Sucker rod

failure analysis
Rod Lift Solutions
 C H A M P I O N X A R T I FF II C
C II A
A LL LLIIFFTT

Table of contents
3 Failure mechanisms
6 Design and operating failures
9 Mechanical failures
10 Bent rod failures
11 Surface damage failures
12 Connection failures
16 Corrosion-fatigue failures
16 Acid corrosion
17 Chloride corrosion
17 CO2 corrosion
17 Dissimilar metals corrosion
17 H2s corrosion
18 Microbiologically influenced corrosion (MIC)
18 • Acid-producing bacteria (APB)
18 • Sulfate reducer bacteria (SRB)
19 Oxygen-enhanced corrosion
19 Stray current corrosion
19 Under-deposit corrosion
20 Manufacturing defects
20 Mill defects
20 Forging defects
21 Processing defects
2
 NORRIS RODS

Root cause failure analysis

Root cause failure analysis (RCFA) is essential for failure
frequency reduction in wells with artificial lift.
Most failures associated with the sucker rod form of artificial lifted wells using the sucker rod lift method can be
attributed to one of three primary downhole components— subsurface pump, sucker rod string or tubing string. All of
these components are defined as any catastrophic event requiring servicing personnel to pull or change-out one or
more of these components.

By this definition, the failure frequency rate is the total number of component failures occurring per well, per year in a
producing field. Marginally producing wells with high failure frequency rates are often classified as “problem” wells.
Thus, effective failure management practices can mean the difference between operating and plugging these wells.
Failure management includes: identifying the problem(s), recording the “real” root cause of each failure, implementing
the appropriate change(s), and preventing future failures from occurring. This process is central to overall cost-effective
asset management. In this special report, we’ll deal only with sucker rod string related failures

Cost-effective failure management begins with prevention, and the time to stop the next failure is now—before
the next incident! Simply fishing, hanging the well on after a sucker rod failure and replacing with the same type of
component that failed will not prevent failure recurrence. Most failures continue with increasing frequency until the
entire rod string must be pulled and replaced.

Failure mechanisms
All sucker rod, pony rod and coupling failures are either tensile or
fatigue failures.
Tensile failures occur when the applied load exceeds the tensile strength of the rod. The load will concentrate at some
point in the rod string, create a necked-down appearance around the circumference of the rod, and fracture occurs
where the cross-section is reduced. This rare failure mechanism only occurs when pulling too much load on the rod
string—such as when attempting to unseat a stuck pump. To avoid tensile failures, the maximum weight indicator pull
for a rod string in “like new” condition should never exceed 90% of the yield strength for the known size and grade of
the smallest diameter sucker rod in the string. If the sizes, grades, or conditions of the sucker rod string components are
unknown, then a sufficient de-rating factor should be applied to the maximum weight that is pulled. All other sucker
rods, pony rods, and coupling failures are some form of fatigue failure.

Achievable failure frequency reductions require accurate failure root cause analysis and the implementation of
corrective action measures to prevent failure recurrence. A database capable of querying the well “servicing” history is
needed to track and identify failure trends. Once a failure trend is identified, remedial measures should be implemented
during well servicing operations to prevent premature rod string failures. The database failure history should include
information on the failure type, location, depth, root cause and the corrective action measures implemented.

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 CHAMPIONX ARTIFICIAL LIFT

Fatigue failures are progressive and begin as small stress cracks that grow under the action of cyclic stresses. The
stresses associated with this failure have a maximum value that is typically less than the yield strength of the sucker
rod steel in the final, heat-treated condition. Since the applied load is distributed nearly equally over the full cross-
sectional area of the rod string, any damage that locally reduces the cross-sectional area will increase the load or
stress at that point and is considered a stress raiser. A small stress fatigue crack typically forms at the base of the
stress raiser and propagates perpendicular to the line of principle stress. This typically is along the axis of the rod body.
However, when there are doglegs, rod buckling, and wellbore deviations, the principal axis may not be along the rod
string length and a resulting tri-axial stress state may occur. As the stress fatigue crack gradually advances, the mating
fracture surfaces opposite the advancing crack front try to separate under load. Then the mating fracture surfaces
become smooth and polished from subsequent rubbing or chafing. As the fatigue crack progresses, it further reduces
the effective cross-sectional area of the sucker rod or coupling until insufficient metal remains to support the load.
Then the sucker rod or coupling simply fractures in two. The fracture surfaces of a typical fatigue failure have a fatigue
portion, tensile tear portion, and final shear tear portion.

Fatigue failures are initiated by a number of stress raising conditions. Stress raisers are visible or microscopic
discontinuities that cause an increase in local stress on the rod string during loading. Typical visible stress raisers on
sucker rods, pony rods, and couplings are bends, corrosion pits, cracks, mechanical damage, threads, and wear or any
combination of the preceding. This increased stress effect is the most critical when the discontinuity on the rod string is
transverse (normal) to the principal tensile stress.

In determining the origin of a stress raiser in fatigue failure, the fatigue portion opposite the final shear tear protrusion
must be carefully cleaned and thoroughly examined. Fatigue failures have visible or macroscopic identifying
characteristics on the fracture surface, which help to identify the location of the crack origin and type of stress raiser.
Ratchet marks and beach marks are arguably two of the most important features in fatigue failure identification.
Ratchet marks are lines that result from the intersection and connection of multiple stress fatigue cracks while beach
marks indicate the successive position of the advancing fatigue crack. Ratchet marks are parallel to the overall direction
of crack growth and lead to the initiation point of the failure. Beach marks are elliptical or semielliptical rings radiating
outward from the fracture origin and indicate the successive location of the advancing stress fatigue crack growth.

The 1B rod body is a casehardened fatigue failure. The case encircling the rod body diameter carries the load for this
high tensile strength sucker rod and if the case is penetrated, the load-carrying capability of this type of manufactured
sucker rod is effectively destroyed. The stress fatigue crack advances around the case and progresses across the rod
body until complete fracture occurs. A fatigue failure on a casehardened sucker rod generally exhibits a small fatigue
portion and a large tensile tear (unless lightly loaded).

The example shown in 1A is a torsional fatigue failure from a progressing cavity pump. Ratchet marks found in the large
fatigue portion, and originating from the surface of the rod body, completely encircle the fracture surface with the small
tensile tear portion shown slightly off middle-center. The two examples on the right, 1D and 1E, are tensile failures. A
tensile failure is characterized by a reduction in the diameter of the cross-sectional area at the point of fracture. The rod
body shown in 1D is a typical tensile failure showing cup-cone fracture halves. The second example in Fig 1E is not
typical in appearance for tensile failures. Fractures from tensile failures rupture, or shear, on 45° angles to the stresses
applied. A good example of the shear is the characteristic cup-con fracture surfaces of a typical tensile failure.

