down list box that
you can use to select the
pumping unit manu-
facturer. As shown in
Figure 3.18, after you
select the manufacturer,
XROD displays a mini-
spreadsheet that you can Figure 3.17 - Cost Database Setup Window
use to enter pumping
unit costs. To enter the you see. Simply enter the cost only for the rod
cost for a pumping unit,
click on the cell to the
right of the pumping
unit and enter the cost.
When you are done
entering pumping unit
costs for the pumping
units you want, click on
OK.
Or, if you want to en-
ter rod string cost data,
Select Rod string costs
and then select the rod
type and rod grade.
XROD will display a
mini-spreadsheet for you
to enter the cost per foot
(or per meter) for each
rod diameter as shown in
Figure 3.19. You do not
have to enter cost data Figure 3.18 - Pumping unit cost database
for all the rod diameters
20 | Starting and Setting Up XROD

grades and diameters you

use.

3.3.7 Batch Mode Options

XROD runs a batch pro-
cess automatically when in
AI mode. This will be ex-
plained in more detail in
the AI Mode Preferences
section of this manual.
The following explains
the use of the batch utility
when operating XROD in
non-AI mode.
When you click on this
tab, XROD displays a
setup page that allows
you to choose different
options relating to the Figure 3.19 - Entering rod string cost in Setup
batch run capabilities of
XROD. The top portion If you check the Create summary spreadsheet
of this input window al-
lows you to select whether
you want XROD to print
the results of each case it
runs in batch, whether to
create a summary spread-
sheet file, or whether to
rerun cases that contain
saved output. Also, it lets
you choose what action to
take when you load a file
that contains custom rod
grades as shown in Figure
3.20. For example, if you
want to update the setup
information with the data
in the file, then select the
option Update Setup
with files information.
If you check the Make
Printouts check box,
XROD will print out ev- Figure 3.20 - Batch mode options
ery case you run in batch.
 XROD| 21

check box, XROD will

summarize the results
of all the files you run
in batch in a Excel
spreadsheet file. If you
select the option View
spreadsheet file, after
you run several cases
with the batch pro-
cess, the program will
automatically create an
Excel spreadsheet and
will load it into Excel
automatically.
Figure 3.21 - Spreadsheet setup
If you check the Dont
re-run cases with saved summarizes the values he is interested in. Later
output check box, XROD will not rerun cases Paul can run the same cases in batch mode and
that have saved output. When you run XROD in create a spreadsheet with the items he is interested
batch mode, XROD saves the output in the same in which are different that Johns. Since John ran
file as the input data. Also, when you run one case all 20 cases, the files now contain both input and
at a time, you can save the output by saving the calculated results. When Paul runs the same cases
file to disk when you are looking at the output. in batch, he checks the Dont re-run cases with
The option to avoid
rerunning cases that
contain output is use-
ful when you want to
create more than one
spreadsheet file using
different spreadsheet
formats. Once the files
have been run with
batch, each file will
contain all the output
calculations.
For example, let us
assume that there are
two different users
(John and Paul) who
are running XROD
and they each have
their favorite spread-
sheet formats. John
can run 20 cases in
batch mode and cre- Figure 3.22 - AI Mode Preferences
ate a spreadsheet that
22 | Starting and Setting Up XROD

saved output option to save time. Since the out-
put results are already saved in the XROD files,
Pauls batch run will proceed very quickly since all
XROD has to do is extract the calculated values
that Paul specified in his spreadsheet format from
these 20 cases.
Creating and/or Changing spreadsheet formats
As shown in Figure 3.20, you can click on the
+ icon at the Spreadsheet Setup section of the
batch window to add a new batch spreadsheet for-
mat (design of the spreadsheet). Also, this section
lists the spreadsheet formats you have saved. To
use one of these spreadsheet formats for your next
batch run, highlight it by clicking on it and then
click the OK button to exit Setup.
If you have not created any spreadsheet formats,
the only format that appears is the (Default)
format that XROD will use when you run it in
the batch mode and choose to create a summary
spreadsheet file. To create a new spreadsheet for-
mat click on the + button. This opens the spread-
sheet setup window that you see in Figure 3.21.
the <<Add Before or <<Add After buttons in the
middle of the screen. However, using the mouse is
much easier. After you are done designing the for-
mat of the spreadsheet, you can save it by entering
a name for it in the Format name: field at the bot-
tom of the screen. Then click OK to return to the
previous screen. From here, you can create another
spreadsheet format, or modify or delete one of the
existing formats.
To modify an existing format, click on its name
and then click on the edit icon (pencil). Or, to de-
lete an existing format, highlight it, and then click
on the delete icon (X).
The format you select in this part of the program
by clicking on the format name will also be used
by XROD when it runs in the AI mode.
3.3.8 AI Mode Preferences
XROD uses these preferences when finding the
best designs for each pumping unit type. Figure
3.22 shows the AI Mode Preferences window.

The list on the left side shows the columns that
are in the spreadsheet now and their order. The
list on the right shows additional variables you can
add to the spreadsheet. You can use drag and drop
to move an item from one list to the other. For
example, to add rod string cost as the last column
in the spreadsheet, locate it on the table on the
right (variables are listed in alphabetical order) and
drag it (click and hold while moving with the left
mouse button) to the other side. When you drag
a value into the table on the left, the cursor shows
an arrow that shows where this new value will be
added. After you drop the new item in the spread-
sheet table, it remains highlighted. Then, to move
it up or down in the list click on the Move Up or
Move Down buttons below the list of spreadsheet
variables. Or, you can click on the Remove>> but-
ton to send the highlighted variable back to the
Available values list on the right.
Another way to add items to your spreadsheet is by
highlighting a value on the list on the right, high-
lighting a value on the list on the left, and clicking
In the Rod Preferences section, you have the
option of running with either steel rods only or
fiberglass with steel on the bottom of the string.
There is a drop down to select your preferred high
strength rod type, fiberglass rod, and sinker bars.
The high strength rods you select will be recom-
mended only if API grades C or D are overloaded.
XROD can design the sinker bar section for you,
and has an option to convert to no-neck bars if
needed (if regular sinker bars with elevator necks
are overloaded). There is also an input field for the
service factor to use in the calculations.
Another option is to select to use your customized
pumping unit list (if you created one) to find if any
of the pumping units you have available can be
used to get the target production you want.
When you select to use the customized pumping
unit list, the program will automatically check
the different pumping unit manufacturers it finds
in your customized list and will automatically
list them and select then in the AI Mode Prefer-
ences window. Also, you can choose to use the
 XROD| 23

general pumping unit list if needed (for example,

if you customized list of units does not contain the
pumping unit size needed for your target produc-
tion).
Rod tubing friction has a special section in
XROD. You can select to use average friction coef-
ficients for upstroke and downstroke, or a multiple
of the average for high friction applications such as
wells with paraffin, scale, or deviation.
You can also select the power meter type you have
and whether to use motor speed variation in the
calculations.
Please note that XROD automatically recommends
a NEMA D motor size only. If you want to use an
Ultra high slip motor, from the batch run log of
XROD, double-click on the design you want, then
switch to non-AI mode and then you can change
the motor to a different type and run the case
again.
 XROD| 25

4 Running XROD

To start XROD, double click on its icon. After XRODs interface has most of the elements that
a few seconds you will see XRODs introductory are common to all Windows programs. For exam-
window and then the XROD main window. When ple, all Windows programs have a menu bar with
XROD first loads, only the new file, open file, drop-down menus and a control menu box at the
setup, and help buttons are active on the toolbar. If top left corner. You can access all menu items using
you have not set up XROD then do so before en- either the mouse or the keyboard. Using the mouse
tering a new case (see Chapter 1 for information on is by far the easiest way.
setting up RODSTAR). It is especially important
When selecting an item from a menu, visual clues
to go to the AI Mode Preferences after you click
tell you what will happen next.
on the Setup icon on the toolbar to select the rod
type, your preferred high strength rods and pump- An item followed by no markings starts an
ing unit manufacturers to consider, etc, since these action. (For example, click on File and then click
are the options the program will use when running on New.
in the AI mode. An item followed by an ellipsis (...) needs
more information before taking action; normally,
the additional information is entered into a dia-
4.1 XRODs User Interface log box. (For example, click on File and click on
Open)
XROD has a user-friendly interface that simplifies
and speeds up data entry. The program uses stan-
dard Windows features along with
other unique features we designed
to make entering and changing
data as easy as possible. Figure
4.1 shows how to access the most
recently saved files and select the
file you want to load into XROD. If
you are not familiar with Microsoft
Windows, please take some time
to study your Windows manual.
Teaching you how to use Windows
is beyond the scope of this manual
(although many Windows proce-
dures are explained). By taking the
time to understand and learn how
to use Windows, you will be able to
Figure 4.1 - The most recently saved file list
effectively use not only XROD, but
any other Windows program.
26 | Running XROD
An easy way to load files you recently saved:
XROD has a most-recently-used file list on the
File menu, as shown in Figure 4.1. Selecting the
Recent Files sub-menu will show you up to nine
of the most recently accessed files. A file is placed
at the top of the list whenever it is loaded, or saved
with a new name. This list can also be accessed by
clicking on the drop-down button on the toolbar
to the right of the open file icon.
You can only open XROD files in the AI Mode.
When in AI Mode you can also open all ROD-
STAR file types and also RODDIAG and
XDIAG files. However, when loading XDIAG or
RODDIAG file, please remember to enter a target
Figure 4.2 - RODSTARs Artificial
Lift Glossary
production before running the program. Also,
when you load a RODDIAG or XDIAG file in
the AI Mode, the program will ignore the existing
system data other than data from the first input
window and target production and will recom-
mend new system designs for each pumping unit
type you selected in the AI Mode Preferences in
Setup.
4.1.1 XRODs Help System
XROD has a powerful help system that provides
context sensitive help for every input item. It al-
lows you to locate help on any subject relating to
system design and simulation. It even includes a
complete artificial lift glossary that provides in-
stant access to definitions for hundreds of artificial
lift terms. Also, the help system helps you learn
how to use it by including extensive help on itself.
Click on the Help drop-down menu to see the
Help menu choices which are:
Contents..
Index..
Search..
About XROD..
To see XRODs version number, and your senti-
nels serial number, click on About XROD.
Click on Contents to see a list of items XROD
can provide help for. As you can see, XROD shows
text and pictures in its help screen. For example,
XROD displays a picture of the toolbar and in-
structs you to click on the button you want help
for. Using the mouse, you can resize or move the
Help window.
Next, click on Help and then click on Glossary to
see an alphabetical listing of artificial lift terms. To
see the definition of any of the terms in the glos-
sary, click on it. For example, click on API grav-
ity to see a definition. Also, you can click in the
list of items in the Glossary and then type a letter
to go to the terms that start with that letter. For,
example, to find the definition for Permissible load

