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Cancun, Mxico
March 4-5, 2010
Premium Connection Rods:Increasing Sucker Rods Working Capacities
Francisco Diaz TelliDaniel Muse
Sucker Rods
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Introduction
Premium Connection Rod Design
Field Experience
Running Operation
Conclusions
Presentation Outline
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3
IntroductionStandard API rod design scenario
Conventional Pumping is the most popular system for
oil production in the world (>600.000 oil wells).
More demanding f ield operating conditions: deeperwells, and higher production f lows.
Rod connection is the weaker link in the Rod PumpingSystem, limiting it s capacity.
Over 30% of system failures are due to fatigue in theconnection.
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In April 2008 the Premium Connection Rod development
was presented in the SPE - ATW Artificial Lift Systemsthat took place in Mendoza.
We talked about:
API Connection l imitations
Design improvements
Lab and 1 field tests
We concluded that:
API Fatigue resistance: Connect ion < body
Premium Connection Fatigue resistance: Connection >body
The objective of this presentation is to show a follow upshowing the field tests.
IntroductionStandard API rod design scenario
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API Design
Gap Main features:
Tapered trapezium profile thread
Diametrical interference with flank-to-
flank contact
Low make-up pin stress
Better stress distribution
Reduction on plastic deformations inthe thread
Trustful make-up operation
Premium Connection
Premium Connection Rod DesignNew design characteristics
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Workingcapacity Rod Body
CapacityPremium Connection
Sucker Rod working capacity
API Sucker Rodworking capacity
API ConnectionCapacity
Premium ConnectionCapacity
New connection fatigue resistance > body resistance
API connection fatigue resistance < body resistance
Rod Pumpingworking capacity
increase
Premium Connection Rod DesignRod Pumping working capacities increase
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Goodman Diagram HS & D Grade Rods
0
10
20
30
40
50
60
70
80
90
100
0 20 40 60 80 100
Smin (Ksi)
Smax(Ksi)
D AR Sm i n Prem i u m YS AR YS Prem i u m
Fatigue stress level is measured with the Modified Goodman Diag.
Theoretical + FEA analysis, full scale lab fatigue tests in addition withfield tests gave a new Modified Goodman Diagram.
Working areaGrade D Rods
High Strength Rods
PC Rods
Note: Schematic diagram
Close to 10%higherworking capacity thanHigh Strength Rods
Premium Connection Rod DesignRod Pumping working capacities increase
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www.oilproduction.net
1,000 2,000 3,000
Flow Rate [bpd]
PumpDepth[ft]
2,000
4,000
6,000
8,000
10,000
Grade D HS Grade Premium Connection
ALS Overlapping Area
Premium Connection Rod DesignRod Pumping working capacities increase
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www.oilproduction.net
1,000 2,000 3,000
Flow Rate [bpd]
PumpDepth[ft]
2,000
4,000
6,000
8,000
10,000
M1824-427-2164 TubingSystem efficiency: 60%Rod Loading: 100%
PointStructureLoading
GrossProduction
A 96% 1600 bpd
A 101% 2100 bpdB 99% 900 bpd
B 104% 1100 bpd
C 96% 660 bpd
C 100% 830 bpd
A
B
C
Premium Connection Rods use100% of the PU capacity.
26%
22%
30%
A
B
C
HS Grade Premium Connection
Premium Connection Rod DesignRod Pumping working capacities increase
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27 wells are working with Premium Connection Rods in Argentina,Canada and USA.
In comparison with a regular Grade D rod, stresses in these wells would
reach up to 220% for a 0.8 SF.
Results:
ESP replacement: 9 wells (four 1280 and one 1824 units). Connection Failure Reduction: 3 failures reduction per year.
Rod string weight reduction: 10%
Reduces the material and energy requirements
3 failures in almost 95 million cycles accumulated in the field.
