energies

Article
Improving the Efficiency of Curved Wells’ Operation by Means
of Progressive Cavity Pumps
Anatoliy Andreevich Isaev 1 , Mekhrali Mirzali Ogly Aliev 2 , Alexander Nikolaevich Drozdov 3 ,
Yana Alekseevna Gorbyleva 3 and Karina Shamilyevna Nurgalieva 4, *

1 Sheshmaoil Management Company LLC, 423458 Almetyevsk, Russia; isaeff-oil@yandex.ru

2 Department of Oil and Gas Equipment and Engineering Technology, Almetyevsk State Oil Institute,
423458 Almetyevsk, Russia; mmaliev@rambler.ru
3 Department of Mineral Developing and Oil & Gas Engineering, Peoples’ Friendship University of Russia,
117198 Moscow, Russia; drozdov_an@mail.ru (A.N.D.); yana_gorbyleva@mail.ru (Y.A.G.)
4 Department of Development and Operation of Oil and Gas Fields, Saint-Petersburg Mining University,
199106 St. Petersburg, Russia
* Correspondence: khaibullina_k@mail.ru; Tel.: +7-9179012180

Abstract: This paper proposes a solution to the problem of improving the reliability of the operation
of progressive cavity pump units in deviated and directional wells. High dogleg severity signifi-
cantly contributes to rod breakage; rods often break close to the “elbows” with a dogleg severity of
2 deg/10 m or higher. Statistical analyses were used to identify the frequency of failures and their
impact on the reliability of a PCP unit. The design layout and mathematical model for pump rods’
torsional vibrations in the curved section of a wellbore were developed. A simulation of the curved
section was performed. This article provides the basic formulas needed to design a rotating rod
string using two reduced discs. The creation of an additional crooked section resulted in multiple
reductions in the “resonant” rotational speed and rigidity in the mathematical model. Determining
the moment of inertia of the reduced discs’ mass made it possible to determine the sucker-rod string’s
Citation: Isaev, A.A.; Aliev, M.M.O.; stiffness, the circular rotation frequency, and the number of sucker-rod revolutions under resonance.
Drozdov, A.N.; Gorbyleva, Y.A.; The number of reduced discs on the sucker-rod string depends on the curvature pattern. In summary,
Nurgalieva, K.S. Improving the a centralizer for a rotating string was designed to reduce the vibration and shock effects of rods on
Efficiency of Curved Wells’ the tubing.
Operation by Means of Progressive
Cavity Pumps. Energies 2022, 15, 4259. Keywords: progressive cavity pump; directional wellbore profile; sucker-rod string; reduced disc; centralizer
https://doi.org/10.3390/en15124259

Academic Editor: Eric James Mackay

Received: 19 April 2022 1. Introduction

Accepted: 1 June 2022
Since 2003, long-term experience with the operation of wells using progressive cavity
Published: 9 June 2022
pumping units (PCPUs) driven by a rotating rod string has shown that screw pumps
Publisher’s Note: MDPI stays neutral are one of the most effective means for artificial lifting of heavy oils under conditions of
with regard to jurisdictional claims in low reservoir productivity rates and high gas content at high saturation pressure [1–7].
published maps and institutional affil- The author of [1] provides a study in which a simplified flow model of a PCP is used
iations.
to control the PCP system and to undertake quick calculations of flow rates. The study
presented in [2] focuses on evaluating the effects of the different variables (such as the
fraction of gas voids, frequency of rotation, and pressure drop) on the performance of
a PCP with two-phase flow. One of the first models used to simulate and analyze PCP
Copyright: © 2022 by the authors.
Licensee MDPI, Basel, Switzerland.
performance was that proposed by Belcher in [3]: it was named the “infinite parallel plate”
This article is an open access article
and simulated the slip effect as that of a convergent–divergent bearing. Models are being
distributed under the terms and developed that combine an analytical model to predict the theoretical performance of a
conditions of the Creative Commons pump with a slippage model [4]. Other studies [5–10] have focused on studying the effect
Attribution (CC BY) license (https:// of the rotor movement on the sealings of stators for various speeds and pressures and on
creativecommons.org/licenses/by/ the improvement of pump design.
4.0/).

Energies 2022, 15, 4259. https://doi.org/10.3390/en15124259 https://www.mdpi.com/journal/energies

Energies 2022, 15, 4259 2 of 14

The simplicity of the PCP design is associated with the absence of valves and complex
junctions, thereby significantly reducing hydraulic losses. With a higher viscosity value,
fewer crossflows occur through the sealing lines of the elastomer–rotor couple; therefore,
the viscosity does not have a significant impact on the screw pump’s delivery rate.
The opposite situation is observed with the other methods of operation (sucker-rod
pump, electric submergible pump (ESP), diaphragm pump, etc.). The average delivery rate
of the sucker-rod pumping unit is 0.35 at a viscosity of 300 mPa·s, whereas for the PCP unit
this indicator equals 0.9 ÷ 0.95. The simplicity of operation makes it possible to reduce
operating costs and, thus, the cost of oil production.
It is essential to consider downhole conditions for the efficient operation of downhole
equipment. Optimization of PCP wear can be achieved through the geometry of the pump,
proper selection of stator elastomers and wear-resistant rotor coatings, and correct selection
of the pump size for a specific application [11–17].
Despite the significant amount of research on the development and optimization
of PCP design for well conditions, the operation of wells with PCP is associated with
a shortage of effective technical means to prevent or significantly reduce complications
in the operation of sucker-rod pumps, particularly in wells with high dogleg severity,
which leads to reductions in equipment operating times and in the efficiency of well fluid
extraction [18,19].
This is why the development of new technical means for PCP-operated wells is an
urgent task and the focus of the present study.
The novelty of this research is the new method developed for modeling the motion of
a sucker-rod string during the operation of curved and directional wells. The mathematical
model of rod motion elaborated, involving a reduced disc in the curved section of the well,
makes it possible to detect hazardous resonance phenomenon. When operating crooked
wells, the sucker-rod string takes the shape of a helix or a sine wave of varying pitch. For
wells with a number of severe dogleg sections, the frequencies of the forced and natural
oscillations of the sucker-rod string may coincide, leading to the increased amplitude of the
oscillations and vibration of the sucker-rod string. We developed a new centralizer with
the friction of mating surfaces in order to increase the mean time between failures (MTBF)
in PCPs.

