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STIPumpCard™ User Manual
STIPumpCard™
User Manual
Contents 1. Introduction ...................................................................................................................1
1.1. What is STIPumpCard? .................................................................................................... 1
1.2. Main User Interface ......................................................................................................... 2
2. Input Parameters ............................................................................................................3
2.1. Project Folder .................................................................................................................. 3
2.2. Simulation Setting ........................................................................................................... 3
2.3. Deviated Well Mode ........................................................................................................ 4
2.4. Pump Load Analysis ......................................................................................................... 6
2.5. Input Parameters ............................................................................................................. 7
3. Rod Properties ................................................................................................................8
3.1. Material Properties Table ................................................................................................ 9
3.2. Rod Properties Table ....................................................................................................... 9
4. Surface Unit ................................................................................................................. 10
4.1. Surface Unit Types ......................................................................................................... 10
4.2. Surface Unit Inputs ........................................................................................................ 11
4.3. Surface Unit Information ............................................................................................... 13
5. Borehole Profile ........................................................................................................... 14
6. Outputs ........................................................................................................................ 15
6.1. Output Plots/Tables ....................................................................................................... 15
6.2. Output Parameters ........................................................................................................ 16
6.3. Output Files ................................................................................................................... 16
6.4. Output Examples ........................................................................................................... 17
7. Tools ............................................................................................................................ 21
7.1. Unit Conversion ............................................................................................................. 21
7.2. Density Calculator.......................................................................................................... 22
7.3. Intake Pressure Calculator ............................................................................................. 23
7.3.1. Pump Intake Pressure from IPR Data ........................................................................ 23
7.3.2. Pump Intake Fluid Level ............................................................................................. 24
7.4. Stroke Rate Calculator ................................................................................................... 24
7.5. Free Gas Calculator ........................................................................................................ 25
List of Figures Figure 1 Main User Interface ........................................................................................................... 2
Figure 2 Input Parameters Panel ..................................................................................................... 3
Figure 3 Project Folder Selection Panel ........................................................................................... 3
Figure 4 Cartesian Borehole Profile File Format ............................................................................. 4
Figure 5 Polar Borehole Profile File Format ................................................................................ 5
Figure 6 Single-Point Survey Borehole Profile File Format ....................................................... 5
Figure 7 Pump Load Analysis File Format ........................................................................................ 6
Figure 8 Input Parameters Panel ..................................................................................................... 7
Figure 9 Valve Spacing Explanation ................................................................................................. 7
Figure 10 Rod properties Panel ....................................................................................................... 8
Figure 11 Material Properties Table ................................................................................................ 9
Figure 12 Material Properties File Format ...................................................................................... 9
Figure 13 Rod Properties Table ....................................................................................................... 9
Figure 14 Unit Types ...................................................................................................................... 10
Figure 15 Surface Unit Panel ......................................................................................................... 11
Figure 16 Surface Unit Information Panel ..................................................................................... 13
Figure 17 Borehole Profile Panel ................................................................................................... 14
Figure 18 Borehole Profile Plot Sample ......................................................................................... 14
Figure 19 Outputs Panel ................................................................................................................ 15
Figure 20 Available Output Plots and Tables ................................................................................. 15
Figure 21 Output Parameters Panel .............................................................................................. 16
Figure 22 Rod Stress vs. Time ........................................................................................................ 17
Figure 23 Maximum Compressive Load on Rod ............................................................................ 17
Figure 24 Fatigue life of Rod .......................................................................................................... 18
Figure 25 % of Goodman Stress .................................................................................................... 18
Figure 26 Torque vs. Angle ............................................................................................................ 19
Figure 27 Dynamometer Cards ...................................................................................................... 19
Figure 28 Pump Speed vs. Position ............................................................................................... 20
Figure 29 Pump Load Analysis Output .......................................................................................... 20
Figure 30 Output Table .................................................................................................................. 21
Figure 31 Input Table ..................................................................................................................... 21
Figure 32 Unit Conversion Panel ................................................................................................... 22
Figure 33 Density Calculator Panel ................................................................................................ 23
Figure 34 Intake Pressure Panel .................................................................................................... 24
Figure 35 Stroke Rate Calculation Panel ....................................................................................... 25
Figure 36 Free Gas Calculation Panel ............................................................................................ 26
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1. Introduction
1.1. What is STIPumpCard?
STIPumpCard™ is a powerful and user-friendly software for simulating dynamic behaviors
of pump jacks. It is capable of predicting the behavior for a wide range of wells.
