varillas - francisco diaz telli_premium connection rod presentation_v00

8/11/2019 VArillas - Francisco Diaz Telli_Premium Connection Rod Presentation_V00

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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



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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



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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



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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



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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.



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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.



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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.



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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).


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.


R i O ti


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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

[email protected]

Daniel Muse

[email protected]

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 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.


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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41

PC IdentificationSucker Rods threads

API

PCStress relief length

Thread profile

PC Identification


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42

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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44

PC IdentificationTest wells

Failures


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Body

Failures

ConnectionFailures

Due to

compression-buckling

Due to unproper Make-Up& Corrosion

FailuresTest wells

varillas - francisco diaz telli_premium connection rod presentation_v00

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