DOWNHOLE PUMP (ENTRY LEVEL)
Emir Syahrir
SECTION I--PUMP TYPES AND PUMP OPERATIONS
SECTION II—COMPONENTS AND TOOLING
SECTION III—DISASSEMBLY AND INSPECTION
SECTION IV– ASSEMBLY
SECTIOIN V—PUMP HANDLING AND DELIVERY
SECTION VI—MATERIAL IDENTIFICATION
SECTION VII—WELL-INTEL (DATA TRACKING SYSTEM)
SECTION I--PUMP TYPES AND PUMP OPERATIONS
Section I will detail the basic function of pumps,
various types, and the API designations.
SECTION I
The Five Basic Pump Components:
 The Barrel Tube
 The Plunger
 The Traveling Valve Assembly
 The Standing Valve Assembly
 The Seating Assembly
SECTION I
The Basic Operation of Sucker Rod Pumps
A sucker rod pump is no more than a cylinder, or tube,
consisting of two sections or chambers. One section is
stationary or secured to the tubing. The other section travels
with the sucker rod string. There are usually two valves
working with these sections taking turns opening and closing.
The valves transfer fluid from the bottom chamber to the top
chamber and ultimately into the tubing and up to the wellhead.
SECTION I
The Basic Operation of Sucker Rod Pumps
The hydrostatic load (weight of
the fluid above the pump) shifts
to the Traveling Valve Ball, which
closes on its Seat.
The fluid, above the traveling
valve, in the upper chamber of
the pump, is lifted up and out of
the pump, upward into the
production tubing.
Production Fluid to Surface
 UP-STROKE
Fluid from the Well
Bore (Formation)
SECTION I
TUBING
TRAVELING
UNIT
STATIONARY
UNIT
The Basic Operation of Sucker Rod Pumps
Production Fluid to Surface
UP-STROKE
At the same time a drop in
pressure is created below the
traveling valve, in the lower
chamber of the pump.
The standing valve ball is lifted
off its seat by the pressure below
the ball.
The formation pressure, or
Pressure Drop
hydrostatic pressure within the
in this lower
chamber
annulus and outside the tubing,
moves fluid into the lower
pressure area (the lower chamber Fluid from the Well
Bore (Formation)
of the pump).
SECTION I
TUBING
TRAVELING
UNIT
STATIONARY
UNIT
The Basic Operation of Sucker Rod Pumps
AT THE TOP OF THE UPSTROKE
The standing valve ball closes.
At this point, momentarily, both
balls are closed.
AT THE BEGINNING OF THE
DOWN-STROKE
The traveling assembly, still
closed and holding the hydrostatic
load, begins to compress the fluid
in the lower chamber between the
valves.
SECTION I
TUBING
TRAVELING
UNIT
STATIONARY
UNIT
The Basic Operation of Sucker Rod Pumps
DOWN-STROKE
At some point during the downstroke, the pressure below the
traveling valve exceeds the
hydrostatic tubing pressure.
The traveling valve ball opens,
and the hydrostatic pressure
shifts to the standing valve. Fluid
below the traveling valve moves
through the valve, and displaces
the fluid above it.
Fluid then moves into the upper
chamber of the pump.
SECTION I
TUBING
TRAVELING
UNIT
STATIONARY
UNIT
Basic Types of Sucker Rod Pumps
API Type RWAM and RWAC
The RWAM is a Top Mechanical Holdown which features a metal to
metal seal that can withstand unseating and reseating several times
without damage to the sealing surfaces. The RWAC is a Top 3Cup
Holdown.
Recommended for Sandy or Trashy wells where a bottom holdown pump
is subject to being sanded in, especially where intermittent pumping
occurs thus requiring the added cost of a stripping job.
Recommended for shallow wells.
This Top Holdown style pump is also available in RHA and RXA
configuration depending on pump bore and tubing size. These heavy wall
barrels can run successfully in medium depth wells.
Not recommended for deep wells where the compression ratio needed to
overcome the greater hydrostatic pressure in the tubing will cause barrel
or fitting failures.
Steel barrels will be subject to erosion where fluid with high solid content
enters the tubing intake; perf subs, separators etc.
SECTION I
Basic Types of Sucker Rod Pumps
API Type RWBM and RWBC
The RWBM is a Bottom Mechanical Holdown which features a metal to metal seal
that can withstand unseating and reseating several times without damage to the sealing
surfaces. The RWBC is a Bottom 3Cup Holdown.
Recommended shallow to medium depth wells, wells with low fluid levels, and while not
designed for sandy wells because of the tendency to become sanded in, additional
components can be added to alleviate this problem such as bottom discharge valve or
top seal assembly with rubber packing element.
Recommended for gassy wells when ran in conjunction with a good separator and
properly spaced out to have max compression ratio in the lower chamber during the
downstroke.
Not Recommended for deep wells especially where pumped off or fluid pound
conditions are likely to occur.
SECTION I
Basic Types of Sucker Rod Pumps
API Type RHBM and RHBC
The RHBM is a Bottom Mechanical Holdown which features a metal to
metal seal that can withstand unseating and reseating several times without
damage to the sealing surfaces. The RHBC is a Bottom 3Cup Holdown.
Recommended medium and deep wells, wells with low fluid levels, and while
not designed for sandy wells because of the tendency to become sanded in,
additional components can be added to alleviate this problem such as bottom
discharge valve or top seal assembly with rubber packing element.
Recommended for gassy wells when ran in conjunction with a good separator
and properly spaced out to have max compression ratio in the lower chamber
during the downstroke.
Can be configured with a ‘Stroke Thru” design to help combat gyp or scale
build up, however this design is not recommended for gassy wells as the lower
extension greatly reduces the compression ratio on the downstroke.
SECTION I
Basic Types of Sucker Rod Pumps
Insert Pumps
With all Insert pumps the valve rod is the weakest link.
Depending on what style valve rod guide is ran, the ID of the tubing is subject
to erosion opposite the pump discharge.
All insert pumps are able to be equipped with modified or specialty parts to
enhance performance in even the most extreme well conditions.
