Optimizing Sucker Rod Components in Rod-Lift Systems: Leveraging Computational Fluid Dynamics (CFD) to Enhance Design and Reliability

Rod-lifted wells in U.S. unconventional fields have been pushed beyond their limits since the onset of the unconventional reservoir (UR) revolution. Sixteen years later, the demand for higher production rates with rod-lift systems remains strong. As the industry progresses toward the Aspirational Goal of 1,000 barrels per day (bfpd) at depths of 10,000 feet (1K @ 10K), new challenges continue to emerge.

While previously identified issues, such as wellbore deviation, high sideloads, and compressive loads, have been mitigated through innovative rod guiding techniques (Oliva & Anderson, SWPSC 2024, Sinker Section Design to Reduce Buckling-Related Failures), operators in the 400 to 600 bfpd range now face additional challenges. Specifically, turbulent flow conditions have led to corrosion-erosion mechanisms around rod guides and connections.

This study explores the use of Computational Fluid Dynamics (CFD) as a tool to enhance the design and reliability of sucker rod components in rod-lift systems. By applying CFD techniques to model fluid dynamics, we optimize key properties of rod guides and connections, such as geometry, dimensions, and Erodible Wear Volume (EWV). This approach allows for precise optimization of component placement and design, ultimately improving runtime and reducing wear-related failures in challenging operational conditions.