2. Analysis of the Operation of Progressive Cavity Pumping Units

The major problems in wells operated by PCP units are the breakage of sucker rods
and the abrasion of the pump’s helical pair [20,21]. For instance, 175 cases of sucker-rod
breakage were observed during the operation of PCP units at five producing companies of
Sheshmaoil Management Limited Liability Company (Republic of Tatarstan). The rotation
of a sucker-rod string creates tensions, which must be calculated by approximation since
a sucker-rod string is not a rod (shaft) with a constant section due to the presence of
couplings and joints; friction forces and other factors have to be considered. The rotation of
the sucker-rod string is influenced by:
(a) axial tension force due to the self-weight of the rods;
(b) fluid pressure;
(c) bending loads in a curved wellbore;
(d) tangential stresses.
Tangential and tensile stresses reach their maximum values in the upper part of the
sucker-rod string. For example, in joint stock company (JSC) Kondurchaneft, rod partings
occur in the upper fifth of the sucker-rod string, in JSC Sheshmaoil, at one third, and in JSC
Ideloil, rods usually break in the second fifth of the string. It appears that the longer the
string of the sucker rods, the closer to the wellhead the rod breakages occur. The greater the
curvature build-up (referred to as the “elbow”), the greater the collision between the rods
and the tubing; therefore, it is recommended that centralizers, preferably also functioning
as bearings, be installed at these points. The arrangement of the centralizers is based on the
placement of their bearings at the points on the rods with maximum radial loads [22]. High
Energies 2022, 15, 4259 3 of 14

dogleg severity means that the curvature gain or decline in a wellbore equals 2 deg/10 m
and higher. Such a section of a wellbore is called an “elbow”.
Table 1 shows that high severity is observed in all companies and significantly con-
tributes to the breakage of rods, and the breakage incidence increases as the rods approach
the “elbow”. If we consider a distance of ±50 m between the depth of the rod breakage
and the nearest location of 2 deg/10 m severity, then we can see that:
(a) 42% of rods breakages within the “elbow” took place at JSC Kondurchaneft;
(b) 45% took place at JSC Sheshmaoil;
(c) 76% took place at JSC Ideloil.

Table 1. The average values for the main parameters of wells where sucker-rod breakages occur.

Parameter JSC Kondurchaneft JSC Sheshmaoil JSC Ideloil

Breakage depth, [m] 263 309 377
Rod string length, [m] 1225 978 940
Maximum severity, [deg/10 m] 2.97 2.42 6.83
Depth of maximum severity, [m] 434 373 260
Dogleg severity at the point of the rod breakage [deg/10 m] 0.86 1.05 1.35
Distance from the point of the rod breakage to the dogleg
105 132 67
severity of 2 deg/10 m [m]
Percentage of broken rods near the dogleg severity
42 45 76
of 2 deg/10 m [%]

The most complicated situation related to the frequency of rod breakages caused
by high dogleg severity. There were accounts for JSC Ideloil in which both artificial
and unintentional (natural) curvature developed while drilling wells, the latter occurring
frequently. It is worth mentioning that, rather than horizontal wells, PCPs mostly operate in
directional wells with deliberately artificial deviations. In wells with high dogleg severity,
no rod breaks along the couplings have been recorded; mainly, the rods break along the
body and, less often, along the wrench square and threads [20,22].
Figure 1 shows that the frequencies of repairs due to rod failures at the facilities of LLC
Sheshmaoil Management Company have changed constantly; for example, the number of
Energies 2022, 15,rod failures
x FOR was minimal in 2008 and 2010. The average percentage of specific dependence
PEER REVIEW 4 of 15
(SD) of rod breakage on the number of PCP repairs is 20%.

Figure 1. Distribution of rod failures by year.

Figure 1. Distribution of rod failures by year.
Table 2 provides information on workovers of wells with PCPs, the number of wells
with PCPs, as well as the specific dependencies of:
(a) PCP repairs on the number of wells with PCPs;
(b) PCP repairs excluding other types of repairs and well interventions (WIs) on the
Energies 2022, 15, 4259 4 of 14

Table 2 provides information on workovers of wells with PCPs, the number of wells
with PCPs, as well as the specific dependencies of:

Table 2. Distribution of PCP unit repair by year.