Figure 4.3 - XRODs Well Information window
diagram, press P and then click on Permissible
load diagram.
XROD has context sensitive help for each input
item. To access the help, simply press ! while in
the input field in question.
4.2 Entering Rod Pumping System
Data into XROD, AI mode
XROD has greatly simplified the rod pumping
system design process. With its built in expertise,
minimal input data is needed.
First be sure to select all the appropriate setup op-
tions in the setup window. Refer to Chapter 3 to
setup XROD.
When entering data in XRODs input windows, it
helps to know the following:
To replace the contents of an input box,
Figure 4.4 - XRODs Production Information window
XROD| 27
double click it before typing in it.
If an input window contains a name that is
made up of more than one word, double click any
word to select it. Then, to replace it, simply type a
new word.
To enter rod system data in XROD for the first
time, click on the first icon on the toolbar or open
the File menu and select New. This opens the
Well Information input window, shown in Figure
4.3. You can move this window with the mouse by
dragging it to the desired location. Also, you can
use the mouse to resize this input window.
XRODs input windows use the following unique
color scheme:
Required data input fields appear with a
yellow background. You must enter data in these
fields before closing the window, continuing to the
next window, or running the calculations.
28 | Running XROD
The active input field or list box appears in
cyan.
This color scheme helps you to easily see what data
you need and where you are in the input window.
There are two ways of moving around in an input
window. You can click the input field you want,
or you can enter data in order by pressing T to
move forward from field to field. Also, you can
press S+ T to move backwards. After enter-
ing data in fields with yellow background color,
their color changes to white when you move to the
next field.
You can get context sensitive help for any input
field by pressing !. Please use the context sensi-
tive help as often as possible because it contains
important information that will allow you to make
Figure 4.5 - XRODs AI Mode Batch Log
better use of XROD. Also, the context sensitive
help makes you aware of program assumptions or
limitations.
With all of your information in setup the only
required fields for input are the following:
Well Name
Pump Depth
Target Production
After the well name and pump depth are entered,
click the next arrow and enter the target produc-
tion in the Production Information window as
shown in Figure 4.4. Click the next arrow again
and you will be prompted to save the file. After
saving the file, click the run button on the toolbar
and the batch log window will open and display
the progress of the batch run.
The batch log page will display all of the system

designs for each pumping unit manufacturer along
with the AI score for each as shown in Figure 4.5.
If a system could not achieve the target produc-
tion, a message will be printed on the batch log
about this problem.
After all the runs are completed you may double-
click on any individual file names highlighted in
blue to find the full report on this system design
recommended by XROD. To return to the batch
log, click on the close button on the bottom right
corner of the Output Results window. From here
you can open another design shown on the batch
run log.
If you wish to change the input information in
any of the individual system designs, double-
click on the case file name to see the detailed
report for this case. Then click the AI button to
switch out of the AI Mode button on the toolbar.
You now can change any of the parameters of the
system and run an individual case by clicking the
run button.
Please note that when you switch out of the AI
batch mode, you cannot go back to the AI batch
log unless you rerun the case after switching back
to the AI mode.
4.3 Entering Rod Pumping System
Data into XROD, non-AI mode
The following procedure is done using XROD in
non-AI Mode. This will
behave like RODSTAR
but with the added scor-
ing feature that comes
with XROD. More about
this feature can be found
in section 5.3 of this
manual.
When entering data in
XRODs input windows,
it helps to know the fol-
lowing: Figure 4.6 - The Well Information input window
XROD| 29
To replace the contents of an input box,
double click it before typing in it.
If an input window contains a name that is
made up of more than one word, double click any
word to select it. Then, to replace it, simply type a
new word.
To enter rod system data in XROD for the first
time, click on the first icon on the toolbar or open
the File menu and select New. This opens the
Well Information input window, shown in Figure
4.6. You can move this window with the mouse by
dragging it to the desired location. Also, you can
use the mouse to resize this input window.
XRODs input windows use the following unique
color scheme:
Required data input fields appear with a
yellow background. You must enter data in these
fields before closing the window, continuing to the
next window, or running the calculations.
The active input field or list box appears in
cyan.
This color scheme helps you to easily see what data
you need and where you are in the input window.
There are two ways of moving around in an input
window. You can click the input field you want,
or you can enter data in order by pressing T to
move forward from field to field. Also, you can
press S+ T to move backwards. After enter-
ing data in fields with yellow background color,
their color changes to white when you move to the
30 | Running XROD

next field.
You can get context sensi-
tive help for any input field
by pressing !. Please use
the context sensitive help as
often as possible because it
contains important informa-
tion that will allow you to
make better use of XROD.
Also, the context sensitive
help makes you aware of
program assumptions or
limitations.

4.3.1 Entering Well

Information Data
Figure 4.7 - The Production Information input window
If you entered a company
name in Setup, it appears in
the Company name field. This saves you from hav- the option of having XROD calculate the required
ing to enter the same company name every time
you enter data. The date defaults to the date in
your computers memory. If the date in your com-
puter is not correct, you can type over it. The well
name is required because XROD uses it to create
the default file name when you save data to disk.
The pump condition panel allows you to select
pump condition and pump efficiency or pump
fillage. To select one of these input fields click on
the input field or its label. Press ! while in one of
these fields for some useful information.
The option to have the pump condition and fil-
lage calculated works along with the Production
Information window. When you select this option
you must enter a pumping speed and IPR data in
the second input window. Based on the SPM you
enter, XROD calculates the pump displacement
versus maximum available production from the
IPR data as well as the final pump intake pressure.
XROD uses an iteration scheme to converge to
the correct pump condition and pump fillage that
will result from the SPM you enter, along with the
calculated pump intake pressure.
The Production Information window also gives you
pumping speed based on a target production you
enter. However, the option of calculating the
SPM from your target production is only avail-
able if you select a full pump. For fluid pound or
gas interference, you must enter a pumping speed
in the Production Information window.
Other input data in the Well Information window:
Comment
You can enter a comment about the case. When
clicking this button you will find the input window
for the cover page. This page is regenerated when
viewing the report so that you can run a case and
edit the cover page to comment on the results of
the run. For more information see chapter 3.
Pump Load Adjustment
The pump load adjustment allows you to increase
the fluid load picked up by the plunger. Usually
this is unnecessary. However, this input allows you
to account for extra downhole loads due to exces-
sive downhole friction (for example due to wellbore
 XROD| 31

deviation), or due to the plunger effect of large
sinker bars. It is recommended that you use zero
for this number unless you have more than 1000
feet of large sinker bars such as 15/8 or 1 bars 100% oil.
in 2 tubing. The value of this number in pounds
is typically 5% to 10% of the pump depth in feet.
For example, for a pump depth of 6000 feet, enter
a value of 300 to 600 pounds (but only if you use
more than 1000 of large sinker bars). XROD will
not allow you to enter a value that is larger than
15% of pump depth. Also, you can use this input
to add pump load for more conservative predic-
tions.
Please note that XROD assumes that the
tubing-casing annulus is full of oil. It cal-
culates 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 want XROD to simulate. For
example, if you want to simulate water in
the casing-tubing annulus instead of oil,
then enter an API gravity of 10 (which cor-
responds to a fluid
specific gravity of
1.0).
Also, as discussed above, XROD uses this num-
ber to calculate the specific gravity of the fluid in
the casing-tubing annulus which it assumes to be
Fluid specific gravity
XROD uses the oil API gravity and percent water
cut you entered to calculate the default specific
gravity of the produced fluid. The program will
display this value when it prompts you to enter the
fluid specific gravity. XROD calculates the default
specific gravity without considering free gas. This
is okay for designing new wells since we prefer to
be more conservative. However, if you want to
simulate an existing system that produces gas, you
must enter a lower number than the one calcu-
lated by XROD. With some experience and with
history-matching between predicted and actual
dynamometer cards you can come up with effective
specific gravities that will accurately model your
rod pumping systems. If you use a specific gravity
that only considers liquids, it will result in higher

Percent water cut

The percent water cut
input along with oil API
gravity allows XROD to
calculate a default specific
gravity for the produced
fluid. Also, it uses this
data to calculate $/bbl (or
$/m3) electricity costs.

Oil API gravity

XROD uses the oil API
gravity to calculate fluid
load on the plunger and
the default specific grav-
ity of the produced fluid. Figure 4.8 - The inflow performance relationship (IPR) plot
32 | Running XROD
predicted loads, power consumption, etc.
If you are designing a new system and you are not
sure what the specific gravity is, use the higher
value you expect to have to make sure that your
system will not be overloaded when in operation.
However, when matching measured dynamometer
cards, use a specific gravity that is as close as pos-
sible to the actual value.
After you finish entering data for the Well Infor-
mation window click on the next screen button
(right arrow) on the toolbar to open the Production
Information input window. To move back to the
previous window, simply press the left arrow icon
on the toolbar.
Remember that pressing @ converts to the op-
posite system of units. For example, if you selected
English units but want to enter the pump depth
in meters, press @ before entering the value. If
the value for any field with units has already been
Figure 4.9 - Fetkovich n value
entered, pressing @ will show it in the opposite
units.
4.3.2 Entering Production Information
The Production Information input window allows
you to enter a fluid level or pump intake pressure as
shown in Figure 4.7. Also, you can select to enter
a pumping speed, enter a target production (the
program will calculate the pumping speed to get
the target production), or you can select to calcu-
late the target production from inflow performance
data.
If you choose to enter IPR data, the Production
Information window expands to reveal the data
you must enter. This includes the correlation you
want to use for the inflow performance relationship
(IPR), the depth from surface to the middle of the
perforations, the static bottom hole pressure, and
bubble point pressure. Also, you can enter from
one to 10 test points. If you select to use the Vogel
method for the oil IPR calculations then you only
need one point. If you use Vogel and enter more
than one point, then only the first point is used.
You can enter more than one test point if you use
the Fetkovich method. The pressure that cor-
responds to each production test point can either
be pump intake pressure or flowing bottomhole
pressure (in the middle of the perfs). To add a new
pair of Pi and Fluid production data, click on the
add button (top right) icon. To delete a set of data
points, click on the remove icon (bottom right).
You can get help for any input item by pressing !
when in the input field or by clicking on the ques-
tion mark icon on the toolbar.
If you do not know what the bubble point pres-
sure is, but you know the well is producing below
the bubble point pressure, then leave the bubble
point pressure field blank and click on Producing
below bubble point or in the check box next to
it. After you enter the last piece of IPR data, click
to a different input field, press T or click on the
Update prod. button to allow RODSTAR to
calculate the maximum oil, water, and fluid pro-
duction rates and target production.
You can see the IPR plot by clicking on the IPR
Plot... button (under the target production field).
When the IPR plot is displayed as shown in Fig-
ure 4.8, you can move the cyan line that you see
on the plot with the mouse to see the calculated
production rate for any bottomhole pressure. To
move this line, point to it with the mouse until
the mouse cursor changes shape and then drag the
line to any pressure point on this plot. As you are
moving this line, the producing bottom hole pres-
sure, pump intake pressure, oil production, water
production and total fluid production are dynami-
cally recalculated. You can print the IPR plot you
see on the screen by clicking on the Print button
at the bottom right hand corner of the screen, or

Figure 4.10 - Options for calculating pump intake pressure
you return to the production information screen by
clicking on Close.
RODSTAR offers you the option to enter the val-
ue of n for the Fetkovich IPR correlation as shown
in Figure 4.9. The window includes a check box,
labeled Calculate n, that tells XROD whether
you want to enter the value or have XROD cal-
culate it from your data. If you enter only one test the plunger size that the program will recommend.
point, XROD uses a value of 1.0 for n unless you
select to input your own value. However, if you
enter two or more test points, XROD calculates n
from a log-log plot.
If you enter inflow performance (IPR) data,
XROD can calculate the pump intake pressure
using the target production you have entered (see
Figure 4.10). You can select to have XROD calcu-
late the pump intake pressure from the IPR data,
or if there is no IPR data available, you can enter a
pump intake pressure or fluid level yourself. Usu-
ally, for new systems, it is recommended that the
system be designed for the highest possible fluid
load on the plunger. This is accomplished by en-
tering a fluid level that is equal to pump depth.
4.3.3 Entering Pump and Tubing Information Data
On the third input screen, you can select the
tubing size, tubing anchor depth (if anchored),
pump type, plunger size, and the upstroke and
downstroke rod-tubing friction coefficients. Also,
for shallow, high rate wells, you can include fluid
inertia effects. If you select to include fluid inertia1
effects then you must also enter the fluid compress-
ibility index. For more information on this option
read the discussion that follows later in this sec-
tion, or use the context sensitive help system.
1 Fluid inertia effects are dynamic effects
that increase fluid load on the plunger in wells less
than 4000 feet with pump plungers larger than 2.0
inches
XROD| 33
You can select the pump
plunger size from a list
of standard sizes, or you
can enter a non-standard
size by selecting Other
from the list of plunger
sizes. If you are simulat-
ing a full pump and you entered a target produc-
tion, you can select to have XROD recommend
the pump plunger size for you. This option is only
available when you enter a target production and
select full pump for pump condition.
Please note that the pump type you select affects
It may be interesting to make one run with an
insert pump type and one with a tubing pump to
see what XROD recommends.
Other input data in the Pump and Tubing Information
window:
Rod-tubing friction coefficients
For rod-tubing friction , XROD allows you to
enter upstroke and downstroke friction coefficients
yourself, or you can have the program calculate
them for you. If you do not know what to enter,
then choose to have XROD calculate the rod-tub-
ing friction for you. The friction factors calculated
by XROD are estimates for average friction for a
vertical wellbore. If you are simulating a system
with excessive downhole friction, you must enter
your own rod-tubing friction coefficients for more
accurate results. There are several downhole con-
ditions that increase rod-tubing friction such as:
wellbore deviation, a well with heavy oil produc-
tion, paraffin or scale problems, etc.
The most accurate way to figure out the rod
tubing friction in XROD is to import a
measured dynamometer card from a ROD-
DIAG or XDIAG file (in non-AI mode).
Then, history-match this actual card by
manually adjusting the friction. You do this
by varying the upstroke and downstroke
rod-tubing friction coefficients until the sur-
34 | Running XROD
Figure 4.11 - Rod string entry options
face dynamometer card predicted by the pro-
gram matches the measured dynamometer
card. This technique allows you to find the
rod-tubing friction that gives the best results
when simulating this system. From then on
you can use these friction factors every time
you simulate this pumping system.
Please note that this history-matching technique
works only if the dynamometer card that you mea-
sure corresponds to a pump condition that XROD
can simulate (full pump, fluid pound, or gas inter-
ference). For example, if the pump is worn out or is
hitting up or down, etc., then this technique will
Figure 4.12 - Steel rod string design options
not work as well. This is because you will be unable
to get a good match between predicted and mea-
sured dynamometer cards.
If you do not have a measured dynamometer card,
use the following guidelines for entering rod-tub-
ing friction coefficients in non-AI mode:
1. First select to have XROD calculate the rod-
tubing friction coefficients for you. You can use
these calculated values as guidelines to decide
what values to enter yourself to better simulate
your rod pumping system.
2. For heavy oil or for wells with paraffin or scale
buildup, use 2-3 times the value calculated by
XROD. You can use the same guideline for
deviated wells when the deviation is close to
the bottom of the wellbore.
3. For deviated wells with the deviation close
to the surface you may need to enter a larger
number such as 4-6 times as high as the values
calculated by the program. Also, it may be
appropriate to use different values for upstroke
and downstroke frictions to better match your
downhole conditions.