4
Sucker rod failure analysis NORRIS RODS

A B C D E
Fig 1 - Fatigue and Tensile Failure Mechanisms

Fig 1 - Fatigue and tensile failure mechanisms

Figure 1 shows examples of fatigue and tensile failure mechanisms. The Fig 1C rod failure is typical in appearance
for most fatigue failures. Typical fatigue failures have a fatigue portion, tensile portion and final shear tear. The width
Figure 1 shows examples of fatigue and tensile failure mechanisms. The Fig 1C rod failure is typical in
of the fatigue portion is an indication of the loading applied when the final fracture occurs. Mechanical damage can
appearance for most fatigue failures. Typical fatigue failures have a fatigue portion, tensile portion and final
prevent or hinder failure analysis by destroying the visual clues and identifying characteristics normally found on
shear tear. The
a fatigue widthsurface.
fracture of the fatigue
Care mustportion is an indication
be exercised when of the loading
handling appliedhalves.
the fracture when the
It isfinal
veryfracture
important to resist
occurs. Mechanical damage can prevent or hinder failure analysis by destroying the visual
the temptation to fit the mating fracture surfaces together since this almost always destroys (smears) clues and identifying
microscopic
characteristics normally found on a fatigue fracture surface. Care must be exercised when handling
features that aid in determining the failure cause. To avoid mechanical damage, fracture surfaces should the fracture
never
halves. It is very important to resist the temptation
actually touch during fracture surface matching. to fit the mating fracture surfaces together since this almost
always destroys (smears) microscopic features that aid in determining the failure cause. To avoid mechanical
damage, fracture surfaces should never actually touch during fracture surface matching.

The 1E body failure is an excellent example of needing to look past the obvious for the not-so-obvious. A stress fatigue
The
crack1Eisbody failureresponsible
primarily is an excellent
for example of needing
this failure to look
even though past the
fracture obvious while
occurred for thetrying
not-so-obvious. A stress
to unseat the pump.fatigue
Visual
examination
crack of the
is primarily fracture for
responsible surface reveals
this failure a small,
even thoughsemi-elliptical, stresswhile
fracture occurred fatigue crack
trying on the the
to unseat rod pump.
body surface.
Visual This
sucker rod had preexisting, transverse stress fatigue cracks, from in-service stresses. One of the stress
examination of the fracture surface reveals a small, semi-elliptical, stress fatigue crack on the rod body surface. This fatigue cracks
opened
sucker during
rod the straight,
had preexisting, steady load
transverse applied
stress in attempting
fatigue cracks, fromtoin-service
unseat the pump, One
stresses. and of
facture occurred.
the stress The
fatigue tensile
cracks
failure is secondary and results in the unusual appearance of the fracture surface with the small fatigue portion, large
opened during the straight, steady load applied in attempting to unseat the pump, and facture occurred. The tensile
tensile portion and unusually large 45° double shear-lip tears.
failure is secondary and results in the unusual appearance of the fracture surface with the small fatigue portion, large
tensile portion and unusually large 45° double shear-lip tears.

5
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Norris

CHAMPIONX ARTIFICIAL LIFT

Design and Operating Failures

Sucker rod failure prevention begins with design. Poorly designed rod strings contribute to other component failures in the
Sucker rod
artificial failure prevention
lift system, such as rodbegins with resulting
cut tubing design. Poorly designed
from out of axialrod strings
load planecontribute
displacingto
of other component
the rods failures
and/or tubing in
or from
the artificial lift system, such as rod cut tubing resulting from out of axial load
wellbore deviations and even dog legs that were not included in the rod string design. plane displacing of the rods and/or tubing
or from wellbore deviations and even dog legs that were not included in the rod string design.

Designing the artificial lift system is a compromise between the amount of work to be done and the expense of doing this
Designing the artificial lift system is a compromise between the amount of work to be done and the expense of doing
work over a cost-effective period of time. Numerous combinations of depths, tubing sizes, fluid volumes, pump sizes and
this work over a cost-effective period of time. Numerous combinations of depths, tubing sizes, fluid volumes, pump
configurations, pumping unit sizes and geometries, stroke lengths, pumping speeds and rod string tapers are available to
sizes and configurations, pumping unit sizes and geometries, stroke lengths, pumping speeds and rod string tapers
the system designer. Sucker rod size and grade selection is dependent upon many factors including predicted maximum
are available to the system designer. Sucker rod size and grade selection is dependent upon many factors including
stresses,
predictedstress ranges,
maximum and operating
stresses, environments.
stress ranges, and operating environments

Commercially
Commerciallyavailable
availablecomputer
computerdesign
designprograms
programsallow
allowsystem
systemdesigner’s
designer’stoto
optimize
optimize production
production equipment at the
equipment least
at the
expense for thefor
least expense well
theconditions existing
well conditions at theattime
existing theof theofdesign.
time However,
the design. after after
However, the initial design
the initial and installation
design of the
and installation
rod string,
of the rodperiodic dynamometer
string, periodic surveys should
dynamometer surveysbeshould
utilizedbetoutilized
confirmtothat equipment
confirm load parameters
that equipment are within those
load parameters are
within those considered acceptable. A good initial design may become a poor design if
considered acceptable. A good initial design may become a poor design if well conditions change. Changes in the pumpwell conditions change. Changes
in the fluid
fillage, pump fillage,fluid
volume, fluidlevel,
volume,
strokefluid level,strokes
length, stroke per
length, strokes
minute per minute
or pump or pump
size severely impactsizethe
severely impact lift
total artificial thesystem.
total
artificial lift
Changes system.
in fluid Changes incan
corrosiveness fluidaffect
corrosiveness
the fatigue can affect thelife
endurance fatigue endurance
of sucker rods and lifemay
of sucker
lead to rods and mayfailures.
premature lead
to premature
When one of the failures. When
preceding one of the
conditions preceding
change, conditions
the design change,
of the the
artificial liftdesign
systemofmust
the artificial lift system must be re-
be reevaluated.
evaluated.

Figures 2 and 3 are examples of design and

Figures 2 and induced
operationally 3 are examples of design
mechanical andWear,
failures.
operationally
unidirectional induced mechanical
bending fatigue failures. Wear,
and stress-fatigue
unidirectional bending fatigue and stress-fatigue
failures indicate rod and/or tubing buckling, deviated
failures indicate rod and/or tubing buckling,
wellbores, fluid pound, gas interference, highly
deviated wellbores, fluid pound, gas interference,
stressed sucker rods, unanchored or improperly
highly stressed sucker rods, unanchored or
anchored tubing or some combination of the
improperly anchored tubing or some combination
preceding.
of the preceding.

Abrasive wear
Abrasive wear causes
causesrodrod
string failures
string by
failures by
reducing the
reducing the cross-section
cross-section of
of the
themetal,
metal,exposing
exposing
newmetal
new metalsurfaces
surfacestotocorrosion
corrosionand
andcauses
causessucker
sucker
rod connection failures
rod failures from
fromimpact
impactand
andshoulder
shoulder
damage. In
damage. In Figure 2,
2, the
theClass
ClassTTcoupling
couplingon
onthe
the
left
left and the Class SM couplings (2A and 2B)
the Class SM couplings (2A and 2B) are are
Fig. 2 -/ Operationally-Induced
Fig. 2 - Design Design / operationally-induced
Mechanical examples
examples of of abrasive
abrasivewear.
wear.
mechanical failures, Couplings
Failures, Couplings