Heavy wall barrel pumps perform well when pumping in the curve if equipped
with spray metal valve rod and a modified valve rod guide or sliding sleeve.
SECTION I
Basic Types of Sucker Rod Pumps
Tubing Pumps
 Typically produces more fluid than a insert pump.
 Barrel is ran as part of the tubing string
 Plunger installed at the bottom of the rod string and is
equipped with a retrievable standing valve, either taptype or sure-hold style
 Application is in shallow to medium depth.
 Not recommended for extremely gassy wells although
a good separator will improve performance.
 More costly service since the tubing must be pulled to
retrieve the barrel assembly.
SECTION I
Basic Types of Sucker Rod Pumps
API Type THBM and THBC
The THBM is a Bottom Mechanical Holdown which features a metal
to metal seal that can withstand unseating and reseating several times
without damage to the sealing surfaces. The THBC is a Bottom 2Cup
Holdown.
Recommended in wells with high fluid level where extreme production
rates are required. Plunger size is only limited by the ID of the tubing it
will drift through when running in the well.
Mainly recommended for shallow and medium depth wells, this style
can be ran deeper given the right size pumping unit and rod string
designed to stand up to the higher loading rates.
Can be configured with a ‘Stroke Thru” design to help combat gyp or
scale build up, however this design is not recommended for gassy wells
as the lower extension greatly reduces the compression ratio on the
downstroke.
SECTION I
API Rod Pump Designations
25
Tubing size
15 1.900-OD
20 2.375-OD
25 2.785-OD
30 3.500-OD
40 4.500-OD
-
150
-
R
H
B
C
-
24
-
5
-
2
Barrel ID
Pump Barrel Seating Seating Barrel Length Plunger Top Extension
106 (1-1/16") Type
Type Position Type
in feet Length in feet in feet
125 (1-1/4") R - Rod
W A-Top
C-Cup
150 (1-1/2") T -Tubing
H B-Bottom
M
175 (1-3/4")
X T-Bottom Mechanical
178 (1-25/32") W- Thin Wall Box End Traveling
200 (2") H-Heavy Wall Pin End Barrel
225 (2-1/4") X-Heavy Wall Box End
250 (2-1/2")
275 (2-3/4")
325 (3-1/4")
* Other Sizes and/or NON API Types are available
375 (3-3/4")
-
0
Bottom
Extension
in feet
SECTION I NOTES
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SECTION II—COMPONENTS AND TOOLING
Section II will detail the basic components of a pumps and
the Industry Standard of Tooling required.
SECTION II
The Five Basic Components of a Sucker Rod Pump:
Barrel Tubes
SECTION II
Thin Wall
RW Barrel
Heavy Wall
RH Barrel
B11
B12
Tubing Pump
TH Barrel
B13
Heavy Wall
ID Threads API
RX Barrel
B16
The Five Basic Components of a Sucker Rod Pump:
Plungers
Pin End
Spraymetal
Plunger
SECTION II
Box End
Spraymetal
Plunger
Box End
Spraymetal
Grooved Plunger
Monel Pin
Spraymetal
Plunger
Pressure Actuated
Ringed Plunger
The Five Basic Components of a Sucker Rod Pump:
Traveling Valve Cages
Open-Type Cage for
Travel Barrel Pump and
Tubing Pump TPA
Closed-Type Cage
For Pin-End Plunger
Insert Style
SECTION II
Closed-Type Cage for
Pin-End Plunger
Closed-Type Cage for Box-End
Plunger and
Double Valving
The Five Basic Components of a Sucker Rod Pump:
Standing Valves
Closed-Type Cage
Steel or Hard lined
guides
Closed-Type
Cage
Insert Style
SECTION II
Open Cage
Traveling
Barrel Type
Open Cage
Tubing Pump
Closed Cage
Tubing Pump
The Five Basic Components of a Sucker Rod Pump:
Ball and Seat Valves - Traveling & Standing
Ball & Seat
Lapped Type Seat also available with Alternate sized ball
in the California Pattern
Ball and Seat Valves are offered in a variety of materials to perform in different downhole environments.
SECTION II
The Five Basic Components of a Sucker Rod Pump:
Seating Assemblies
3 Cup API
Bottom
Hold Down
3 Cup API
Top
Hold Down
2 Cups Tubing Pump HD?
SECTION II
3 Cup Type O
Bottom
Hold Down
Mechanical
Bottom Lock
API Type
Mechanical
Top Lock
API Type
PUMP DISASSEMBLY – TOOLING REQUIREMENT
–Friction Vises, Friction Tongs, & Open End Wrenches (or
Spanners) used in the disassembly and repair of the pump
shall be in good working condition.
–Friction Vise Components shall not be worn to the point that
excessive force must be applied in order for the vise to grip and
hold the pump or pump component.
SECTION II
PUMP DISASSEMBLY – TOOLING REQUIREMENT (cont.)
• Friction Vise Bushings (or blocks) must be clean and hold or
grip the pump component without the use of abrasive
paper (or cloth) the enhance its gripping force.
• Friction Tongs (or wrenches) must be clean and hold the pump
component without the use of abrasive paper (or cloth) to
enhance its gripping force.
• Open-End Wrenches must not be worn (spread apart), to the
point that with its use, it causes the wrench flats, on the pump
component, to “round off”.
SECTION II
BAD PRACTICE
NOTE: Worn pump friction vise (blocks) bushings may be
machined or re-bored to the next larger size.
SECTION II
BAD PRACTICE
Pipe wrenches may be used on TAC,
and some TH connections.
But NEVER should a pipe wrench be
used on any insert pump component or
assembly
- INTERNAL -
INDUSTRY STANDARD
TOOLING STANDARD
“Industry Standard”
Friction Vise and Vise
Bushing.
Requirement:
Friction Vises capable of securing all barrel
assemblies, plunger assemblies, and any other
tubes or rods that require being secured for
disassembly and repair.
SECTION II
INDUSTRY STANDARD
TOOLING STANDARD (cont.)
