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Sucker rods - Sucker rods are a key component of a sucker- rod lift type of artificial lift system. This page discusses rod types, design of the rod string, couplings, maintenance and replacement.
The three main grades of steel rods follow. Grade C rods that have minimum and maximum tensile strengths of 9. Grade K rods that have a minimum tensile strength of 9. These rods are made with 1. Grade C rods, but may have improved corrosion- related properties.
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Grade D rods that have a minimum tensile strength of 1. Three types of this grade are covered by Spec.
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B: plain- carbon, alloy, and special- alloy steels. Spec. 1. 1B allows for rod lengths of 2.
The acceptable rod diameter goes from 5/8 to 1 1/8 in. The most common rods in use will meet API specifications and will probably be in 2.
The most important selection requirement is that the pulling rig can accommodate single- , double- , or triple- length rod segments. Where the yield strength of a rod string is necessary in calculations, it is recommended that if the manufacturer is not known, a minimum yield of 6. Grade C and K and of 1. Grade D should be used. If the manufacturer and rod type are known, the actual yield- strength values should be used. For good operating practices, the minimum yield strength should not be exceeded. They are most commonly placed adjacent to the polished rod at the top of the rod string, on top of the downhole pump for handling purposes, and on top of the polished rod with appropriate couplings to prevent the string from falling downhole if the polished- rod clamp slips.
Old pony rods normally should not be used in the load- carrying part of a new rod strings. Thus, when placing the rod string with new suckers, new pony rods should be used. These rods are normally made from protruded fiberglass. They also are standardized in size and performance by API Spec.
Reviewing this standard shows that temperature, load reversals, and fatigue life have a bigger effect on FRP rods than on steel rods. It is important to keep the following in mind when screening a well for FRP- rod use. FRP- rod bodies will not corrode, but the rest of the steel components, including the fiberglass pin connectors and couplings, the steel rods making up the rest of the string, the pump, tubing, casing, flowlines, etc., still have to be protected if producing a corrosive fluid. Thus, fiberglass rods should not be used alone to prevent rod- string corrosion or system failures or to eliminate the need for an effective corrosion- inhibition program. FRP rods should be considered when the pumping- unit gear- reducer torque or structure rating exceed design limitation and need to be decreased.
Reducing the weight of the sucker- rod string reduces the torque measured at the polished rod. However, if the well is expected to produce long term, it may be more cost effective to upsize the pumping unit. It should be determined if it will be possible to stroke the subsurface pump plunger because of the increased elasticity and effect on Sp . If the well deviation is very large at any point, the increased friction may cause buckling and compressive stresses on the sucker rods. Increased buckling is very damaging to FRP rods; thus, these probably should not be run in deviated wells. Allowing fluid or gas pounding may produce damaging compressive forces in the FRP rods; thus, maximum drawdown is not possible.
Currently, there is no recognized formula for calculating overtravel when a mixed FRP and steel rod string is used. An attempt was made by an API task group to try modifying API RP 1. L. A study of several FRP string- design analyses indicate that rod- string overtravel may be approximately equal to the following. S = stroke length, in.; N = pumping speed, spm; and LPSD = seating nipple/pump depth, ft.
This overtravel approximately equals twice the expected value when using steel sucker- rod strings. Thus, a full economic analysis should be conducted and good operating records obtained to determine if use of these rods is cost effective. This cable was a continuous strand that required special pulling equipment.
Sufficient sinker bars or a special pull- down pump had to be used to keep any compressive force from acting on the strand. The connectors used at the pump or at the top of the sinker bars were the weakest portion of the flexible strand. If any of the strands furnished the weight that was required to help open the traveling valve, the strands immediately above the sinker bars failed in short order because of the compressive forces. This type of rod string was less expensive than a normal API steel string and was found useful for unloading gas wells. The biggest disadvantages that restricted the use of this type of string were lack of service- company support and the inability to make field repairs. The advantage of this rod is its ability to pull the entire rod string in one piece with a special pulling unit. These rods are available in either round or elliptical configurations and vary in size from 1.