Specific
Dependence of
Number of
PCP Repairs Number of PCP Repair Specific Specific
Workovers of Number of
Year without WI, Wells with (Excluding Well Dependence Dependence
Wells with Rod Failures
etc. PCPs Interventions and of Rod Failure of PCP Repair
PCPs
Other Types of
Repairs)
2001 0 0 1 0 0 0 0
2002 0 0 2 0 0 0 0
2003 11 9 12 0.75 3 0.25 0.92
2004 30 20 43 0.47 2 0.05 0.70
2005 69 43 65 0.66 14 0.22 1.06
2006 64 47 74 0.64 15 0.20 0.86
2007 61 48 75 0.64 14 0.19 0.81
2008 63 41 83 0.49 3 0.04 0.76
2009 33 22 69 0.32 8 0.12 0.48
2010 38 30 75 0.40 3 0.04 0.51
2011 72 45 86 0.52 17 0.20 0.84
2012 94 65 93 0.70 14 0.15 1.01
2013 95 70 98 0.71 19 0.19 0.97
2014 66 41 104 0.39 6 0.06 0.63
2015 72 45 102 0.44 7 0.07 0.71
2016 81 55 99 0.56 19 0.19 0.82
2017 61 31 95 0.33 9 0.09 0.64
2018 60 38 91 0.42 11 0.12 0.66
2019 41 25 91 0.27 7 0.08 0.45
2020 34 30 85 0.35 9 0.11 0.40
2021 48 35 85 0.41 10 0.12 0.56

(a) PCP repairs on the number of wells with PCPs;

(b) PCP repairs excluding other types of repairs and well interventions (WIs) on the
number of wells with PCPs;
(c) rod breakages on the number of wells with PCP.
Table 2 shows that the specific dependence of PCP unit repairs on the number of
PCP-operated wells is decreasing: while the specific dependence was equal to 0.9 when
PCPs were first implemented, it has been about 0.5 in recent years, indicating one repair
per two PCP-operated wells per year. If we exclude other types of repairs, which have no
effect on the MTBF, the specific dependence drops, particularly in the years 2004, 2009, 2014,
2017, and 2019. Other types of repairs include well interventions (hydraulic fracturing,
bottom-hole zone treatment, re-perforations, etc.), replacing the surface drive and the
electric motor, troubleshooting the well-head fittings, readjusting the rotor without needing
to lift the downhole pumping equipment, and flushing the well.
The highest SD values were recorded in 2005, 2012, and 2013. SD displays a positive
trend, in accordance with the growing application of PCPs.
Table 3 indicates that the majority of rod failures occur across the bodies.

Table 3. Rotating string failure across structural elements.

Rotating String Part Body Thread Coupling Wrench Square

Failure ratio 0.853 0.076 0.041 0.03

Table 4 presents the distribution of rotating string failures at the facilities of LLC MC
Sheshmaoil by pump type and size, and it indicates that the failure rate is higher for screw
pumps of larger sizes, as well as for ShVN-7 pumps. The digit in the name of the ShVN
pump refers to the pump’s capacity in m3 /day at a rotor speed of 100 rpm.
Energies 2022, 15, 4259 5 of 14

Table 4. Rotating string failures by type and size.

Type and Size of Oil Production ShVN-2, ShVN-5, ShVN-10, ShVN-13, ShVN-21, ShVN-23,
ShVN-4 ShVN-7 ShVN-16 ShVN-33 ShVN-40
Pumps Company ShVN-3 ShVN-6 ShVN-11 ShVN-14 ShVN-22 ShVN-24

JSC Sheshmaoil 8 145 27 7 83 12 22 8 13 2

JSC Ideloil 2 34 29 70 4 29 7 1 4 3
Retrieved pumps JSC Kondurchaneft 28 36 38 13 13 1
JSC Elabuganeft 1 1 1 1
General 38 215 94 7 166 29 52 15 14 4 5

JSC Sheshmaoil 2 12 1 4 13 8 4 2 3
Number of JSC Ideloil 7 6 24 12 3 2 2
rotating string JSC Kondurchaneft 3 5 6 2
failure cases JSC Elabuganeft 1 1 1 1 1
General 5 24 13 4 37 10 16 5 3 2 2

Failure
General 0.132 0.112 0.138 0.571 0.223 0.345 0.308 0.333 0.214 0.500 0.400
ratio

To represent the dangerous phenomenon of resonance that can occur during the rota-
tion of rods, a mathematical model of rod motion using a reduced disc in the curved section
of a well was here developed for the first time ever, and data from the implementation
of this model in an actual wellsite are shown. The presence of the reduced disc as part
of the sucker-rod string reduces the angular frequency of the sucker-rod rotation, as well
as helping to determine the source of the resonant oscillations. Without a reduced disc,
the sucker-rod string has a maximum rotational frequency that is lower than the forced
oscillation frequency of the sucker-rod string. As the length of sucker rods is much greater
than the length of machine shafts, the time required for dangerous resonance to fade away,
for example, will be much greater. Hence, the sucker rods remain in this position for quite
a long period and are subjected to impacts from the tubing.

3. Materials and Methods

The aspiration to increase PCPs’ operating times in deviated wells is understandable
both from the economic and technical perspectives [22,23].
To do this, it is necessary to advance beyond the existing technical solutions and the
experience of specialists by:
1. developing a mathematical model of a sucker-rod string in a deviated well;
2. installing efficient centralizers on sucker rods.
The solution to the first problem involves the application of a reduced disc with
eccentricity to the sucker-rod string, thereby making it possible to create a model of sucker-
rod rotation with deviation from the axis that corresponds to the motion of sucker rods in a
borehole. When the rod string rotates with an angular velocity, the reduced disc’s center
of gravity creates a circular motion that generates centrifugal force. The reduced disc on
the rod is located in the crooked section. The reduced disc allows for the deviation of the
sucker rods from the vertical axis of a wellbore. Determining the moment of inertia of the
reduced disc’s mass makes it possible to determine the sucker-rod string’s stiffness, the
circular rotation frequency, and the number of sucker-rod revolutions under resonance. The
number of reduced discs on the sucker-rod string depends on the curvature pattern. The
main method used in the current study was to determine the frequency of natural torsional
oscillations of the rods, and in this paper, a model with two arms (elbows) is considered.
Modeling the proposed sucker-rods with reduced discs the formulas, developed here for
the first time, makes it possible to determine the resonant oscillations that occur when
sucker-rod strings start and stop their rotations. Using curvature data from wells, this
model makes it possible to determine the angular frequencies and numbers of revolutions
of sucker rods during resonant oscillations by increasing the mass and overall dimensions
of the reduced disc.
The solution to the second problem involves the development, manufacture, and
testing of centralizers that additionally function as bearings. Due to the limited overall
dimensions, plain bearings were considered, and the drilling centralizers” bowsprings
were used as centralizing bars, reliably fixed to the detachable half-shells. The centralizers
were tested at the following test benches:
(a) a vertical test bench with an electric motor and a frequency converter;
Energies 2022, 15, 4259 6 of 14