Field ExperienceSummary
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Well PE-03P PE-04P PE-05P PE-20P PE-22P PE-18O PE-12Y PE-26T
Installation date 14-Oct-08 2-Nov-08 24-Dec-08 18-Jun-09 25-Aug-09 1-Jun-09 20-Feb-0921-Set-
09
Estimated cycles [million] 6.6 5.5 5.1 2.6 2.2 3.7 5.5 2.0
Working days 506 487 435 259 191 377 377 164
SPM 6.1 7.9 8.1 6.9 8 6.8 10.1 8.5
Pumping Unit1280-427-
1921280-427-
1921280-427-
1921824-427-
216912-365-
168912
912-365-168
912-365-168
Pump depth [ft] (m)6724
(2050)7475
(2279)7347
(2240)7216
(2200)8747
(2667)6399
(1951)5874
(1791)8049
(2454)
Production flow [bpd] (m3/d) 421 (67) 377 (60) 528 (84) 654 (104) 346 (55) 616 (98) 1130 (180) 566 (90)
String
Design
1" PC sucker rods 106 99 116 99 101 107 96 52
7/8" PC suck er rods 155 111 100 116 115 134 119 125
3/4 PC sucker rods - 70 65 58 119 - - 130
Sinker Bars 8 (1 5/8 ) 20 (1 ) 13 (1 5/8 ) 15 (1 5/8 ) 15 (1 5/8 ) 15 (1 ) 20 (1 ) 15 (1)
Pump 2" 2.25" 2.25" 2.5" 2" 2.25" 2.5 2.25
Observations 4 p/year 2 p/year3 p/year in
7/83 p/yearin 7/8
Field Experience1) ESP replacement / Production increase
Bigger depths and higher flow rates are possiblethanks to the increase in the rod pumping system
capacity.
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Well PE-01 PE-08
Installation date 23-Set-05 25-Nov-08
Estimatedcycles
[million] 16.2 8.0
Working days 1623 464
SPM 7.8 12
Pumping Unit 912 C320-305-100
Pump depth [ft] (m) 7157 (2182) 6700 (2043)
Production flow [bpd] (m3/d) 440 (70) 390 (62)
String
Design
1" PC sucker rods 93 High Strength 100
7/8" PC sucker rods 94 PC 114
3/4" PC sucker rods 77 High Strength -
Sinker Bars 20 (1 ) 54 (1 )
Pump Size 2" 2"
Observations
3 body &
3 connection
failures in
2 year
3 High
Strength
body failures
In less than
6 months
Less brittle material has
shown to be more reliable incorrosive environments,
therefore reducing rod bodyfailures although they work
under the same loads.
16.2 million cycles(4 years)
Field Experience2) Replacing High Strength in corrosive wells
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Installation took place in September 2005. Since then, failures in HS rodshave taken place but not in the 7/8 taper.
Premium Connection accumulates ~16 million cycles working at 62%Goodman (SF 0.9) -replacing High Strength rods-.
A test well is working with 7/8 Premium Connection sucker rods with in aHigh Strength rod string:
Well PE-01 main characteristi cs
Pump depth 7155 ft (2181 m)
Pump bore size 2
Tubing 2 7/8
Production 478 bpd (76 m3/d)
Pumping Unit M 912-365-168
SPM 7.81
Fluid Mainly water
Well PE-01 Rod Strin g in fo
Quantity
Stress Level
(0.9 SF)
1" HS 93 83%
7/8" PC 94 62%
3/4" HS 77 81 %
1 SB 20 NA
Field Experience2) Replacing High Strength in corrosive wells
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Goodman Diagram HS & D Grade Rods
0
10
20
30
40
50
60
70
80
90
100
0 20 40 60 80 100
Smin (Ksi)
Smax(Ksi)
D AR Sm i n Prem i um YS AR YS Prem i um
Working area
Grade D Rods
High Strength Rods
PC Rods
Note: Schematic diagram
62% (0.9 SF)
83% (0.9 SF)
PC Rods1 HS Rods
The Premium Connection works in similar conditions as High Strength rods,indicating that the latter could be replaced by the first ones.