The Class T coupling on the far right (2C) has a work-hardened ridge from tubing-slap. Tubing-slap is the result of the
The Class T coupling on the far right (2C) has a work-hardened ridge from tubing-slap. Tubing-slap is the result of the rod
rod string “stacking out”— probably as a result of severe fluid pound, gas interference or pump tagging. The work-
string “stacking out”— probably as a result of severe fluid pound, gas interference or pump tagging. The workhardened
hardened material doesn’t wear as fast as the softer material on either side of the work-hardened area and it leaves a
material doesn’t wear as fast as the softer material on either side of the work-hardened area and it leaves a ridge of
ridge of material as the rest of the softer material wears.
material as the rest of the softer material wears.
6

6
 NORRIS RODS

InFigure
In Figure3,
3,the
therod
rodbody
bodyononthe
theleft
left(3A)
(3A)isisan
an
example of abrasive wear. Abrasive-wear on the
example of abrasive wear. Abrasive-wear on the
rod string is defined as the progressive removal
rod string is defined as the progressive removal
of the surface metal by contact with the tubing
of the surface
string. metal bythat
Abrasive-wear contact withinthe
is equal tubing
length,
string. Abrasive-wear
width and that
depth usually is equalaindeviated
suggests length, width
and depth usually
or crooked suggests
wellbore. Angledaabrasive-wear
deviated or crooked
patterns indicate rod strings that
wellbore. Angled abrasive-wear patterns are aggressively
indicate
rod strings that are aggressively contactingasthe
contacting the tubing at an angle, usually a
A result of fluid pound, gas interference, severe
A tubing at an angle, usually as a result of fluid
B pump tagging, or unanchored or improperly
B pound, gas interference, severe pump tagging, or
C anchored tubing. The middle rod body in figure
C unanchored
3C represents or improperly anchoredAbrasive
corrosion-abrasion. tubing. The
D
D E middle rod removes
wear also body in figure 3C represents
corrosion inhibiting corrosion-
films and
E abrasion.
exposes newAbrasive wear
surface also to
metals removes corrosion
corrosive fluids
Fig. 3 - Design / Operationally-Induced Mechanical which accelerates the rate of corrosion.
inhibiting films and exposes new surface metals
Failures, Rods to corrosive fluids which accelerates the rate of
Fig. 3 - Design / operationally-induced
corrosion.
mechanical failures, Rods
Sucker rod failure prevention begins with design. It is possible for poorly designed rod strings to contribute to other
component failures in the artificial lift system, such as rod cut tubing resulting from out of axial load plane displacing
of the rods and/or tubing or from well bore deviations and even dog legs that were not included in the rod string
Sucker rod failure prevention begins with design. It is possible for poorly designed rod strings to contribute to other
design.
component failures in the artificial lift system, such as rod cut tubing resulting from out of axial load plane displacing of
the rods and/or
Designing thetubing orlift
artificial from well bore
system deviations and
is a compromise even dog
between thelegs that of
amount were nottoincluded
work be doneinandthe the
rod expense
string design.
of doing
this work over a cost-effective period of time. Numerous combinations of depths, tubing sizes, fluid volumes, pump
sizes andthe
Designing configurations, pumping
artificial lift system is aunit sizes andbetween
compromise geometries, stroke lengths,
the amount of workpumping
to be donespeeds
and theandexpense
rod string tapersthis
of doing
are over
work available to the system
a cost-effective designer.
period of time.Sucker rod failure
Numerous prevention
combinations begins with
of depths, design.
tubing sizes,Poorly designed
fluid volumes, rod strings
pump sizes and
contribute to other component failures in the artificial lift system, such as rod cut tubing resulting
configurations, pumping unit sizes and geometries, stroke lengths, pumping speeds and rod string tapers are available from out of axial
load plane displacing of the rods and/or tubing or from well bore deviations and even dog legs that were not included
to the system designer. Sucker rod failure prevention begins with design. Poorly designed rod strings contribute to other
in the rod string design.
component failures in the artificial lift system, such as rod cut tubing resulting from out of axial load plane displacing of
the
Therods and/orrod
second tubing
bodyorfailure
from well bore
(Figure deviations
3B) and evenfailure.
is a stress-fatigue dog legs that were
Stress not
fatigue included
failures in the
occur on rod string
highly design.
stressed
sucker rods as a result of worn-out sucker rods, overloads or extremely high rod loads for short periods of time.
The second rod body
Stress-fatigue failure
failures have(Figure
closely3B) is a stress-fatigue
spaced, fine, transversefailure. Stress
stress fatigue
fatigue failures
cracks occur on highly
that completely stressed
encircle the sucker
circumference of the rod body. The stress fatigue cracks will be on the wrench square and over the
rods as a result of worn-out sucker rods, overloads or extremely high rod loads for short periods of time. Stress-fatigueentire length
of the have
failures rod body.
closely With very old
spaced, fine,worn out sucker
transverse rods,
stress stress
fatigue fatigue
cracks thatcracks and failure
completely may
encircle occur
the within everyday
circumference of the rod
operating loads.
body. The stress fatigue cracks will be on the wrench square and over the entire length of the rod body. With very old
worn out sucker rods, stress fatigue cracks and failure may occur within everyday operating loads.

