Sucker rod guide design, manufacture heating up!

Sucker rods are critical components in artificial lift systems, specifically sucker rod pumps used in wells. Sucker rod guides protect rods by minimising metal-to-metal contact between them and tubing.

However, these guides currently struggle to prevent early production tubing failure, especially in high-temperature settings.

This project is engineering, developing and commercialising a novel composite material and design for rotary and reciprocating SRGs used in high-temperature well conditions, with the main project outcome being a "best-in-class" high-temperature composite sucker rod wear guide.

“We plan to leverage our unconventional proprietary and patented composite over-moulding method, built in collaboration with UQ, to identify a new SRG design, and expand our wear guide portfolio to include SRGs suitable for high-temperature applications,” said Mr Tony Chapman, Operations Manager and Industry Partner Project Supervisor at OPS.

“The high temperature guide will be a critical addition to our portfolio, both with respect to addressing our local market needs, as well as those overseas through new export opportunities."

Natural gas is viewed as the critical transition fuel for the foreseeable future, and there is therefore high demand for products that can extend well life and enhance productivity.

Temperature and wear requirements for SRGs are increasing, demanding enhanced durability.

The new thermoplastic matrix composite wear materials being developed will be able to withstand the harsh service conditions brought about by the deeper and more complex geological formations in which they’ll be used. The development process itself will also be enhanced to account for mass production requirements.

“The material will be specifically designed to be suitable for mass production of composites via the novel injection overmoulding process, and the compounds will have optimised flow and solidification characteristics, to improve part compatibility and cycle time in the hybrid injection overmoulding process,” explained Dr Luigi Vandi, Co-Deputy Director for the Centre for Advanced Materials Processing and Manufacturing (AMPAM) and Research Partner Project Lead at UQ.

Chapman added, “What this basically means is that the process can be automated and improved, making it suitable for true mass production.

“It’s anticipated that this process will reduce labour input and cycle time by at least 50%. As such, we’ll be looking to implement these improvements within other OPS guide manufacturing operations, thus amplifying potential benefits,” he added.

The improved SRGs and advanced manufacturing processes to come out of this project are predicted to unlock new domestic and international markets, enhancing OPS’s – and Australia’s competitiveness in the global oil and gas industry.

“The small SRG plays a very big role in oil and gas industries, which is why we can’t afford reduced asset efficiency when it comes to SRGs in high temperature settings,” said Mr Luke Preston, CEO of ACM CRC.

“This project’s outputs will be essential for upstream oil and gas operations, with sucker rods critical components for wells. High-temperature well servicing and drilling markets, with their deep and complex reservoirs, are also set to benefit. And then there’s the natural gas sector, which is a transitional energy source requiring durable and efficient infrastructure.

“Essentially, what’s being developed through this industry-led collaborative project is a new value proposition to end-users here and overseas, offering improved wear performance at higher operation temperature. This will translate to lower operational costs and reduced rates of failure.”

ACM CRC welcomes engagement from industry and research partners interested in collaborating on advanced composites manufacturing initiatives. Contact us here.