5 --- presentation --- upco --- development, testing, and field results of new sucker rod grade
TRANSCRIPT
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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
Field Tests and Results
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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%
Field Tests and Results
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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.
Field Tests and Results
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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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Sept. 14 - 17, 20102010 Sucker Rod Pumping Workshop 24
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Sept. 14 - 17, 20102010 Sucker Rod Pumping Workshop 25
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