6th Annual Sucker Rod Pumping Workshop

Wyndham Hotel, Dallas, Texas September 14 17, 2010

Development, Testing and Field Results of New Sucker Rod Grade

Erik Tietz, P.E Arun Sriraman

Why did UPCO perform this project?

Some of the questions which were raised from customer feedback and led us into this project are as follows: What are some of the factors to consider before choosing a particular grade of sucker rod? Why are KD rods overloaded in some environments? Why HS (High Strength) rods cannot be used in corrosive environment? When both KD and HS rods fail, is fiberglass the only option?

Summary
Sucker rod characteristics (Toughness studies and their results). In-house Development of new grade of sucker rod. Chemistry Development Heat Treatment (Normalize and Temper) Validation (Tests) & Field studies

Key Sucker Rod Concepts

Key Sucker Rod Characteristics - Stress and strain related to sucker rods - Yield and Tensile strengths of sucker rods - Concept of Toughness for different grades of sucker rods - Toughness as a parameter in choosing the sucker rod grade for a particular application

Stress and Strain

Stress and Strain

Two Key characteristics from the Graph: - Load carrying capability (Vertical axis) - Amount of stretching ability (Elongation) of sucker rod. - The load carrying capability and Elongation are two key parameters which needs to be used in combination (Toughness) in selecting a sucker rod. - Using load carrying capability alone as a factor will lead to wrong choice of sucker rod grades.

Stress Strain Curves for Sucker Rod Grades

Grade C, K - Low Strength and high toughness Grade CD, AD, KD - Medium strength and medium to high toughness. Grade HS - High Strength and Low toughness

Novel illustration
A graph which shows the relationship between load carrying capability and elongation is called a toughness curve. The vertical height of the bars indicates the relative load carrying capability. The horizontal width represents the capability of the sucker rod to elongate.

Brief History

A good understanding of sucker rod characteristics will reduce / eliminate the majority of the application failures.

Analysis of Toughness Curve

Practical Consequences
No sucker rod with high strength and toughness. Overloading KD rods and using HS rods in harsh environments. A grade in between KD and HS having good load carrying capabilities and toughness. In-house Development: Developed, tensile, heat treating methods and chemistry to fill the gap between KD and HS.

Results from Toughness Studies

Process Development (Heat Treat)

Heat treatment of any specific grade of sucker rod is a very critical process. Proper heat treatment at appropriate temperature and soak time is key in achieving the desired physical and toughness properties. Two stage process of heat treatment applicable to sucker rods: Normalize (Stress relieve) Temper (Achieve desired physical properties and improve toughness)

Chemical Composition
Element
Carbon Manganese Nickel Chrome Moly Vanadium

Characteristics
Increases the tensile strength of the material or in other words, it provides strength. Added in tandem with carbon to increase the tensile strength and improves wear resistance. Makes the rod tougher. Increases the hardness and corrosion resistance. Increases corrosion resistance, hardenability and strength. Increases hardenability, fatigue resistance and creep. Increases strength and toughness. Grain enhancer.

Validation - Charpy test Results

Rod Actual Tensile Actual Yield Charpy (FT-LBS)

KD

115 KSI

91 KSI

100, 102, 94 (98.6 AVG)

SD

138 KSI

107 KSI

63, 65, 53 (60.3 AVG)

HS

145 KSI

122 KSI

16, 16, 15 (15.6 AVG)

Field Tests and Results

End User: Resaca Operating Company, University B Test Well 1 Characteristics: Slightly sour environment with a pump depth of 11172. 33 TBPD, 5 BPDO, 28 BPDW, 39% run time. 1 pump, 8 strokes/min, 144 stroke length.

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Field Tests and Results

Rod Breakdown: Rod 1 X 22 polished Rod 1 X 14 Linear 8,4,4,2 1 HS pony rods 1 SD rods w / full hole couplings 7/8 SD rods w / full hole couplings 3/4 SD rods w / full hole couplings 1 SD rods w / slim hole couplings 2 X 1 X 24 Pump Quantity 1 18 115 122 168 40 1

Field Tests and Results

Test Well 1 Characteristics: The rod loads were evaluated based on the modified Goodman diagram with a service factor of 0.9 for mild corrosion. Rod body design loading was done based on T/4 modified Goodman diagram with a tensile of 135000 PSI. 1.0 steel 0.875 steel 0.75 steel 1.0 steel 86% 92% 100% 36%

Field Tests and Results

Well ran 1.25 fiberglass rods. (MTBF for rod failures was 237 days). String was changed to Steel rods (SD) with HS subs (High Strength Ponnies). After 373 days, the 2 HS pony rod failed due to H2S corrosion fatigue. From Jan 15, 2009 to now (600 days), No rod problems.

Field Tests Well 2

End User: Cambrian Management, Othella # 2A 8282 depth, slightly sour environment. 40.5 TBPD, 8.5 BPDO, 32 BPDW 1 Pump, 9.5 SPM, C 320 250 84 KD rods could not handle the load and high strength were not an option due to corrosion

Field Tests Well 2

2625 2000 3500 100 7/8 X 25 SD 7/8 X 25 AD 3/4 X 25 AD 1 X 25 Grade 1 Sinker Bars

Average failure rate for this well is 0.3. So, expectations are pulling the well due to rod failure every 3 years.

Field Tests Well 2

10/17/2008, Replaced a HS sub with SD rods. HS failed due to sulphide reducing bacteria (SRB), large thumb shaped pit No SD rod failure for 2 1/2 years The average failure rate is every three years

Field Test Well #3

Well depth 8600 feet and has 8% H2S and 7% CO2. 1 - 1 X 26 Polished rod 136 - 7/8 SD Rods 207 - 3/4 SD Rods 8 - 1 1/2 Sinker Bars Well Started on 1/12/2009 and has not had rod failures since then.

Conclusion
Customer feedback indicates a lack of balance between the KD and HS rods (Better load carrying capabilities than KD rods and better ductility than HS rods) SD rods are 33% stronger than KD rods and 12% tougher than HS rods. SD rods fills the application gap between a KD and HS rods. 12 test wells indicate improvements in rod performance after using SD rod string.

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