Buoyancy effects
The option to include buoyancy effects should
be left unchecked in most cases. This is because
buoyancy does not cause buckling of the rod string.
However, for fiberglass-steel rod strings, after the
design is finalized, It is recommended that an ad-
ditional run be made including buoyancy effects to
ensure that the fiberglass portion of the rod string
is not in compression. If it is in compression, then
more sinker bars must be used, the pumping speed
need to be reduced, or both.
When buoyancy is not included, the bottom of
each rod section except the last section should have
a positive stress. Otherwise the rods may be going
into buckling. It is normal for the very bottom of
the rod string to be in compression if you enter a
pump friction that is not zero (a minimum pump
friction of 200 lbs is recommended).
For more information on the theory behind these
recommendations, please read SPE paper number
25416 Interpretation of Calculated Forces on
Sucker Rods by J. F. Lea and P. D. Pattillo. Pre-
sented at the Production Operations Symposium
in Oklahoma City, March 1993.
Figure 4.13 - Fiberglass rod string design window
XROD| 35
Fluid inertia effects
If the well depth is less than 4250 feet and the
pump plunger size is larger than 2.00 inches,
XROD allows you to consider fluid inertia effects.
These dynamic effects become important in wells
with plungers larger than 2.0 and pump depths
of 4000 feet or less. However, there is no exact
magic depth for which fluid inertia becomes
important. Therefore, XROD allows you to include
these effects for wells up to 4250 feet deep and
with a plunger size equal to or larger than 2.0.
Another important factor is fluid compressibility.
The more compressible the fluid is, the less promi-
nent the fluid inertia effects are.
If you include fluid inertia effects, XROD will
prompt you for the fluid compressibility index. The
default is 3 but you can vary this number between
1 and 7 (x10-6 psi-1). The compressibility index
tells XROD how compressible the fluid in the
tubing is. The value of the compressibility index af-
fects the shape of the predicted dynamometer cards
(surface and downhole). If you are not sure what
number to use, experiment with different values
until you can match measured dynamometer cards
for the well you are simulating.
36 | Running XROD
When you include fluid inertia effects, pump
efficiency becomes a variable that affects the
dynamic fluid load on the plunger. Therefore,
using 90% pump efficiency gives higher peak
polished rod load than using 80%.
The option to include fluid inertia effects is only
available if you are modeling a full pump. Please
do not confuse fluid inertia effects with the mo-
ments of inertia of the pumping unit that have to
do with gearbox torque due to prime mover speed
variation. Fluid inertia effects refer to additional
dynamic forces on the plunger caused by the
pickup and rapid acceleration of the fluid load.
XROD simulates fluid inertia effects with a second
wave equation that models the pressure waves in
the fluid in the tubing. This increases simulation
accuracy by accounting for pressure pulses travel-
ing up and down in the tubing fluid. These pres-
sure waves have a direct affect on the pump plung-
er. Since the program has to do many additional
calculations when you include fluid inertia effects,
XROD may take 60%-80% longer to run.
4.3.4 Entering Rod String Data
The fourth input window deals with the rod string
design. As Figure 4.11 shows, you can select one of
the three available rod string entry options:
XROD Steel design, XROD Fiberglass-Steel de-
sign, or Manual rod string entry. The symbols for
these options are explained in Figure 4.11.
XROD Steel Design
Figure 4.14 - RODSTAR Designed Fiberglass-Steel Rod String
If you select this option, XROD displays a window
such as the one shown in Figure 4.12. Here, you
can select the maximum and minimum rod diam-
eters to consider, whether to include sinker bars,
the service factor, and additional rod costs.
If you want to include sinker bars then you must
enter the diameter and length of the bar (or sinker
rod). XROD does not calculate the length of the
sinker bar section because there is no industry
consensus on how to design sinker bars. However,
XROD will design the rod string above the sinker
bar section you specify.
XROD attempts to design an optimum rod string
based on the rod grade and the maximum and
minimum rod diameters you enter. First, XROD
figures out how many rod tapers are needed. Then,
it automatically adjusts the length of each section
until the stress loading is the same at the top of
each rod section. This equalizes and minimizes
stress loading on the rod string. This stress bal-
ancing approach gives the lowest cost rod string
with equally distributed stress loading, for the rod
grade you select.
This approach works the same regardless of steel
rod grade or type. For example, you can have
XROD design a Corod rod string for semi ellipti-
cal Ultra Corods using a maximum diameter
of 17/16, a minimum diameter of 13/16, and a
375 section of 1 5/8 sinker bars on the bottom.
XROD uses only the rod sizes it needs. For exam-
ple, if the loads are not high enough to require the
use of the 17/16 rod diameter then XROD will go
to the next size (16/16). If this is still too big, it
will use the 15/16.
The maximum rod loading used by XROD to de-
 XROD| 37

cide when the next larger diameter rods are needed you entered it yourself. Then, you can make any
is 95% by default. However, you can change this changes you want to the rod string without having
number if you like by going to the Setup De- to reenter everything.
faults window. Also, you can have XROD design the rod string
Fiberglass/steel XROD design while calculating the pumping speed and plunger
size, to get the target production. However, be-
If you select the option to have XROD design a cause of the complexity of the calculations, si-
fiberglass-and-steel rod string, you will see the multaneous use of all or most of XRODs smart
data input screen in Figure 4.13. For example, let options will result in longer run times. This is
us say you want to use a design with fiberglass rods especially true if you also select to include the ef-
on top followed by a tapered steel section with 1 fect of prime mover speed variation. Also, depend-
and 7/8 rods, and then 375 feet of 1 sinker bars. ing on the case, XRODs run time may be longer
XROD is able to design this rod string for you. if you enter a target production that is too large for
Also, it balances the steel design under the fiber- the pumping system.
glass section (for two or more rod sections) so that
If you select only sinker bars on the bottom (with-
there is equal stress loading at the top of each sec-
tion as shown in Figure 4.14. out regular steel rods between the fiberglass and
sinker bar) then XROD will calculate the length
This Figure shows a fiberglass-steel rod string of the sinker bar section for you. If you select both
designed with XROD. XROD can design tapered sinker bars and a tapered steel design between the
steel rod strings under the fiberglass section for sinker bars and the fiberglass rods, then you must
any type of steel rod, including non-API high enter the length of the sinker bar (or sinker rod)
strength rods, and Corods. If you want to fine- section. XROD will determine the length and
tune a XROD design, in non-AI mode, select to diameters of the tapered steel portion based on
enter your own rod string design by clicking on the the maximum and minimum diameter limits you
manual rod string entry icon. XROD will show enter.
you the current rod string design in memory as if

Figure 4.15 - Selecting rod grades in Non AI-Mode

38 | Running XROD
XROD may reject a steel rod diameter if it is
not needed. For example, if you asked XROD to
design a rod string with fiberglass on top, a tapered
steel section under the fiberglass, and a 500 foot
1.5 inch sinker bar section on the bottom. XROD
will determine the fiberglass diameter and length
you need, and the steel rod section and tapers you
need. If XROD cannot balance the steel rod string
design because the 3/4 section is not needed, it
will not use any 3/4 rods.
Another interesting capability of XROD is that if
you use continuous rods (Corod or Prorod) instead
of regular rods under the fiberglass, it may skip a
rod diameter, if it has to, in order to balance the
rod string stress loading. This is not a bug. Some-
times the program has to do this to successfully
balance the steel portion of the rod string.
Figure 4.16 - Pumping unit manufacturer list
Entering Your Own (Manual) Rod String
This option is primarily used for entering rod
string data for an existing system you want to
simulate, or to modify a design that XROD itself
came up with (when you select to have the pro-
gram design the rod string for you). This is not a
good option to use when you first design a new
system because it requires the most work and expe-
rience.
When you select this option, you can enter data for
either steel or fiberglass rods as Figure 4.15 shows.
This can only be done in the non-AI mode. You
can enter the number of rod sections, the service
factor you want to use, and rod string data for up
to eight rod sections. For each section, you can
select the rod type or grade, diameter, and length.
For Fiberflex fiberglass rods you can also specify
the sucker rod length.
If you select one of the fiberglass manufacturers
listed on the drop down list next to the rod grade
input field, the program knows the weight per
foot and modulus of elasticity and will not prompt
you for them. The program warns you about rods
that do not fit in the tubing. Also, it warns you if

the rod string length is shorter or longer than the
pump depth. The total length of the rod string
can be up to 50 feet shorter than the pump depth.
However, it cannot be longer than the pump
depth. For example, if the pump depth is 5000
feet, you can enter a rod string that is between
4950 and 5000 feet. When entering rod string data
for the first time, XROD shows a default length
for the last rod section equal to the difference
between the pump depth and the rod string length
you entered so far.
Selecting the option to enter your own rod string
gives you maximum flexibility. However, it re-
quires the most expertise to come up with a good
rod string design. You can use this option to select
different rod grade or manufacturer for each rod
section. In general, this option allows you to enter
any rod string design, no matter how unusual. The
minimum length you can enter for any rod section
is 25 (length of a single sucker rod).
When entering the rod string data manually,
XROD allows you to add and remove rod sections
from anywhere in the rod string, instead of only
Figure 4.17 - Measured pumping unit list
XROD| 39
at the bottom. The window has icons on the left
side for inserting a rod section, for removing a rod
section, or for moving a section up or down. For
example, if you want to remove a rod section, first
click on it and then click on the Delete Rod rod
section icon.
To add a rod section, click on an existing rod sec-
tion and then click on the Insert/Add Rod Sec-
tion icon. The new section will be added below
the selected section.
XROD asks for confirmation whenever you re-
move sections from the rod string, whether by us-
ing the Remove rod section button or by reducing
the number of rod sections.
The meaning of the term Sinker Bar in XROD
In XROD, the term sinker bar means a steel rod
that is made specifically to be used at the bottom
of the rod string for weight such as 1 3/8, 1,
1 5/8, etc. The term sinker rod means a regular
rod such as a 1 or 7/8 rod that is placed on the
40 | Running XROD
bottom of the rod string for weight. For a 1 or
7/8 rod to be considered a sinker rod it must be from the list. This is a unique ID for each pumping
larger than the diameter of the rod above it.
When entering the rod string manually,
make sure you select Sinker bars in the list
of rod grades for sinker bars as shown in
Figure 4.14. Do not select Steel rod type
and then Other for the rod size.
4.3.5 Entering Pumping Unit Data
The pumping unit input screen allows you to select
a pumping unit from the database that comes with
XROD, or from your measured pumping unit
database (if you entered your own pumping unit
dimensions in Setup).
Another option is to enter a pumping unit ID.
The pumping unit ID is a unique string of letters
and numbers. XROD displays the pumping unit
ID along with other unit information after you
select a unit. If you make a note of this unit ID (in
the well file for example), you can use it to specify
Figure 4.18 - The custom pumping unit list
the pumping unit instead of having to select it
unit in the programs database.
Selecting a pumping unit manufacturer
XROD allows you to easily select a pumping unit
manufacturer and unit size with drop-down list
boxes. To display the menu with all pumping unit
types available, click on the drop arrow next to the
Manufacturer field (see Figure 4.16). This is a
scrollable list of all units in the programs database
in alphabetical order. You can go to the top of the
list by pressing }. You can jump to the bottom
of the list by pressing ~. You can also move up
or down by pressing O (Page up) or N (Page
Down). A convenient way to move through the list
is to press the first letter of the unit name you want
to use. For example, to locate the National E
Series pumping unit entry, you can press n and
the highlight bar will jump to the first name in the
 XROD| 41

list that starts with N. Then simply click on the After you select a manufacturer you can use the
National E Series entry. At the top of the list same procedure to select the unit size you want
of pumping unit manufacturers is the item Mea- from the pumping unit drop-down list box . You
sured pumping units. This option allows you to can move through this list the same way as with
select a unit for which you entered geometric data the pumping unit manufacturer selection menu.
in Setup. The pumping units on this menu are ordered from
largest to smallest stroke length, gearbox size, and
When you select the Measured pumping units
structure size. However, if the window shows the
option, XROD will display a list that only shows
pumping unit name (for old units) the units are
the measured pumping units, as Figure 4.17 shows.
listed alphabetically.
As Figures 4.16 and 4.17 show, there is a check
When you enter a unit, the Unit ID, the program
box that allows you to use the custom pumping
automatically displays the unit that the ID corre-
unit list instead of the main pumping unit list. If
sponds to. XROD displays the information nec-
you check this option, before you select a unit,
essary for you to correctly identify your unit. For
the Manufacturer list will show a shorter list that
example, for American conventional units you will
contains only the manufacturers you selected in
see that certain unit sizes appear more than once
Setup in your custom unit list as shown in Figure
on the selection list. However, they have different
4.18. When the Use custom pumping unit list
cranks.
option is checked, when you select a pumping unit,
you will see a short list containing only the unit
sizes you selected for your customized list for this
manufacturer. How to add units to the custom pumping unit list