“Industry Standard” Shop Equipment
2
3
1
SECTION II
1. Pump Bench-Single
2. Pump Bench-Adjustable
3. Floor Plate for Adjustable Bench
INDUSTRY STANDARD
TOOLING STANDARD (cont.)
“Industry Standard” Shop Equipment
2
4
5
6
3
11
SECTION II
1. Plunger Bench, double, for
work bench
2. Valve Cage Bench Wrench
3. Sliding Socket Plate
4. Bench Saddle Clamp
5. Bench Vee Saddle
6. Bench Wrench
INDUSTRY STANDARD
TOOLING STANDARD
“Industry Standard” Shop Equipment
1
1. Portable Tool Cady with
pump wrap paper
dispenser & cutter.
2. Pump Support Dolly
2
SECTION II
INDUSTRY STANDARD
TOOLING STANDARD
Hand Tools Needed:
SECTION II

Friction wrenches to fit all size components that will be
required at your shop.

Bench wrenches that will fit all component wrench flats for
pump sizes repaired at your shop.

Shop wrenches (plater wrenches & wrench handles) to fit all
component wrench flat sizes within your shop.

Hook wrenches for open cages (optional).
INDUSTRY STANDARD
TOOLING STANDARD
2
1
3
•
•
•
•
•
•
SECTION II
Friction wrench
Open Valve Cage Wrench
Plater Wrench handle-straight
Plater Wrench handle-offset
Plater Wrench head
Shop Wrench-fixed sizes
4
5
6
INDUSTRY STANDARD
TOOLING STANDARD
OD MICROMETER – PARTS DESCRIPTION
The Parts of
the Outside
Diameter
(OD)
Micrometer
SECTION II
TOOLING STANDARD
AIR GAGE – CONTROL BOX
The Mahr “Dimensionair” Air Gage
“older style”
SECTION II
BALL AND SEAT TESTER
Vacuum
Gauge in
inches Hg
Electric Ball and Seat
Tester with “Bubble
Sight”.
Rubber Test Pad
Oil filled, “Bubble
Sight” chamber
SECTION II
TOOLING STANDARD
1. Torque Wrench
2. Torque Wrench
Adaptor
(for Bench Wrench)
SECTION II
SECTION II NOTES
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SECTION III—DISASSEMBLY AND INSPECTION
Section III will detail the proper steps of
Disassembly and inspecting components.
SECTION III
BEFORE DISASSEMBLY – PUMPS BROUGHT IN FOR REPAIR.
–Pumps may be steam cleaned or pressure washed prior to
disassembly. But, every effort to collect foreign material
samples must take place before the pump is steam cleaned
or pressure washed.
–All insert pumps shall be vacuum tested prior to
disassembly or washing.
SECTION III
BEFORE DISASSEMBLY – PUMPS BROUGHT IN FOR REPAIR.
Insert Pumps are to be
Vacuum Tested - prior to
disassembly.
Beginning your Failure
Analysis by checking the
traveling assembly for leakage.
SECTION III
DURING DISASSEMBLY
–IF Foreign Material is suspected to be the cause of the
pump failure !!!
SECTION III
1.
The Pump shall be disassembled prior to any steam cleaning or pressure washing.
2.
All foreign material should be collected and tagged with: what type of material,
where in the pump it was found, name of the company, lease, and well; date of pull
and date of pump inspection.
3.
Photos should be taken of the material such as inside of cages, plugged plunger
etc. and downloaded into Well-Intel during the repair.
4.
A diagnosis of the failure should be made in the remarks or comments of the repair
report in Well-Intel
PUMP DISASSEMBLY – TOOLING REQUIREMENT
–Pump Assemblies (Barrel Tubes) are to be held securely with a minimum of
2 friction vises, in the locked and secured position.
Remember: No “Abrasive” paper or cloth to shim the bushings
(friction blocks).
• Primary holding force shall be the friction vises.
• “Back Up” or friction tongs may also be used, but the primary holding
force is the vises.
SECTION III
PUMP DISASSEMBLY – TOOLING REQUIREMENT
Be sure the Pump Barrel is properly supported.
SECTION III
PUMP DISASSEMBLY – TOOLING REQUIREMENT
–Plunger Assemblies (Plunger Tubes) are to be held securely with a
minimum of 1 friction vise, in the locked and secured position.
Remember: No “Abrasive” paper or cloth to shim the bushings
(friction blocks).
• Primary holding force shall be the friction vise.
• “Back Up” or friction tongs may also be used, but the primary
holding force is the vise.
SECTION III
PUMP DISASSEMBLY – AFTER VACUUM TEST
THE PUMP BARREL SHALL BE SECURED IN VICE WITH 3 INCHES
PROTRUDING AS TO NOT CLAMP ON THE BARREL THREADS.
The entire Standing valve and
hold down subassembly shall
be removed as a single unit in
it’s entirety and broken into
separate components on the
plunger bench. This will ensure
that no undue stress will be
applied to the end of the pump
barrel (box/pin).
SECTION III
PUMP DISASSEMBLY – API
–All pumps disassembled will generally conform to API RP11AR, Pump Repair Section.
–ALTHOUGH, Insert Pumps will require an initial 1st step during the disassembly process.
SECTION III
PUMP DISASSEMBLY – INSERT PUMP – 1ST STEP (cont.)
 Check the “Un-Swept” area of the pump for:

SECTION III
API Pumps-RHT, RWT, & RXT
Stroke the standing assembly completely into the pump.
1.
2.
Remove the traveling valve and upper barrel connector.
3.
Measure the distance from the top of the standing valve, to where bottom of
the upper barrel connector would be when “made up”.
4.
Record the measurement in the repair report.
PUMP DISASSEMBLY – INSERT PUMP – 1ST STEP (cont.)
 Check the “Un-Swept” area of the pump for:

ALL INSERT PUMPS (API AND NON-API)
SECTION III
5.
This measurement shall be within the parameters of ELS and established
Customer pump specifications.
6.
In the absence of a ELS specification, the parameters established by API
RP11AR shall apply.
7.
This API protocol is ¼ inches {6.35 mm} minimum to 2 inches {50.8 mm}
maximum.