STIPumpCard has three main simulation modes; "Vertical Well", "Deviated Well" and "Pump
Load Analysis".
"Vertical Well" and "Deviated Well" simulations can be used for the design process. They
produces a number of plots, including Dynamometer Cards, Fatigue Life predictions,
Compressive Load distribution and Speed Reducer Torque. STIPumpCard also predicts
other parameters such as the minimum required Motor Power and required speed reducer
torque rating. Additionally, STIPumpCard is capable of predicting a wide range of
phenomena such as fluid pound, gas interference, and gas locking.
STIPumpCard can also be used to troubleshoot downhole conditions, and record surface
load data to predict the load at the plunger.
STIPumpCard comes with a set of tools, including Unit Conversion Tool, Stroke Rate
Calculator, Pump Intake Pressure Calculator and Free Gas Calculator. The Unit Conversion
Tool is very easy to use and allows the conversion between to a wide selection of units. The
Stroke Rate Calculator determines the stroke rate required to produce a target production.
The Pump Intake Pressure Calculator determines the intake pressure from fluid level or IPR
data. Finally, the Free Gas Calculator determines the amount of free gas in the pump based
on conditions of the well and gas anchoring.
The user can save input information and load the project later or pass it on to another user.
After each simulation, all the simulated input and output data or figures are automatically
stored in the specified project directory.
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1.2. Main User Interface
Figure 1 Main User Interface
The following is a description of tabs in the main user interface.
1. Input Parameters: Allows the user to specify the relevant simulation input parameters.
Details may be found in Section 2.
2. Rod Properties: Allows the user to specify the relevant rod properties. Details may be
found in Section 3.
3. Surface Unit: Allows the user to specify the available surface unit types. Details may be
found in Section 4.
4. Borehole profile: Allows the user to specify the borehole profile for the Deviated Well
mode as detailed in section 5.
5. Output: Allows the user to choose the required output plots or tables, as detailed in
Section 6.
6. Tools: Provides the user with calculation and conversion tools as detailed in section 7.
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2. Input Parameters
Figure 2 Input Parameters Panel
2.1. Project Folder
Figure 3 Project Folder Selection Panel
The 'Project Folder...’ button selects the current Project Folder, where the Project
input/output files are stored.
Some input parameters, such as borehole profile (when using Deviated Mode), and surface
load file (when using Pump Load Analysis) must be placed into this project folder.
2.2. Simulation Setting
The user is able to select the number of strokes and simulation modes in this panel.
Simulate Number of Strokes represents the number of cycles that the program will
simulate. STIPumpCard™ simulates the dynamic behavior of the sucker rod starting at rest,
therefore, it is recommended to simulate at least two strokes before the rod reaches its
steady state behavior. Simulating a large number of strokes will result in unnecessary and
additional computation time.
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Three Simulation Modes are available in STIPumpCard:
Vertical Well: Simulates wells that are not significantly deviated
Deviated Well: Simulates deviated wells by accounting for the contact friction
between the rod and the tubing.
Pump Load Analysis: Obtains the load on the plunger for a given surface
Time/Displacement/Load Data Set
2.3. Deviated Well Mode
This panel is enabled when the user selects "Deviated Well" in the Simulation Settings.
Friction Coefficient represents the kinetic contact friction coefficient between the rod and
the tubing.
Model Name is a name given to the well and borehole profile. Contact force data will be
computed and stored in a folder with the Model Name in the project folder directory.
