Title: Research on the sucker rod automation of minor workover operations based on process reconfiguration

Authors: Jixiang Yue; Lingling Wang; Wenyu Zhu; Yangli Zhou; Hongying Zhu; Kunyuan He

Addresses: Shandong Institute of Petroleum and Chemical Technology, No 271, Beier Road, 257061, Dongying, Shandong, China ' College of Mechanical and Electrical Engineering, Binzhou Polytechnic, China ' Shandong Institute of Petroleum and Chemical Technology, No 271, Beier Road, 257061, Dongying, Shandong, China; China University of Petroleum (East China), Qingdao City, China ' Shandong Institute of Petroleum and Chemical Technology, No 271, Beier Road, 257061, Dongying, Shandong, China; China University of Petroleum (East China), Qingdao City, China ' Shandong Institute of Petroleum and Chemical Technology, No 271, Beier Road, 257061, Dongying, Shandong, China ' Shengli Oilfield Kangbei Petroleum Engineering Equipment Co. Ltd, Dongying, China

Abstract: Automating operations is challenging due to the structural characteristics of the sucker rod. This article proposes an automation approach based on process reconstruction, which includes wellhead positioning, 90-degree flipping of the upper and lower rods, and vertical replacement; alternating between gentle and harsh clamping while using a double sucker rod and elevator guidance system; combining hoisting and clamping through the elevator's rotary action on the flange and core; enabling simultaneous operations and process improvements; and visible master/slave control. Using the sucker rod as an example to split the process path, Gantt chart analysis is used to propose improvement measures. The completion of the on-site prototype manufacturing application demonstrates the practicality of both the equipment and process, as well as a significant increase in operational efficiency compared to manual methods. This technology leads the development of automation in minor workover operations and makes the non-landing operation mode of vehicle-mounted root box pipe poles feasible. [Received: November 25, 2024; Accepted: February 22, 2025]

Keywords: wellhead automation; workover service; process reconfiguration; rotating elevator; vertical tubing and sucker rod connection operations.

DOI: 10.1504/IJOGCT.2026.153035

International Journal of Oil, Gas and Coal Technology, 2026 Vol.39 No.3, pp.322 - 343

Received: 06 Nov 2024
Accepted: 22 Feb 2025
Published online: 20 Apr 2026 *

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