PUMP DISASSEMBLY – INSERT PUMP – 1ST STEP (cont.)
The “Un-Swept” area of the pump Protocol.
 If the “Un-Swept” area exceeds the maximum allowable distance,
within the specification, the Valve Rod or Pull Tube should be replaced.
 If the “Un-Swept” area is less than the minimum allowable distance,
within the specification, the Valve Rod or Pull Tube should be cut and
re-threaded if it is able to be re-ran.
SECTION III
PUMP DISASSEMBLY – TUBING PUMP
 No measurement of the un-swept area is required for
Tubing type pumps. It is recommended that API RP11AR
be followed as the standard disassembly procedure.
 Hydraulic Pressure Pump – To pressure test complete
tubing pump barrel units after repair. Normally utilize a
range from 0 to 10,000 psi.
SECTION III
PRESSURE TESTING – TUBING PUMP
PRESSURE TESTING – TUBING PUMP
All tubing pump assemblies, sent into ELS
facilities for repair are to be hydraulically
pressure tested, to verify the integrity and
sealing status of all connections making up
the barrel assembly.
–Testing is to be performed preferably with
hydraulic oil or equivalent, this will require
a reservoir. Water can be used as will
require less clean up if/when leaks are
detected.
PRESSURE TESTING – TUBING PUMP
1.
Tubing pump barrel assemblies may be tested with the
standing valve seated, or my be tested without the
standing valve seated.
2.
If the standing valve is not seated, the opposite end of
the pressured inlet must be plugged.
3.
Testing pressure should be a minimum of 3,500 psi,
and not to exceed a maximum of 5,000 psi.
4.
The pressure within the range shall be held for 5
minutes, with no apparent leakage.
PRESSURE TESTING – TUBING PUMP
5.
Tubing pump barrel assembly pressure test is Good or
Passing:
– A.
–
–
Drain testing fluid from barrel assembly.
B. Record test results on repair report
C. Follow protocols for Labeling, wrapping, and storage.
PRESSURE TESTING – TUBING PUMP
6.
Tubing pump barrel assembly pressure test is Not
Good or Not Passing:
– A.
Identify location of the leak.
– B. Drain hydraulic fluid from barrel assembly.
– C. Disassemble the barrel unit and repair the flaw.
– D. Repeat the test protocols as stated in the previous
slides.
TRAVELING SECTION
Tighten the vise on the top end of the barrel, then loosen the barrel connector and valve rod guide
as a single unit.
Remove the plunger from barrel, visually
inspecting the condition of the valve rod,
while removing the traveling assembly from
the barrel.
Place plunger and traveling valve with the
valve rod, as a single unit, on the plunger
bench. Be sure an adequate number of pump
dollies are used to keep the valve rode level
and in line with the plunger.
Secure the plunger in the vice and remove
the traveling valve as a single unit.
SECTION III
Barrel cleaning, inspection and measurement.
Once the traveling assembly has been removed from the barrel, it needs to be swabbed clean using
solvent followed by dry rags. (if scale is present then brushing may be required. BE SURE to collect
samples).
Visually inspect the barrel ID from both ends to ensure it’s clean before attempting to measure.
AIR GAGE-BARREL INSPECTION-REQUIRED FOR:
All pump barrel Tubes are to be INSPECTED with
Air Gage Equipment that is within current inspection /
calibration status.
The pump shops will, standardized with Mahr
“Dimensionair” Equipment.

SECTION III
Barrel cleaning, inspection and measurement.
Select the Air Plug and Ring Gage of the proper size to
match the barrel bore size to be inspected. Make sure the plug and
ring gage are wiped clean and dry before use.
Attach the Air Plug to the Air Plug Handle on the end
of the Inspection Air Hose. Make sure the O-Ring seal is in
place and “Hand Tighten” (SNUG) only.
Turn on the air and allow it to blow through the Air
Plug. Make sure (your best estimate) that equal amounts of air are
blowing through both orifices.
Consult your documents for the “KNOWN VALUE”.
The “Known value is calculated from when the probes and rings were last calibrated with a
MASTER set. Each shop will vary but rarely will the setting be exactly ‘zero’. Pay close
attention to the example next.
SECTION III
Barrel cleaning, inspection and measurement.
If during the last calibration of the equipment the following was
found:
The Average of “Position 2” is 1.2502 inches.
The “Known Value” for this Ring Gage is 1.2502
inches.
Or we could say the “Known Value” for this 1-1/4”
(Nominal) size Ring Gage is TWO TEN THOUSANDS
over, or above Zero on the Gage.
Since each graduation is 2/10,000 of an inch, it is
safe to say the “Known Value” for this Ring Gage is
“One Graduation ABOVE ZERO”.
SECTION III
Barrel cleaning, inspection and measurement.
RING GAGE “KNOWN VALUE” FOR SETTING THE AIR GAGE (cont.)
 We would set our
Air Gage at:
One Graduation
Above Zero.
SECTION III
Barrel cleaning, inspection and measurement.
 Place the air plug into the CLEAN
barrel tube and slide it all the
way to the end.
 Measurement shall begin at the
farthest point away from the
entry point. You may start at the
top or bottom. Just remember at
which end your first reading will
be so that it may be recorded
correctly.
SECTION III
Barrel cleaning, inspection and measurement.
API Barrel tubes are measured, and provided in, even “one foot” , increments. Air gage
measurements shall be recorded in “one foot” increments (or approximately every 30.5 cm).
The air gage, air plug hose should be marked in “one foot” increments.
After the air plug reaches the end, pull it back approximately 1 foot (30.5 cm) from the end. This is
the first measurement point.
Turn the probe 90 degrees and record the highest reading of the first point, on the pump shop record
(PSR).
Pull the hose toward you and gently turn it to the right. This can be accomplished by coiling the
hose, as it is pulled, or turning the barrel, as it is pulled.
The plug pulling speed, between recording points, shall be max of 6 to 10 seconds. This will allow
the technician to notice any deflection of the air gage dial needle.
Any deflection of the needle shall be investigated. An abrupt deflection will indicate a worn,
corroded, cracked or flaked plating within the barrel.