Field Experience2) Replacing High Strength in corrosive wells
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Well PE-02P PE-06P PE-19P PE-21P PE-19O PE-07O PE-25CN
Installation date 5-Oct-08 8-Jan-09 15-Jun-09 3-Jul-09 15-Jun-0921-Nov-
0814-Set-09
Estimated cycles [million] 3.5 4.4 2.6 2.4 2.6 4.8 1.5
Working days 515 420 262 244 262 468 171
SPM 4.7 7.3 6.8 6.7 6.8 7.1 5
Pumping UnitRotaflex
900912-365-
1681280-427-
1921280-
427-1921280-427-
192 912912-365-
192
Pump depth [ft] (m)6547
(1798)6724
(1981)5750
(1753)6820
(2080)5750
(1753)8672
(2644)3723
(1135)
Production flow [bpd] (m3/d] 925 (158) 440 (77) 554 (88) 616 (98) 862 (127) 440 (70) 679 (108)
String
Design
1" PC sucker rods 117 78 103 81 103 95 -
7/8" PC sucker rods 119 89 90 94 90 112 77
3/4" PC sucker rods - 93 24 72 24 126 64
Sinker Bars 26 (1 ) 9 (1 5/8 ) 13 (1 5/8 ) 26 (1 ) 13 (1 5/8 ) 14 (1 ) 8 (1 )
Pump 2.75" 2" 2.25 2.25 2.25 2" 2.75"
Failure History 2 p/year 4 p/year 5 p/year 4 p/year 4 p/year 3 p/year
Field Experience3) Connection failures reduction
Higher reliability in deep wells with high flows.
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Reduces the rod string price.
Reduces the rod string weight:Less Pumping Unit Requirements
Increase flowing area
Reduce flow loses
Well PE-16P PE-15O
Installation date 19-Apr-09 17-Apr-09
Estimated cycles [million] 3.7 0.66
Working days 318 64
SPM 8.0 7.2
Pumping Unit1280-427-
192912
Pump depth [ft] (m) 9675 (2949) 6124 (1867)
Production flow [bpd] (m3/d] 377 (60) 786 (125)
String
Design
1" PC sucker rods 52 0
7/8" PC sucker rods 160 116
3/4" PC sucker rods 160 116
Sinker Bars 15 (1 5/8 ) 13 (1 2/8 )
Pump 1.75" 2.75"
Failure History 2 p/year 4 p/year
Reduction in 1 rods quantity to reduce loading inthe Pumping Unit.
Eliminates 1 rods
Changed String Design(Still with PC rods)
9675 deep well with only 13% of 1 rods in order
to reduce the Pumping Unit load
Field Experience4) Rod string weight reduction
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Higher connection reliabilityfacing over torque and backspin effect.Well Name PE-09 PE-10 PE-14 PE-23 PE-27Installation date 3-Oct-08 4-Oct-08 15-Apr-09 10-Set-09 30-Set-09
Estimated cycles [million] 239 200 140 38 71
Working days 415 311 204 175 155
RPM 370 350 323 150 320
Pump depth [ft] (m) 2775 (846) 3323 (1013) 3175 (968) 3550 (1082) 2975 (907)
Production flow [bpd] (m3/d) 1598 (254) 1283 (204) - - -
SR quantity (1 ) 111 133 127 142 119
PumpNTZ
400-150-ST78
NTZ
400-150-ST62
NTZ
400-150-ST78
NTZ
400-75-ST62
NTZ
400-150-ST78
Observations
Fiberglasstbg. leakage
(Oct-08).Reinstall
sucker rods.
Fiberglasstbg. l eakage
(Nov-08).Reinstall
sucker rods.
- - -
Max. Workingtorque
[lbs*ft] 711 603 - - -
Average Workingtorque
[lbs*ft] 689 574 - - -
ObjectivesSuspended
(tubing wear)Suspended
(tubing wear)
The thread interference provides higher torque resistance
in the thread and reduces possibility to get loosen duringbackspin effects.