The disadvantages include the need for a special wheeled pulling rig, and the two different pulling units are required to service the well if the tubing has to be pulled. There is some concern that the COROD's heat treatment is not consistent throughout its length. This is especially problematic if field welds are made and the rods are used in an inadequately protected corrosive environment. Despite having high strength and a small cross- sectional area, it was expensive and ran into field support problems similar to those of flexible strands and CORODs.
These currently are available only in 3/4- , 7/8- , and 1- in. They should be selected for wells in which operating stresses do not exceed 5. These rods have a special heat treatment that should put the surface in a compressive set. Thus, they could be used in a hydrogen sulfide (H2.
S) environment in which the strength of Grade C rods is exceeded. These rods have been effectively used to produce approximately 1. BFPD from a depth of approximately 1. These rods take advantage of the newer alloys and heat- treating procedures currently available and are based on American Iron and Steel Inst.
The tensile strength is generally greater than 1. API Grade D. The fine- grain heat treatment done on these alloys theoretically should provide increased fatigue life. However, this rod type may be more notch- sensitive and may require better handling and corrosion protection than normal API- type rods. This is often illustrated by the use of a Goodman diagram, as discussed in API RP 1. BR. If the environment is corrosive and not properly treated, the sucker rods and their associated downhole equipment life is minimal. In such cases, corrosion- fatigue failures occur frequently in the rod string.
However, in the presence of H2. S and a corrosive environment, steel may become susceptible to hydrogen embrittlement/sulfide- stress cracking. Steels that have a Rockwell C hardness greater than . The harder the steel is, the more susceptible it becomes. API Grade C sucker rods normally have a Rockwell C hardness < 2.
API Grade D sucker rods normally have a Rockwell C hardness > 2. Thus, API Grade D rods should be used with caution in the presence of hydrogen sulfide. Chemical inhibition may not prevent embrittlement. This results in a significantly decreased run life. Corrosion pits are one type of stress raiser. Stress raisers may be notches caused by improper handling, tool cuts, bending, and subsequent cold straightening, for example, and may also result from the manner in which the threads are formed on the rod pin (i.
Corrosion pits may have rounded or notched shape; notch- shaped pits are more serious and are more likely to occur in Grade D rods than in Grade C rods. Manufacturers of non- API rods should specify the rod's allowable stress. An allowable load or stress curve should be developed to discern during the design of a rod string if it is overloaded, and adjustments should be made to prevent this. Recent discussions have promoted a hyperbolic relationship for allowable load using the Gerber parabola, rather than a straightline relationship.
Rod strings that are considered . Additionally, RP 1. L. Recommendations are presented for derating based on the class of the inspected rod, according to the inspection- criteria classes in API RP 1.
BR. Using four or more sizes of rods in a taper is not normally recommended. The primary factor determining the proportion of each size of rod in the rod string is the size of the pump. However, typically only one grade of rod is used in the string to avoid mixing during running and pulling operations. The first column of Table I in this reference contains the rod- string size designation. The first number in the column refers to the largest rod size in the string, while the second number refers to the smallest rod size in the string, both representing the size in eighths of an inch. An example rod number of 7.
Rod number 8. 6 is a three- way taper of 8/8 - , 7/8- , and 6. The taper percentages published in RP 1. L were calculated from the Neely, .
The tables gained wide acceptance, and thousands of rod strings have been installed since then that used these recommended taper lengths. The use of the API taper lengths, of course, saves the time of a detailed string design, but the wide availability of personal computers today has eliminated the need to resort to such a shortcut method. The need for carrying out actual rod designs is further augmented by limitations of the published taper percentages; note that taper lengths are the sole function of plunger size which is oversimplification of the design. As presented by Gault & Takacs . The differences lead to the conclusion that an accurate rod string design should be based on calculations using actual pumping conditions.
The diameter of the pump plunger determines the fluid load lifted during the pumping cycle. However, the ID of the seating nipple determines the fluid load that must be lifted to unseat the pump.