Figure 4.19 - XROD recommends a unit size based on target production

42 | Running XROD
You can use the Use custom pumping unit list
check box to add units from the main list to your
custom list. For example, if you run across a pump-
ing unit that is not in your custom list yet, clear
the Use custom pumping unit list check box so
that you can use the general pumping unit list.
After you select the pumping unit then click on
the Use custom pumping unit list check box.
XROD asks if you want to add this pumping unit
to the custom pumping unit database. Select Yes to
add this unit to your custom list. The program will
add this unit to the custom list and also switches
to the custom list.
This option allows you to add units to your custom
list without having to do it from Setup. To remove
units from your custom list or to add more than
one unit, go to the setup window and customize
the list of units as described earlier in this manual.
You can also use this feature as a way to main-
tain an inventory of available pumping unit types.
When this custom pumping unit list has been
completed, you can select to have XROD use this
list when designing your system. (see AI Mode
Preferences in Setup). This way, you can quickly
find if a unit in your inventory will work for the
new system design.
Selecting to enter a pumping unit ID
The unit ID option is the fastest way to enter
pumping unit information if you already know
the pumping unit ID for your unit. You can see
the pumping unit ID on the pumping unit entry
window after you select a unit. Once you locate
your unit, you can make a note of its ID in the well it recommends. XROD in non-AI mode makes
file. Then, the next time you want to use this unit, this recommendation without running through the
you can select to enter its ID. For example, for a
Lufkin Mark II M-456-305-144, the unit ID is
ML32.
To identify some units correctly, it is necessary
to know the crank number since they may have
the same API designation but different geometric
dimensions depending on crank number (primarily There are other important factors that you must
units made by American International Manufac-
turing Company).
TIP: If your unit is not listed in XROD and you
do not have the unit dimensions, then use a unit
that is closest to it. As long as you use the same
unit geometry and a unit with the same stroke
length and gearbox rating, the results should be
close to actual as long as the pumping unit is the
same unit type as the one you selected.
If after you enter a pumping unit ID XROD dis-
plays The pumping ID you entered is not valid
this means that ID you entered is not recognized
by XROD. This can happen for two reasons:
1) You entered the wrong ID such as R0 (which
does not exist), or CL901 instead of CL91.
2) You have erased the pumping unit file by acci-
dent, or the pumping unit files are not in the same
directory as the program.
XROD Recommended unit size
If you enter a target production instead of pumping
speed, XROD will display a recommended pump-
ing unit size to help you select a pumping unit. This
recommendation can be very helpful if you are
designing a new pumping system and must decide
what size unit you need. XROD recommends a
unit size based on the type of pumping unit you
selected. For example, if you select a Lufkin Mark
II then XRODs recommendation will be for a
Mark II unit. If you select a Lufkin Conventional,
then its recommendation will be different since
it is for a conventional unit. The program will
automatically select the closest unit available from
the selected manufacturer as compared to the size
predictive calculations. Therefore, it may not nec-
essarily recommend the best pumping unit size for
your application. However, in most cases it should
be pretty close to the size you need. If you want
the program to recommend the best pumping unit,
then use the AI mode.
consider when deciding what unit size you need.

These include: available used pumping units, ex-
pected changes in well conditions, desired pump-
ing speed, etc. When you enter data for a case
for the first time and you are at the pumping unit
selection screen, XROD will not only display the
recommended unit size, but will automatically se-
lect the unit closest to the recommended size from
the available list. If you do not want to use the
unit recommended by XROD then select another
one. The recommended unit size is a push button,
as shown in Figure 4.19. So, whenever you want
to return to the pumping unit size recommended
by XROD, just click the button and XROD will
automatically select the unit size that is closest to
the recommended size.
In general, the size recommended by RODSTAR
will be close to the minimum required unit size to
avoid overloading the unit. Also, XRODs recom-
mendation depends on the manufacturer and unit
type you select and whether you are using steel
rods only, or fiberglass with steel on the bottom.
In some cases you may be able to use a smaller unit
by selecting a pumping unit geometry that is better
suited for your application. There are several factors
that determine what unit is best. They include,
cost, gearbox loading, system efficiency, rod com-
pression, minimum polished rod load (indicates
separation of the polished rod from the carrier bar
if close to zero), etc.
Selecting crank hole number and crank rotation
After you select a pumping unit you must select
the crank hole number, and the direction of rota-
tion with the well to the right (if you are using a
unit that can rotate either way). For units with a
required direction of rotation, like the Mark II ,
Torqmaster, Lufkin Reverse Mark, or American
Producer II, the program will not allow you to
change crank rotation. For units that can rotate
either clockwise or counterclockwise, XROD de-
faults to the direction of rotation that will usually
give the lowest torque. However, this default direc-
tion of rotation may not always be ideal for your
system design. To find out for sure which rotation
XROD| 43
is best for your system you must make two runs:
one with clockwise crank rotation and one coun-
terclockwise. Then look at the effect of rotation on
gearbox torque, system efficiency, rod loading, etc.
Entering your own pumping unit data
If the pumping unit you want to simulate is not
in XRODs database, you can enter your own
pumping unit dimensions. To enter the data in the
program you have to first access the setup screen of
XROD (click on fourth button on toolbar). Then,
click on the + next to Pumping Unit Options
tab and select Measured Pumping Unit List as
explained in section 3.3.4 in this manual. Then,
select to add a new unit to enter data for a pump-
ing unit not in the programs database.
The data you must enter consists of geometric
dimensions as defined in the API 11E publication.
You can get these dimensions from the pumping
unit manufacturer or measure them yourself. Or,
you may be able to find most of the dimensions
you need from catalogs or blue prints. 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 in thousands of in-lbs. Measure the
stroke length, and try to decipher additional infor-
mation from the units nameplate for the structure
rating, stroke length, and structural unbalance.
If the nameplate is legible then write down the
units serial number or order number. If the units
manufacturer is still in business, you may be able
to get the data you need from the serial number
or order number. For help in locating dimensional
data for pumping units not in the manual call
Theta Oilfield Services, Inc..
XROD allows you to enter data for Conventional,
Mark II, Air Balanced, Enhanced Geometry, or
Long Stroke units. When you enter your own
pumping unit dimensions, XROD calculates and
displays the stroke length based on the dimen-
sions you enter. For all pumping unit types you
must first enter the name of the manufacturer, the
unit name or model number, the gearbox rating
44 | Running XROD
in thousands of inch pounds, the structure rating
in hundreds of pounds, and the maximum stroke
length in inches. From these numbers XROD puts
together the API pumping unit designation. The
API pumping unit designation is a standard way of
describing the size and capacity of pumping units
as the following example explains:
The first number is the gearbox rating in thousand
inch-pounds. In this example the gearbox rating is
320,000 inch-lbs. The second number is the struc-
ture rating in hundreds of pounds. In this case the
structural rating is 256. This means that to avoid
overloading the structure of the unit, polished rod
load must not exceed 25,600 lbs. The last number
shows the maximum stroke length of the unit in
inches (100 inches in this case). Following is an
explanation of the rest of the data needed for each
unit type (refer to Figure 3.12):
Conventional and Enhanced Geometry
Pumping Unit Data
For these units you must enter pumping unit di-
mensions R, A, C, I, P, and K in inches, the struc-
tural unbalance in pounds, and the crank offset
angle in degrees. For enhanced geometry units the
crank offset angle must be negative. Figure 3.12
shows the dimensions XROD needs.
The API spec. 11E defines the above dimensions
as follows:
Dimension: Description:
R Radius of the crank (inches)
A Distance from the centerline of the
saddle bearing to the centerline of
the polished rod (inches)
C Distance from the centerline of the
saddle bearing to the centerline of
the polished rod (inches)
I Horizontal distance from the
centerline of the saddle bearing to
the centerline of the crankshaft
(inches)
P Effective length of the pitman
arm, in inches (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
saddle bearing (inches). Some-
times, instead of the K dimen-
sion, pumping unit manufacturers
supply data for dimensions H and
G instead (described below). From
these dimensions and dimension I
(defined above) you can calculate
)2 2
K as follows: K= ( H-G + I
H Height from the center of the
saddle bearing to the bottom of
the base beams (inches)
G Height from the center of the
crank shaft to the bottom of the
base beams (inches)
Mark II Pumping Unit Data
For Mark II units you must also enter pumping
unit dimensions R, A, C, I, P, and K in inches,
the structural unbalance in pounds, and the crank
offset angle in degrees. This angle is positive for
Mark II units.
The API spec. 11E defines the above dimensions
as follows:
Dimension: Description:
R Radius of the crank (inches)
A Distance from the center of the
Sampson Post bearing to the cen-
terline of the polished rod (inches)
C Distance from the centerline of the
Sampson Post bearing to the cen-
ter of the equalizer (or cross yoke)
bearing (inches)
I Horizontal distance between the
centerline of the Sampson Post
bearing and the centerline of the
crankshaft (inches)
 XROD| 45

P Effective length of the pitman M Geometry constant (in2). It is the

arm, in inches (from the center of distance from the Sampson Post
the equalizer (or cross yoke) bear- bearing to air tank bearing (dis-
ing to the center of the crank-pin tance X in Figure 2.3) multiplied
bearing) by the area of the piston in the air
K Distance from the center of the cylinder divided by dimension A
crankshaft to the center of the or: X*Ap/A, where Ap is the area
Sampson Post bearing (inches) of the air cylinder piston in square
inches.
H Height from the center of the
saddle bearing to the bottom of
the base beams (inches)
G Height from the center of the
crank shaft to the bottom of the
base beams (inches)

Air Balanced Pumping Unit Data

For these units you must also enter pumping unit
dimensions R, A, C, I, P, and K in inches. In ad-
dition, you need data for M, S and V0.
The API spec. 11E defines the above dimensions
as follows:
Dimension: Description:
R Radius of the crank (inches)
A Distance from the center of the
Sampson Post bearing to the cen-
terline of the polished rod (inches)
C Distance from the centerline of
the Sampson Post bearing to the
center of the equalizer bearing Figure 4.20 - Dimensions for long stroke units
(inches)
I Horizontal distance between the
centerline of the Sampson Post
bearing and the centerline of the
crankshaft (inches)
P Effective length of the pitman
arm, in inches (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 (inches).

