Rod Pumping Research Articles

DEVELOPMENT OF DOWNHOLE PUMP VALVE ASSEMBLY

The purpose of the work is modernization of the valve, in order to increase reliability, wear resistance, increase the pump flow and reduce the load on the rod string, as well as improve durability. The sucker rod pump is one of the most popular and extensively utilized artificial lift systems. It is a frequently chosen option for lifting oil because of its fundamental simplicity, low operating costs, and adaptability in power supply. In the long run of oil production history, sucker-rod pumping was the first option—and frequently the only option—when artificial lift was required. For this reason, the oldest and most popular method of producing oil wells worldwide is sucker-rod pumping. Since the steel used to make rods has limited strength, sucker-rod pumping is typically thought of as a way to raise moderate to low liquid production rates from shallow to medium well depths due to depth restrictions. Since the correct working of the standing and traveling valves is largely responsible for an efficient pumping operation, valves are regarded as the heart of the sucker-rod pump. The extremely high differential pressures across the valve during pumping necessitate a highly dependable sealing action between the ball and the seat. Small initial flaws in the sealing surfaces or subsequent corrosion- or abrasion-related problems result in greater liquid slipping and a quick decline in valve function because of fluid cutting. Subsurface pumps using traditional ball-and-seat valves suffer a number of basic operational issues: • Because of the greatly high number of pumping cycles per day, the sealing surfaces may sustain significant damage from the frequent collision of the two parts against one another. • In deviated wells, valve wear is uneven and can cause premature failure. • Typical cage constructions, meant to limit impact damage, typically restrict the flow area available through the valve and can be the source of pumping inefficiencies due to low fillage of the pump barrel. Keywords: sucker rod pumps, downhole pump, traveling valve, standing valve, valve assembly.

A Novel Method for Predicting the Behavior of a Sucker Rod Pumping Unit Based on the Polished Rod Velocity

Fault dynamometer cards are the basis of the diagnosis technique for sucker rod pumping systems. Predicting fault cards with a pumping condition model is an economical and effective method. The usual model is described by a mixed function of the pump displacement and pump load, and it is difficult to use in the prediction method based on the analytical solution of the sucker rod string wave equation. In this paper, a normal pumping condition model described by a function of polished rod velocity is proposed. For the analytical solution of the sucker rod wave equation, an iterative prediction algorithm with pumping condition models is proposed, its convergence is analyzed, and then it is validated by classical finite difference method simulated cards and measured surface dynamometer cards. The results show that the proposed algorithm is accurate. The algorithm has a maximum relative error of 0.10% for the classical method simulated card area and 1.45% for the measured card area. The research of this paper provides an effective scheme for the design, prediction, and fault diagnosis of a sucker rod pumping system with an analytical solution.

USING A WIRELESS SENSOR NODE TO MEASURE THE ACCELERATION OF THE SWING ROCKING MACHINE NODES

Technical diagnosis of the drive of well rod pump units (WRPU) remains an urgent task, despite the significant amount of research in this field. One of the areas of diagnosis is the measurement and control of the angular velocity of the rocking machine elements, which requires the provision of synchronous registration and control of acceleration signals at many points of the control object. The authors proposed to implement such a system based on the wireless sensor module Steval-MKSBOX1V1 of STMicroelectronics. The results of the experimental approbation of the use of the specified module showed the effectiveness of its use for solving diagnostic tasks, since the module contains a significant set of sensors in combination with a unit for processing, storing and transmitting information via a wireless Bluetooth interface. An additional advantage of using the selected measuring module is the possibility of remote reprogramming of the module's software to perform the tasks of controlling the kinematic parameters of the installation in the process of conducting research directly at the technological facility. The use of three coordinate accelerometers as part of the measuring module allows to significantly increase the reliability of control in the diagnostic process.