The Borehole profile file is a 3-column, comma-delimited text file which specifies the
length and orientation of the borehole. This file must be saved in the project folder.
Survey listings can be in one of three formats; Cartesian, Polar or single-point survey. Both
the format and the units are automatically detected. Units of length can either be in feet
(specified by the abbreviation ft) or meters (specified by the abbreviation m). The units of
the angular measure are assumed to be in degrees. A description of each of the file formats
is given below.
Cartesian
In this format, the three columns represent True Vertical Depth (TVD), N(+)/S and E(+)/W.
The TVD corresponds to the negative z-axis, the N(+)/S to the +y/-y axis and the E(+)/W to
the +x/-x. An example of a file in Cartesian format is shown in Figure 4.
TVD,N(+)/S,E(+)/W
ft,ft,ft
0.00,0.00,0.00
0.00,2788.71,0.00
8.20,2962.55,0.00
Figure 4 Cartesian Borehole Profile File Format
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Polar
In this format, the three columns represent the Measured Depth (MD), Inclination and
Azimuth. Inclination is defined as the angle that the borehole makes with the vertical.
Therefore, a 0 degree inclination is vertical (downward pointing) and a 90 degree
inclination is horizontal in direction. An angle greater than 90 degrees refers to drilling
up . Azimuth is defined as having a value of 0 degrees for a North heading, 90 degrees for an
East heading, 180 degrees for a South heading, and 270 degrees for a West heading. An
example of a file in polar format is shown in Figure 5.
MD,INC,AZ
ft,deg,deg
0.00,0.00,0.00
266,0.14,187.83
327,0.31,257.33
Figure 5 Polar Borehole Profile File Format
Single-point survey
This is a condensed version of the survey file and consists of one line with five entries. The
first three entries specify the location of the bit using measured depth, inclination and
azimuth. The next two entries specify constant build and walk rates between the between
the bit and the top of the BHA. The wellbore profile along the length of the BHA is calculated
by DSD. A sample entry is shown in Figure 6.
MD,INC,AZ,Build Rate,Walk Rate
ft,deg,deg,deg/100 ft,deg/100 ft
16500,19.9,202.42,0.1,-0.76
Figure 6 Single-Point Survey Borehole Profile File Format
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2.4. Pump Load Analysis
This panel is enabled when the user selects "Pump Load Analysis" in the Simulation Settings.
Surface Load File is a 3-column, comma-delimited text file which includes the rod surface
Time/Displacement/Load information. The units for Time, Displacement and Load should
be in (Seconds), (inches) and (pounds) respectively. Time increments must be monotonic
and reasonably small, in order to obtain an accurate pump load estimation.
Figure 7 shows a sample input file for the pump load analysis.
Time(s),Displacement(in),Load(lbf)
0,141.5559598,17024.53563
0.1,146.9631956,16622.07724
0.2,151.9146617,15961.56614
0.3,156.3219355,15272.84255
0.4,160.0907556,14833.8992
0.5,163.1506159,14691.84388
0.6,165.4594406,14594.13445
0.7,166.9670209,14415.65519
0.8,167.602792,14314.54812
0.9,167.3130376,14347.6785
1,166.0793871,14291.11012
1.1,163.8931065,13957.76437
1.2,160.7356656,13472.80681
...
Figure 7 Pump Load Analysis File Format
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2.5. Input Parameters
Figure 8 Input Parameters Panel
Figure 9 Valve Spacing Explanation
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Valve Spacing: Defined in Figure 9
Plunger Diameter: Diameter of the plunger
Tubing Outer Diameter: Outer diameter of the tubing
Tubing Inner Diameter: Inner diameter of the tubing
Fluid Temperature: Temperature of the well fluid
Pump Intake Pressure: Pressure at pump intake, in PSIG
Tubing Pressure: Pressure in the tubing at the surface, in PSIG
Gas Specific Gravity: Specific gravity of gas in the well
Oil Specific Gravity: Specific gravity of oil in the well
Water Cut: Ratio of water with respect to the total volume of fluid
Free Gas Fraction: Fractional amount of free gas presented in the plunger at pump intake
pressure
Damping Factor: Damping coefficient of the rod, dimensionless, usually 0.1 could be used
for most wells
Service Factor: Depending on the operation environment of the polished rod, the service
factor is usually between 0.4 and 1
3. Rod Properties
Figure 10 Rod properties Panel
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3.1. Material Properties Table
Figure 11 Material Properties Table
The material properties table specifies the tensile properties of different grades of material.