Field Experience5) PCP applications
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Running OperationGeneral comments
Differences with API connection make-up
7/8 PCrods have a reinforced wrench squarewith EL (Electra) or PL (Plus)rods size. These rods are regularly used in the oil industry.
Diametric interference also makes the connection to have stand off (spacebetween faces in the hand-tight position) so, power tong calibrations is done in
two steps.
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Rod Pumping Wells PCP Wells
Conventional API Polished Rod
1 API polished rod x 1 PC Coupling
1 PC Sucker Rods
1 PC x 7/8 PC 2 Cross Over
7/8 PC Sucker Rods
7/8 PC x 3/4 PC 2 Cross Over
3/4 PC Sucker Rods
3/4 PC x 3/4 API 2 Cross Over
Sinker Bars
Conventional Pump
Conventional API Polished Rod
1 API polished rod x 1 PC Coupling
1 PC Sucker Rods
1 PC x 1 API 2 Cross Over
1 API Coupling
Progressive Cavity Pump
3/4 PC
3/4 API
Typical string designconsists on the following:
Running OperationGeneral comments
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22
Step #1: Threads Cleaning
Complete remove of solid particles must be assured.
Running OperationFive steps process
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23
Step #2: Dope application
Standard tubing dope applying is recommended in order toavoid galling on the thread.
Running OperationFive steps process
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24
Step #3: Hand-tight
Hence the thread has diametricinterference after hand tight theconnection still shows a stand-off between pin a boxshoulders.
Running OperationFive steps process
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25
Step #4: Pin/Box shouldercontact control
A power tong is required in orderto make contact between pin and
box shoulders (a 0,05 mm gaugeis used for its control).
Running OperationFive steps process
R i O i
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26
Step #5: CircumferentialDisplacement Control
After shoulder contact is
assured a vertical line isdrawn and by applyingpower torque the requiredcircumferential displacement
is achieved.
Running OperationFive steps process
R i O ti
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Running OperationFive steps process
Summary:
4 Pin/Box shouldercontact control
5 CircumferentialDisplacement Control
3 Hand-tight
Power tong Power tong
Power tongpressure: ~1000 psi
Power tongpressure: ~500 psi
Power tong
DisplacementPower tong
pressure: ~1000 psi
POWER TONGCALIBRATION
ALL RODS(like conventional rods)
C l i
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The weakest part in a Rod Pumping application is the API connection. If
we increase the connection capacity, we increase the whole systemcapacity.
Using a stronger connection rods address the following applications :
1. Expand beam pumping system applications / increase production.
2. Replace High-Strength rods in corrosive environments.
3. Reduce WO operations due to sucker rod connection failures.
4. Reduce the rod string weight.
5. Increase Sucker Rod reliability in PCP applications.
Running time with a Premium Connection is similar to that required forconventional rods. Dont require special training or equipment.
Conclusions
C l i
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Field Experiencesummary:
A new connection design is being tested in 27 wells (5 wells in PCP).Not all of them were shown in this presentation.
There are test wells in Argentina, Canada and USA (there are plans toinstall also in Colombia).
Rod PumpingProgressive Cavity
Pumping
Number of test wells 22
9
(4 suspendedbecause tbg wear)
Number of Premium Connection rods intest
6300 1022
Averageworking life
Days 376 185
Cycles [milli on] 3.9 112
Max.working life
Days 1623 380
Cycles [milli on] 16.2 275
In comparison with a regular Grade D rod, stresses in these wells would
reach up to 220%for a 0.8 SF.
Conclusions
Q ti ??
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30
Questions??
Francisco Diaz Telli
Daniel Muse
I t d ti
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API Thread Premium Connection
The Gap allows movement between the threadswhen compression loads appear on the string.
Gap
IntroductionImprovements of API connection design
Connection loosing (gap on the thread).