Optimasi laju produksi dengan cara desain ulang sucker rod pump pada sumur “EP” lapangan “NM”

Background: In general the production method is divided into two, namely natural flow and artificial lift. Natural spray is a method of flowing fluid from the perforation zone to the surface of the well naturally, this is due to the reservoir pressure that drives the fluid up to the surface is still very high. Along with the time of production, a decrease in reservoir pressure will occur and this condition will reduce the level of production of the well, so to overcome this problem can be done by artificial lift. The purpose of the artificial lift is to help lift fluid from the well to the surface. Methods: One method of this appointment is the sucker rod pump. To increase the productivity of a pump sucker rod pump, it is necessary to pay attention to the pump production capacity, step length, pumping speed, and location of the pump depth. Finding: EP wells are oil and gas wells in the Kenali Asam Atas field, PT Pertamina EP Asset 1 Field Jambi. Based on Vogel's IPR curve analysis, the maximum production rate (Qmaks) for EP wells is 1089 BFPD. Conclusion: Based on the results of the analysis and optimization that has been done, the production rate that can be achieved by EP wells is 762 BFPD.

A hydraulic drive with self-oscillating operation for reciprocating downhole pump

Rod pumps (pumping units) are widely used for pumping products from production wells. Their simplicity and low cost are undoubted advantages. However, when operating in inclined wells, these pumps are susceptible to accidents caused by friction forces between the rod string and oil well tubing in the contact zone, particularly when the well axis is bent. The rod and rope drive for the plunger pump is suitable for use in wells with a slight inclination of up to 15°, but it is not suitable for use in deviated wells. The article aims to evaluate the feasibility of discontinuing the use of the rod drive in deep well plunger pumps and to suggest an alternative solution. One of the options considered is a self-oscillating hydraulic drive with a spool switch located inside the piston of the drive hydraulic cylinder. This drive provides the large rod displacement necessary to operate a plunger well pump. To supply the working fluid to the distributor, a hollow rod is used. The rod is pressurized with a pressure higher than the downhole pressure from the pump located on the surface near the wellhead through the oil well tubing. A piston switch with an original design is proposed, which provides a self-oscillating mode of the drive and allows for changing the oscillation period. The methods for changing the oscillation period are briefly discussed. A mathematical model of the hydraulic drive is compiled, and the dynamic and power characteristics are determined. The design is developed, and a mockup of the drive and a bench for testing are created. The test results confirm the theoretical characteristics and reliability of the drive. The use of a self-oscillating hydraulic drive for plunger well pumps enables their application in wells of any curvature.

Comparative Analysis of Technical and Operational Characteristics of Controllers Used to Automate the Operation of Rod Depth Pumps

The paper examines the technical and economic characteristics of the most common controllers from popular manufacturers in the United States, designed to automate the operation of rod depth pumps installed in oil-producing pumping machines. The main functional components, including sensors and actuators, are presented. A comparative analysis of the functionality is made, namely, the operating modes of the automation systems for switching on and off electric motors of rod pumps.
 The main distinguishing features of the presented controllers is that some of them lack any sensors and in which the dynamograms are controlled in the function of currents and voltages. In addition, there are also types that use radio communication with the main control and control panel, which greatly simplifies wiring diagrams, eliminates the need to install relatively long cable networks.

Impact Toughness and Fractographic Peculiarities of a Composite Pump Rod Fracture

Impact Toughness and Fractographic Peculiarities of a Composite Pump Rod Fracture

Association rules mining for long uptime sucker rod pumping units

The uptime of sucker rod pumping units (SRPUs) varies significantly due to differences in geological reservoir conditions, as well as design and operation parameters of the SRPUs. Conventional approaches encounter challenges in accurately quantifying the intricate interplay of these factors with uptime. This study investigates the application of association rules mining in exploring reliable measures in long uptime SRPUs. We create an uptime dataset for 5789 sucker rod pumping wells with 16 features encompassing reservoir conditions, production characteristics, SRPUs design, operational settings, and uptime. A novel algorithm is proposed to mine association rules between uptime and other features, yielding over 1,000,000 rules. These rules reveal relationships and impacts on long uptime. By following these rules, adjustments can be made to improve the uptime of SRPUs through alterations in design and operational parameters. Two case studies were presented to illustrate that by adjusting the design and operational parameters of SRPUs based on the association rules, the probability of improved operational performance can be increased by 30 % and 8 % respectively. This study explores the association rules of long uptime SRPUs from a data-driven paradigm, providing scientific guidance for subsequent oil well design. The research methodology is also valuable for other mechanical equipment.