(b) a horizontal test bench for bow spring centralizers (SITs-2) with a pipe simulator;
(c) a vertical test bench for spring centralizers (SITs-2).
A detailed description of the calculation of the rods’ rotational motion is provided
in [24,25]. The authors of the present study recently [26] presented a design model for
rod strings with one arm that makes it possible to determine the frequency of the natural
torsional oscillations of rods. It was revealed that the presence of a reduced disc leads
to a decrease in the circular rotation frequency of the sucker rods and the number of
their revolutions. In practice, wells often have multiple “elbows” (shoulders) [27], so it
is necessary to consider the design scheme and the mathematical model of the torsional
oscillations of sucker rods in two curved sections of a well (Figures 2 and 3). The distance
from the wellhead A to the reduced disc D1 corresponds to a1 , the distance from D1 to the
point of the nodal joint M corresponds to a2 , the distance from M to the reduced disc D2 is
Energies 2022, 15, x FOR PEER REVIEWb2 , the distance from D2 to the sucker-rod screw pump B equals b1 , and l represents
Energies 2022, 15, x FOR PEER REVIEW
7 of the
15
7 of 15
distance between the reduced disc D1 and the reduced disc D2 . All distances are measured
in meters.

Figure
Figure2.2.
2.Diagram
Diagramofof
ofaaarod
rodstring
stringwith
withtwo
tworeduced
reduceddiscs
discsDD
D111and
andDD
D2.22..
Figure Diagram rod string with two reduced discs and

Model of a sucker-rodstring
Figure3.3.Model
Figure string in a deviateddouble-arm
double-arm well.
Figure 3. Modelofofaasucker-rod
sucker-rod stringininaadeviated
deviated double-armwell.
well.
Thecircular
The circular frequency
frequency ofof the
the shaft
shaft within the sections AM and MB is determined by a
Thesimilar
formula circulartofrequency
that for the shaftwithin
of single-arm
the within the
layout:thesections
sectionsAM AMand
andMB
MBisisdetermined
determinedby
by
aaformula
formulasimilar
similartotothat
thatfor
forthe
thesingle-arm
single-armlayout:
layout:
-
- - forfor the
the AM
AM section:
section:
for the AM section:
s
C1
ω1 = C (1)
ωω == JD1 +CK·Jr1 (1)
(1)
J J ++KK∙ ∙J𝐫J𝟏
𝐫𝟏
- for the MB section:
s
- - forforthe
theMBMBsection:
section: C2
ω2 = , (2)
JD2 + K·Jr2
C
where K is the mass reductionωω == (K = C1/3), ,J,D is the moment of inertia of (2)
factor the
(2)
J J ++KK∙ ∙J𝐫J𝟐
reduced disc, and J is the moment of inertia of the𝐫𝟐 rods.
r
where
The
where KK isisthe
moments ofmass
the reduction
inertia
mass factor
of the rods
reduction are (K
factor (K ==1/3),
1/3),JDJDby
determined isisthe
the moment
momentof
thefollowing ofinertia
inertiaofofthe
formulas: the
- reduced
reduced
for disc,
the AMdisc, and J
section: is the moment of inertia of the
and J is the moment of inertia of the rods. rods.
The
Themoments
momentsofofinertia
inertiaofofthe
therods
rodsare
aredetermined
determinedby bythe thefollowing
followingformulas:
formulas:
-- for the AM section:
for the AM section: πrr4
Jr1 = (a1 + a2 )ρst , (3)
2
πr
J J == πr (a(a ++aa )ρ )ρ , ,
(3)
(3)
- for the MB section: 22
-- for
forthe
theMB
MBsection:
section:
πr
J J == πr (b + b )ρ , (4)
22 (b + b )ρ , (4)
Energies 2022, 15, 4259 7 of 14

πr4r
J r2 = (b1 + b2 )ρst , (4)
2
where ρst is the density of the sucker-rod steel (kg/m3 ).
The rod string stiffness is calculated as follows:
- for the AM section:

GJp
C1 = , (5)
a1 + a2
where G is the shear modulus (MPa).
Jp is the polar moment of inertia of a rod with a diameter dr :

πd4r πr4
Jp = = r. (6)
32 2
- for the MB section:

GJp
C2 = , (7)
b1 + b2
By equating ω1 and ω2 , we obtain:
C1 C2
= (8)
JD1 + K·Jr1 JD2 + K·Jr2

Considering that a2 + b2 = l, Formula (8) can be given the following form:

GJp GJp
=
(9)
(a1 + a2 )(JD1 + K·Jr1 ) b1 + l − a2 )(JD2 + K·Jr2

Therefore:
(b1 + l )z2 − a1 z1
a2 = , (10)
z1 + z2
where z1 = JD1 + K·Jr1 ; z2 = JD2 + K·Jr2 .
The circular oscillation frequency is defined as follows:
s
GJp
ω=
, (11)
(a1 + a2 ) JD1 + K·Jr1

where a2 is derived from (10).

