Design Optimization of Valve Assemblies in Downhole Rod Pumps to Enhance Operational Reliability in Oil Production

Zaurbekov S. Zaurbekov K. Balgayev D. Boiko G. Aksholakov E. Klyuev R.V. Martyushev N.V.
August 2025 Multidisciplinary Digital Publishing Institute (MDPI)

Energies
2025 #18 Issue 15

This study focuses on the optimization of valve assemblies in downhole rod pumping units (DRPUs), which remain the predominant artificial lift technology in oil production worldwide. The research addresses the critical issue of premature failures in DRPUs caused by leakage in valve pairs, i.e., a problem that accounts for approximately 15% of all failures, as identified in a statistical analysis of the 2022 operational data from the Uzen oilfield in Kazakhstan. The leakage is primarily attributed to the accumulation of mechanical impurities and paraffin deposits between the valve ball and seat, leading to concentrated surface wear and compromised sealing. To mitigate this issue, a novel valve assembly design was developed featuring a flow turbulizer positioned beneath the valve seat. The turbulizer generates controlled vortex motion in the fluid flow, which increases the rotational frequency of the valve ball during operation. This motion promotes more uniform wear across the contact surfaces and reduces the risk of localized degradation. The turbulizers were manufactured using additive FDM technology, and several design variants were tested in a full-scale laboratory setup simulating downhole conditions. Experimental results revealed that the most effective configuration was a spiral plate turbulizer with a 7.5 mm width, installed without axis deviation from the vertical, which achieved the highest ball rotation frequency and enhanced lapping effect between the ball and the seat. Subsequent field trials using valves with duralumin-based turbulizers demonstrated increased operational lifespans compared to standard valves, confirming the viability of the proposed solution. However, cases of abrasive wear were observed under conditions of high mechanical impurity concentration, indicating the need for more durable materials. To address this, the study recommends transitioning to 316 L stainless steel for turbulizer fabrication due to its superior tensile strength, corrosion resistance, and wear resistance. Implementing this design improvement can significantly reduce maintenance intervals, improve pump reliability, and lower operating costs in mature oilfields with high water cut and solid content. The findings of this research contribute to the broader efforts in petroleum engineering to enhance the longevity and performance of artificial lift systems through targeted mechanical design improvements and material innovation.

downhole rod pumping units (DRPU) , flow turbulizer , oilfield equipment , shut-off element rotation , valve assembly optimization

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Institute of Metallurgy and Ore Beneficiation, Satbayev University, Almaty, 050010, Kazakhstan
Department of Technique and Technology of Mining and Oil and Gas Production, Moscow Polytechnic University, Moscow, 107023, Russian Federation
Department of Information Technologies, Tomsk Polytechnic University, Tomsk, 634050, Russian Federation

Institute of Metallurgy and Ore Beneficiation
Department of Technique and Technology of Mining and Oil and Gas Production
Department of Information Technologies

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