Enhancing Dynagraph Card Classification in Pumping Systems Using Transfer Learning and the Swin Transformer Model

The dynagraph card plays a crucial role in evaluating oilfield pumping systems’ performance. Nevertheless, classifying dynagraph cards can be quite difficult because certain operating conditions may exhibit similar patterns. Conventional classification approaches mainly involve labor-intensive manual analysis of these cards, leading to subjectivity, prolonged processing times, and vulnerability to human prejudices. In response to this challenge, our study introduces a novel approach that leverages transfer learning and the Swin Transformer model for classifying dynagraph cards across various operating conditions in rod pumping systems. Initially, the Swin Transformer model undergoes pre-training using the ImageNet-22k dataset. Subsequently, we fine-tune the model’s weights using actual dynagraph card datasets, facilitating direct classification analysis with dynagraph cards as input variables. The adoption of transfer learning significantly reduces the training time while enhancing the accuracy of condition diagnosis. To assess the effectiveness of our proposed method, we conducted a comparative evaluation against conventional models like ResNet50, DenseNet121, LeNet, and ViT. The findings demonstrate that our approach outperforms other methods, achieving an accuracy of 96%, thereby improving classification accuracy by 3–4%. Therefore, our approach, based on transfer learning and the Swin Transformer model, provides a better solution for practical problems involving similar dynagraph cards. It meets the requirements of oil field operations, enhancing economic benefits and work efficiency.

Improving the rod well pumpfor production of watered oil from deep wells

At the moment, the bulk of the total reserves of well oil fields in Kazakhstan are developed using sucker rod pumping units at a late stage of development. Experience in operating sucker rod pumping units has shown that the problem of rod chain failure in the form of breakage and rupture is still relevant today, given that the production of medium-high water oil during well operation significantly increases corrosion processes and applied loads. This article discusses methods for analyzing and optimizing the method of oil production using sucker rod pumping units. Methods used to prevent corrosion of metal structures under the influence of mineralized water are shown.

Improving the electrohydraulic drive of sucker rod pumping units

Improving the electrohydraulic drive of sucker rod pumping units

Badanie wpływu wybranych kontrolowanych czynników na współczynnik tarcia ślizgowego za pomocą eksperymentalnych metod planowania

The article presents the use of mathematical statistics to determine controllable factors that influence the coefficient of friction in a dual-flow three-stage spur gear transmission of a newly designed sucker rod pumping unit. The load acting on the bearing units, the rotational speed of the main and auxiliary shafts, and the diametrical gap between the shaft and the bushing were assessed through tests. The tests were carried out in random order. The multivariate testing was used to determine the number of tests to be performed as well as the test conditions in order to achieve the required accuracy bushing. In the statistical analysis of the results, the Cochrane criterion was applied to verify the homogeneity of the variance values. Student's t-test was used to verify the significance of the coefficients included in the regression equation, Fisher’s F-test was used to determine the suitability of the adopted output function for describing the real object of study, i.e., the adequacy of the model, and sensitivity coefficients were used to assess the influence of the corresponding parameters on the optimization parameter. The analysis also considered the dispersion of optimization parameters, measurement repeatability, and errors in the model coefficients. Experimental values of the criteria, along with the dispersion of the adequacy and repeatability of the mathematical model, were evaluated to determine whether the model is fully suitable for the object of study. The impact of significant factors and their combinations, as well as their critical values, were assessed by comparing calculated values of the criteria. The significance or insignificance of the corresponding coefficients of the regression equation was determined. To investigate the impact of these controlled factors — load, rotational speed of the main and auxiliary shafts, and the diametrical gap between the auxiliary shaft and the bushing — on the sliding friction coefficient, a modernized device was developed. This device simulates the operating conditions of a double friction sliding bearing in a dual-flow, three-stage spur gearbox bushing. The experiments were conducted using I-40A industrial oil at room temperature. It has been determined that these factors significantly impact the coefficient of friction in a double friction bearing. Consequently, it is necessary to calculate their limit values to ensure the bearing assembly operates without failure during the required service life. Compared to other examined parameters, the optimization parameter, i.e., the coefficient of friction, is most significantly influenced by the diametrical gap between the auxiliary shaft and the bushing, and least affected by the magnitude of the load acting on the bearing assembly. The overall impact of controlled factors on the coefficient of friction is minimal. Employing the test planning method, a mathematical formula was derived, enabling the determination of the coefficient of friction in a double sliding friction bearing without additional tests within the range of limit bushing values of contact parameters.