Figure 4.21 - Definition of structural unbalance

46 | Running XROD

S Pressure in the air counterbal- hydraulic unit then the torque calculations, energy
ance cylinder required to offset consumption, and other results that depend on
the weight of the walking beam, torque will be incorrect or meaningless. However,
horsehead, equalizer, pitman arms, the predicted polished rod dynamometer card,
etc. (psig). polished rod horsepower, stress analysis, etc. will
V0 Minimum air volume between the be valid. This technique can be used as long as the
plunger and cylinder at the bottom upstroke and downstroke polished rod velocities
of the stroke (in3).
of the hydraulic or long stroke unit you want to
simulate are approximately equal.
Long Stroke Pumping Unit Data Tip: To predict energy consumption more ac-
For these units you must enter the sprocket diam- curately for hydraulic units using the long stroke
eter (D), the centerline distance between the top pumping unit model, input a pitman arm length of
and bottom sprockets (distance C), the pitman arm zero and a drum diameter ratio of 2.
length (P) if one exists (usually this is zero), andAnother thing to keep in mind is that even though
the top drum diameter ratio (usually equal to 1). the combination of C and D dimensions deter-
You can see a diagram of the dimensional data you mines the stroke length of long stroke units, the
need by pressing F1 in any input field, or you can ratio of C/D determines the acceleration and de-
take a look at Figure 4.20. celeration of the polished rod. For the long stroke
You can also use this pumping unit model to sim- geometry shown in Figure 4.20, when the connec-
ulate any non-beam pumping unit with a long, tion point between the belt and the chain touches
slow stroke. You can do this by entering data that the sprocket, the polished rod speed changes
will produce the same stroke length as the unit you (accelerates or decelerates). When the connection
want to model. The stroke length of a long stroke point leaves the sprocket (C section in Figure 4.20)
unit is given by: the speed is constant. Therefore, different com-
binations of C and D dimensions may be needed
Stroke = C + D to correctly simulate the polished rod motion of a
For example, to simulate a hydraulic pumping unit hydraulic pumping unit.
with a stroke length of 200 inches, you can enter a
sprocket diameter (D) of 20 inches and a centerline
distance between sprockets equal to 180 inches. Definition of Structural Unbalance
If you use this approach to design a system with a Structural unbalance is a term used for pumping
units with walking beams. It is defined in API
11E as the force you need at the polished rod to
hold the walking beam horizontal with the pitman
arms disconnected from the crank pins. This force
is positive when acting down and negative when
acting up. See Figure 4.21 for a visual explanation
of structural unbalance. Structural unbalance for
conventional units can be either positive or nega-
tive. For Mark II units it is always negative. If you
do not know the structural unbalance for the unit
you want to simulate then enter zero. In most cases
the structural unbalance will not affect the results
significantly (especially for Conventional geometry
Figure 4.22 - Definition of crank offset angle units).

Definition of Crank Offset Angle
The crank offset angle (or crank phase angle) is
the angle between a line through the crank holes
and a line through the counterweight arm. Figure
4.22 shows how the crank offset angle is defined.
XROD expects a positive crank offset angle for
Mark II units and a negative one for enhanced
geometry units such as the Torqmaster, Lufkin
Reverse Mark, or American Producer II. For
conventional pumping units the crank offset angle
is zero.
Entering Counterbalance Information
After you select a pumping unit or enter your own
pumping unit data, the crank hole number, and
direction of rotation, you must enter counterbal-
ance information.
Entering an existing maximum counterbalance
moment allows you to simulate an existing system
to find out if the unit is overloaded or out of bal-
ance. If you only want to find the maximum coun-
terbalance moment required to balance the unit
(which is usually the case for new designs) then
click on the Unknown check box and XROD
will calculate it for you.
For beam pumping units except for air balanced,
Figure 4.23 - Entering motor information
XROD| 47
you can enter a maximum counterbalance mo-
ment in thousand inch-lbs. XROD also gives you
the option to import the maximum counterbal-
ance moment from a CBALANCE / XBAL file
or from the clipboard. If you ran CBALANCE
or XBAL before running XROD, then the value
of the existing maximum counterbalance moment
will be in the clipboard. Then, as soon as you click
on the Use CBALANCE/XBAL information
button, XROD will allow you to use the value
exported by CBALANCE or to read a CBAL-
ANCE file from disk.
For air balanced units you must enter the air cyl-
inder pressure in psig at the bottom of the stroke.
For long stroke units you must enter the counter-
balance weight in thousands of pounds. For these
units, the option to read a CBALANCE file is
disabled since it does not apply.
If you enter existing counterbalance data, XROD
calculates and displays the permissible load dia-
gram for existing conditions. Also, the recom-
mended prime mover size and overall system
efficiency will be for the existing conditions. If you
select unknown for maximum counterbalance
moment then XROD calculates all these numbers
and the permissible load diagram for balanced con-
ditions only.
The range of allowable counterweight is different
48 | Running XROD
for different Rotaflex units. XROD takes this into
account when validating your entry for counterbal-
ance weight. For example, the minimum counter-
weight possible for the 1200 model is 13,500 lbs.
Therefore, if you try to enter a counterweight that
is less than 13.5 M lbs, (M =thousands) XROD
will warn you that the counterweight for this unit
must be between 13.5 and 32.5 M lbs.
Changing Structural Unbalance
In some cases, when the pumping unit is signifi-
cantly oversized for the downhole equipment, you
may have to add counterweights on the walking
beam next to the horsehead to balance the unit.
This changes the structural unbalance from the
catalog value. XROD allows you to change the
structural unbalance even when you select a pump-
ing unit from the programs database.
The structural unbalance field can also be used to
simulate beam balanced units. By changing the
value of the structural unbalance, you can figure
out how much weight you need to add or remove
from the walking beam to balance a beam bal-
anced unit.
4.3.6 Entering Motor Information and Energy Cost
XROD can simulate NEMA D or ultra high slip
motors and calculates power consumption from
actual motor efficiency curves. The program uses
the electricity cost you enter to predict the monthly
electricity bill, $/bbl fluid, and $/bbl oil (based on
water cut). XROD defaults to the cost number you
specify in Setup. The $ symbol here is meant to
represent currency (not just US dollars). As Figure
4.23 shows, under the electricity cost input box
there are option buttons that you can use to se-
lect the power meter type. You have two options:
Detent, or Non-detent. A Detent KWH meter can
rotate only in one direction. A ratchet prevents it
from turning the other way. Therefore, if your unit
is generating electricity, you do not get credit for
it. The non-detent meter can rotate either way and
so it credits you for electricity the pumping unit
generates.
Prime mover type selection
Using drop-down list boxes you can select the mo-
tor type you want to simulate. XROD has motor
performance and efficiency data for NEMA D,
Sargent Ultra High Slip, Reliance Ultra High Slip
motors, and Rotaflex Multi-HP NEMA C mo-
tors. If you select a NEMA D motor you can enter
a motor size, or you can choose to have XROD
recommend a NEMA D motor for you. If you
select an ultra high slip motor then you must select
the motor size and torque mode. If you select a
motor size or mode that is too small for the well
conditions then XROD will display a warning
message and will give you the option to change
your data.
XROD warns you if you select an ultra-high-slip
motor when you have selected an air-balanced or
long stroke pumping unit. These units have little or
no rotating moment of inertia, so using an ultra-
high-slip motor does not result in any significant
differences in the calculations. Therefore, for these
units, do not select an ultra high slip motor or to
include speed variation effects.
If you select a NEMA D motor type for a new
case, or switch from an ultra-high-slip motor to a
NEMA D motor, XROD automatically selects the
option to recommend the motor size.
Motor speed variation
The option to include the effect of motor speed
variation is only available for conventional, en-
hanced geometry, and Mark II units. Inertia ef-
fects are negligible for long stroke and air balanced
units.
If you select not to include speed variation effects
then XROD assumes constant prime mover speed
and will not model the effect of pumping unit in-
ertia. If you choose to include speed variation then
XROD gives you the option to enter a percent
speed variation or have the program calculate the
speed variation for your prime mover.

Pumping unit moments of inertia
If you select to include the effect of motor speed
variation then you can enter a rotating moment of
inertia in lbs-ft2, or have the program estimate this
number for you. For the articulating moment of
inertia XROD defaults to a number that is either
the actual articulating moment of inertia supplied
by the pumping unit manufacturer, or an estimate
based on unit size. Therefore, unless you have an
even more accurate number for the articulating
moment of inertia, it is recommended that you use
the default number displayed by the program.
For more accurate results, have XROD calculate
the prime mover speed variation. However, you
can also enter a speed variation value if desired. If
you select to enter speed variation, XROD shows a
default value of 8% which corresponds to a rec-
ommended average speed variation for NEMA
D motors. You can get more conservative results
by entering a speed variation that is less than the
maximum expected speed variation for your prime
mover. Selecting to include prime mover speed
variation will approximately double XRODs run
time.
What is moment of inertia?
Although this manual is not intended to teach
engineering or physics, it is important to briefly
explain moment of inertia and how it can affect
XRODs results. The mass moment of inertia of a
body is a measure of its resistance to acceleration.
In other words, the higher the moment of inertia
of a body, the more difficult it is to quickly speed it
up or slow it down.
The rotating and articulating moments of inertia
are important in accurately simulating the behavior
or the pumping unit and in calculating net gearbox
torque when you use a high speed variation prime
mover. The rotating moment of inertia that XROD
needs is the total rotating moment of inertia. This
includes the individual rotating moments of inertia
of the cranks and counterweights about the slow
speed shaft of the pumping unit, the total gear
reducer inertia, and the motor rotor inertia. The
articulating moment of inertia of the pumping unit
XROD| 49
around the saddle bearing includes the inertia of
the walking beam, horsehead, and pitman arms.
As mentioned above, you can either enter a rotat-
ing moment of inertia, or you can have XROD
estimate it for you. To calculate accurately the
rotating moment of inertia you must have moment
of inertia data for the cranks and counterweights,
gearbox, motor rotor, etc. Also, the rotating mo-
ment of inertia depends on the position of the
counterweights on the cranks. Since this data may
not be known, it is recommended that you let
XROD estimate the rotating moment of inertia for
you.
Since the articulating moment of inertia depends
on the walking beam size, horsehead and pitman
arms, it is a fixed number for any given pumping
unit. Therefore, it is easier to calculate than the
rotating moment of inertia. XRODs pumping unit
data base contains accurate articulating moment
of inertia values that were either obtained from
unit manufacturers, or were estimated based on
unit size. The articulating moment of inertia from
the pumping unit database appears as the default
number when the program prompts you for the
articulating moment of inertia.
Including speed variation and moments of inertia
will usually result in lower predicted peak gearbox
torque, lower peak polished rod load, and higher
minimum polished rod load. This is because a
high speed variation prime mover slows down as
the torque on it increases. The rotational inertia of
cranks and counterweights causes a release of ener-
gy that lowers the torque the gearbox must supply.
The articulating inertia adds torque to the gearbox
since it opposes the acceleration of the walking
beam and horsehead. However, the effect of the
articulating moment of inertia is usually small
compared to the effect of the rotating moment
of inertia. When the prime mover slows down in
response to high torque, it causes the polished rod
to slow down as well. This results in lower dynamic
forces and therefore lower peak polished rod load.
 XROD| 51

5 Changing, Loading and Saving Data

5.1 Visual Input Save button on the toolbar (third from left with
diskette icon), or by selecting File from the menu
Figure 5.1 shows XRODs visual input facility bar and then choosing Save As... This brings up a
that makes it easy to locate a system parameter you standard Windows dialog box that allows you to
want to change. As you are entering the data for save your file with the file name you want. XROD
a new case, or after you have loaded a case from shows the default file name it creates from the well
disk, the visual input window can be displayed by name and by adding an .RSVX file name exten-
clicking on the Visual Input button on the toolbar.
This shows an interactive picture of the pump-
ing system. This feature is useful when running
in non-AI Mode since the AI mode has only two
input windows.
As you move your mouse over the picture of the
system, tool tips appear naming various parts of
the system. Whenever a tool tip is showing, you
can right-click with the mouse to get a pop-up
menu listing input variables associated with that
part of the system. This visual way of changing
data is more useful when you are changing data
in existing files or when you are making what
if... runs. If you are entering a case from scratch,
menu items that correspond to data you havent yet
entered will be disabled.
Left-clicking when a tool tip is displayed opens the
data entry window associated with the part of the
system you clicked on. Another way to change data
is to click on the Alphabetical list button at
the bottom of the visual input window. This brings
ups an alphabetical listing of all variables you can
change. You can locate the variable you want to
change by scrolling down using the mouse.