STIPumpCard comes with the following grades: K, C, D, KD and SB. The user can add more
grades to the table using +/- button or click on the "Read From File" button to add grades
from a comma delimited text file, an example is shown below:
Grade,Min Tensile Strength (PSI),Max Tensile Strength(PSI)
N97,140000,150000
Figure 12 Material Properties File Format
3.2. Rod Properties Table
Figure 13 Rod Properties Table
The Rod Properties table specifies the dimension, grade, and material for the polished rod
string. The rod is defined with segments from top of the rod to the bottom of the rod. The
first column represents the length of each segments, the second column represents the
diameter, the third column is the material grade (Note that the grade specified here must be
listed in the table above). A blank entry or S in the last column indicates steel. F is entered to
indicate fiberglass.
Once rod properties have been specified, a preview is shown on the right hand side. If no
preview was shown, it is likely that one or more dimensions have been incorrectly specified.
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4. Surface Unit
4.1. Surface Unit Types
STIPumpCard can model four types of units, including Conventional, Mark II, Air Balanced
or Reverse Mark (Torque Master) Units. Unit dimensions are defined as follows, note that:
K = √I2 + H − G 2
Conventional Unit Mark II Unit
Air Balanced Unit Reversed Mark Unit (Torque Master)
Figure 14 Unit Types
For the Air Balanced Unit, the user also needs to specify parameters such as M, S, Pmax, and
Pmin. M and S are geometrical and pressure constants supplied by the manufacturer. Pmax and
Pmin are the maximum and minimum pressures in the cylinder during operation.
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4.2. Surface Unit Inputs
Figure 15 Surface Unit Panel
Stroke Rate (per min): Stroke rate of the polished rod in SPM
Stroke Length (in): If you do not specify a surface unit, a simple sinusoidal rod motion will
be assumed
Calculate From Surface Unit Geometry: check this box if you know which unit you are
using and the unit geometries
Database: Click on this button to select an Excel file that contains unit information
Search Unit: Search unit name in the database selected
Select Unit: Click on any unit in the dropdown list and import the unit geometries into
the fields on the left hand side
The Excel file, PumpUnitDesignation.xlsx, contains the default pumping unit database. If a user
needs to add additional units or create their own database, the following rules have to be
followed:
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The unit has to be named according to the following rules: Conventional units start with C-, Air
balanced unit start with A-, Reversed mark start with RM-, and Mark II unit start with RM-
The first row of the data base consists of column headers, designating a particular variable e.g.
Unit means the name of the unit.
Every unit must have the following variables:
A
C
P
I
G
H
R1 (If a unit has only crank shaft hole, specify its radius under R1. If there are multiple
holes, specify each radius under R1, R2, R3... respectively)
Additional Variables needed for conventional units
SU
Additional Variables needed for Torque Master units
SU
Tau
Additional Variables needed for Mark II units
SU
Tau
Additional Variables needed for Air Balanced Units
M
S
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4.3. Surface Unit Information
Figure 16 Surface Unit Information Panel
A,C,I, P, R: Unit Dimensions as defined in the diagram
K: K = sqrt(I^2+ (H-G)^2 ) , where H,I,G are Dimensions as defined in the diagram
Structural Unbalance: This is the variable SU in the Database
Counter Weight Angle: This is the variable Tau in the Database
Maximum Moment: Maximum counter weight moment on crank shaft
S: Pressure constant supplied by manufacturer
M: Geometric constant supplied by manufacturer
Pmax: Maximum pressure in the cylinder during operation
Pmin: Minimum pressure in the cylinder during operation
Mechanical Efficiency(%): Overall mechanical efficiency of the speed reducer and
pumping unit, this will affect the required horse power for the motor
Calculated Stroke length: Calculated stroke length based on the given unit geometrical
data
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5. Borehole Profile
Figure 17 Borehole Profile Panel
Use this tab when "Deviated Well" is selected in the Input Parameter - Simulation Setting
- Simulation Mode, and the borehole profile is specified in the Input Parameter -
Deviated Well Mode - Borehole Profile. The data will be loaded and shown in the table
above. Click on "Display Borehole Profile" button and the 3D borehole profile will be
plotted.
