Pump Installation and Maintenance

LEARNING OUTCOME

When you complete this module you will be able to...

Describe sucker rod strings as a component of artificial lift systems.

Learning Objectives

Here is what you will be able to do when you complete each objective.

1. Identify three types of sucker rod design systems.

2. Describe criteria used in selecting sucker rods for pumping systems.
3. Describe care and handling of sucker rods.

INTRODUCTION

In the first module on the pumping system, Module 027-31-36-10 (PUMP 6004), we discussed
the pumpjack. The subject of the second Module 027-31-36-12 (PUMP 6001), was the bottom
hole pump. This module, the sucker rod string, is the third component of the pumping system and
ties the previous two subjects together.

Because of its long length relative to its diameter, the sucker rod string becomes somewhat like
an elastic band in that it stretches with an increase in load and shrinks as the load lessens. It is
also like a rubber band in that it cannot be pushed (rod buckling results in early failure). We will
first discuss the kinds of sucker rods available.

OBJECTIVE ONE

When you complete this objective you will be able to...

Identify three types of sucker rod design systems.

Learning Material

TYPES

There are three types of sucker rods commonly available today in Canada:

1. Conventional steel rods.

2. Fibreglass rods.
3. Corod

Conventional

Conventional rods are manufactured with various qualities of carbon steel and are the most
common rods in use. They can be purchased in diameters of 13, 16, 19, 22, 25, 29 and 32 mm
(1/2, 5/8, 3/4, 7/8, 1, 1 1/8 and 1 1/4 inch) and are manufactured to three different API material
specifications. Normal sucker rods are about 7.6 m or (25 feet) long. The most common rod
diameters are 19, 22 and sometimes 25 mm.
 1. API Designation

Grade C is a carbon steel composition for medium to heavy loads and non-corrosive
fluids. They cannot stand the high loads that a Grade D rod can nor can they stand
corrosion as good as a Grade K rod. Grade C rods are the general workhorse and most
commonly used. The metal used to make Grade C rods has a tensile strength of 620 -
793 MPa (90 000 - 115 000 psi). Tensile strength is the point at which a sucker rod will
break when pulled too hard.

Yield strength, (the point at which a rod is permanently stretched out of shape) is less
than the tensile strength and should not be exceeded. API does not specify a yield
strength but it will be in the neighbourhood of 60% of the tensile strength. The yield
strength multiplied by the cross sectional area tells us the maximum straight non-jerk load
the rod can take. For a 22 mm (7/8") Grade C rod the maximum pull of a new rod would
be:

Rod area multiplied by yield strength or

(0.022/2)2   x   3.142   x   448 175 = 170 351 N

or

(0.875/2)2   x   3.142   x   65,000 = 39,090 pounds pull force.

Table 1
Recommended Maximum Pull Loads

API Sucker Rods

(For use on stuck pumps).

This table uses 80% of yeild point of sucker rods as the recommended maximum
pull. Damage to the sucker rod string can result if these values are exceeded.

  Type C Type K Type D Type D(N-M)

(Carbon)

Min. Yeld Min. Yeld Min. Yeld Min. Yeld

ROD 65, 000 psi 68, 000 psi 100, 000 psi 105, 000 psi
SIZE 448 175 kPa 468 860 kPa 689 500 kPa 723 975 kPa

5/8" 16, 000 lbs. 16, 000 lbs. 24, 000 lbs. 26, 000 lbs.
16 mm 71, 00 N 74, 000 N 109, 000 N 115, 000 N

3/4" 23, 000 lbs. 24, 000 lbs. 35, 000 lbs. 37, 000 lbs.
19 mm 102, 000 N 107, 000 N 157, 000 N 165, 000 N

7/8" 31, 000 lbs. 33, 000 lbs. 48, 000 lbs. 50,000 lbs.
22 mm 139, 000 N 146, 000 N 214, 000 N 224, 000 N

1" 41, 000 lbs. 43, 000 lbs. 63, 000 lbs. 66, 000 lbs.
25 mm 182, 000 N 190, 000 N 279, 000 N 294, 000 N
Grade K is suitable for medium to heavy loads and medium corrosive fluids. The metal tensile
strength is 586 - 793 MPa (85 000 - 115 000 psi). Grade K rods are used where corrosion is a
problem. They are a bit softer than the Grade C, mostly due to the increased nickel content.

