5 --- presentation --- upco --- development, testing, and field results of new sucker rod grade

8/13/2019 5 --- Presentation --- UPCO --- Development, Testing, And Field Results of New Sucker Rod Grade

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6th Annual Sucker Rod Pumping

Workshop

Wyndham Hotel, Dallas, Texas

September 14 17, 2010

Development, Testing and Field Results of New

Sucker Rod GradeErik Tietz, P.E

Arun Sriraman


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Summary

Sucker rod characteristics (Toughness studies and theirresults).

In-house Development of new grade of sucker rod.

Chemistry Development

Heat Treatment (Normalize and Temper)

Validation (Tests) & Field studies


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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


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Stress and Strain


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Two Key characteristics from the Graph:

- Load carrying capability (Vertical axis)

- Amount of stretching ability (Elongation) ofsucker rod.

- The load carrying capability and Elongationare two key parameters which needs to be usedin combination (Toughness) in selecting asucker rod.

- Using load carrying capability alone as a factorwill lead to wrong choice of sucker rod grades.

Stress and Strain


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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


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Novel illustration

A graph which shows the relationship between

load carrying capability and elongation is called atoughness 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.


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Brief History

A good

understanding of

sucker rodcharacteristics will

reduce / eliminate the

majority of the

application failures.


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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 loadcarrying capabilities and toughness.

In-house Development:

Developed, tensile, heat treating methods and

chemistry to fill the gap between KD and HS.


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Results from Toughness Studies


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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)


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Chemical Composition

Element Characteristics

Carbon Increases the tensile strength of the material or inother words, it provides strength.

Manganese Added in tandem with carbon to increase the tensile

strength and improves wear resistance.

Nickel Makes the rod tougher. Increases the hardness and

corrosion resistance.

Chrome Increases corrosion resistance, hardenability and

strength.

Moly Increases hardenability, fatigue resistance and

creep.

Vanadium Increases strength and toughness. Grain enhancer.


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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)


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Sept. 14 - 17, 20102010 Sucker Rod Pumping Workshop 15

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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Rod Breakdown:

Rod Quantity

1 X 22 polished Rod 1

1 X 14 Linear

8,4,4,2 1 HS pony rods 18

1 SD rods w / full hole couplings 115

7/8 SD rods w / full hole couplings 122

3/4 SD rods w / full hole couplings 168

1 SD rods w / slim hole couplings 40

2 X 1 X 24 Pump 1



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Test Well 1 Characteristics:

The rod loads were evaluated based on the modifiedGoodman 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 86%

0.875 steel 92%

0.75 steel 100%

1.0 steel 36%



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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 toH2S corrosion fatigue.

From Jan 15, 2009 to now (600 days), No rod

problems.



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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 highstrength were not an option due to corrosion


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2625 7/8 X 25 SD

2000 7/8 X 25 AD

3500 3/4 X 25 AD

100 1 X 25 Grade 1 Sinker Bars

Average failure rate for this well is 0.3. So,

expectations are pulling the well due to rodfailure every 3 years.

Field Tests Well 2


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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 Tests Well 2


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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 Rods207 - 3/4 SD Rods

8 - 1 1/2 Sinker Bars

Well Started on 1/12/2009 and has not had

rod failures since then.


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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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5 --- presentation --- upco --- development, testing, and field results of new sucker rod grade

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