After reaching the next one foot (30.5 cm) increment, stop and record the highest reading on the
pump shop record (PSR).
Repeat this process until the entire barrel has been measured internally.
SECTION III
Barrel cleaning, inspection and measurement.
 Barrel Measurement Criteria for pass or reject:
 New barrels: API allows new barrels to measure from 0.00 to 0.002; However Customer Specification
may call for tighter tolerances, be sure and check this document when measuring New barrels.
The inside “undercut” of an RH or TH barrel tube is not considered part of the sealing surface, but is
to be included in calculating the 8 inch (20.23 cm) distance from the end.
The internal threads of an RW or RX barrel tube is not considered part of the sealing surface, but is
to be included in calculating the 8 inch (20.23 cm) distance from the end.
 Barrel Measurement Criteria for pass or reject:
Used barrel measurement criteria must be established by the production asset team members and /
or engineering and recorded in the shop Customer Specification file.
SECTION III
BALL AND SEAT TESTING
 Electric Ball and Seat
Tester with “Bubble
Sight”.
Vacuum
Gauge in
inches Hg
SECTION III
Rubber Test Pad
Oil filled, “Bubble
Sight” chamber
BALL AND SEAT TESTING
Ball and seat test devices shall be in current inspection status, with documentation, and within the
calibration / inspection interval as stipulated by ELS.
Ball and seat test devices, used in the pump shops shall be equipped with a bubble sight glass or
chamber.
The device “Test Pad” shall be in good condition, composed of rubber, and have a hardness, not to
exceed, 50 durometer.
 Test Specifications for “ALL” Balls & Seats:
Both “New” and “Used” ball and seat assemblies, selected for testing shall be tested in a CLEAN
and DRY condition.
 Note: There should not be a need to oil the balls & seats or oil the test pad. A drop or two of oil
may be applied to the test pad and gently wiped dry to clean it.
SECTION III
BALL AND SEAT TESTING
 Test Specifications for “ALL” Balls & Seats:
The testing device shall be able to pull, a MINIMUM, 19 inches Hg of vacuum, during each test, in
order to qualify as to be in “functioning status”.
 Note: Testing devices, placed at different location altitudes, will produce different maximum vacuum
pull readings. This is due to the difference in air pressure.
 Specifications for: “NEW” Balls & Seats as required by API Specification 11AX: 7.3.4.1
 Criteria 1: The B&S shall seal “BUBBLE TIGHT”, for 3 seconds, after the vacuum source has been

isolated.
Criteria 2: Following 3 seconds, some bubbles may be allowed, but the B&S assembly shall display
less than 1 inch Hg vacuum drop during 30 seconds of testing.
Place the B&S on the test pad and turn on the vacuum pump.
Allow the pump to reach the maximum pull (vacuum).
Verify that it equals to, or exceeds 19 inches Hg.
Once the devices maximum pull (vacuum) is achieved, close the valve. This isolates the vacuum
pump from the test pad.
SECTION III
BALL AND SEAT TESTING
Without breaking the seal around the ball and seat, gently spin the ball on the seat during this test.
If the assembly meets both Criteria 1 and Criteria 2 (specification for new ball and seat testing), the
ball and seat may then be install in the valve cage of the pump to be assembled.
If the assembly does not meet the test specification, replace the ball, seat, or both and repeat the
process.
 IMPORTANT: In repairing pumps, always test the ball on the side of the seat that it was
previously installed on, in the pump.
SECTION III
INSPECTING PLUNGERS
–Visually inspect the plunger OD for grooves or cutting. Replace the plunger if the grooves or cutting
exceed Customer specifications.
–Visually inspect the plunger ID for pitting or scale build up. Plungers that are severely pitted on the
inside should be replaced.
–Visually inspect the threads for damage or pulled threads.
–Some thread damage may be repaired in the pump shop if the tooling is available.
–Steel pin plungers may also be sent to the machine shop to be cut and re-threaded.
–If these practices are not feasible, the plunger should be replaced.
SECTION III
OD MIC. – PUMP SHOP INDUSTRY STANDARD METHOD
Plungers should be measured and recorded in 1ft increments
Can be used to measure plungers from most pump
bore sizes, including the most common sizes.
Nominal pump bore size must be in ¼” increments.
LIMITATIONS:
Can not be used to measure plungers sizes for:
1-1/16” {26.33 mm} or 1-25/32” {45.2 mm} bore pumps.
OD MIC. – PUMP SHOP INDUSTRY STANDARD METHOD (cont.)
Select an OD Micrometer with a range of measurement that has the capability to measure the
“Nominal” diameter size of the plunger to be measured.
Place the micrometer so that the largest portion, of the outside diameter of the plunger aligns with the
anvil and spindle of the micrometer.
Makes sure the surface of the Plunger to be measured is clean and free of oil, water, dirt or
debris.
With a clean cloth, wipe the surface area of the anvil and spindle.
OD MIC. – PUMP SHOP INDUSTRY STANDARD METHOD (cont.)
Using the “Ratchet Cap”, close the spindle into
the plunger, so that the plunger becomes “snug”
between the anvil and spindle.
Holding the micrometer’s frame with you left hand, remove it from the plunger, and
hold it up for the reading.
OD MIC. – PUMP SHOP INDUSTRY STANDARD METHOD (cont.)
Locate the zero graduation on the thimble.
Count the graduations (backwards-or toward
you), from zero till the graduations intersect with
the horizontal line on the micrometer’s Hub.
Each graduation is equal to, “minus” one thousand of an inch from the
nominal OD.
OD MIC. – PUMP SHOP INDUSTRY STANDARD METHOD (cont.)
This Micrometer
just measured a
plunger from a
1-1/2” Bore
Pump.
OD MIC. – PUMP SHOP INDUSTRY STANDARD METHOD (cont.)
ZERO
ONE
TWO
THREE
A Closer Look at the
READING
From the Zero
Graduation line, on
the THIMBLE, to the
intersection at the line
on the HUB, is Three
Graduations of the
THIMBLE.