Analysis of the Possibility of Import Substitution in the Production of Sucker Rod Pump Cylinders at JSC “Neftemash”

Chemical-thermal treatment is aimed at saturating the surface layer with elements that change the microstructure and properties of the surface layer of the part. The most common chemical-thermal treatment processes are carburization, nitriding and nitrocarburization. However, the use of these processes, despite increasing surface hardness, fatigue strength and wear resistance, also has disadvantages leading to loss of productivity. These include the duration of the chemical-thermal treatment process and, most importantly, the need for subsequent mechanical processing to eliminate possible deformations and warping when obtaining high-precision surfaces. For cylinders of sucker rod pumps operating under conditions of contact friction, dimensional accuracy after chemical-thermal treatment without subsequent mechanical treatment is of great importance. The article presents the results of experimental studies to test the effectiveness of the carbonitration process of rod pump cylinders, in order to ensure the longevity of the tubular parts of rod pumps at the Izhevsk enterprise Neftemash JSC and to search for possible ways of import substitution of German technology. As a result of experimental studies, it was found that in order to achieve the hardness required by the design documentation, it is necessary to either significantly increase the exposure time during gas carbonitration, or, to increase productivity and efficiency, conduct experimental studies using the process of liquid carbonitration in a molten salts of cyanates and carbonates; and also, the carbonitration process is certainly more effective than ion nitriding, which is currently carried out for 26 hours for cylinders of sucker rod pumps, since even with a holding time of 1.5 hours, the hardness results obtained are somewhat better than those of Chinese samples.

Integrated Production Optimization of Mature Field Y Under Network Constraints

The Y Field, a mature field experiencing declining reservoir pressure, the production of hydrocarbons is declining, leading to the need for production optimization. One crucial aspect of this optimization is the selection of suitable artificial lift methods. The choice of artificial lift methods in Field Y is dependent on the unique reservoir conditions of each well. The commonly utilized equipment for artificial lift methods in Field Y includes the Sucker Rod Pump (SRP) and the Electrical Submersible Pump (ESP).This bachelor thesis aims to develop an integrated production optimization strategy for maximizing well production in Structure X, a mature field. The study involves analyzing and optimizing artificial lift methods and integrating surface network simulation. The Inflow Performance Rate (IPR) curve is utilized to identify the production potential of each well in Structure X.By evaluating the pump performance and surface network in Structure X, it is possible to identify wells that utilize artificial lift or existing pumps and have the potential to be improved up to their maximum operating range, based on their gross flow rate (BFPD). Through optimization, adjusting the stroke per minute for the Sucker Rod Pump (SRP) and the operating frequency for the Electrical Submersible Pump (ESP) can lead to a significant increase in production. Specifically, with a design production rate of 2308.59 BFPD, an improvement of 82.23 BOPD can be achieved.

STUDY OF OPTIMIZATION OF THE STRUCTURAL DESIGN OF SUPPORT UNITS OF PUMPJACKS

Oil extraction is carried out in three ways: fountain, gas elevator, and pumping. The claim that the time of flowing wells is long over is not negotiable. But we can agree that the leading role in oil production is. Although there are different types of pumps, such as plunger, centrifugal, screw, hydraulic piston, jet, etc., more common for this method are. And the main drive of downhole rod pumps has been pumpjacks for more than a century. This article considers the justification of the possibility of improving the pumpjack design through self-lubricating sliding bearings in low-speed units. Keywords: oil production pumping, balancing pumpjack, rolling bearings, self-lubricating sliding bearings.