7
 Norris
CHAMPIONX ARTIFICIAL LIFT

Norris
Figure 4 is an example of coupling-to-tubing wear.
Downhole,
Figure 4 the coupling
is an examplemay
of slap and then rub against
coupling-to-tubing
thewear.
tubing and may
Downhole, the cause
coupling extremely
may slap aggressive
and then
Figurecontact
angle 4 is antoexample
the tubingof coupling-to-tubing
by the rod string. wear.
This
rub against the tubing and may cause extremely
Downhole, the coupling may slap and then
aggressive contact is the direct result of severe fluid rub against
aggressive angle contact to the tubing by the
the tubing
pound, and may
unanchored cause extremely
(or improperly anchored) aggressive
tubing,
rod string. This aggressive contact is the direct
angle contact to the tubing by the rod
sticking (or stuck) pump plungers, rod buckling from string. This
result of
aggressive severe
contact fluid pound,
is the unanchored
direct (or
result of sinker
severebars fluid
over pumping the well, lack of sufficient
improperly
pound, anchored)
unanchored (or tubing sticking
improperly (or stuck)
anchored) tubing,
to help keep the section of the rod string above the
pump plungers,
sticking (or stuck) rod
pump buckling fromrod
plungers, overbuckling
pumping
sinker bars in tension, or any combination of from
the
the
over well, lack
pumping
preceding. of
the sufficient
well, lacksinker
of bars to
sufficient help
sinkerkeepbars
tothe
helpsection
keep ofthethe rod string
section above
of the rod the sinker
string bars
above the
sinker
in tension, or any combination of the preceding. the
bars in tension, or any combination of
Fig. 4 - Coupling-to-Tubing Slap
Fig. 4 - Coupling-to-tubing slap preceding.
One thing that must be clarified is that bucking or bending
in the rod string does not mean the rods are going into
compression.
One Fig. 4 - that
thing Compressive
Coupling-to-Tubing
must loading
Slap
be clarified is thatmeans
bucking theor minimum
bending inloads
the rodarestring
less than
does zero, whichthe
not mean is rods
a difficult thinginto
are going to happen
when the rods are designed to bemeans
kept and One thing that must be clarified is that bucking or bending
compression. Compressive loading theoperated
minimumin tension.
loads are less than zero, which is a difficult thing to happen
in the rod string does not mean the rods are going into
when the rods are designed to be kept and operated in tension.
compression. Compressive loading means the minimum
While bending and buckling are similar since both require bending loads are less than
moments to zero, which bending
be applied, is a difficult
is duething to happen
to transverse
when the
loading rods to
applied arethedesigned
normally to applied
be keptaxial
and operated in tension.
loads. Buckling requires axial compression loading to occur and results in
While bending and buckling are similar since both require bending moments to be applied, bending is due to transverse
a local instability and ultimately causes a failure or collapse of the supporting structure.
loading applied to the normally applied axial loads. Buckling requires axial compression loading to occur and results in a
While bending and buckling are similar since both require bending moments to be applied, bending is due to transverse
local instability and ultimately causes a failure or collapse of the supporting structure.
loading
Many applied
years ago to the normally
there applied axial
was a misnomer loads.
typically Buckling
shown on requires
dynamometeraxial compression loading that
card interpretation to occur
the and
rodsresults
go intoin
a local instability
compression anddownstroke.
on the ultimately causes a failure or collapse
This compression loading is ofdifficult
the supporting
to do whenstructure.
the rest of the rods, pump, and fluid
Many years ago there was a misnomer typically shown on dynamometer card
load act to continuously keep the rods in tension. Bending or an out of plane displacement can occur for a variety of
interpretation
Many years that the rodswas
go into compression on the downstroke. This compression
reasons such ago
as a there
local dog a misnomer
leg, typically
or over-pumping, shown
tapping on dynamometer card interpretation that the rods go into
loading is difficult
compression onto do
the when the
downstroke. rest of
Thisthe rods,
compression
or tagging bottom, etc. The bending moment of the rods pump, and
loading fluid
is load act
difficult toto continuously
do when the rest of the rods, pump, and fluid
keep theact
isload rods in tension.
to continuously
constrained or resistedBending
keep
by the ortubing
the an outin
rods oftension.
ID plane
as welldisplacement
Bending
as rod or an can
outoccur for adisplacement
of plane variety can occur for a variety of
ofguides
reasonsandsuch
theas aa local
local dog
assistance of leg,
dog leg, or
or over-pumping,
sinker over-pumping,
bars. tapping
tapping or tagging bottom, etc. The
or tagging
bending bottom,
moment of the etc. Theis bending
rods constrainedmoment of theby
or resisted rods
the tubing ID as well as rod
is constrained
guides or resisted
and the assistance of by the bars.
sinker tubing ID as well as rod
guides and the assistance of sinker bars.
The fracture surface of the rod in Figure 5A
is an example of rod guide related damage.
TheThis example
fracture surfaceon the leftrod
of the is ainreconditioned,
Figure 5A is
high
The tensile
fracture strength
surface sucker
of the
an example of rod guide related damage. rod.
rod inTurbulent
Figure
This5A
fluid
is anflow, associated
example of rod with
guide short,
relatedblunt end
damage.
example on the left is a reconditioned, high
injection molded
This example on rod
the guides,
left is a allowed crevice
reconditioned,
tensile strength sucker rod. Turbulent fluid flow,
corrosion
high tensilein the criticalsucker
strength wash rod.areaTurbulent
around
associated
the end
fluid with
flow, theshort,
of associated blunt
guide. Priorend
with toinjection
bluntmolded
inspecting,
short, the
end
rodmold-on
guides, allowed
injection rod crevice
guides
molded rodwere corrosion
removed
guides, in from
allowed thecrevice
critical
the
wash
rod area
bodyaround
corrosion for the end ofwash
in reconditioning.
the critical the guide. Prior to
area around
Fig. 5 - Guide-related damage
the end of the guide. Prior to inspecting,
inspecting, the mold-on rod guides were removed the
frommold-on rod guides
the rod body were removed from the
for reconditioning.
rod body for reconditioning. Fig. 5 - Guide-related damage
Fig. 5 - Guide-related damage
8

8
 NORRIS RODS

The fracture surface of the rod in Figure 5A is an example of rod guide related damage. This example on the left is a
reconditioned, high tensile strength sucker rod. Turbulent fluid flow, associated with short, blunt-end injection molded rod
guides, allowed crevice corrosion in the critical wash area around the end of the guide. Prior to inspecting, the mold-on
rod guides were removed from the rod body for reconditioning.

Class1 reconditioned sucker rods cannot have discontinuities greater than 20 mils (0.020”) per API Standard 11BR. The
crevice corrosion was under the 0.020 inch allowed in a Class 1 reconditioned sucker rods. However, the notch sensitivity
(discontinuity intolerance) of a high tensile strength sucker rod is high. In other words, small pits can be detrimental to
the high tensile stresses associated with the high strength sucker rod. As such, reconditioned high strength sucker rods
should be de- rated for future design loads.

The example in the middle is an erosion-corrosion failure resulting from short, blunt-end, field-applied rod guides in small
tubing with high fluid velocities. Erosion-corrosion pits will be “fluid cut” with smooth bottoms. Pit shape characteristics
may include sharp edges and steep sides if accompanied by CO2 or broad smooth pits with beveled edges if
accompanied by H2S. The example on the right is abrasion-wear from a field applied rod guide moving up and down on
the rod body during the pumping cycle. Generally speaking, mold-on rod guides provide better laminar flow, a minimum
of three to four times more bonding and retention and are more cost-effective than are field-applied rod guides.

Mechanical failures
Mechanical failures account for a large percentage of the total number of all rod string failures. Mechanical failures
include every failure type except corrosion-fatigue failures and manufacturing defects. Mechanical damage to the rod
string causes a stress raiser which ultimately will cause the sucker rods or coupling to fail.

The time to failure will be influenced by many variables. These typically include: maximum stress, operating environment,
orientation of the damage, sucker rod chemistry, sucker rod heat treatment, stress range, and type of damage are the
most important variables. Mechanical damage can be caused by poor artificial lift design, improper rod care & handling
procedures, careless makeup & breakout procedures, out-of-date operating practices, or any combination of these
conditions.