4. Results
4.1. Calculation Results fo a Sucker-Rod-String Model for a Specific Well
We next consider the application of the above formulas in a proper case using the data
obtained from well no. 3633 managed by JSC Ideloil, which operates the Bashkirian stage
of the Dachnoye field. Twelve cases of rod body breakage occurred within two years of
PCP operation in well no. 3633. The average rod breakage depth was 287 m, and 11 cases
of rod breakage occurred within an average distance of 8 m from the area of maximum
dogleg severity of 2 deg/10 m; i.e., this well illustrates the effect of dogleg severity on the
rod breakage rate. The maximum dogleg severity at well no. 3633 was 2.39 deg/10 m at the
depth of 250 m, and the average severity at the points of rod breakage was 1.85 deg/10 m
(Figure 4).
Energies 2022,
2022, 15,
15, 4259
x FOR PEER REVIEW 98of
of 15
14

Figure 4. Axonometric
Figure 4. Axonometric projection of well
projection of well 3633
3633 operated
operated by
by JSC
JSC Ideloil.
Ideloil.

We proposed
proposed to to compensate
compensate for forthe
theeffect
effectofofcurved
curvedsections
sectionson onthethetorsional
torsionaloscilla-
oscil-
lations
tions ofof sucker
sucker rods
rods by by replacing
replacing these
these sections
sections withwith sufficiently
sufficiently longlong rectilinear
rectilinear rods
rods with
virtual (reduced)
with virtual discs placed
(reduced) on them
discs placed on at the centers
them of the sections.
at the centers For thisFor
of the sections. model
this to lead
model
to realistic results, the
lead to realistic most the
results, difficult
mostchallenge was to determine
difficult challenge the initial characteristics
was to determine the initial char- of
the discs, such
acteristics as discs,
of the their mass
suchand moment
as their massofand
inertia. To solve
moment this problem,
of inertia. To solve thethis
radius of the
problem,
curvature
the radiusinofthethecurved sections
curvature in thewas defined
curved as the radius
sections of a circular
was defined as thearc in theofform
radius of the
a circular
conjunction with two branches of straight lines, allowing for a smooth
arc in the form of the conjunction with two branches of straight lines, allowing for transition from one
a
branch totransition
smooth the other.from
The distance
one branch between
to thethe points
other. Theofdistance
tangencybetween
correlated thewith the of
points length
tan-
of the rods
gency in the first
correlated withapproximation;
the length of the based
rodsoninthis
thelength, the mass of thebased
first approximation; reducedon disc
this
was determined.
length, the mass of Then, by varying
the reduced the
disc radius
was of the circular
determined. Then,arc, the effectthe
by varying of radius
the obtained
of the
characteristics
circular arc, theoneffect
the results
of theofobtained
the vibration process was
characteristics on analyzed.
the resultsInofcontrast to the cases
the vibration pro-
of torsional vibration in rather short machinery shafts, the mass of which
cess was analyzed. In contrast to the cases of torsional vibration in rather short machinery can be neglected
in comparison
shafts, the masswith the mass
of which canof bethe discs, we
neglected inhad to consider
comparison withthethe
distributed
mass of the mass, which
discs, we
had a substantial value, when a sucker-rod string vibrates. To achieve
had to consider the distributed mass, which had a substantial value, when a sucker-rod this, the mass of the
rod string
string was replaced
vibrates. To achieve withthis,
a concentrated
the mass ofmass,the rodwhich
stringwaswasrelocated
replaced to with
the suspension
a concen-
points of the discs. In this case, it was accepted that the value of such a mass
trated mass, which was relocated to the suspension points of the discs. In this case, it was is proportional
to the value
accepted thatofthe
thevalue
true mass.
of such a mass is proportional to the value of the true mass.
The coefficient of
The coefficient of proportionality
proportionality used used toto determine
determine the the value
value ofof aa true mass is
true mass is called
called
the mass reduction factor.
the mass reduction factor.
When discs
When discs D and D
D11 and D22 rotate
rotate in
in opposite
opposite directions
directions to to each
each other,
other, there
there willwill be
be some
some
segment with the center at point M whose angle of rotation from the condition of equi-
segment with the center at point M whose angle of rotation from the condition of equi-
librium is equal to zero. Then, the sections AM and MB of the rod will have the same
librium is equal to zero. Then, the sections AM and MB of the rod will have the same
frequencies of natural vibrations, and each of these sections can be regarded as a single-arm
frequencies of natural vibrations, and each of these sections can be regarded as a sin-
system. The cross-section of the rod with the point M in its center is called a nodal or dead
gle-arm system. The cross-section of the rod with the point M in its center is called a
point. Thus, the solution to the problem of determining the natural oscillation frequencies
nodal or dead point. Thus, the solution to the problem of determining the natural oscil-
of a system with two curved sections comes down to determining the position of the
lation frequencies of a system with two curved sections comes down to determining the
point M.
position of the point M.
When there is an “elbow” in the rod string, the frequencies of natural oscillations in
When there is an “elbow” in the rod string, the frequencies of natural oscillations in
comparison with a straight string are lower; i.e., the resonant frequency of the system is
comparison with a straight string are lower; i.e., the resonant frequency of the system is
Energies 2022, 15, 4259 9 of 14