Figure 18 Borehole Profile Plot Sample
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6. Outputs
Figure 19 Outputs Panel
6.1. Output Plots/Tables
Figure 20 Available Output Plots and Tables
Rod Stress Distribution: Display rod Stress vs. Time and Measured Depth
Rod Compression: Display a color shaded plot of the rod with maximum compressive
load (negative if the rod is constantly in tension)
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Rod Fatigue Plot: Display a color shaded plot of the rod with minimum fatigue life, and a
plot showing the % Goodman Stress vs. depth of the rod
Dynamometer Cards: Display a plot showing the surface and plunger load vs.
displacement (If program simulates the surface pumping unit, then permissible load will
be plotted based on the minimum required torque rating)
Pump Velocity: Display a plot showing the plunger speed vs. displacement
Torque: Display a plot showing the torques (polished rod torque, counter balance torque,
and net torque) vs. angular displacement of the crank shaft
Result Summary: Display a table showing the result summary.
Input Summary: Display a table showing the input summary.
Pump Load Analysis: Available for "Pump load Analysis" Simulation mode, displaying the
Dynamometer Cards determined from surface time/displacement/load data
6.2. Output Parameters
Figure 21 Output Parameters Panel
Rod Fatigue Life: Displays the expected life time of the rod before failure
Motor Requirement: Minimum Required Name Plate HP of the Motor
Speed Reducer Torque Requirement: Minimum Required Speed Reducer Torque Rating,
permissible load is plotted on the dynamometer card based on this rating
6.3. Output Files
Inside the project directory, a folder with the name "OutputFigures" will be created. All output
plots will be stored in this folder. In addition, an Excel workbook will be created, containing plot
data.
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6.4. Output Examples
Figure 22 Rod Stress vs. Time
Figure 23 Maximum Compressive Load on Rod
Figure 22 shows the stress in the rod over the simulated period of time, Figure 23 shows the
maximum compressive load in the rod over the simulated period of time, where negative is load
tension, and positive load is compression, rod sections that are in compression is marked with
red color.
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Figure 24 Fatigue life of Rod
Figure 25 % of Goodman Stress
Figure 24 shows the fatigue life of the rod, this is the maximum operating time of the rod before
fatigue failure. Figure 25 shows the percentage of Goodman stress in the rod.
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Figure 26 Torque vs. Angle
Figure 27 Dynamometer Cards
Figure 26 shows the torques in the speed reducer, this plot is available only when pump unit
information is entered. Figure 27 shows the surface and downhole dynamometer cards.
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Figure 28 Pump Speed vs. Position
Figure 29 Pump Load Analysis Output
Figure 28 shows the speed of the plunger as a function of plunger displacement. Figure 29 is
plotted when user uses "Pump Load Analysis" mode. Downhole card (Shown in blue) is
determined from the surface load card (Shown in red)
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Figure 30 Output Table
Figure 31 Input Table
Figure 30 Shows a summary of output information. Figure 31 shows a summary of input
parameters.
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7. Tools
7.1. Unit Conversion
Figure 32 Unit Conversion Panel
STIPumpCard provides a unit conversion tool that allows conversion between specified
units. The input and output unit have to be consistent, for example, kg*m/s^2 is consistent
with N but not consistent with J.
All of the available units are shown in the table, and the user can combine any of the units
using operators such as: * / sqrt() ^ .