9
 CHAMPIONX ARTIFICIAL LIFT

Norris

Bent rod failures

Bent Rod
Bending fatigue Failures
failures account for a significant number of all mechanical failures. It is a fact that all bent sucker rods
eventually fail. New sucker rods are manufactured to a body straightness of no less than 1/16 inch in any twelve inches
Bending fatigue
of rod body failures
length. account
Sucker for a significant
rods within number
this tolerance of all mechanical
of straightness will rollfailures. It is aafact
easily along rackthat
withallfive
bent sucker
level rods
supports.
eventually fail. New sucker rods are manufactured to a body straightness of no less than 1/16 inch in any twelve inches
Any degree of bend greater than this amount will cause an increase in local stress at the point of the bend during
of rod body length. Sucker rods within this tolerance of straightness will roll easily along a rack with five level supports.
applied load.
Any degree of bend greater than this amount will cause an increase in local stress at the point of the bend during
applied load.
When the bent rod body is pulled straight during loading, the ultimate strength of the material is quickly reached. The
cycle of continually exceeding the material strength is repeated during the pumping cycle and causes stress fatigue
When the bent rod body is pulled straight during loading, the ultimate strength of the material is quickly reached. The
cracks
cycle ofon the concave
continually side of the
exceeding the bend. These
material stress isfatigue
strength cracks
repeated progress
during across the
the pumping bar, and
cycle during loading,
causes untilfatigue
stress
insufficient
cracks on themetal remains
concave in of
side thethe
barbend.
to support
Thesethe load, fatigue
stress then fracture
cracksoccurs.
progress across the bar, during loading, until
insufficient metal remains in the bar to support the load, then fracture occurs.
Straightening the raw bar stock is the first step in the process of manufacturing sucker rods. Cold straightening the bar
deforms the grain
Straightening the rawstructure below
bar stock its first
is the recrystallization temperature,
step in the process putting a strain
of manufacturing in the
sucker barCold
rods. thatstraightening
is accompaniedtheby
bara
deforms the grain structure below its recrystallization temperature, putting a strain in the bar that is accompanied
work hardening effect. During the manufacturing process, the function of heat treatment is to stress-relieve the residual by a
work hardening
and induced effect. caused
stresses During the manufacturing
by the process,
bar straightening the function
processes of heat
and from treatment
forging the rodis to stress-relieve the residual
upsets.
and induced stresses caused by the bar straightening processes and from forging the rod upsets.
Heat treatment changes the metallurgical structure of the forged ends to match that of the rod body and also controls
Heat treatment changes
the mechanical theofmetallurgical
properties structure
the sucker rod. Any rodofbody
the forged ends toafter
bend created match that
heat of the rod
treatment body work
causes and also controls
hardening,
the mechanical properties of the sucker rod. Any rod body bend created after heat treatment causes work hardening,
which creates an area of hardness different than the surrounding surfaces. This condition is referred to as a “hard spot”
which creates an area of hardness different than the surrounding surfaces. This condition is referred to as a “hard spot”
and is a stress raiser to load. Mechanical processing, such as passing the finished bent sucker rod through a systemFig. 6 -ofBending Fati
and is a stress raiser to load. Mechanical processing, such as passing the finished bent sucker rod through a system of
rollers, will attempt to remove the bend so the rod body appears to be straight. However, reconditioning processes are
rollers, will attempt to remove the bend so the rod body appears to be straight. However, reconditioning processes are
not capable of stress relieving bent sucker rods. A bent sucker rod is permanently damaged and should not be used
not capable of stress relieving bent sucker rods. A bent sucker rod is permanently damaged and should not be used
because all bent sucker rods will eventually fail.
because all bent sucker rods will eventually fail.

Figure 6 show examples

Figure 6 show fatigue
of bending examples of bending
failures.
Bending
fatigue fatigue
failures. failures
Bending can
fatigue
be identified by the angled
failures can be identified by the
fracture
angled surface,
fracture which
surface, will will
which
be at some angle other than
be at some angle other than 90° to
90° to the axis of the rod
the axis of the rod body. The example
body. The example on the
on left
the (6A)
left (6A) illustrates
illustrates a fracture
a fracture
caused
causedby by
a long
a longradius
radiusbend, or
bend,
or gradual
gradual sweeping
sweeping bow inbow
theinrod
the rod body (Figure 7B).
body (Figure 7B). The fracture Thesurface
fracture surface is normal in
is normal in appearance, but has a
appearance, but has a slight
slight angle exists when compared to
angle exists when compared to
the axis of the rod body.
the axis of the rod body.
Fig.Failures
Fig. 6 - Bending Fatigue 6 - Bending fatigue failures

10
10
 Sucker rod failure analysis
NORRIS RODS

Sucker rod failure analysis

TheThe middle
middle example
example (6B) (6B)
is is
aa short
short radius
radius bend
bend
(Figure 7A). The fracture surface is at a greater
(Figure 7A). The fracture surface is at a greater
The middle
angle example
to the axis of (6B)the rodis a body
shortwithradius bend
a small
angle to the axis of the rod body with a small fatigue
(Figure 7A). The fracture surface is
fatigue portion and a large tensile tear portion. at a greater
portion
angle toand
The exampletheaaxis
large
onofthe tensilerodtear
theright body
(6C) portion.
iswith aThe
small
the result example
of a
on the
fatigue right (6C)
portion is
and thea result
large of a
tensile
corkscrewed sucker rod. Notice how convoluted corkscrewed
tear portion. sucker
The
rod. example
theNotice
fracturehowon the right
convoluted
surface is in(6C)
theisfracture
the result
appearance. ofgeneral
surface
As a a is in
corkscrewed
rule, the greater
appearance. sucker
As a general rod.
the bend Notice
in the
rule, how
the rod convoluted
body,
greater thethe
bend
the fracture
more surface
convoluted is
the in appearance.
fracture
in the rod body, the more convoluted the fracture surfaces As a general
appear.
rule, the greater
In operation, thethe bend
time in thethe
before rod rodbody, the is
fractures
surfaces appear. In operation, the time before the rod
more
greatlyconvoluted
shortened. thePoorfracture
caresurfaces
& handling appear.
procedures
fractures is greatly shortened. Poor care & handling
Inusually
operation, the time before the
cause bent sucker rods even before therod fractures is
procedures
greatly
rods have usually
shortened.
been run cause
Poor in a bent
care
well. sucker rods even
& handling procedures
Fig. 7 - Bending Fatigue Failures
before
usuallythe rodsbent
cause havesucker
been rods run ineven
a well. before the
Fig. 7 - Bending fatigue failures
rods have been run in a well.
Fig. 7 - Bending Fatigue Failures

Surface Damage Failures

Surface
Surface damage
Damage
Everything possible failures
Failures
should be done to prevent mechanical surface damage to sucker rods, pony rods and couplings.
Everything possible should be done to prevent mechanical surface damage to sucker rods, pony rods and couplings.
Surface damage increases stress during applied loads, potentially causing rod string failures. The type of damage,
Everything
Surface
and itsdamage possible
orientation,should
increases be done
stress
contributes to to prevent
during
this appliedmechanical
increased loads, surface
potentially
stress effect. The damage
causing to string
rod
orientation sucker
of the rods,
failures.
damage pony
The rods of
type and
contributes couplings.
damage,
to higher and
Fatigue Failures
Surface
itsstresses damage
orientation, increases
withcontributes
transverse to stress during
this increased
damage applied
resultingstress loads, potentially
effect. The
in increased causing
orientation
stresses rod string
of theassociated
over those failures.
damage contributes The type of damage,
to higher
with longitudinal stresses
damage for
and its orientation,
same applied contributes
stress. A to
sharp this
nickincreased
will create stress
a effect.
higher The
stress orientation
concentration of the
with transverse damage resulting in increased stresses over those associated with longitudinal damage for the same
the and damage
would be contributes
more to higher
detrimental to load
atigue Failures
stresses
applied with transverse
than astress.
shallow,
A sharp damage
broad-based
nick resulting
willdepression.
create in
a higher increased
Sucker rods
stress stresses
with overand
indications
concentration those
of associated
surface
would damage
be more with longitudinal
should
detrimental not
to bedamage
loadused
thanandafor
the same applied
shouldbroad-based
shallow, stress.
be replaced in A sharp nick
the rod string
depression. will create
to provide
Sucker rods with a higher
long stress
term operating
indications concentration
of surface and would be more detrimental
life. damage should not be used and should be to load
than a shallow, broad-based depression. Sucker rods with indications of surface damage should not be used and
replaced in the rod string to provide long term operating life.
Care should
should be used
be replaced to avoid
in the all metal-to-metal
rod string to provide long contact that mightlife.
term operating result in dents, nicks or scratches. To prevent
potential sucker rod damage, strips of wood should be placed between metal storage racks and between each layer
Care
Care should be
shouldrods
of sucker beused
used to
toavoid
avoidallallmetal-to-metal
so metal-to-metal metal-to-metal
contact can be contact
contact that
avoided. might
thatSucker result
mightrods in
indents,
resultshould benicks
dents, nicksor
used orscratches.
for what theyTo
scratches. Toprevent
wereprevent
designed
potential
- to lift asucker
potential sucker rod
roddamage,
damage,
load. Sucker strips
stripsof
rods should ofwood
wood
never beshould
should
used as be
beaplaced
placedbetween
walkway between metal
metalstorage
or workbench. storage racks
Keep metal and
andbetween
rackstools between
not each layer
eachfor
intended useof
layer
ofon
sucker
sucker rods
sucker rods
so
rods soand
metal-to-metal
metal-to-metal contact
all other contact
metal cancan
objects be
beawayavoided.
avoided. Sucker
fromSucker
the rods
suckerrods should
should
rods. be
be used
Make used
surefor for
thewhat
toolwhat
youthey
they were
use were designed
is designed
intended - tothe
for lift
- to lift
a load.
purpose a load.
Sucker Sucker
androds rods
should
ensure should
thatnever
it is inbenever be
used as
proper used as
a walkway
working a walkway or workbench. Keep metal tools not intended for
order.or workbench. Keep metal tools not intended for use on sucker use
on sucker rods and all other metal objects away
rods and all other metal objects away from the sucker rods. from the sucker
Make rods. Make
sure the toolsure
you the
usetool you usefor
is intended is intended for and
the purpose the
purpose
ensure thatand ensure
it is thatworking
in proper it is in proper
order. working order.