Machinist method of using Micrometer
The hub {or sleeve} contains 40 divisions. Each division represents one fortieth {1 / 40”} of an inch, or
twenty-five thousands {0.025”}. Every fourth line equals one tenth {0.10”}, and is numbered 0, 1, 2, 3, etc.
The beveled edge of the thimble is marked in twenty-five divisions. Every line is numbered from 0 to 25.
Rotating the thimble, from one of these marks, to the next mark, moves the spindle longitudinally one twentyfifth {1 / 25} of twenty-five thousandths of a revolution, or one thousandth {0.001”} of an inch.
Twenty-five divisions will indicate a complete revolution (0.025 inches).
The following illustrations
represent measuring a 11/2” plunger with a 1” to 2”
OD micrometer.
SECTION III
Machinist method of using Micrometer
Step #1: record the whole number that represents the minimum size the micrometer should read.
Assume the illustration represents a 1” to 2” OD micrometer. 1.000
Sleeve
SECTION III
Index Line
Thimble
Machinist method of using Micrometer
Step #2: Using the end of the Thimble as an Index Line, record the whole number of .100 inch
increments to the left of the Index line. The illustration shows that there are five .100 inch
increments to the left of Index line. Which equals .400
Sleeve
from Index Line
Thimble
1.000
0.400
SECTION III
Machinist method of using Micrometer
Step #3: Still using the end of the Thimble as an Index line, record the whole number of
.025 increments to the left of the Index line. The illustration shows that there is .075
Sleeve
Index Line
Thimble
1.000
0.400
0.075
SECTION III
Machinist method of using Micrometer
Step #4: Using the Axial lines on the Thimble, read the number of .001 increments from
the Thimble that is closest to the Index Line. The illustration shows the mark representing
Twenty two lines up the Index line which equals 0.022.
Sleeve
Index Line
Thimble
1.000
0.400
0.075
0.022
1.497
1.500 minus 1.497 equals a
minus 0.003 fit.
SECTION III
INSPECTING CAGES
One piece valve cages shall be inspected for “Beat Out” condition.
This is caused when the ball guides, within the cage are beaten flat.
Cages with “Beat Out” ball guides will not allow the ball to fall straight down on the seat. This causes
undue wear on both ball & seat. Beat Out cages should be discarded.
“Cut Away” of
a valve cage
with
“Beat Out”
condition.
INSPECTING CAGES
Insert guided cage inserts shall be shall be inspected closely for cracks in the casting.
Occasionally, depending on the insert’s metallurgy, they may show wear or a “beat out” condition.
Cracked or “beat out” inserts shall be replaced.
All valve cage components shall be inspected for bad threads, corrosion, wear, or seal face damage.
Any valve cage displaying one or more of these conditions, shall be replaced.
After clean and determined to be re-ran, it is recommended to vacuum test the cage by placing on the
Ball and Seat tester and covering the top with the palm of your hand. On insert guided cages, this step
needs to be done after they are reassembled and torqued properly.
VALVE RODS, PULL TUBES, & GUIDES
Valve Rods & Pull Tubes
Valve rods and pull tubes shall be visually checked for corrosion. If
there is any reason to question the reliability of another run with these
components, the valve rod or pull tube should be replaced.
Valve rods and pull tubes shall be checked for wear. It may be
necessary to measure the amount of wear with an OD micrometer
Any rod or tube, that exceeds a 10% loss in diameter,
shall be replaced.
VALVE RODS, PULL TUBES, & GUIDES
Valve Rods & Pull Tubes (cont.)
Valve rods and pull tube threads should be closely inspected.
If it is suspected that the valve rod threads are not API modified, the
valve rods should be rethreaded. This can be easily verified by
spinning on an threading die head, containing API modified threads.
It should spin on by hand and meet no resistance.
Valve rods with bad or damaged threads may be cut and rethreaded, as long as the result will not exceed the acceptable
distance for “un-swept” area.
VALVE RODS, PULL TUBES, & GUIDES
Valve Rods & Pull Tubes (cont.)
Pull Tubes with damaged threads may be cut and re-threaded by a
skilled machinist.
This may be done as long as the end result does not exceed the
maximum distance for the “un-swept” area, as stated in the
specification.
Pull tubes also have a seal face, at the end of the tube, that must be
checked for damage
VALVE RODS, PULL TUBES, & GUIDES
Valve Rod & Pull Tube GUIDES
Guides shall be checked for corrosion. Any corrosion visible shall be
reason for replacement, unless specifications state otherwise.
Visibly inspect the ID of the Guide for “Out of Round” condition. This
condition indicates wear and the guide should be replaced.
The inside of the guide should fit snug, but allow the rod or tube to
stroke freely. A guide that is too loose will cause the rod or tube to
wear.
TOP PLUNGER ADAPTORS
Top plunger adaptors shall be checked for thread damage. If any
damage is present, the component shall be replaced.
Any corrosion on this component is reason for replacement.
SEATING ASSEMBLY COMPONENTS
Seating cups are always discarded after use.
Mechanical seal rings should be checked for scoring or fluid
cutting. Any indication of this is reason for replacement.
It is recommended that this sealing component be replaced
every time the pump is pulled. Unless Customer
specifications state otherwise.
SEATING ASSEMBLY COMPONENTS
Rubber “packer type” elements used in re-settable
pump anchors, or pack off (top seals) should be
replaced each time the pump is pulled.
All other seating assembly components shall be
checked for thread damage or corrosion. If either
of these conditions are apparent, the components
should be replaced.
OTHER PUMP COMPONENTS
On top hold down pumps, either mechanical or cup
Type, the mandrel should be check for rod wear in
The ID
All other pump components shall be visibly checked for thread
damage, corrosion, and wear.
If any of these conditions are apparent, the components should be
replaced.
SECTION III NOTES
______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
Component Assembly
 Thread connection makeup
 Pump Fittings
Plunger Assembly
 RW and RH Traveling assembly
 TH, Standing valve and Traveling valve
Barrel Assembly
• RH and RW Stationary Assembly
• TH Stationary Assembly
Hold Downs and Seating Nipple
Valve rod Threading
This is what happens
when the valve rod
is not properly
threaded.
