Francisco More, Jordan Anderson, Ricardo Pulido, and Esteban Oliva, TENARIS
Justin Murdoch, Continental Resources
As rod lift systems are extended to greater depths and tasked with higher production rates, operators face increasing complexity in maintaining reliability and cost-effectiveness. Elevated loads, deeper pump landings, and aggressive environments introduce compounded risks, including rod and tubing wear, bending fatigue failures, corrosion fatigue, and connection reliability issues, among others. Simultaneously, business strategies demand earlier conversion to rod lift and compatibility both with large size (long stroke) and mid-size pumping units such as 912 and 640 to deliver more production and deeper.
To address these challenges, a structured development program was initiated in 2016, aimed at expanding the operational envelope of rod lift through a portfolio of engineered solutions. This effort progressed from proof-of-concept designs to full integration by 2024, incorporating advanced materials, optimized geometries, finishing technologies and string design optimization to mitigate the challenges and enhance system performance.
Field validation across diverse environments demonstrated measurable improvements in runtime, reliability, and production capacity. The 1K @ 10K framework reflects a systematic approach to design and integration, enabling rod lift systems to meet the demands of modern high-value wells while maintaining operational integrity.