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I t d ti
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API
Thread
Relative Principal Stresses
Tpi/Ty
(Ty = 59,77 kg/mm2)
Principal Stresses Distribution (100% Goodman Load)
Premium
Connection
IntroductionImprovements of API connection design
Connection loosing (gap on the thread).
Thread deformation during make-up and operation.
Non-uniform stress distribution along the thread profile.
Fi it El t A l i
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La fatiga multiaxial simple se refiere al caso en el que las principalessolicitaciones alternativas no cambian su direccin relativa a la parteen trabajo. En este caso, se puede utilizar el mtodo de Sines.
a
mT
D
= 3
3321 mmm
m
SSS ++=
2])()()[(
2/12
13
2
32
2
21 aaaaaaa
SSSSSS ++=
2
mn,mx. ii
ai
SSS
=
2
mn,mx. ii
mi
SSS
+
=
Donde:
D: indicador de fatiga. ( D >1) T: Tensin de rotura mnima.
Sm i: Componente principal de solicitacin.
Si max: Componente mxima de lasolicitacin principal.
Si min: Componente mnima de lasolicitacin principal.
(componente alternativa de la solicitacin principal)
(componente principal de solicitacin)
Finite Elements AnalysisMultiaxial fatigue failure
Finite Elements Anal sis
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A
BCEF
API Connection
AB
CEDPremium Connection
Finite Elements AnalysisMultiaxial fatigue failure
Manufacturing & Quality Control
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No-Go Profile threadgauge
Go profile thread
gauge
Manufacturing & Quality ControlThread Profile Control
Manufacturing & Quality Control
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Manufacturing & Quality ControlContour tracer Control
Field Experience
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PE-01 Well Background Failures (1stStage)
Year Month Failure SR # Grade Observations
2004 1 coupling 7/8 96 - 1 x 7/8 subcoupling failure
2004 7 Rod body 7/8 3 -
2004 12 pin 7/8 18 HS Inferior pin failure
2005 2 pin 7/8 59 HS Couplings changed for wear and corrosion
2005 3 Rod body 7/8 15 HS Failure at 2 from the pin.
2005 9 Rod body 7/8 1 D Failure at 2 from the pin.
With an average reparationcost of 9500 U$D, savings
of 114000 U$D were
obtained after the fouroperative years of the PC
rods working.114000 U$D savings
(9500 U$D x 12 Failures)
PremiumConnection Rods
installation
0
1
2
3
4
5
6
7
2004 2005 2006 2007 2008 2009
Ao
NrodeFa
llas
Fallas
Acumulado
Year
FailureQua
ntity
FailuresAcc umulated
3 ConnectionFailures in 2 years
3 body failures in 2years (corrosion)
Field Experience2) Replacing High Strength in corrosive wells
Field Experience
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PC 1 year long expected Scenario
API 1 year long Scenario
Rod String 22,000 u$d 28,600 u$d
Anual Interven tions 6 yearly 2 yearly
Costs
Rig 20,000 u$d 20,000 u$d
Interventions 120,000 u$d 40,000 u$d
Material 44,000 u$d 28,600 u$d
Total 164,000 u$d 68,600 u$d
* Worst scenario
API String PC Str in g
PE-08
95,400 U$D savingsin one year
New Rod string installation
Rod failure
Expected rod failure
References
* Production loss savings not included.
Field Experience2) Replacing High Strength in corrosive wells
PC Identification
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PC IdentificationCrates
API
PC
Pinklabel
Grayend
Distributors should be able to identify easily the crates.
PC Identification
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PC IdentificationSucker Rods threads
API
PCStress relief length
Thread profile
PC Identification
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PC IdentificationSucker Rods marking
Side 1Regular marking
DPC
PC Identification
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PC IdentificationCouplings
PC
API PC
PC couplings came in pink boxes, not in the rods.
PC Identification
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PC IdentificationTest wells
Failures
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Body
Failures
ConnectionFailures
Due to
compression-buckling
Due to unproper Make-Up& Corrosion
FailuresTest wells