Wpływ czynników mechanicznych na wydajność i proces starzenia się kiwona

"The paper discusses the influence of mechanical factors on the performance and aging process of rocking machines, specifically focusing on oilfield equipment such as the downhole rod pump jack. The authors emphasize the importance of analyzing the condition and aging process of oilfield equipment to ensure reliability, safety, and efficiency in oil production processes. The mechanical factors discussed in the paper include vibrations, loads, wear, and corrosion. Vibrations can be caused by improper balance, bearing failures, or other factors, and they have a negative impact on equipment performance and can lead to breakdowns. High mechanical loads associated with raising and lowering sucker rods can cause wear and damage to the pump jack. Operating in harsh environments with sand, abrasive particles, or chemicals can also cause wear on surfaces and equipment parts. Corrosion of metal components can occur due to moisture, chemical attack, or improper storage and maintenance, leading to deterioration and breakage of equipment. The consequences of these mechanical factors on the aging of an oil pump jack include accelerated aging, decreased performance, and an increased risk of accidents. Continuous exposure to vibration, stress, wear, and corrosion accelerates the aging process, resulting in deterioration and reduced equipment life. Damage and breakdowns caused by mechanical factors lead to decreased efficiency, negatively impacting oil production processes. Moreover, insufficient maintenance and failure to address mechanical influences increase the risk of accidents, downtime, and damage to other parts of the manufacturing process. To assess the health and aging status of an oil pump jack, various analysis and diagnostic methods are used, including visual inspection, strength testing, monitoring of parameters, and non-destructive testing. Visual inspection helps identify visible damage, wear, and defects. Strength testing evaluates the reliability of pump jack parts and identifies potential issues. Monitoring parameters like vibrations, temperature, and pressure allows for detecting deviations from normal operation and preventing breakdowns. Non-destructive testing methods such as ultrasonic testing, magnetic particle testing, and radiography help identify hidden defects and damage. The authors recommend several strategies to maintain the reliability and efficiency of an oil pump jack. These strategies include implementing a preventive maintenance program with regular inspection, testing, and parts replacement based on manufacturer’s recommendations and equipment condition analysis. Determining optimal service and part replacement intervals based on historical data, monitoring results, and manufacturer’s recommendations is crucial. Additionally, utilizing more durable materials, anti-corrosion coatings, improved designs, and technologies can increase equipment resistance to mechanical stress and improve performance. The paper also describes the device and components of a pump jack, such as the installation base, platform, balancer, electric motor, crank, connecting rod, and control station. It emphasizes the importance of considering various characteristics when selecting and evaluating the effectiveness of a pump jack, including working load, maximum plunger stroke, reducer dimensions, output torque, and swing frequency. The kinematics of the pump jack drive system are discussed, highlighting the need for reconfiguration to adapt to changing operating conditions and optimize oil production performance. Overall, the paper emphasizes the importance of analyzing mechanical factors, managing the aging process, and implementing maintenance strategies to ensure the reliable and efficient operation of oilfield equipment, specifically the pump jack used in oil production processes.

Diagnosing injection-production system faults in the same well using the rough set-LVQ neural network.

This study proposed a reverse calculation model of the unique rod pump injection and production system structures in the same well to diagnose and resolve defects, after which dynamometer diagrams of the system production and injection pumps were drawn. The invariant moment feature method was applied to identify seven such characteristics in the injection pump power graph, establishing a downhole system for fault diagnosis in rod pump injection and production systems in the same well using Rough Set(RS)-Learning Vector Quantization(LVQ). On the premise of keeping the classification ability unchanged, the Self-Organizing Map(SOM) neural network was used to discretize the original feature data, while RS theory was employed for attribute reduction. After establishing the LVQ fault diagnosis subsystem, the reduced decision table was entered for learning and training. The test results confirmed the efficacy and accuracy of this method in diagnosing downhole faults in rod pump injection-production systems in the same well. After comparing the test results with the actual working conditions, it can be seen that the rod pump injection-production diagnosis system based on RS-LVQ designed in this paper has a recognition rate of 91.3% for fault types, strong recognition ability, short diagnosis time, and A certain practicality. However, the research object of fault diagnosis in this paper is a single fault, and the actual downhole fault situation is complex, and there may be two or more fault types at the same time, which has certain limitations.