Figure 8 shows various surface damage failures. The example

on the left (8A) shows a slight depression from a wrench, tool, or
Figure
Figure
other 8other
shows
8 shows various
various
metal surface
surface
object. damage
damage
The failures.
secondfailures.
example TheThe example
example
(8B) is damageon
on the
the left
from left
(8A) (8A)
shows
a pipe shows a
a slight
wrench slight
used depression
depression from
in applying from a wrench,
a wrench, tool,
field-installed rod or tool, or
other
guides.
other
otherThe other
example
metal metal
object. object.
shown
The secondThe
in 8C second
has a small
example example
(8B) (8B) is
longitudinal
is damage damage
scratch
from afrom
pipe
from a pipe wrench used in applying field-installed
wrench used in applying field-installed rod guides. The example run
metal- to-metal contact; possibly by allowing suckerrod guides.
rods to
The
downexample
other shown inin 8C
rodhas a small longitudinal scratch example
from
shown in 8C hasrods
a small alongitudinal
bundle during
scratch installation.
from metal-The to-metal
metal-
on the to-metal contact;
right (8D) showspossibly by allowing
transverse surface sucker rods to run
contact; possibly by allowing sucker rods to run damage.
down other rods in a
Fig.8 - Surface Damage Failures down other rods in a rod bundle during installation. The example
rod bundle during installation. The example on the right (8D) shows
on the right (8D) shows transverse surface damage.
Fig.8 - Surface Damage Failures transverse surface damage.
Fig. 8 - Surface damage failures
11

11
11
 CHAMPIONX ARTIFICIAL LIFT

Figure 9 shows examples of surface damage

caused
Figure by sucker
9 shows rod elevators.
examples Bent
of surface sucker
damage
rod failures that occur below the
caused by sucker rod elevators. Bent suckersurface upset
rod
bead may be from bad elevator seats. The top
failures that occur below the surface upset bead
example (9A) shows damage caused by the
may be from bad elevator seats. The top example
elevator latches. This type of damage normally
(9A) shows
occurs as adamage
result ofcaused
pickingbyupthe elevator
or laying down
latches. This type of damage normally
in doubles. Never pick up or lay down anythingoccurs as
a more
result than
of picking up orsucker
one single laying rod.
down in doubles.
Anything else
causes
Never pickthe
upelevator latches
or lay down to act asmore
anything a fulcrum
than
and allows bending stresses to concentrate
one single sucker rod. Anything else causes the
in the transition zone of the rod body and the
elevator latches to act as a fulcrum and allows
forged upset.
bending stresses to concentrate in the transition
zone
The of the rodshown
example body and
in 9Bthe
is forged
damageupset.
from worn
or misaligned elevator seats. After an extended
The example
period shown
of service, in elevator
the 9B is damage from worn
seats become so
orworn and damaged
misaligned elevatorthat theyAfter
seats. develop an oval
an extended
Fig. 9 - Surface Damage Caused by Elevators shape rather than a round shape.
period of service, the elevator seats become so
worn and damaged that they develop an oval
Fig. 9
As the oval - Surface
shape growsdamage caused
from wear, by elevators
the tangency ring of the rod upsetshapeto rather than aseat
the elevator round shape.
face is lowered in the front
half of the seat. As the seat continues to wear, the seating position of the rod upset is moved forward of the elevator
trunnion centerline. This causes an offset in the elevator lifts the rod string load, the hook load will bend the sucker
rodthe
As centerline
oval shapeto coincide withwear,
grows from the elevator trunnion
the tangency ringcenter-line. As thetorod
of the rod upset thestring weight
elevator seatincreases, the hook
face is lowered load
in the will
front
bend
half of every sucker
the seat. rodseat
As the engaged by this
continues to elevator
wear, theuntil it is replaced.
seating position of the rod upset is moved forward of the elevator
trunnion centerline. This causes an offset in the elevator lifts the rod string load, the hook load will bend the sucker rod
Connection Failures
centerline to coincide with the elevator trunnion center-line. As the rod string weight increases, the hook load will bend
every sucker rod engaged by this elevator until it is replaced.
The API sucker rod connection is designed as a rotary shouldered, liquid free, friction preloaded connection. Since
the fatigue endurance of the sucker rod connection is low when subjected to cyclic loads, it is necessary to limit cyclic
Connection failures
loading by applying a preload between the pin and coupling. If the connection preload is greater than the applied load
during producing the well, the load in the connection remains constant and no fatigue occurs in the connection from
The API sucker rod connection is designed as a rotary shouldered, liquid free, friction preloaded connection. Since the
cyclic loads.
fatigue endurance of the sucker rod connection is low when subjected to cyclic loads, it is necessary to limit cyclic loading
by applying
The friction aload
preload
that between
develops the pin and
between thecoupling. If the face
pin shoulder connection
and thepreload
coupling is greater
shoulderthan
facethe applied
helps lock load
the during
producing
connection the well, thetoload
together in theit connection
prevent from coming remains constant and
loose downhole. no fatigue
However, occurs
if the in the
preload connection
is less than thefrom cyclic
applied loads.
load,
the pin shoulder face and the coupling shoulder face will separate under load during the cyclic motion of the pumping
unit.friction
The Once load
thesethat
faces separate
develops the connection
between is cyclically
the pin shoulder faceloaded
and the and will result
coupling in a loss
shoulder ofhelps
face displacement, or loss
lock the connection
of tightness/make-up
together failure.
to prevent it from Lossloose
coming of displacement failures may
downhole. However, bepreload
if the causedisfrom
lessimproper lubrication,
than the applied load,inadequate
the pin shoulder
makeup, over-torque, tubing-slap wear, over pumping the well, gas interference and fluid (liquid or gas) pounds or any
face and the coupling shoulder face will separate under load during the cyclic motion of the pumping unit. Once these
combination of these conditions.
faces separate the connection is cyclically loaded and will result in a loss of displacement, or loss of tightness/make-up
failure.
When Loss
theseoffaces
displacement
separate, failures may
a bending be caused
moment from improper
is added lubrication,
to the tensile load ininadequate
the pin. Themakeup,
threadedover-torque, tubing-
section of the pin
slap wear,
is held over
rigid pumping
while the
the rest ofwell, gasflexes.
the pin interference and fluid
The motion (liquid
of the rod or gas)causes
string poundsstress
or any combination
fatigue ofto
cracking these
startconditions.
in the
first fully formed thread root above the undercut.
When these faces separate, a bending moment is added to the tensile load in the pin. The threaded section of the pin is
12
held rigid while the rest of the pin flexes. The motion of the rod string causes stress fatigue cracking to start in the first
fully formed thread root above the undercut.