SECTION IV– RW and RH Traveling ASSEMBLY
1. Select the correct vice blocks and secure the plunger in the vise. Using a micrometer, check the plunger
to verify the size and fit
2. Test balls and seats (new and used) and install in the cages (Primary and Secondary TV)
3. Back up the traveling cage, install the DV cage and/or seat plug and tighten to specs.
4. Using a friction wrench of the correct size, install the TPA, and traveling cage. Tighten to ELS specs
unless otherwise noted in Customer specifications.
5. Thread or rethread the valve rod (procedure in previous slide), install and tighten into TPA if New build. If
reran VR from repair first install and tighten into VR bushing, slide assembled bushing and guide, flip and
install and tighten into TPA.
6. Leave aside until Barrel is ready for assembly.
Barrel Preparation and Installing Traveling Assembly
1. Select the correct vise blocks on the barrel benches and secure the barrel (loosely).
2. Swab the barrel clean (measure and record if New build) check seal faces for any damage.
3. Lubricate the ID of the barrel and the OD of the plunger with light oil and insert the plunger assembly
into the barrel. Rotate the plunger going in to ensure complete lubrication.
4. If repair with rerun valve rod, stroke in and install the bushing/guide assembly into top of barrel and
tighten to specification. Stroke completely in and clutch the bushing into the guide. On the bottom end
check the distance of the ‘un-swept’ area to verify compliance.
5. If new build, stroke the plunger assembly into the barrel until desired distance for ‘un-swept area at
bottom is reached. At the top slide the bushing/guide assembly on (hand tight). Using the bleeder hole in
the VR bushing as a guide, hold along side the valve rod (clutched against VR guide) and mark the valve
rod for cutting.
6. Cut and thread using the aforementioned procedure. Tighten the bushing onto the valve rod and stroke
in until clutched. Re-check the ‘un-swept’ distance at the bottom. If correct, tighten bushing/guide
assembly at the top of the barrel to specification.
Standing Valve (SV) and Hold Down Assembly
1. If Cup Type hold down, place the cups and spacer rings onto the mandrel and tighten the Lock Nut firmly,
securing the cups. Place the lock nut in wrench flat and tighten GAC (Gas Anchor Connector) against the
Lock Nut with Plater wrench.
2. If Mechanical hold down, install the seal ring onto the bushing and install the lock. Place the bushing in
wrench flat and tighten the lock firmly with friction wrench securing the seal ring.
3. Insert the ball and seat into the Primary SV (and Secondary SV if called for). If Double valve, place the
flat of the Primary in wrench flat and tighten Secondary SV into with friction wrench, torque to specs.
4. Place the flat of either the Cup Type Mandrel/Mechanical bushing in wrench flat and tighten the Cage
assembly with friction wrench, torque to specs.
5. Once completely assembled, install into bottom of Barrel and torque to specs using friction wrench or
plater wrench where flats are available.
Vacuum Test, Record Stroke Length (SL), Wrap
1. Install vacuum gauge into GAC, at the top of the pump, lightly tag the VR
bushing against the guide the stroke the traveling assembly completely out
until the TPA contacts the inside of the barrel bushing/guide. Tag lightly to
ensure the TPA doesn’t stick into bushing. Be sure to have an adequate
number of pump dollies for the valve rod to rest on to prevent bending.
2. Ensure the vacuum holds and while still stroked all the way out, measure and
record the maximum stoke length of the pump. Stroke back in and leave
unclutched. Remove vacuum gauge and ensure the pump serial number is
stamped onto a non-stress area, preferably the wrench flat of either Primary
SV or mandrel.
3. Wrap each end of the pump with waterproof wrapping for storage/delivery.
Create two pump tags, one to remain with the pump all the way to the well and
one to be left at the shop for records when the pump does go out.
Vacuum Test, Record Stroke Length (SL), Wrap
EXAMPLE PUMP TAG, ALL OF THIS INFORMATION IS MANDATORY.
SECTION IV NOTES
______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
SECTIOIN V—PUMP HANDLING AND DELIVERY
PROPER HANDLING AND STORAGE
Subsurface pumps look like a bar of steel and give the impression that they are as strong as tubing.
However, due to their relatively thin wall, a small flexion can result in permanent damage. When handling,
storing, and transporting subsurface pumps, it is essential to prevent mechanical damage by flexing,
bending, denting, dropping, or contacting other objects. Improper handling may damage precision
components, measured in thousands of an inch, or their plating or coating, and negatively affect their run
life.
To prevent bending and denting of the barrels and/or other components, pump assemblies should never
have any objects laid on top of them. Never carry pump rods from one point, or drag an end. Always have
enough personnel to move, shelve, and load/unload them in and from a vehicle. Providing adequate
support can prevent damage to the pump and/or injury to workers. Never use chains, pipe wrenches, or
hammers.
PROPER HANDLING AND STORAGE
Proper handling of a pump, with at least two people giving enough support to prevent bending.
PROPER HANDLING AND STORAGE
Stored pump assemblies must have a waterproof wrapping on each end, sealed with tape, to prevent
moisture, dirt, or any other object from entering the pump. This wrapping must be thick enough to provide
cushioning, and be attached so it is not rubbed off or blown off during handling, storage, and transport. This
protective wrapping should not be removed until the pump is ready to be installed in the well.
PROPER HANDLING AND STORAGE
All stored pump assemblies must be supported on horizontal racks, off the ground or floor (wooden boards
may be used as temporary storage to keep assemblies off the floor). The maximum distance allowed between
supports is eight feet (243.8 cm).
Sucker-rod pumps may also be supported on a flat surface or shelf that supports the entire length of the
pump, and places it off the floor or ground. Maximum overhang from the outside support should not exceed
three feet (91 cm).
TRANSPORTATION
Pumps 24ft or less may be hauled on the side of a truck with proper racks installed.
Pumps exceeding 24ft must be hauled on a trailer long enough to prevent excessive overhang.