5.2 Storing Data Files

After you finish entering data for a system, you
can save the data to disk by clicking on the Quick Figure 5.1 - XRODs Visual Input window
52 | Changing, Loading and Saving Data
sion for RODSTAR or .XRVX for XROD. You
can change the file name by typing over it, but you
cannot change the file name extension. When you
type your own file name, you do not have to type
the file name extension. XROD automatically adds
this extension for you.
You do not have to store your data every time
you make a change. It is recommended that you
save the original data and then wait until you get
a good design before storing data to disk. After
saving data once, XROD makes it very easy to
update the file with the data in memory with a
single mouse click on the Quick Save button on
the toolbar.
If you save your data after running XROD and
the output is displayed on screen, then the non-
AI mode saves both the input and output in the
file. This is advantageous because once you save
the output then you can view and print the output
without having to rerun the case. XROD AI mode
Figure 5.2 - Summary output report - upper half
allows you to save the output as well but as indi-
vidual files. On the batch log window click Save
All Cases and all of the cases from the run will be
saved individually with their output.
5.3 Running and Viewing the
Output
After you enter all your data and you press the
Next Screen button from the motor information
window, the Run button on the toolbar becomes
active. To run the program simply click on the
Run button on the toolbar (the dynamometer card
icon to the right of the right arrow icon). Another
way to run the program is to click on Run on the
menu bar. After XROD runs, it displays the out-
put report, as Figure 5.2 shows. At the bottom of
this screen there are buttons that allow you to view
the dynamometer, torque, or IPR plots and the
report. When you select to see the dynamometer
 XROD| 53

Figure 5.3 - Summary output report - lower half

plots, you can select to animate the surface and Results window. Any action to close this window
downhole pump cards. without using this button will close the batch log
and you will not be able to return to the batch log.
When running XROD, these output reports can
If you wish to make adjustments in a specific sys-
be opened by double-clicking the file directory in
tem but do not want to lose the cases in the batch
the batch log, see Figure 5.4. These reports will
log, you may save all cases with the Save All Cases
display all the specific parameters of the systems
button on the top right of the batch log window.
that XROD designed for your well.
These cases will be saved by default to your C:\
To look at different parts of the output you can THETA\SavedXROD_Runs folder.
click the appropriate buttons at the bottom of
XROD will also create an Excel spreadsheet with
the screen (Dynamometer, Torque, IPR Plot, or
all the cases listed in order for you to make a side
Report). When you click on Report, you can scroll
by side comparison of the cases. This spreadsheet
up or down with the mouse, or you can click and
will automatically open once the run is completed.
drag on the report itself. Figure 5.3 shows the bot-
You may edit these spreadsheets to any format you
tom section of the summary report. The summary
would like by using the Batch Mode setup options.
report looks exactly the same as the printed report.
Refer to Chapter 3.
To return to the batch log simply click the close
If you have XBAL on your computer, you can have
button on the bottom right corner of the Output
XROD export the balanced maximum counterbal-
54 | Changing, Loading and Saving Data
Figure 5.4 - XRODs AI Mode Batch Log
ance moment it calculates to CBALANCE. You
can do this any time the calculations have been
run (whether or not you are actually viewing them)
by clicking on the Export CBM button on the
toolbar ( ).
XROD can calculate two possible ways to bal-
ance a unit: for minimum torque, or for minimum
energy consumption.
The most common way to balance a unit is for
minimum torque. However, if the gearbox is not
overloaded, you may want to balance the unit for
minimum energy consumption instead.
After viewing the output you can decide which
value of balanced counterbalance moment you
want to export to CBALANCE (so that CBAL-
ANCE can calculate the counterweight positions
required to balance the unit). When you click on
the Export CBM... button RODSTAR displays
the window shown in Figure 5.6 (if there are
two possible ways to balance the unit). Click on
the option you want and click on the OK button.
RODSTAR confirms that the value of the maxi-
mum counterbalance moment has been exported
by displaying the message box shown in Figure 5.7.
5.3.1 Saving the output
If you save the file while the output is being dis-
played on the screen, in non-AI mode, XROD
saves the output along with the input in the same
file. Then, you can load a file with output and you
can display and print the output without having to
rerun the program. To save the output, click on the
quick save icon on the tool bar, or select File on
the menu bar and then select Save As..
 XROD| 55

Figure 5.5 - XRODs Output Results

When you load a file that has output saved, the 5.3.2 Running in Batch Mode
program will tell you that output results are avail-
XROD runs batches as a default but you may run
able on the status bar (at the bottom of the XROD
more than one case at a time using the non-AI
window).
mode by selecting to run two or more files in batch
With XROD, you may save all cases with the Save mode. The batch mode starts automatically when
All Cases button on the top right of the batch log you select to load more than one file. This capabil-
window. These cases will be saved
by default to your C:\THETA\
SavedXROD_Runs folder. These
files will be saved as RSVX files.
If you save the XROD file (XRVX)
it will only be the settings and input
parameters and you must run the file
to obtain the output results.

Figure 5.6 - Exporting the maximum CB moment

56 | Changing, Loading and Saving Data

Figure 5.7 - Maximum CB moment exported

ity allows you to make an unlimited number of to run in batch, click on the first file and then,
XROD runs automatically, and without you hav- while pressing S, click on the last file in the
ing to be at the computer. XROD even allows you list. Or, you can click on the first file and then
to schedule the batch run to start at any time (from drag the mouse to highlight all the files you want
the Setup window). to run (it must be a continuous group). To select
To start the batch, select to open a file (either by individual files, click on the files you want to select
clicking the Open File toolbar button, or by select- while pressing C. The selected files are high-
ing Open from the File menu). This brings up lighted as Figure 5.8 shows. When you are done
the open file dialog box. To select a group of files selecting files, click OK.
At this point, XROD will
display the option box in
Figure 5.9 asking you to
choose the options you
want for the batch run. The
first option causes XROD
to create printouts for all
the files it runs. This option
is unselected by default.
The second option causes
XROD to create a sum-
mary spreadsheet file for
all the cases it runs. The
option to view the spread-
sheet in Excel means that
once the cases are pro-
cessed and the spreadsheet
is created, XROD will au-
tomatically load Excel and
Figure 5.8 - Selecting files for a batch run display the results for you.

Figure 5.9 - Batch run options
The last option allows you to specify whether you
want XROD to rerun cases with saved output or
not.
If you do not select the option View spreadsheet
in Excel when you click on Proceed, XROD
asks you for Excel file name as shown in Figure
5.10. Otherwise, if you select to view spreadsheet
in Excel, XROD starts running in batch immedi-
ately.
Creating a summary spreadsheet is very useful
because it allows you to summarize many runs in a
very concise way. After the results are in a spread-
sheet file, you can plot one variable versus another,
you can sort the spreadsheet columns by rod string
Figure 5.10 - Selecting a spreadsheet file to create
XROD| 57
cost, system efficiency, energy cost per barrel of oil,
etc. There is no limit to what you can do with the
results.
The spreadsheets that XROD create summarize
the results of all the runs and loads it directly into
Excel. Under the Setup window you can design
and save an unlimited number of spreadsheet
formats. If you do not specify a spreadsheet format
before running many cases in batch mode, XROD
uses the default spreadsheet format that comes
with XROD and contains the most common sys-
tem design comparison variables.
The option Dont re-run cases with saved out-
put allows you to create different summary
spreadsheet files with the same set of XROD files.
When you select this option XROD runs very fast
in batch because all it has to do is extract the cal-
culated values that have already been saved in the
XROD files and enter them in the spreadsheet.
When XROD starts to run the files you selected,
it displays a batch run log window such as that
shown in Figure 5.11 that shows the number of
files you selected, the number of runs that have
been completed so far, and the overall percent
completion. XROD
shows the name of each
file that it runs. XROD
prints warnings or errors
after the name line while
running each case. After
each new run is complete,
the program prints **
Run Complete **.
This is a useful record of
the cases that XROD ran
and any warning or errors
generated while running
them. You can cancel a
batch run at any time by
clicking on Cancel. The
program will stop after
it finishes running the
current case and it will
display a message box
58 | Changing, Loading and Saving Data

that says: The batch run

was canceled.
After the batch run is
done, click OK to close
this information box.
Then, click on the print
icon on the tool bar. We
recommend printing the
batch run log, especially
when running many
XROD cases. The batch
run log shows what files
you ran, and any errors or
warnings for each case.
Using the batch process
can save you from hav-
ing to wait for each case
Figure 5.11 - A batch run log
to run. You can have
your case execute while at
lunch or even overnight.

Figure 5.12 - Selecting a file to open
5.4 Loading
Data from Disk
After you enter data and
store a file you can easily
modify it by loading it
back in memory. Also,
you can load a file with
saved output and view or
print the output results
without having to rerun
a case (non-AI mode).
You can do this by:
- Clicking on the Open
button on the toolbar
(second from left).
- Clicking on File on

the Menu bar and then on Open, or by pressing
C+ o.
Also, XROD keeps track of up to nine of the most
recent files you saved or loaded and allows you to
quickly load any of them. To see a list of these files
click on the drop-down icon between the file open
and file save icons on the tool bar and then click on
the file you want to load. Or, you can click on File
from the menu bar and select Recent Files
If there is data in memory, XROD will warn you
that loading new data will erase the existing data
in memory. This alerts you and helps prevent ac-
cidental loss of your data before you have a chance
to save it.
XROD has a powerful and easy-to-use file man-
agement system. When you select to load data
from disk, XROD displays the current path and
a list of files in the current directory in alphabeti-
cal order. Also, XROD allows you to read ROD-
DIAG files, XDIAG files, and even older XROD
files. XROD displays a list of the file type you
selected in the current directory as the Figure 5.12
shows.
To load one of these files, double click on it, or
Figure 5.13 - Minimized input windows
XROD| 59
click on it once and then click on OK. If the file
you want is not in the current directory, you can
easily move to any directory on any drive in your
system since this window also lists sub directories,
and system drives.
If your current directory contains many XROD
files, it may be faster to press the first character of
the file you are looking for. For example, if you are
looking for well name PR101.XRVX, click in the
list once, and then press p and the program will
jump to the first file in the list that starts with P.
5.4.1 Viewing Previously Saved Output
When you load a RSVX file that contains output
you can display the output without having to rerun
the case. When you load a case that contains input
data only (no output results were saved), XROD
displays the first input window (well information).
Also, the report and print icons on the toolbar are
not available. However, when you load a file that
contains both input and output, XROD does not
open any input windows. The status bar at the bot-
tom of the screen shows a message like the follow-
ing:
Successfully loaded file: C:\The-
ta\XROD cases\special cases\
abc#1.rsvx (output results are
available).
Also, the report and print icons
on the tool bar are active. To see
the output without having to re-
run the case, click on the report
icon on the tool bar. To print the
output, click on the printer icon
(next to the e-mail icon).
5.5 Manipulating
Input Windows
XROD is a standard Microsoft
Windows application and it al-
60 | Changing, Loading and Saving Data

lows you to manipulate the input windows several

different ways. After entering data for all the input
windows, or after you load a file from disk, you
can display one window at a time, you can open
all windows, or you can arrange them any way you
want as explained below:
After entering data for a case or after load-
ing a file from disk, click on each windows icon on
the toolbar. This loads all input windows.
You can click on the minimize button of
each form to minimize them into icons at the
bottom of the main window as Figure 5.11 shows.
To open any of the minimized windows, double
click on its icon or click on it once and then select
Restore.
You can use the mouse to resize windows,
or to drag a window or an icon anywhere in the
XROD main window.

