Design Optimization of Valve Assemblies in Downhole Rod Pumps to Enhance Operational Reliability in Oil Production

Seitzhan Zaurbekov (), Kadyrzhan Zaurbekov, Doszhan Balgayev, Galina Boiko, Ertis Aksholakov, Roman V. Klyuev and Nikita V. Martyushev ()
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Seitzhan Zaurbekov: Institute of Metallurgy and Ore Beneficiation, Satbayev University, Almaty 050010, Kazakhstan
Kadyrzhan Zaurbekov: Institute of Metallurgy and Ore Beneficiation, Satbayev University, Almaty 050010, Kazakhstan
Doszhan Balgayev: Institute of Metallurgy and Ore Beneficiation, Satbayev University, Almaty 050010, Kazakhstan
Galina Boiko: Institute of Metallurgy and Ore Beneficiation, Satbayev University, Almaty 050010, Kazakhstan
Ertis Aksholakov: Institute of Metallurgy and Ore Beneficiation, Satbayev University, Almaty 050010, Kazakhstan
Roman V. Klyuev: Department of Technique and Technology of Mining and Oil and Gas Production, Moscow Polytechnic University, 107023 Moscow, Russia
Nikita V. Martyushev: Department of Information Technologies, Tomsk Polytechnic University, 634050 Tomsk, Russia

Energies, 2025, vol. 18, issue 15, 1-22

Abstract: This study focuses on the optimization of valve assemblies in downhole rod pumping units (DRPUs), which remain the predominant artificial lift technology in oil production worldwide. The research addresses the critical issue of premature failures in DRPUs caused by leakage in valve pairs, i.e., a problem that accounts for approximately 15% of all failures, as identified in a statistical analysis of the 2022 operational data from the Uzen oilfield in Kazakhstan. The leakage is primarily attributed to the accumulation of mechanical impurities and paraffin deposits between the valve ball and seat, leading to concentrated surface wear and compromised sealing. To mitigate this issue, a novel valve assembly design was developed featuring a flow turbulizer positioned beneath the valve seat. The turbulizer generates controlled vortex motion in the fluid flow, which increases the rotational frequency of the valve ball during operation. This motion promotes more uniform wear across the contact surfaces and reduces the risk of localized degradation. The turbulizers were manufactured using additive FDM technology, and several design variants were tested in a full-scale laboratory setup simulating downhole conditions. Experimental results revealed that the most effective configuration was a spiral plate turbulizer with a 7.5 mm width, installed without axis deviation from the vertical, which achieved the highest ball rotation frequency and enhanced lapping effect between the ball and the seat. Subsequent field trials using valves with duralumin-based turbulizers demonstrated increased operational lifespans compared to standard valves, confirming the viability of the proposed solution. However, cases of abrasive wear were observed under conditions of high mechanical impurity concentration, indicating the need for more durable materials. To address this, the study recommends transitioning to 316 L stainless steel for turbulizer fabrication due to its superior tensile strength, corrosion resistance, and wear resistance. Implementing this design improvement can significantly reduce maintenance intervals, improve pump reliability, and lower operating costs in mature oilfields with high water cut and solid content. The findings of this research contribute to the broader efforts in petroleum engineering to enhance the longevity and performance of artificial lift systems through targeted mechanical design improvements and material innovation.

Keywords: downhole rod pumping units (DRPU); valve assembly optimization; flow turbulizer; shut-off element rotation; oilfield equipment (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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