12
Sucker rod failure analysis
NORRIS RODS
Suckerrod
Sucker rodfailure
failureanalysis
analysis

Small stress fatigue cracks begin to form along

Small stressroot
the thread fatigue
duringcracks begin
applied loadto form along the
and eventually
thread
Small root
stress
consolidate during
fatigue applied
cracks
into a major load
begin and to eventually
form along the
Small stress fatigue cracksstress
beginfatigueto form crack.
along The
the
consolidate
threadroot rootinto a major
during applied stressload fatigue crack. The
andeventually
eventually
thread
fracture during
surface of applied
a typicalload lossand of displacement
fracture
consolidatesurface into ofa amajor
typical loss of
stress displacement
fatigue crack.The
The
consolidate
pin failure has intoaasmall
majorfatigue
stressportion
fatigue covering
crack.
pin failuresurface
fracture has a small typical
fatigueloss portion covering
fracture surface ofofaatypical loss ofofdisplacement
displacement
approximately
approximately
pin failure has one-third
one-third
a small ofthe
of
fatiguetheportion
fracturecovering
fracture surface with
surface with
pin failure has a small fatigue portion covering
the
the tensiletear
tensile
approximately tearportion
portion and
one-third and final
final shear tear
shear tear covering
covering
approximately one-third ofofthe
thefracture
fracture surface
surface with
with
the
the remaining
remaining
tensile tear fracture
fracture
portion surface.
surface.
and The
finalThe examples
shearexamples
tear on
on the
coveringthe
the tensile tear portion and final shear tear covering
left
theand
left and ininthe
remaining themiddle
fracture
middle (10
(10 AA&&B)
surface. will
The
B)The occur
occuras
examples
willexamples asaa result
on the
result
the remaining fracture surface. on the
ofofstress
left and loading
in the when
middle stress-raising
(10 A & B) will factors
occur such
as a as
result
left stress
and inloading
the middle when (10stress-raising
A & B) will occur factors
as asuch
result as
corrosion
of stress or mechanical
loading when damage is present
stress-raising factors on the as
such
of stress loading
corrosion when stress-raising
or mechanical damage is present factors on suchtheas
surface
corrosion of the stress reliefdamage
ormechanical
mechanical or pin undercut.
ispresent
presenton onthethe
Fig.
Fig.1010
- Pin Failure
- Pin Duedue
failure to Loss of Displacement
to loss of displacement corrosion or damage
surface of the stress relief or pin undercut. is
surfaceofofthe
surface thestress
stressrelief
reliefor orpin pinundercut.
undercut.
Fig.10
Fig. 10- -Pin
PinFailure
FailureDue
DuetotoLoss
LossofofDisplacement
Displacement

Figure 11 is another example of two types of pin

Figure 11 is another example of two types of pin
failures.
Figure11 The
11 sample
anotheron the leftof(11A) istypes
typical in
Figure
failures. isisanother
The sampleexample
example
on the left
twotypes
of(11A)
two ofofpin
is typical
pin
in
appearance
failures.The for
Thesample a loss
sampleon of
onthedisplacement
theleft
left(11A) pin
(11A)isistypical failure.
typicalinin
failures.
appearance
However,
appearance thisfor pinaafracture
for loss
lossof of displacement
was caused by
ofdisplacement
displacement pin
pinthefailure.
failure.
appearance for a loss pin failure.
However,
hydraulic
However,this this
rod
thispin pin
tongs fracture
during
pinfracture
fracturewas was
makeup caused
wascaused
causedby as isby the
evidenced
bythethe
However,
by the stair-stepped
hydraulic rod
rod tongs
tongs tensile
during
during tear.
makeup
makeup It isas not
as is
isuncommon
evidenced
evidenced
hydraulic rod tongs during makeup as is evidenced
for
by pin
bythe
the fractures
thestair-stepped
stair-stepped
stair-stepped to occur at makeup,
tensile
tensile tear.ItItItisis
tear. ifnot
isnot theuncommon
not pin has
uncommon
by tensile tear. uncommon
afor
preexisting
pin fracturestostress fatigue crack, due
to occur at makeup, if thepin to the high
pin has
for
forpin
pin fractures
fractures to occur at makeup, if the pin has
has a
torque
a required
preexisting with fatigue
stress large diameter
crack, due Class to D and
the high all
apreexisting
preexistingstress stressfatiguefatiguecrack,
crack,due duetotothe thehighhightorque
sizes
torqueof high
requiredtensile with strength sucker rods.
largediameter
diameter ClassThe sample
torque required with large Class DDandand all
all
required
on the
sizesofofhighwith
right large
(11B)
hightensile is diameter
an
tensilestrength example Class
strengthsucker of D and
excessive
suckerrods. rods.The all sizes
torque
Thesample of
sample
sizes
on
onathe
high soft pin.strength
tensile
the right The fracture
(11B) suckersurface
rods.ofof has
The a large fatigue
sample on the
Fig. 11 - Pin failures on right (11B) isisanan example
example excessive
excessive torque
torque
portion,
onaasoft
right softwith
(11B) pin. multiple
Theexample
is The
an ratchet
fractureof marks
surface
excessive in the
hasatorque pin-thread
alarge
largefatigue
fatigue
on a soft
on pin. fracture surface has
root, and with
portion, a small tensileratchet
multiple portion marks in the pin-thread
Fig. 11 - Pin Failures pin. Thewith
portion, fracturemultiplesurface has marks
ratchet a largeinfatigue portion,
the pin-thread
root,and
root, andaasmallsmalltensile
tensileportion
portion
Fig.11
Fig. 11- -Pin
PinFailures
Failures with multiple ratchet marks in the pin-thread root, and
a small tensile portion.