6 Rod Pump System Design
You can use XROD to quickly design any rod
pumping system, compare pumping units, sucker
rod designs, insert versus tubing pumps, clockwise
versus counterclockwise crank rotation, include
IPR modeling in your predictions, etc. XROD can
calculate the pumping speed, pump plunger size,
and rod string design for you. Also, it can recom-
mend motor size and pumping unit size based on
your target production. These powerful features
help you design rod pumping systems faster than
ever before. Also, because XROD uses state-of-
Figure 6.1 - XROD Summary Report
XROD| 61
the-art design algorithms, it is very accurate and
reliable. The biggest advantage of XROD is that
it lets you design rod pumping systems very fast
using your AI mode preferences. You can then go
into the individual design and fine tune it if neces-
sary. This dramatically reduces the time it takes to
design rod pumping systems. I also improves the
designs since the AI capabilities of XROD result
in excellent system designs with very high scores.
Because XROD can predict energy consumption
very accurately, you can use it to select the most
62 | Rod Pump System Design
economic system designs. The following sections
explain how to apply XROD to solve common de-
sign problems. As you become more familiar with
XROD you will discover many different applica-
tions for this powerful rod pump system design
tool. XRODs capability to read RODDIAG and
XDIAG files (in non-AI mode) and overlay the
measured dynamometer card on the same plot as
the predicted one is very useful. With this capabil-
ity you can:
1. Perform a History Match on existing rod
pumping systems before you make a design
change. This allows you to figure out unknown
quantities such as rod-tubing friction.
2. Detect an out-of-calibration load cell (used
to record the actual dynamometer card) by
checking for a consistent shift in actual versus
predicted dynamometer card shape.
3. Detect incorrect fluid level measurements due
to foam in gassy wells.
Figure 6.2 - Dynamometer plots and Permissible Load diagram
6.1 Understanding XRODs Output
To maximize the benefit of using XROD, it is
important to understand its output. After XROD
runs in non-AI mode, it displays the summary
output report page. Also, it shows buttons on the
bottom of the output window that allows you to
access the predicted dynamometer plot, torque
plot, IPR plot (if IPR data was entered), or return
to the output report as Figure 6.1 shows.
6.1.1 Dynamometer and Permissible Load Plots
When you click on the Dynamometer button
then you see the predicted surface and downhole
dynamometer card plots along with the permis-
sible load diagram as shown in Figure 6.2 . These
plots show the predicted surface and downhole
dynamometer cards, measured surface dynamom-
eter card from a RODDIAG or XDIAG file (if

you selected that option), and the permissible load
diagram. XROD uses a permissible load diagram
that shows if the gearbox or structure of the
pumping unit are overloaded or if the minimum
polished rod load is negative. This is different
than the traditional permissible load diagram that
only shows whether the gearbox is overloaded. This
extended permissible load diagram can be made
up of curved lines only, combination of curved and
straight lines, or straight lines only. If the upstroke
part of the predicted surface dynamometer card
exceeds the curved line of the permissible load
diagram this indicates that the gearbox is over-
loaded at that point. If the dynamometer card cuts
into the straight line section of the permissible
load diagram on the upstroke, this indicates that
the structure of the pumping unit is overloaded
because the polished rod load is larger than the
structure rating of the unit.
For the exact numbers of peak net gearbox torque
and gearbox loading, look at the torque analy-
Figure 6.3 - Torque plot
XROD| 63
sis section of the printout. The permissible load
diagram corresponds to existing conditions if you
entered a counterbalance moment. If you did not
enter an existing max. CB moment then the pro-
gram shows a permissible load diagram for bal-
anced condition (for minimizing gearbox torque).
Note!: The above discussion about XRODs
permissible load diagram refers to beam pump-
ing units. The permissible load diagram for
long stroke units such as the Rotaflex will have
straight line segments that correspond to gear-
box loading or structure loading. Please look at
the structure loading number on the first page
of the output and the percent gearbox loading
under torque analysis 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
64 | Rod Pump System Design
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 of the
permissible load diagram, this shows that design
changes are necessary to avoid overloading the
pumping unit and to better match it to the rest of
the system. If the permissible load has a trend that
is opposite than the predicted dynamometer card,
it may indicate that the pumping unit you se-
lected is not the best geometry for this application.
You may have to change the spm, plunger size,
rod string design, or stroke length to get a better
match between the dynamometer card and permis-
Figure 6.4 - Inflow performance relationship (IPR) plot
sible load diagram.
Including prime mover speed variation and inertia
effects will alter the shape of the permissible load
diagram. The lines will be smoother if you do not
include prime mover speed variation. If you include
speed variation the permissible load diagram will
tend to reflect changes in polished rod load. This
is because the permissible load diagram in XROD
includes the effect of rotating and articulating mo-
ments of inertia. As the prime mover speed chang-
es, this causes changes in polished rod velocity and
acceleration which in turn changes the polished
rod load and the distance between the dynamom-
eter card and the permissible load diagram.

The output window has new buttons that allow
you to animate the calculated dynamometer cards.
Figure 6.2 shows a play button (the one with the
double arrow) which causes small dots to move
around the surface and downhole dynamometer
cards; a stop button which makes the movement
stop; and a step button (the one with the single
arrow) which lets you move the dots one time-step
at a time, while holding the button down moves
the dots in slow motion. This facility can be used
to get a better understanding of rod stretch effects
and other phenomena such as the position and
speed of the pump plunger and how this relates to
the surface dynamometer card.
From this screen you can look at any other part of
the output by clicking the appropriate option at
the bottom of the screen. For example, to view the
torque plots click on Torque. Also, you can select
to view the report on screen, or you can send the
output to the printer. After you are done viewing
the output, close the screen by clicking on Close.
6.1.2 Torque Plot
When you click on the Torque Plot button
XROD displays the net gearbox torque plots for
existing and balanced conditions. If you entered an
existing maximum counterbalance moment, then
you may see a plot with up to three curves: one for
existing conditions, one for balanced conditions for
minimum torque, and one for minimum energy
consumption. If there is no difference between
the curve for minimum torque and the one for
minimum energy, then the program shows only
two curves (existing and balanced). If you selected
unknown max. CB moment then XROD will
only show one curve if there is little difference
between balanced for min. torque vs balanced for
minimum energy consumption (see Figure 6.3).
Otherwise, it will show two balanced curves: one
for minimizing torque and one for minimizing
energy consumption.
XROD| 65
6.1.3 IPR Plot
When you click on the IPR Plot button, XROD
displays separate oil, water, and fluid production
versus flowing bottomhole pressure plots as Figure
6.4 shows. Also, it shows a line with the current
bottom hole pressure and the test points you en-
tered. The line below the title of the plot shows the
correlation you selected to use for the oil IPR and
if you selected the Fetkovich method, it shows the
value of n. If you only enter one test point, n is set
to one. If you enter two or more test points then
XROD calculates the value of n by doing a log-log
plot. For water, XROD uses a straight line IPR.
6.1.4 Report
To see the report, click on the Report button.
To open a report from the batch log simply click
on the file name. You can scroll this window using
the mouse by clicking or the up or down arrows
at the top or bottom of the range bar on the right
edge of the window.
Or, you can click and drag the range bar or the
report itself with the mouse.
Cover Page
If this page is enabled, it will be the first page of
the report. This page is designed to create a pre-
sentable cover page when sending reports to other
parties. You may put your company logo and con-
tact information as well the recipients information
clearly documenting who performed the run and
who the run is addressed to.
Scoring
This page will display the overall score of the
design in a basic letter grade format. If there are
any areas of concern which may have caused a low
score, XROD will display the issues here and rec-
ommend solutions to the problems. If the system
receives a good score without recommendations,
then the scoring page will not be displayed.
66 | Rod Pump System Design
Input and Output Summary
The summary report that appears when you first
run XROD shows input data on the left side of the
page and calculated numbers on the right size. The
top part of the printout shows the company name,
well name, user name, date of the run, and com-
ment. Following is a detailed explanation of each
item on the output.
Polished Rod Loads and Horsepower
The peak and minimum polished rod loads show
the polished rod load fluctuation predicted by
XROD. The polished rod horsepower shows how
much work the pumping system is putting into the
rod string to lift the predicted production from the
present fluid level to the surface.
If you entered a target production or used IPR data
to determine the target production, XROD calcu-
lates the SPM required to get the target produc-
tion.
System Efficiency
The system efficiency is calculated by regarding
the whole pumping system as a black box with
electricity going in and produced fluid coming out.
This number shows how efficiently the system con-
verts electric power to work needed to lift the pro-
duced fluid to the surface. A system efficiency of
45% or above is excellent. In General, deeper wells
will have lower efficiencies than shallow wells since
deep wells have more rod-tubing frictional loses.
Efficiencies of 35%-45% are average, while system
efficiencies of less than 35% are poor and can usu-
ally be increased by using a longer, slower stroke
(with larger pump plunger).
Permissible Load HP
Permissible load horsepower is defined as 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.
The ratio PLHP/PRHP (permissible load HP
divided by polished rod HP) is a number that
should be as large as possible without overloading
the pumping unit. The larger this number is, the
more of the pumping unit potential capacity you
are using.
Fluid load on Pump
Fluid load on the pump shows how much fluid
load the plunger is carrying on the upstroke. This
is a function of pump depth, fluid level from sur-
face, and plunger size. Fluid load on the pump is a
function of pressure difference across the plunger
and pump plunger diameter.
Unit Structural Loading
Pumping unit Structural Loading indicates wheth-
er or not the pumping unit structure is overloaded.
This is a function of the peak polished rod load
and the structural capacity of the pumping unit
(the middle number in the API pumping unit
designation).
Buoyant Rod Weight
Buoyant rod weight shows how much the rod
string weighs in fluid. Since the rod string is im-
mersed in the fluid inside the tubing, it weighs
less than in air. You can compare this number to
a measured standing valve load. A good standing
valve check should be close to the weight of rods in
fluid as calculated by XROD for a pump that is in
good mechanical condition. If these two numbers
differ by more than 10% and the standing valve is
in good condition, it may be an indication that the
load cell is out of calibration or that the standing
valve load was incorrectly measured. Also, the sum
of the buoyant rod weight plus fluid load on the
pump should be close to the traveling valve load
for a good pump.

Figure 6.5 - Section of XROD Output Report
N/No and Fo/Skr
The dimensionless numbers N/No and Fo/SKr
are defined in API RP 11L1 . N/No is the ratio
of pumping speed to natural frequency of the rod
string. Fo/SKr is the rod stretch caused by the
static application of fluid load, as a percent of the
polished rod load stroke. In general, the higher
the Fo/Skr is, the shorter the pump stroke will be.
Also, the higher the N/No the larger the pump
stroke is. These numbers also relate to system ef-
ficiency. In general, the larger N/No is, the lower
the efficiency will be. The larger the Fo/SKr is,
the better the system efficiency is. However, this
relationship is not linear.
For low Fo/Skr numbers (below 0.25) fiberglass-
steel rod strings will have very low system efficien-
cies and should be avoided. For fiberglass rods try
1 API RP 11L (Third Edition) Recommended
Practice for Design Calculations for Sucker Rod
Pumping Units. American Petroleum Institute,
Dallas TX.
XROD| 67
to keep Fo/Skr above 0.3 and below .8 for best
results. Also for fiberglass rod strings, you should
keep N/No below 1.0 and above .4 for best results.
Prime Mover Speed Variation
If you select to have XROD calculate the motor
speed variation for you then this section shows
what this number is. For NEMA D motors this
number will vary from 2% to 14% depending on
motor size. For correctly sized ultra high slip mo-
tors it can be as high as 50%. If motor speed varia-
tion is not considered then this will be indicated
on the output report.
Pumping Unit Data
This section (see Figure 6.5) shows the pumping
unit you selected, the pumping unit ID, the cal-
culated stroke length, the structural unbalance,
the crank offset angle, crank rotation with the
well to the right, and the crank hole number. If
68 | Rod Pump System Design
you entered your own pumping unit dimensions
for a unit not in the programs database, if the
calculated stroke length is different from what you
think it should be, check the pumping unit data to
make sure you entered the right dimensions. If you
selected to include speed variation and inertia ef-
fects in the calculations, XROD will also print the
rotating and articulating moments of inertia.
Torque Analysis and Electricity Consumption
In this section, the program prints the predicted
peak gearbox torque, percent gearbox loading, cy-
clic load factor, maximum counterbalance moment,
and counterbalance effect. Also, it calculates elec-
tricity consumption. XROD predicts the KWH
consumed per day, the estimated monthly bill, and
cost per barrel of fluid and per barrel of oil per day.
Use the cost per barrel numbers when comparing
system performance to ensure a valid comparison.
This is because a system that shows a lower month-
ly bill may also be producing less fluid.
If you enter a non-zero maximum counterbalance
moment the program calculates the above num-
bers for both existing and balanced conditions. If
the existing max. CB is unknown, it will calculate
the above numbers for balanced conditions only.
XROD has the capability to balance pumping
units for minimum torque and minimum energy. If
the maximum counterbalance moment for mini-
mum energy equals the one for minimum torque
then the program shows only one recommendation
for balanced conditions. However, if the two values
are more than 2% different then it shows two bal-
anced columns: One for minimum torque, and one
for minimum energy. The torque plots show how
net gearbox torque changes throughout the pump-
ing cycle for existing and balanced conditions.
To maximize gearbox life you must keep gearbox
loading less than 100%. The cyclic load factor
indicates how smooth the gearbox torque is. The
smaller this number is, the more uniform the net
gearbox torque is. Also, a smaller cyclic load factor
will result in higher system efficiency because of
less thermal losses in the motor.
Tubing, and Pump Information
Here you see the tubing inside and outside di-
ameters, the anchor depth, the calculated tubing
stretch, the upstroke and downstroke rod-tubing
friction factors you entered or that were calculated
by XROD, pump load adjustment., etc. Also, this
section shows the pump depth, the pump type,
and plunger size.
XROD uses the pump volumetric efficiency you
enter to calculate the expected production rate.
When you ask the program to calculate the spm
by entering a target production, it will calculate a
larger spm if you enter 80% pump efficiency than
when you enter 90% pump efficiency.
Tubing, Pump and Plunger Calculations
This section shows tubing stretch and production
loss due to tubing stretch, gross pump stroke, the
pump spacing recommendation, minimum re-
quired pump length, and recommended plunger
length. The pump spacing recommendation should
be used as follows:
After working on the well and before you
are ready to restart the pumping unit, make
sure the tubing is full of fluid. Then lower
the rod string slowly until it tags bottom.
Then raise the rod string a distance equal
to the one recommended by XROD next to:
Pump spacing (in. from bottom): Then,
attach the polished rod to the bridle with the
unit stopped at the very bottom of the down-
stroke.
Please note that the working fluid level makes a
big difference in pump spacing and pump length.
This is especially true for fiberglass rods since the
plunger travel is strongly dependent on fluid load
on the plunger.
Rod String Design and Stress Analysis
This section shows the rod string design and ser-
vice factor you selected, the calculated percent rod