reduced significantly, depending on the geometric shape and size of the curved section.
When comparing the frequency of free torsional vibrations with the resonant frequency,
deceleration due to the contact between the rods and the tubing occurs at the points of
curvature. The sucker rod is exposed to shock by the tubing, and this can happen both
when the ground drive is started and when it is stopped because there can be no immediate
rotation gain in or instantaneous stopping of the sucker-rod string.
When an “elbow” emerges, the rod string resonates; after passing the “elbow” zone,
the resonance torque disappears. In these places (“elbows”), slowdown occurs. As the
rods pass the resonance point, they are exposed to shock action by the tubing, and this can
occur both when the surface drive is started and when it is stopped. Once in a complex
stressed state, the rod can break after such shocks because the rod is not designed to twist
(combined with its vibration) in such a way; i.e., the rod is designed without regard for
these type of shocks. If the rod is positioned vertically and upright, the resonance will be
higher than the actual RPM.
The number of revolutions of a rod with reduced discs is not the actual number of
the rod’s revolutions, but the “resonance” number or the frequency of natural torsional
oscillations. Should two reduced discs be placed in any section of an ordinary shaft, twisted
in opposite directions, and released, the shaft will oscillate with the frequency referred
to as the frequency of natural torsional oscillations of the shaft. To distinguish between
the rotational frequency of the sucker-rod string and the rotational frequency of the string
based on the proposed mathematical model with reduced discs, the latter frequency is
referred to as the “resonant” rotational frequency.
Mathematical model calculations based on data obtained from well no. 3633 indicated
the following:
- the main design parameters required for the functioning of the mathematical model
increase as the sucker rod diameter increases (Table 5);
- when the rods rotate under the proposed model, the rod enters the resonance zone
when its natural oscillation frequency reaches 4.41 (or 5.91 or 7.63) rpm, depending on
the rod’s diameter;
- if the point M approaches the point B—for example, by 200 m—the “resonant” fre-
quency of the model’s rotation decreases by 30% and, vice versa, as the point M moves
towards the point A, the “resonant” frequency of the model’s rotation increases;
- if the point M moves toward the point A by 100 m, the “resonant” frequency of
rotation increases by 30%; moving the point M further by 80 m increases the “resonant”
frequency of rotation by more than three times, and in this case, the rigidity of the
mathematical model is multiplied by many times;
- increasing the mass of the reduced disc results in a decrease in the “resonant” fre-
quency of rotation (Figure 5).

Table 5. Estimated data for well no. 3633 operated by Ideloil JSC.

Rigidity of the
Circular Speed “Resonant” Rotation
Sucker Rod Diameter [mm] Mathematical Model with
2πω [s−1 ] Frequency [rpm]
Reduced Discs
19 0.46 0.51 4.41
22 0.62 0.92 5.91
25 0.8 1.53 7.63

4.2. Application of Centralizers as Part of a Sucker-Rod String

To reduce the adverse effects of dogleg severity and the existence of “elbows” in
PCP-operated wells, centralizers should be used to keep a sucker-rod string in the center
of the tubing while rotating [28]. Application of centralizers helps reduce the number of
well workovers caused by rod breakages and abrasion of tubing and rods. The Innovation
and Examination Department of Sheshmaoil MC LLC has designed centralizers for sucker
 Energies 2022, 15, 4259 10 of 14

Energies 2022, 15, x FOR PEER REVIEW 11 of 15

rods (TsNShP) that involve sliding bearings with centering ribs (bars) similar to those of a
drilling centralizer (Figure 6).

Figure 5. Effect of the upper reduced disc’s weight on the circular speed in well no. 3633.

4.2. Application of Centralizers as Part of a Sucker-Rod String

To reduce the adverse effects of dogleg severity and the existence of “elbows” in
PCP-operated wells, centralizers should be used to keep a sucker-rod string in the center
of the tubing while rotating [28]. Application of centralizers helps reduce the number of
well workovers caused by rod breakages and abrasion of tubing and rods. The Innova-
tion and Examination Department of Sheshmaoil MC LLC has designed centralizers for
sucker rods (TsNShP) that involve sliding bearings with centering ribs (bars) similar to
those
Figureof5.aEffect
drilling centralizer
of the (Figure
upper reduced 6).weight on the circular speed in well no. 3633.
disc’s
Figure 5. Effect of the upper reduced disc’s weight on the circular speed in well no. 3633.

4.2. Application of Centralizers as Part of a Sucker-Rod String

To reduce the adverse effects of dogleg severity and the existence of “elbows” in
PCP-operated wells, centralizers should be used to keep a sucker-rod string in the center
of the tubing while rotating [28]. Application of centralizers helps reduce the number of
well workovers caused by rod breakages and abrasion of tubing and rods. The Innova-
tion and Examination Department of Sheshmaoil MC LLC has designed centralizers for
sucker rods (TsNShP) that involve sliding bearings with centering ribs (bars) similar to
those of a drilling centralizer (Figure 6).
Figure
Figure6.
6.Centralizer
Centralizerfor
foraaPCP
PCPunit.
unit.