Grade D rods are suitable for heavy loads, with or without corrosive fluids. The metal
tensile strength is 793 - 965 MPa (115 000-140 000 psi). Grade D rods are used for high
loading jobs and their chemical makeup can be adjusted to make them capable of
withstanding corrosion. Maximum pull for a new 22 mm (7/8") rod would be:

(0.022/2)2   x   3.142   x   689 500   =   262 079 N

or

(0.875/2)2   x   3.142   x   100,000   =   60,140 pounds of pull force.

Some suppliers also sell higher strength, special application rods whose specifications are in
excess of the Grade D rods.

Further Sucker Rod Information

Tables 1 and 2 contain useful information on sucker rods. API Specification 11B (SPEC 11B)
SPECIFICATION FOR SUCKER RODS (PONY RODS, POLISHED RODS, COUPLINGS AND
SUBCOUPLINGS) covers the design criteria for those items.

Table 2
Sucker Rod Information

Sucker Rod Weights

Size 5/8" 3/4" 7/8" 1"

16 mm 19 mm 22 mm 25 mm

Weight        

Pounds/foot 1.135 1.634 2.224 2.900

Kilograms/m 1.692 2.436 3.316 4.320

Cross-Sectional Area

Rod Size 5/8" 3/4" 7/8" 1"

16 mm 19 mm 22 mm 25 mm

Area        

Inches2 0.307 0.442 0.601 0.785

Millimeters2 198 285 388 506

Maximum Sucker Rod Tourque for Screw Pump Driving

 Sucker Rod Rod Size Yield Point
API Grade (foot-pounds torque)

C 3/4" 295

C 7/8" 450

C 1" 760

D 3/4" 450

D 7/8" 640

D 1" 955

Round Corod 3/4" 450

Round Corod 7/8" 800

Round Corod 1" 1020

Fibreglass

Fibreglass rods are fitted with steel ends so that they can be fastened together. They have the
advantage of low weight and are therefore good for deep wells (mainly in light oil operations).
Their lack of weight makes them a poor choice for the heavy oil fields because they tend to float
in heavy oil during the downstroke. Fibreglass rods should not be allowed to go into compression
(or float on the down stroke) because they will shatter since they are made of multiple strands of
straight glass string held together by epoxy.

Corod

Corod is a brand name for the only continuous sucker rod manufactured in the world. It is
manufactured in Nisku, Albs.erta. The main advantage of Corod is reduced rod and tubing wear
because there is more rod surface area contacting the tubing. Also there are no couplings thus a
larger flow area for the fluids. The rod can be tripped in and out of the hole faster because no
stops are needed to make rod connections. Corod manufactures two types: oval and round.

Most Corod strings are oval shaped because this shape has a longer life than the round design.
This is because more of the rod is contacting the tubing wall and therefore less rod wear on any
segment of the rod. In heavy oil fields and highly deviated or slant wells, the extra contact area
(with the oval design) has an adverse effect due to the extra friction or hang-up caused by the
extra rod/tubing contact. For this reason, Corod recommends the round design for use in the
heavy oil fields.

It should be noted that many oil companies working in the Cold Lake area of Albs.erta use Corod
sucker rod strings. Most Corod rigs are not equipped for handling tubing. If the tubing must be
serviced, the Corod rig pulls the rods and pump, then rigs off so that a conventional service rig
can move on to work on the tubing.

OBJECTIVE TWO

When you complete this objective you will be able to...

Describe criteria used in selecting sucker rods for pumping systems.

Learning Material

TAPERED ROD STRINGS

In deep wells, it is an accepted procedure to taper a rod string. This means a combination of
different sizes of sucker rods are used to make up a rod string that is as light as possible and still
maintains the strength necessary to move the bottom hole pump. Obviously, the larger rods are
placed at the top of the string and the lighter rods, even fibreglass, are placed at the bottom of the
hole where the loads are lighter.