Prefixes such as kilo or mega are treated as a dimensionless unit, a kiloN should be specified
as kilo*N.
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7.2. Density Calculator
Figure 33 Density Calculator Panel
STIPumpCard allows the user to convert liquid or gas density into specific gravity as gas/oil
specific gravity are required inputs to simulate vertical/deviated wells. A user can click on
Use This Value button to fill the input parameters form with calculated value.
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7.3. Intake Pressure Calculator
Figure 34 Intake Pressure Panel
If the user does not know the Pump Intake Pressure value, it can be calculated in two ways,
either from IPR data or based on the dynamic fluid level in the annular region.
7.3.1. Pump Intake Pressure from IPR Data
Test Pressure: This is the known dynamic pressure based on test data, it could be taken
at the pump intake or at the bottom hole (Mid-Perforation Depth)
Measured At: Select where the test pressure is measured at
Test Fluid Production: Liquid flow rate from the well at the given test pressure
Static Bottomhole Pressure: Without liquid flowing out of the well, the pressure
measured at the bottom hole (Mid-Perforation Depth)
Bubble Point Pressure: At the given Fluid Temperature, what is the pressure at which gas
starts coming out of the solution? Above this pressure, there will be no free gas
presented in the solution
Target Production Rate: Specify the rate of fluid that the well is going to produce. As the
required production rate goes higher, the pump intake pressure reduces
Mid-Perforation Depth: The mid depth of the perforations
Water Cut: Fraction of water with respect to total fluid volume
Pump Setting Depth: True Vertical Depth of the pump standing valve
Oil Density: Density of Oil can be specified with API degrees, specific gravity or density
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7.3.2. Pump Intake Fluid Level
Well head Pressure: This is the casing pressure at the surface
Pump Setting Depth: True Vertical Depth of the pump standing valve
Annular Gas Density At Standard Condition: Density of the gas column in the casing at
standard temperature and pressure (1atm, 70 deg F)
Annular Fluid Density: Density of fluid in the casing, for most of the wells, because oil has
a lower specific gravity than water, it can be assumed that the annular fluid consists
entirely of oil
Annular Liquid Level: This is the dynamic liquid level of the well under production,
therefore the calculated pump intake pressure is only valid at this rate of production
Fluid Temperature: Specify the temperature of the well fluid
7.4. Stroke Rate Calculator
Figure 35 Stroke Rate Calculation Panel
This tool is used to estimate the Stroke Rate. This tool uses many parameters in the Input
Parameters tab and the user can import entries using the Populate Form With Values
From Input Parameters button.
Rod Dimensions and Properties must be filled in the Input tab, under the Rod Properties
section.
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7.5. Free Gas Calculator
Figure 36 Free Gas Calculation Panel
This tool provides a way to estimate the amount of free gas presented at the pump intake
with or without gas anchoring.
Gas Anchor Type: Specify the type of gas anchor or select no gas anchor to obtain the
free gas fraction without gas anchoring
Pump Intake Pressure: Pressure at pump intake
Fluid Production Rate: This variable affects the effectiveness of gas separation, the
higher the volume of fluid produced, the less effective the gas separator becomes
Water Cut: Fraction of water with respect to total fluid volume
Down Flow Cross Sectional Area In Separator: Based on the geometry of the gas anchor,
what is the average cross sectional area of at which the liquid is flowing down
Bubble Point Pressure: At the given Fluid Temperature, what is the pressure at which gas
is starting to come out of the solution. Above this pressure, there can be no free gas
present in the solution
Production Gas Liquid Ratio(GLR): The ratio of gas to liquid in the well, in standard cubic
feet per standard barrel (scf/STB). This ratio does not depend on the well pressure; it is a
property of the fluid.
Gas Density At Standard Condition: Density of the gas at STP (1atm, 70 deg F)
Oil Density: Density of Oil can be specified with API degrees, specific gravity or density
Fluid Temperature: Specify the temperature of the well fluid