Unveiling Deep Learning Insights: A Specialized Analysis of Sucker Rod Pump Dynamographs, Emphasizing Visualizations and Human Insight

This study delves into the heightened efficiency and accuracy of 11 deep learning models classifying 11 dynamograph classes in the oil production sector. Introducing a novel framework with the Grad–CAM method, we address the “black box” issue, providing transparency in the models’ decision-making processes. Our analysis includes a comparative study with human experts, revealing a comprehensive understanding of both machine and human interpretive strategies. Results highlight the notable speed and precision of machine learning models, marking a significant advancement in rapid, reliable dynamograph classification for oil production decision-making. Additionally, nuanced findings in the model’s diagnostic accuracy reveal limitations in situations featuring the simultaneous occurrence of multiple pump issues. This underscores the need for additional features and domain-specific logic to enhance discernment and diagnostic precision in complex scenarios. The exploration of qualitative aspects distinguishes interpretive approaches, highlighting strengths and limitations. Machines, driven by algorithmic patterns and data processing, excel in rapid identification, albeit with occasional misclassifications. In contrast, human experts leverage experience and domain-specific knowledge for nuanced interpretation, providing a comprehensive understanding of both quantitative metrics and qualitative nuances. In conclusion, this study not only demonstrates the accelerated and enhanced accuracy of dynamograph classification by machine learning models compared to junior and medior domain experts, but also provides valuable insights into specific features and patterns guiding the decision-making process. This understanding allows continuous refinement, combining machine speed with human understanding for improved results in oil production. The potential for further studies and improvements in this domain is substantial.

Intelligent intertraverse dynamograph of the mesdoza of sucker-rod deep-pumping units

Rod downhole pumping units widely used in oil production are described. It is shown that oil production depends on the mode of operation of these units, which is selected based on the results of the analysis of closed dynamometer charts. Dynamograms describe the load on the suspension depending on the course of the polished rod of the installation, the quality of the construction of the dynamograms is decisive for diagnosing the technical condition of the installation. The trends in the development of existing dynamometer systems and methods for diagnosing the state of a sucker rod pumping unit are analyzed. One of the ways to create an intelligent intertraverse mesdoza dynamograph based on the mesdoza of a pocket dynamograph using modern pressure, acceleration, temperature sensors, STM32 controllers, a graphic liquid crystal display with an I2C interface, radio communication protocols and digital technologies for processing periodic sensor signals is presented. Based on the analysis of existing dynamometer systems and force and stroke sensors installed in various places of the installation design, and taking into account modern advances in technology and technologies for analyzing the noise of the measured signals, the possibility of developing an intelligent stationary dynamograph is shown. This dynamograph must provide early diagnostics of the technical condition of the installation and meet the following criteria: low cost; ease of installation; high sensitivity, reliability, flexibility and accuracy. A block diagram of an intelligent intertraverse dynamograph of the mesdoza of a sucker-rod deep pumping unit, based on the mesdoza of a pocket dynamograph, is presented. The proposed intelligent intertraverse dynamograph will be useful for early diagnostics of the technical condition of downhole pumps and tubing pipes connecting them with ground equipment, which will ultimately help to improve the reliability of oil production equipment. The proposed intelligent intertraverse dynamograph can also be used in other areas of technology where there is a need to measure force.

Working condition recognition of sucker rod pumping system based on 4-segment time-frequency signature matrix and deep learning

High-precision and real-time diagnosis of sucker rod pumping system (SRPS) is important for quickly mastering oil well operations. Deep learning-based method for classifying the dynamometer card (DC) of oil wells is an efficient diagnosis method. However, the input of the DC as a two-dimensional image into the deep learning framework suffers from low feature utilization and high computational effort. Additionally, different SRPSs in an oil field have various system parameters, and the same SRPS generates different DCs at different moments. Thus, there is heterogeneity in field data, which can dramatically impair the diagnostic accuracy. To solve the above problems, a working condition recognition method based on 4-segment time-frequency signature matrix (4S-TFSM) and deep learning is presented in this paper. First, the 4-segment time-frequency signature (4S-TFS) method that can reduce the computing power requirements is proposed for feature extraction of DC data. Subsequently, the 4S-TFSM is constructed by relative normalization and matrix calculation to synthesize the features of multiple data and solve the problem of data heterogeneity. Finally, a convolutional neural network (CNN), one of the deep learning frameworks, is used to determine the functioning conditions based on the 4S-TFSM. Experiments on field data verify that the proposed diagnostic method based on 4S-TFSM and CNN (4S-TFSM-CNN) can significantly improve the accuracy of working condition recognition with lower computational cost. To the best of our knowledge, this is the first work to discuss the effect of data heterogeneity on the working condition recognition performance of SRPS.