SECTION V NOTES
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_______________________________________________________________________________________
_______________________________________________________________________________________
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SECTION VI—MATERIAL IDENTIFICATION
API MATERIAL IDENTIFICATION CODES
MATERIAL SELECTION FOR DIFFERENT CONDITIONS
- INTERNAL -
API 11AX DESIGNATIONS OF BARREL MATERIALS
(tables A, B, and C)
API 11AX (tables D & E)DESIGNATIONS OF BALL & SEATS AND CAGES
API 11AX DESIGNATIONS OF PULL TUBES, VALVE RODS, AND
FITTINGS (table F) TABLE G FOR SEATING CUPS
API 11AX DESIGNATIONS OF SPRAY METAL PLUNGERS (table H)
And PLATED PLUNGERS (table I)
MATERIAL IDENTIFICATION
BARREL TUBE SELECTION
PREC STEEL STEEL 501SS PREC BRASS STEEL BRASS STEEL BRASS
STEEL CP
CZ
CP
BRASS CP
NCC NCC TBG TBG
Rockwell Hardness
15
70
62
70
50
70
71
71
70
70
Well Conditions
None
A
A
A
A
A
A
A
A
A
A
None + Abrasion
X
A
A
A
X
A
B
B
A
A
Severe H2S
X
X
X
C
A
C
B
A
B
A
Severe H2S+Abrasion X
X
X
C
X
C
C
B
B
A
Mild H2S+Abrasion
X
X
X
B
X
A
C
B
B
A
Severe CO2+Abrasion X
X
X
C
X
B
C
B
C
A
Mild CO2+Abrasion
X
C
X
B
X
A
C
B
C
A
Severe
H2S+CO2+Abrasion
X
X
X
X
X
C
C
B
C
A
Mild
H2S+CO2+Abrasion
X
X
X
C
X
C
C
B
C
A
A
B
C
X
Material suitable under most conditions
Corrosion and erosion expected; material may be suitable under some conditions
Corrosion and erosion too usually too severe for longterm successful use
Material not suitable for use
MATERIAL IDENTIFICATION
PLUNGER SELECTION
CHROME SPRAY METAL SPRAY METAL TUNGSTEN
PLATE
STEEL PIN
MONEL PIN
SPRAY M.P.
Rockwell Hardness
70
62
62
62-65
Well Conditions
None
A
A
A
A
None + Abrasion
A
A
A
A
Severe H2S
X
C
A
A
Severe H2S+Abrasion
X
C
A
A
Mild H2S+Abrasion
C
B
A
A
Severe CO2+Abrasion
X
C
A
A
Mild CO2+Abrasion
C
B
A
A
Severe
H2S+CO2+Abrasion
X
X
A
A
Mild
H2S+CO2+Abrasion
X
B
A
A
A
Material suitable under most conditions
B
Corrosion and erosion expected; material may be suitable under some conditions
C
Corrosion and erosion too usually too severe for longterm successful use
X
Material not suitable for use
* Chrome plated plungers CAN NOT run in Chrome plated barrels.
*Recommend grooved plungers for high solids content.
*Recommend Box End plungers for high downhole temps.
MATERIAL IDENTIFICATION
BALL AND SEAT SELECTION
COBALT COBALT TUNGSTEN TUNGSTEN NICKEL NICKEL
SILICON
440C SS 440C SS ALLOY ALLOY CARBIDE CARBIDE CARBIDE CARBIDE TITANIUM NITREDE
BALL
SEAT
BALL
SEAT
BALL
SEAT
BALL
SEAT
BALL
BALL
Rockwell Hardness 58-65
56-61
57-63
52-61
89
89
90
90
89
90-92
Well Conditions
None
A
A
A
A
A
A
A
A
A
A
None + Abrasion
A
A
B
B
A
A
A
A
A
A
Severe H2S
C
C
B
B
A
A
A
A
A
A
Severe H2S+Abrasion C
C
C
C
A
A
A
A
A
A
Mild H2S+Abrasion
C
C
C
C
A
A
A
A
A
A
Severe CO2+Abrasion C
C
B
B
A
A
A
A
A
A
Mild CO2+Abrasion
B
B
A
A
A
A
A
A
A
A
Severe
H2S+CO2+Abrasion
C
C
C
C
A
A
A
A
A
A
Mild
H2S+CO2+Abrasion
C
C
B
B
A
A
A
A
A
A
A
B
C
X
Material suitable under most conditions
Corrosion and erosion expected; material may be suitable under some conditions
Corrosion and erosion too usually too severe for longterm successful use
Material not suitable for use
MATERIAL IDENTIFICATION
FITTINGS SELECTION
1045
CARBON
STEEL
Well Conditions
None
None + Abrasion
Severe H2S
Severe H2S+Abrasion
Mild H2S+Abrasion
Severe CO2+Abrasion
Mild CO2+Abrasion
Severe
H2S+CO2+Abrasion
Mild
H2S+CO2+Abrasion
17-4 DOUBLE
8620 ALLOY 3000 SERIES HEAT TREAT NAVAL
400 SERIES
STEEL
STAINLESS SS
BRASS 70-30 MONEL
A
C
X
X
X
X
C
A
A
C
C
B
X
C
A
A
C
C
B
A
A
A
A
X
X
C
A
A
A
A
B
B
B
B
A
A
A
A
A
A
A
A
X
X
B
X
B
A
C
C
B
C
A
A
A
B
C
X
Material suitable under most conditions
Corrosion and erosion expected; material may be suitable under some conditions
Corrosion and erosion too usually too severe for longterm successful use
Material not suitable for use
SECTION VI NOTES
______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
SECTION VIII—WELL-INTEL (DATA TRACKING SYSTEM)
THIS SECTION WILL COVER THE BASIC WORK INSTRUCTIONS FOR DATA ENTRY INTO WELL-INTEL
1. Create JOBS and Phone Orders
2. Create Pump Order-Repair
3. Create Pump Order-Junk out
4. Create Pump Order-Well Status Change
5. Create existing Spare Pumps
6. Install a Pump on Well Status Change well (going from gas lift to Beam, reentry of TA etc.
7. Customizing API designations