SINKER BARS

Sinker bars are simply large diameter (heavy) rods run on the bottom end of a rod string to add
weight to help alleviate hang-up or rod floating on the down stroke. Sinker bars come in a variety
of sizes. Although they do reduce hang-up in the heavy oil wells and do increase the minimum
polish rod load on conventional wells, they also increase rod wear in directional and slant wells.
This is because there is more horizontal force working or rubbing on the sidewall of the tubing
string.

PARAFFIN (WAX) CONTROL

Paraffin or wax is a naturally occurring product in most light oil fields. It is the heavy ends of the
complex mixture that makes up a crude oil. Wax becomes deposited in the tubing string or
flowline as the temperature and pressure on the fluid is dropping (and the wax precipitates out).

There are a variety of ways wax can be handled. Use plastic lined tubing and plastic coated
sucker rods with a number of plastic guides on the body of the rod itself. This should assist in
preventing wax from sticking to the rods or tubing. Have scrapers installed on the sucker rod
body. These scrapers are usually metal and may be flat or spiraled around the rod and fastened
to the rods with clips. Add chemical dewaxers to the wellbs.ore. Hot oil the well to melt the wax
that has formed.

SPECIALIZED SUCKER ROD COUPLINGS

Specialized rod couplings are used for rod on tubing wear reduction and friction and/or hang-up
reduction. These couplings are normally used in trouble spots or high angle portions of the
wellbs.ore. There are two common types.

Wheeled couplings are long couplings with 3 or 4 small wheels to keep the coupling centralized in
the tubing. Wheels can be steel, nylon, etc. They are used with conventional pumps only, not
screw pumps.

Coated rod couplings are regular length couplings with about a 0.7 cm thick coating of plastic
bonded to the coupling. The plastic wears out instead of the tubing. They can be used with
conventional or screw pumps.

ROD ROTATORS

A rod rotator is a mechanism placed on the polish rod above the carrier bar. Its function is to
rotate the rods a few degrees every stroke so that the rods wear more evenly, thus experiencing
a longer run life. In waxy wells, this rotation helps scrape the wax off the tubing wall. Positive load
must be maintained on the rod string at all times to keep the rotator functioning.

OBJECTIVE THREE

When you complete this objective you will be able to...

Describe care and handling of sucker rods.

Learning Material

CARE AND HANDLING OF SUCKER RODS

One of the greatest hazards to a sucker rod is abuse while it is at the surface. Sucker rods are
exposed to corrosive fluids down hole and any mishandling of the rods on surface can set up a
potential corrosion cell. Sucker rods must be handled carefully to prevent this. Things to
remember:

a. Never walk on rods lying on the ground.

b. If storing rods is necessary, support them in at least 4 spots to eliminate sagging and
bending.
c. It takes at least two people to carry a sucker rod to minimize bending.
d. Never put wrenches, pup joints or heavy objects on stacks of rods.
e. Do not hit sucker rods or couplings with a hammer.

The list can go on and on but the message is to treat sucker rods with care!

SUMMARY

The sucker rod string is used to move the bottom hole pump plunger up and down. Sucker rods
can be conventional, fibreglass or continuous Corod. Conventional rods vary in metallurgy to fit
the required load and corrosion conditions. Fibreglass rods are good for deep wells but cannot be
used in a compressive (rod floating) state. In a deep well, the rod string can be tapered to keep
the total string weight minimized. The bottom end of a rod string can be made heavier by using
sinker bars. Paraffin can be controlled in a wellbs.ore by either preventing it from sticking to the
metal or removing it once it is formed. There are couplings available to help reduce rod and
tubing wear. Sucker rods must be handled carefully if they are to last a long time in a wellbore.

  Learning Module: 027-31-36-14 PUMP 6006 Assignment

[ Print Assignment ]

1. Answer questions a and b.

a. Explain the purpose for installing sinker bars in a sucker rod string.
b. Where are sinker bars placed?
2. Describe the main benefit derived from using fibreglass sucker rods.
3. Describe at least three (3) guidelines for proper handling of sucker rods.
4. Describe outcomes, which could result if sucker rods are pulled beyond their tensile
strength and yield strength.