The lower
The lower (2) (2) and
and upper
upper (3) (3) detachable
detachable restrainers
restrainers of of the
the centralizer
centralizer movement
movement are are
installed on the body of the sucker rod (1); these restrainers are
installed on the body of the sucker rod (1); these restrainers are comprised of detachable comprised of detachable
half-bushingsand
half-bushings andare are bolted
boltedto to each
each other
other by by fasteners.
fasteners. ItIt is
is recommended
recommendedto to install
install the
the
centralizer and the restrainers on a short rod with a length of
centralizer and the restrainers on a short rod with a length of 0.5 … 1.5 m. A centralizer 0.5 . . . 1.5 m. A centralizer
consisting of
consisting of the
the lower
lower (4)(4) and
and upper
upper (5) (5) detachable
detachable half-shells
half-shells pulled
pulled together
together through
through
mounting holes by fasteners is placed between the restrainers
mounting holes by fasteners is placed between the restrainers on the sucker rod. on the sucker rod. A min-A
imum of three centering ribs (6) (d = 73.2 mm) made in the
minimum of three centering ribs (6) (d = 73.2 mm) made in the shape of elastic arc-shaped shape of elastic arc-shaped
slats of
slats of aa specified
specified cross-section
cross-section are are installed
installed in in the
the half-shells.
half-shells. The The end end sections
sections ofof the
the
centering
centering ribs (6) are
ribs (6) area PCP bent to
bentunit. fit into the slots of the lower detachable
to fit into the slots of the lower detachable half-shells. The half-shells. The
Figure 6. Centralizer
lower detachablefor half-shells are plain bearings. Application of centering ribs ensures the
lower detachable half-shells are plain bearings. Application of centering ribs ensures the
concentric placement of the sucker rods in the tubing and prevents the sucker rods from
concentric placement of the sucker
The lower (2) and upper (3) detachable rods in the tubing and
restrainers prevents
of the the sucker
centralizer movementrods from
are
touching the tubing walls. The outer diameter of the centering ribs in a free state is greater
touching
installed onthethetubing
body ofwalls. The outer
the sucker rod (1); diameter of the centering
these restrainers ribs in of
are comprised a detachable
free state is
than the inner diameter of the tubing.
greater than the
half-bushings andinner diameter
are bolted of the
to each tubing.
other byasfasteners. It is recommended to the
install thethe
The centralizer’s operation principle is follows. Prior to installation in well,
centralizer
lower (2) and the restrainers
and upper on a short
(3) detachable rod with
restrainers a length on
are installed of 0.5
the … 1.5 m.
sucker A centralizer
rods (1), and then
consisting of the lower (4) and upper (5) detachable half-shells
a centering device is positioned between them. The centralizer can also be installed pulled together through on a
mounting holes by fasteners is placed between the restrainers on
short rod at the factory; in this case, the centralizer will be delivered as a set. The centering the sucker rod. A
minimum
ribs becomeof three centering
deformed ribs (6)
as they (d =through
move 73.2 mm)different
made intubing
the shape of elasticdepending
diameters, arc-shapedon
slats of a specified cross-section are installed in the half-shells.
the tubing wall thickness; shrinking and expanding, they travel further together with The end sections of the the
centering ribs (6)
sucker rods. The are bent force
elastic to fit ofinto
thethe slots of ribs
centering the (6)
lower
keepsdetachable
the sucker half-shells.
rods (1) in The the
lower detachable
center of the tubing. half-shells are plain
The centering ribsbearings. Application
regain their of centering
initial form ribs ensures
once the centering the is
device
concentric placement
recovered to the surface. of the sucker rods in the tubing and prevents the sucker rods from
touching the tubing walls. The outer diameter of the centering ribs in a free state is
greater than the inner diameter of the tubing.
Energies 2022, 15, 4259 11 of 14

According to the approved test program and procedure for verifying TsNSh-22-73
centralizers, they were successfully tested on test benches at Sheshmaoil MC LLC, Tatprom
Holding LLC, and Naberezhnye Chelny Pipe Plant LLC (N.Chelny) (Figure 7). It is planned
to deploy 14 TsShNP centralizers in the first quarter of 2022 in two wells. The annual
Energies 2022, 15, savings
x FOR PEER
inREVIEW
costs for JSC Sheshmaoil as a result of the implementation of centralizers will 13

amount to 494,691 rubles, excluding value-added tax (VAT).

(a) (b) (c)

Figure 7. Testing Figure 7. Testing

the TsNShP the TsNShP
centralizer: (a) on acentralizer: (a) with
vertical bench on a an
vertical bench
electric with
motor andan electric motor and
a frequency
quency converter, (b) on the SITs-2 horizontal bench with a pipe simulator, and (c) on the S
converter, (b) on the SITs-2 horizontal bench with a pipe simulator, and (c) on the SITs-2 vertical test
vertical test bench for bow spring centralizers.
bench for bow spring centralizers.

5. Discussion
The restoring force directed perpendicularly towards the longitudinal axis of the
This is the
centralizer was determined on afirst time that
horizontal calculations
test bench. Thehaveloadbeen undertaken
was applied forpipe
in the a well with
curved sections
simulator to determine using
the bending reduced discs
deflection as deflectors
until the minimumofrestoring
sucker rods
forcefrom
valuethewas
vertical axi
obtained. In thisaxes
way,ofcentralizer
the discs do notwere
slats align withinthe
tested axis of positions
different the wellbore.
(TableWith
6). the design mod
sucker-rod strings developed, the stiffness of the sucker-rod string increases as th
Table 6. Loads onameter
the slatsofasthe
a function
suckerofrodouter pipe displacement
increases, and the when
angulara centering
rotationdegree
speedofof67%the sucke
was obtained. strings also increases. The resonant RPM increases in proportion to the growth o
angular frequency. The curvature pattern of the sucker rods in the well is influence
the weight and size of theLoad [kN] disc. Using centralizers as part of a sucker-rod s
reduced
Sucker Rod Diameter [mm] Displacement
can help minimize dangerous resonant [mm] oscillations and increase PCPs’ service lives.
1 2 3 4 5 6 7 8 9
6. Conclusions
1 0.31 0.39 0.48 0.56 0.64 0.72 0.83 1.08 2.12
1–2 0.29 0.45 1. High
0.57 dogleg 0.71severity0.76
significantly
0.88 contributes
1.02 to rod 1.28breakage;
1.49rods often b
2 0.16 0.28 close
0.35 to the0.42
“elbows” 0.50
with a dogleg0.59 severity of 2 deg/10
0.67 0.90m or higher.
2.19
2–3 0.24 0.43 2. 0.55 design0.64
The layout and 0.73 0.88 model
mathematical 1.12for the 1.45 2.33
torsional oscillations of su
3 0.26 0.34 0.41 with two
rods 0.48 reduced0.55discs at 0.66
two curved 0.78
sections 1.02 1.36 here devel
of a well were
3–4 0.27 0.37 0.49
for the first 0.58
time. 0.64 0.72 0.89 1.10 1.31
4 0.17 0.28 0.35 0.42 0.49 0.61 0.74 0.93 1.57
4–5 0.24 0.39
3. Increasing
0.51
the
0.66
number, size, and0.87
0.75
weight of1.17
the reduced discs and
1.61
approximatin
2.43
curved sections to the screw pump reduced the circular speed and rigidity o
sucker-rod string proposed by the mathematical model.
Thanks to 4.this The
typeTsShNP
of centralizer, it isdeveloped
centralizer possible tobyoperate horizontal
the Innovation andand strongly Depart
Examination
deviated wells, thus increasing productivity and making it possible to gain
of Sheshmaoil LLC enhances the reliability of the sucker-rod string and access to ensure
hard-to-reach pay zones.
required coaxiality of the sucker-rod string and the tubing is maintained.
5. Discussion
Author Contributions: Conceptualization, A.A.I., M.M.O.A. and A.N.D.; Methodology, A.A.
This is the M.M.O.A.;
first time that calculations
Software, have
A.A.I. and been undertaken
M.М.A.; for a well
Validation, A.A.I., withand
A.N.D. twoY.A.G.;
curved Format ana
sections using reduced discs as deflectors
A.A.I.; Investigation, of suckerand
A.A.I., M.M.O.A. rodsA.N.D.;
from the verticalA.A.I.
Resources, axis; the
and axes of Data cur
K.S.N.;
A.A.I. and M.M.O.A.; Writing—original draft preparation, A.A.I. and M.M.O.A.; Writing—re
and editing, A.A.I. and Y.A.G.; Visualization, A.A.I. and M.M.O.A.; Supervision, A.N.D.; P
administration, Y.A.G.; Funding acquisition, A.A.I., A.N.D. and Y.A.G. All authors have rea
agreed to the published version of the manuscript.
Energies 2022, 15, 4259 12 of 14

