Bringing Sustainability to Operations by Deploying Coated Continuous Rod to Extend Tubing & Rod Run Life in Highly Corrosive Applications

Abstract

Historically, corrosion has become a challenging condition for oilfield operations when selecting a robust yet reliable Artificial Lift Systems (ALS). Continuous Rod revolutionized the industry during the 2000's, by mitigating tubing and rod wear effect in deviated wells. However, this technology was not a solution in a highly corrosive environment. This paper shows the results of a sustainable project that saved more than fifteen workover interventions and 504 tons of greenhouse gases (GHG) through a coated continuous rod deployed in highly corrosive heavy oil wells. An innovative solution is presented to decrease interventions in wells with rod-driven ALS (extending run life by reducing failures from rod-tubing wear and friction-corrosion) by implementing coated continuous rod technology, avoiding the capital expenditure (CAPEX) for specialized installation equipment. Additionally, this document presents all the benefits (economical and environmental) obtained because of implementing the technology in three wells in operating fields in Colombia.

One of the challenges in implementing recent technology is the cost of installation. The proposed solution was to deliver the product prefabricated from manufacturing (upper rod string coated with epoxy, with welded connector pins and a gooseneck attached to the string under the same conditions and with predetermined/agreed lengths). This approach minimized implementation costs and, in parallel, reduced the operational time at the well site. It also contributed to enhancing the sustainability of the technology under evaluation, demonstrating the benefits that a double-layer, fusion-bonded coating shield on the continuous rod string could provide to three deviated wells.

This article compiles the positive results obtained after correctly transporting the rod string and gooseneck on the same reel from the manufacturing plant to the well location, adapting the available well service units in the field for the correct installation of the technology, and meeting the requirements of the established new technologies protocol.

The document aims to present the optimization process implemented that allowed for a perfect scenario to develop a technological application, starting with the technical process, economic analysis, and the respective benefits obtained in three pilot wells after implementation. Key performance indicators (KPIs) such as Average Run Life, Sucker Rod Failure, and Intervention Frequency were established, showing excellent results after 3 years of operation without any failures in the ALS.