loading for each rod section, the maximum and
minimum stresses at the top, and the bottom min-
imum stress for each rod section. To ensure your
rods are in tension, do not include buoyancy effects
(this should always be the case for steel rods).
Then, make sure there are no negative stresses on
any other rod section other than the sinker bar sec-
tion on the bottom of the rod string.
If you are using fiberglass rods you would not want
to use a design with a negative bottom minimum
stress on the fiberglass section even with buoyancy
effects included. Compressive loading will cause
fiberglass rods to part. Also, to maximize rod life,
stress loading must be less than 100% in all cases.
For sinker bars, XROD calculates stress loading,
top maximum and top minimum stresses based on
the elevator neck or pin undercut diameter of the
sinker bars. However, XROD still uses the full
body diameter in the calculation of stress at the
bottom of the sinker bar section.
Rod String and Pumping Unit Cost Analysis
This section shows the cost of each rod section as
well as the total rod string cost (see Figure 6.6).
Figure 6.6 - System cost analysis
XROD| 69
Also, below the rod string cost is the pumping unit
cost. XROD shows the cost information only if
you select this option in Setup. You must first enter
rod string and pumping unit cost data in Setup
before XROD can show you accurate cost infor-
mation here.
Inflow Performance Relationship Information
This section shows the correlation used for oil
IPR, mid-perf depth, the static bottomhole pres-
sure, and the bubble point pressure (if entered) or
whether the well is producing below the bubble
point pressure. Also, it shows a table of input test
point data of flowing bottomhole pressure versus
measured production, and a table of pressure vs.
production table. As Figure 6.7 shows, this table
shows separate oil, water, and fluid production
rates for different pump intake pressures.
6.2 Rod Pump System Design
Guidelines
The following discussion applies to XRODs
non-AI mode. When designing a rod pumping
70 | Rod Pump System Design
system you must specify the equipment, strokes
per minute, and stroke length required to get the
desired production at the lowest possible cost. In
your efforts to select the best system design for
your well you will be mostly concerned with the
following parameters:
Production Rate
Capital costs
Rod loading
Gearbox loading
System efficiency and power costs
Ideally, the system you select will give the highest
present value profit after tax, considering capital
and operating costs. Up to now, rod system design
was a tedious trial and error process that usu-
ally resulted in a system that could be far from
ideal. Since achieving an optimum design requires
equipment and data that may not be available, only
the most obvious system parameters are usually
considered. In most cases production rate is of
highest priority, followed by rod loading, gear-
box loading, and energy cost. If electricity cost is
high, you can lower it by using a larger pump and
a slower pumping speed. However, a large pump
will increase rod loading and gearbox torque.
Also, a large pumping unit must be used. This will
increase capital cost. On the other hand, a small
pump demands a faster pumping speed and longer
stroke to maintain production. This increases ener-
gy consumption but reduces the required pumping
unit size. Usually, you must reach a compromise
Figure 6.7 - IPR report
between efficiency, rod loading, pumping unit size,
and cost.
A very important aspect of system design is pump-
ing rate. If you know the maximum production
rate you can expect then design the pumping sys-
tem for a production rate a little higher than that.
This ensures enough pump capacity to account for
normal pump wear and inaccurate data. However,
if the pumping rate is substantially higher than
what the well is capable of producing, then the
well will pump off. Fluid pound is a problem that
results from the common practice of over-design-
ing the pumping capacity. Fluid pound is damag-
ing to pump, rods and pumping unit. If you do not
take steps to minimize fluid pound it will reduce
efficiency and equipment life. You can reduce fluid
pound by slowing down the unit, shortening the
stroke length, using a smaller pump, or by install-
ing a percentage timer or pump off controller.
Because XROD can simulate fluid pound, you can
use it to see what will happen if the well pumps
off.
6.2.1 Shallow, High Rate Well Simulation
XROD can simulate any pumping unit geometry
and gives accurate results for any pump depth or
production rate. This is especially significant for
shallow well applications because conventional
design computer programs such as the API RP
11L and other wave equation programs give poor
results. This is because at shallow depths, polished

rod load is increasingly dependent on the dynamic
effects of fluid in the tubing. This is especially
true for high production rate shallow wells (pump
depth less than 4000 feet with larger than 2.00
plunger).
To accurately simulate these wells, XROD uses two
wave equation models simultaneously, one for the rod
string and one for the fluid in the tubing. This unique
capability allows very accurate predictions. XROD
can predict the expected surface and downhole
dynamometer card shapes common to shallow,
high rate wells. When designing shallow high rate
wells it is recommended that you use pump ef-
ficiencies of 90%-95% to avoid under-predicting
peak polished rod load, torque, etc. This higher
pump efficiency will result in higher fluid velocity
in the tubing and higher fluid inertia forces on the
plunger. However, when you are trying to history
match an existing system, you may need to use a
pump efficiency of less than 90% to better match
the actual pump slippage of your system.
6.2.2 Selecting the Target Production
To avoid severely over-sizing the displacement
capacity of your pumping system, design it with a
pump efficiency of 80%-85% or even 75% if you
expect the downhole pump to wear out quickly.
This ensures that you will get your production
without grossly over-designing the system.
To minimize energy consumption and stress load-
ing, use the largest plunger diameter and slow-
est pumping speed combination possible without
overloading the rod string and pumping unit. If
you have to make a choice between stress loading
and power consumption, opt for lower stress load-
ing especially if you are close to 100% since rod
breaks are more costly than a slightly lower system
efficiency.
Note that these are only general guidelines. Eco-
nomics and local field conditions may require a
different design philosophy than the one described
above. Regardless of your objectives and design
philosophy, with XROD you can design rod
XROD| 71
pumping systems faster and more accurately than
with any other computer program.
6.2.3 Avoiding Rod Compression
XROD calculates rod stresses at the top and bot-
tom of each rod section. It calculates the maximum
and minimum stress at the top of each rod section
in order to calculate the percent stress loading. It
also calculates the minimum stress at the bottom
of each rod section. The bottom minimum stress
shows if the rods are in compression.
Steel rods can tolerate some compressive force but
fiberglass rods cannot tolerate any compression
at all. This is why fiberglass rods must have steel
rods or sinker bars at the bottom. The weight of
the sinker bars overcomes the opposing hydrostatic
force and pump friction. If correctly designed, the
sinker bars or steel rods ensure that the fiberglass
rods are always in tension.
Although steel rods can be subjected to some com-
pression without adverse effects, excessive negative
stresses can cause buckling problems. The recom-
mended way to use XROD to determine how
many sinker bars you need to avoid compres-
sion is to select to have the program design the
sinker bars for you in the AI Mode Preferences in
Setup. Other ways of minimizing buckling prob-
lems include using smaller pumping speeds and
avoiding use of small diameter rods such as 5/8 or
even .
Please note that XROD can design the sinker bars
you need to keep the rods in tension and avoid
buckling even in non-AI mode.
6.2.4 Minimizing Power Consumption
In general, the slower the pumping speed and the
larger the pump plunger size, the less energy the
pumping system will use. However, minimizing
energy consumption must not be the sole purpose
of system design because a large pump plunger
diameter will result in large polished rod load and
72 | Rod Pump System Design
gearbox torque. This will require the purchase of a
larger unit, larger rods and bigger prime mover. To
come up with the best pumping system design you
must consider the economics of the whole system
and whether you plan to use existing equipment or
buy new ones.
XRODs power and ease of use allows you to get
the most economic pumping system based on
your economic criteria. Because XROD calculates
the predicted energy consumption, rod sizes, rod
loading, and recommends a pumping unit size,
it provides you with the data you need for sound
economic decisions.
6.2.5 Reducing Gearbox Torque
Sometimes, using the largest unit stroke may not
be the best way to maximize production since it
can result in severe gearbox overload. If this oc-
curs you may be able to use the next smaller unit
stroke and speed up the unit to get your produc-
tion without overloading the gearbox. Another way
of reducing gearbox loading is by using a smaller
pump plunger. Another way is to use a lighter rod
string by using either high strength steel or fiber-
glass rods.
Also, you can reduce gearbox torque with an ultra
high slip motor. XROD can predict the gearbox
torque depending on the pumping unit size and ul-
tra high slip motor size. Also, XROD can calculate
the motor speed variation and power consumption
very accurately.
6.2.6 Using XROD for Correct Equipment Sizing
When designing a new rod pump system you must
ensure that the system you select has sufficient ca-
pacity to produce the well under the heaviest loads
possible during its operating life. For most systems
this will occur when the fluid level is at the pump.
Therefore, even if you do not expect the fluid level
to be at the pump, it is a good idea to design the
pumping system (especially when using steel rods)
for fluid level at the pump. This ensures that the
equipment you plan to use will not be overloaded if
the fluid level drops in the future.
For systems with fiberglass-steel rod strings, you
may get higher gearbox torque loads and higher
polished rod horsepower when the fluid level is
above the pump. This occurs because fiberglass rods
are very sensitive to fluid load. When the fluid
level is above the pump, the fluid load on the pump
is reduced. This causes a longer pump stroke which
in turn affects the shape of the surface dynamome-
ter card making it fatter. This in many cases brings
the predicted surface dynamometer card closer to
the permissible load diagram causing the gearbox
load to increase. Also, when the area of the surface
dynamometer card increases, the system requires
a larger motor size. This means that when you use
fiberglass rods you should run system simulations
using different fluid levels (within the expected
fluid level range) to see which fluid level results in
the highest loads and largest required motor size.
Using different fluid levels also affects the calculat-
ed pump stroke length and therefore the required
pump length and pump spacing . XROD can
recommend a NEMA D motor size based on the
fluid level or pump intake pressure you enter.
TIP: You can speed up your system design con-
siderably by asking XROD to design a rod string
for you. Even if you do not plan to use the design
XROD recommends, it is easy to grab XRODs
recommended design and modify it. To do this,
after the program runs, go to the rod string entry
screen and select the Manual rod string entry
option. The program will default to the rod string
it calculated, and it will display this data as if you
had entered it yourself. So, you can simply change
only the data you want to modify. Please keep in
mind that XROD expects the length of the rod
string you enter to be within 50 feet of the pump
depth. However, it cannot be longer than the
pump depth.
6.2.7 Using XROD for Diagnostic Analysis
Although XROD is primarily a design tool it can
 XROD| 73

be a very powerful diagnostic aid, when used in
conjunction with RODDIAG or XDIAG. This
is due to the powerful overlay feature that allows
direct comparison of predicted versus measured
dynamometer cards.
Rod-tubing friction is especially important
for fiberglass rods. Higher friction than
normal may actually reduce the area of the
predicted surface dynamometer card because
it causes the rods to stretch which results in a
small stroke at the pump.

Using XRODs Dynamometer Overlay Feature

This feature has many different uses. For example,
it can help you figure out if your load cell is out
of calibration, if the fluid level you measured was
incorrect, etc. XROD can help you find these
problems by comparing the shape and load range
of the measured dynamometer card versus the one
predicted by the program. Also, it 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 of zero feet
from surface. This will result in zero fluid load on
the pump plunger.
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. Then,
by comparing the actual dynamometer card shape
with the theoretical shape, you can have more
confidence in your diagnosis of the problem. For
example, if you have a traveling or standing valve
leak or a worn out pump, then the pump will be
doing less work and the surface dynamometer card
will have less area than the theoretical polished rod
dynamometer card.
If the pump is sticking, or if there is more friction
than normal between rods and tubing (due to par-
affin, scale, etc.), the measured dynamometer card
will be fatter than normal. The theoretical polished
rod dynamometer card predicted by XROD (for
average friction calculated by the program) will be
smaller than the measured dynamometer card. By
entering a larger rod-tubing friction coefficient you
can get a better match between actual and predict-
ed dynamometer cards. This technique helps you
figure out what rod-tubing friction factor to use for
better simulation of your rod pumping wells.
Theta Oilfield Services, Inc., 3075 E. Imperial Hwy Suite 125, Brea, CA 92821 USA
Phone: (562) 694-3297 | gotheta.com