the discs do not align with the axis of the wellbore. With the design model of sucker-rod
strings developed, the stiffness of the sucker-rod string increases as the diameter of the
sucker rod increases, and the angular rotation speed of the sucker-rod strings also increases.
The resonant RPM increases in proportion to the growth of the angular frequency. The
curvature pattern of the sucker rods in the well is influenced by the weight and size of the
reduced disc. Using centralizers as part of a sucker-rod string can help minimize dangerous
resonant oscillations and increase PCPs’ service lives.

6. Conclusions
1. High dogleg severity significantly contributes to rod breakage; rods often break close
to the “elbows” with a dogleg severity of 2 deg/10 m or higher.
2. The design layout and mathematical model for the torsional oscillations of sucker
rods with two reduced discs at two curved sections of a well were here developed for
the first time.
3. Increasing the number, size, and weight of the reduced discs and approximating the
curved sections to the screw pump reduced the circular speed and rigidity of the
sucker-rod string proposed by the mathematical model.
4. The TsShNP centralizer developed by the Innovation and Examination Department
of Sheshmaoil LLC enhances the reliability of the sucker-rod string and ensures the
required coaxiality of the sucker-rod string and the tubing is maintained.

Author Contributions: Conceptualization, A.A.I., M.M.O.A. and A.N.D.; Methodology, A.A.I. and
M.M.O.A.; Software, A.A.I. and M.M.O.A.; Validation, A.A.I., A.N.D. and Y.A.G.; Format analysis,
A.A.I.; Investigation, A.A.I., M.M.O.A. and A.N.D.; Resources, A.A.I. and K.S.N.; Data curation,
A.A.I. and M.M.O.A.; Writing—original draft preparation, A.A.I. and M.M.O.A.; Writing—review
and editing, A.A.I. and Y.A.G.; Visualization, A.A.I. and M.M.O.A.; Supervision, A.N.D.; Project
administration, Y.A.G.; Funding acquisition, A.A.I., A.N.D. and Y.A.G. All authors have read and
agreed to the published version of the manuscript.
Funding: This paper has been supported by the RUDN University Strategic Academic Leader-
ship Program.
Conflicts of Interest: The authors declare no conflict of interest. The funders had no role in the design
of the study; in the collection, analyses, or interpretation of data; in the writing of the manuscript, or
in the decision to publish the results.

Nomenclature

PCPU progressive cavity pumping units

PCP progressive cavity pump
ESP electric submersible pump
MTBF mean time between failures
MC LLC management company limited liability company
SD specific dependence
WI well interventions
ShVN PCP, sucker-rod screw pump
SITs-2 test bench for bow spring centralizers
TsShNP centralizer for sucker rods
RPM rotations per minute
VAT value-added tax
A the point of the wellhead
B the point of the sucker-rod screw pump
D1 and D2 discs 1 and 2, respectively
a1 m the distance from the wellhead A to the reduced disc D1
a2 m the distance from D1 to the point of the nodal joint M
M the point of the nodal joint
Energies 2022, 15, 4259 13 of 14

b2 m the distance from M to the reduced disc D2

b1 m the distance from D2 to the sucker-rod screw pump B
l m the distance from disc D1 to disc D2
ω1 and ω2 2πs−1 the circular frequencies for the AM section and the MB section, respectively
Jr1 and Jr2 kg/m2 the moments of inertia of the rods for the AM section and the MB
section, respectively
JD1 and JD2 kg/m2 the moments of inertia of the reduced discs D1 and D2 , respectively
C1 and C2 the rod string stiffness for the AM section and the MB section, respectively
G MPa the shear modulus
Jp kg/m2 the polar moment of inertia of a rod
K the mass reduction factor
ρst kg/m3 the density of the sucker-rod steel
dr mm the diameter of a rod

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