Dynamometric study of rod pumps with physical wear

Abstract

Rod pumping units are widely used in mature oil fields to artificially lift crude oil to the surface. However, during operation, common failures include rod breaks, pump valve malfunctions, and stuck rods. Incorrect diagnosis of these issues leads to inefficient repair planning and significant financial losses. Rod breaks in particular are dangerous as they can cause sparks, increasing explosion and fire risk. This paper analyzes the causes of sucker rod pump failures using the Novo-Elkhovskoye field as a case study. The authors propose introducing modern technologies and protection systems to improve reliability. Field tests were conducted to identify the root causes of rod string breaks in directional wells, which often experience increased friction between rods and tubing. Dynamometry monitored pump performance and mechanical issues, while chemical analysis linked produced fluid properties to failure rates. Results indicate rod breaks are more common in directional wells due to higher rod-tubing friction. Preventive measures were evaluated for effectiveness. The authors recommend advanced diagnostics, optimized rod string design, and improved corrosion and wear resistance to reduce failures. Implementing these solutions can enhance the stability and safety of rod pumping operations in mature fields.