New Rotator Technology Addresses Challenges with Rod Pumping Units
In the artificial lift market, a new type of rod rotator is available to provide users with an intelligent, versatile and reliable rod string wear solution for all rod pumping units.
During rod pumping operations, the constant up-down motion can cause erosional wear on the sucker rod. Rod
string rotation used in conjunction with rod guides not only removes paraffin from inside the production tubing, but it
also distributes wear evenly for the rods and rod couplings. This process extends periods between workovers and minimizes downtime.
The new type of rod rotator represents a departure from traditional mechanical rod rotators in the industry. This specific artificial lift technology helps to overcome common industry headaches that operators face with benefits such
as eliminating difficult setup for easier installation and
adding rotational monitoring, both on-site and remotely.
Some experts recommend that end users use tubing rotators during artificial lift operations in conjunction with any type
of rod rotators to increase tubing wear life in the same fashion. Wear prevention systems allow the operator to reduce downhole maintenance costs and production downtime by extending the service life of rods and tubing in a wide range of well conditions.
An intelligent, versatile and reliable rod string wear solution for all rod pumping units
Our new Hercules ERR is an evolution from traditional mechanical rod rotators. The ERR is actuated using an electric motor coupled to a control box. By using an electric motor you remove the headaches of setting up a traditional mechanical arm and cable setup. The elimination of the mechanically actuated arm and cable in our current designs allows operators to install a much more reliable system. Our newly integrated rotation sensor coupled with the control box monitors performance and alerts failures.
Traditionally, rod rotators are designed to operate with traditional pump jacks in mind. With the market introducing many modern unconventional rod pumping systems, installing traditional rod rotators can be very difficult and sometimes impossible. Our ERR can be used on NOV hydraulic rod pumping systems, as well as many other unconventional systems.
Industry Challenges
This technology’s development addresses some artificial lift industry challenges that users in the field currently face. Traditionally, rod rotators were designed
to operate with conventional pump jacks in mind. With
so many modern unconventional rod pumping systems
being introduced to the market today, installing
traditional rod rotators can be a difficult and sometimes impossible assignment.
In certain situations, operators may not know where to install traditional rod rotators on unconventional technology because the equipment is not capable of fitting on the unit.
This requires having to set up extra equipment, such as
custom brackets.
Using the new addition of the electric motor on the rod rotator can remove some difficulties associated with setting up the traditional mechanical arm and cable system. Because of the removal of the two pieces of equipment from the traditional rotator in the new type of rod rotator, operators
may more easily and safely install a system on unconventional units.
A second major concern behind developing this technology was that operators were not always aware of an issue occurring during rod rotation. Users had no visuals or feedback and would have to physically check the unit in remote environments to see the rod rotator’s condition. If the rod rotator is left unchecked, rod erosion can be costly to repair.
This new type of rod rotator offers an added integral rotation sensor that monitors optimal performance and immediate failures during operation. The integrated rotation sensor, coupled with the control box, monitors performance and generates an alert if a failure occurs.
This technology can increase sucker rod life, increase well production and decrease downtime during operations. It can be used on various hydraulic rod pumping systems, as well as many unconventional systems.
Features and Benefits
Ground level and remote rotation monitoring
Eliminates cable used to actuate the gear which rotates the rod string
Uses low voltage motor with a high gear ratio to rotate rod string
Provides greater control over rotations per day
Reduces rod stress related to torsion
Class 1 /Division 1 Rated 12 Volt DC Motor
Reporting system capabilities
Available cold weather configuration
Other Potential Benefits
The new rod rotator includes ground-level and remote-rotation monitoring results that can be sent directly to a user’s portable device. The technology can also be configured during cold and harsh environments.
The low-voltage Class 1/Division 1 rated motor is used with a high gear ratio to rotate the rod string. Because of the elimination of the cable used to actuate the gear that rotates the rod string, there is greater control over rotation per day and a reduction of rod stress related to torsion.
The low-voltage Class 1/Division 1 rated motor is used with a high gear ratio to rotate the rod string. Because of the elimination of the cable used to actuate the gear that rotates the rod string, there is greater control over rotation per day and a reduction of rod stress related to torsion.
Operators can receive notification through their added supervisory control and data acquisition (SCADA) system software to inform them that the rotator has stopped turning.Remote monitoring is an important feature for the artificial lift industry today and in the future. Access to troubleshooting issues and feedback
via a user’s supervisory software is crucial to keep production up in a changing market.
Ideally, all equipment will have monitoring, and maintenance personnel will be dispatched when they receive an alarm if there is an issue with the operating technology. By using remote monitoring, operators will cut down on labor and costs, especially in isolated locations and extreme environments.
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