Figure 12 shows an example of a loss of displacement

coupling
Figure 12 failure.
showsThe fracture
exampleinitiated
anexample of a lossin ofthe coupling-
displacement
Figure
Figure12 12shows
showsan an exampleofofaaloss lossofofdisplacement
displacement
thread
coupling root opposite
failure. The the first fully-formed
fracture initiatedininthe pincoupling-
the
coupling
couplingfailure. The
Thefracture
fracture initiated
failure.One-third/two-third initiated in the coupling-
coupling-
starting-thread.
thread root opposite the first fracture
fully-formed halves,
pin
thread root opposite the first fully-formed pin
inthread
length, root
withopposite
ratchet the first
marks
starting-thread.One-third/two-third fully-formed
originating
One-third/two-thirdfracture in pin
the starting-
fracturehalves,thread-
halves,
starting-thread.
root indicate a loss of displacement coupling infailure.
inthread.
inlength,
length, One-third/two-third
with
with ratchet
ratchet marksfracture
marks halves,
originating
originating ininthe
the length,
thread-
thread-
The
rootfracture
indicate
withindicate surface
a
ratchet amarks loss of
of a typical
displacement
originating loss of displacement
coupling
in thecoupling
threadroot failure.
root loss of displacement failure.
coupling
The failure
fracture has a of
surface small
a fatigue
typical and
loss of large tensile
displacement
The fracture
indicate surface
a loss of a typical coupling
of displacement loss of displacement
failure. The
tear portion
coupling failurehashasaasmall
smallfatigue
fatigueand andlarge
largetensile
tensile
coupling failure
fracture surface of a typical loss of displacement
Fig. 12 - Coupling Failure Due to Loss of tearportion
tear portion
Displacement coupling failure has a small fatigue and large tensile
Fig.12
Fig. 12- -Coupling
Coupling
Fig. Failure
12 -Failure
CouplingDueto
Due toLoss
Lossof
failure of to
due
Displacement tear portion.
Displacement
loss of displacement
13
13
13
13
 CHAMPIONX ARTIFICIAL LIFT
Norris
Norris
Norris
Loss of displacement coupling failures are primarily associated with Class D sucker rods and high tensile strength
sucker
Loss ofrods.
displacement coupling failures are primarily associated with Class D sucker rods and high tensile strength
Loss of displacement coupling failures are primarily associated with Class D sucker rods and high tensile strength
Loss ofrods.
sucker displacement coupling failures are primarily associated with Class D sucker rods and high tensile strength
sucker rods.
sucker rods.
Mid-length coupling fractures, with ratchet marks leading from the outside, indicate another type of failure. The
Mid-length
stress coupling
fatigue fractures,
crack starts fromwith ratchet coupling
the outside marks leading from
surface, the outside,
progressing indicate
inward towardanother type of failure.
the threads, The stress
then around the
Mid-length coupling fractures, with ratchet marks leading from the outside, indicate another type of failure. The stress
Mid-length
fatigue crackcoupling
starts fractures,
from the with ratchet
outside coupling marks leading
surface, from theinward
progressing outside, indicate
toward the another
threads, type
then of failure.
around The
the stress
coupling
coupling wall starts
fatigue crack to a tensile
from thefracture.
outside Mid-length fracturesprogressing
coupling surface, from mechanical
inwarddamage
toward the to the coupling
threads, thensurface,
aroundexceeding
the coupling
fatigue
wall to crack
a starts
tensile from the
fracture. outside coupling
Mid-length fracturessurface,
from progressingdamage
mechanical inward toward
to the the threads,
coupling thenexceeding
surface, around thethe coupling
stress
the
wall to a tensile fracture. Mid-length fractures from mechanical damage to the coupling surface, exceeding the are
stress fatigue endurance limit of the material, or a manufacturing defect. Most mid-length coupling fractures the
stress
wall to a tensile fracture. Mid-length fractures from mechanical damage to the coupling surface,
fatigue endurance limit of the material, or a manufacturing defect. Most mid-length coupling fractures are the result of exceeding the stress
result
fatigueofendurance
mechanicallimit damage
of theor overload.
material, or Mid-length
a manufacturingcoupling fractures
defect. Most due to overload
mid-length havefractures
coupling a small fatigue
are theportion
result of
fatigue
mechanicalendurance
damage limit
or of the material,
overload. or a manufacturing
Mid-length coupling fractures defect.
dueMost mid-length
to overload havecoupling
a smallfractures are theand
fatigue portion result of
large
and large tensile
mechanical damagetearor portion.
overload. ThisMid-length
failure is common
couplingwith high strength
fractures sucker rods
due to overload have and Classfatigue
a small SM couplings. Full-sized
portion and large
mechanical
tensile tear damage
portion. Thisor overload.
failure isMid-length
common with coupling fracturessucker
high strength due torods
overload have SM
and Class a small fatigueFull-sized
couplings. portion andAPI large
Class
tensile
API Class tear portion. This
T couplings failure is common
or, preferably, with high
high strength strength
couplings sucker
should berods
usedand withClass
highSM couplings.
strength Full-sized
sucker rods toAPI Class
avoid
tensile tear portion.
T couplings This failure
or, preferably, high is common
strength with high
couplings strength
should sucker
be used rods
with and
high Class SM
strength couplings.
sucker rods toFull-sized API Class
avoid mid-length
T couplingscoupling
or, preferably, high strength couplings should be used with high strength sucker rods to avoid mid-length
Tmid-length
couplings or,
coupling failures.
failures.
preferably, high strength couplings should be used with high strength sucker rods to avoid mid-length
coupling failures.
coupling failures.

Figure 13
Figure 13isisan
anexample
exampleof of thread
thread galling
gallingin inthe
the sucker
sucker rod
rod connection.
connection.
Figure 13 is an example of thread galling in the sucker rod connection.
Figure
Thread 13 is an is
galling example of thread
mechanical damage galling in
totothe the
pin sucker
and/or rod connection.
coupling
Thread galling is mechanical damage to the pin and/or coupling threads.
Thread galling is mechanical damage the pin and/or
Thread
Threadgalling
threads. Thread
galling is galling
mechanical
is theofdamage
result oftodamaged
the pin and/or coupling
or contaminated
threads. Threadisgalling
the result
is the damaged
result or contaminated
of damaged threads
or contaminated
threads.
threads Thread galling
causing the is the result
interference of damaged
between the or contaminated
threads to be great
causingcausing
threads the interference betweenbetween
the interference the threads to be great
the threads to be enough
great to
threads causing the interference between the threads
enough to rip and tear the thread surfaces. The threads weld together to be great
enough to ripthe
rip and tear and tear the
thread threadThe
surfaces. surfaces.
threads The threads
weld weldduring
together together
enough to rip and
during makeup andtear theapart
strip thread surfaces. and
at breakout The the
threads weld together
connection is
during
makeup makeup
and strip and strip
apart apart
at at
breakout breakout
and theandand the connection
connection is
is damaged and
during makeup and strip apart at breakout
damaged and destroyed beyond use. Hard stabbing damage to the the connection is
damaged and destroyed beyond use. Hard stabbing damage to the
destroyed
damaged
leading beyond
and
thread anduse.
destroyed Hard
beyond
contaminated stabbing
use. damage
Hard
threads to the
stabbing
are the leading
damage
primary thread
to
causes the
leading thread and contaminated threads are the primary causes
and contaminated
leading
of threadthread
thread galling.and threads
contaminated
galling. Cleaning
Cleaning the are the
the threads primary
threads
threads prior causes
are
prior to the of thread
primary
tomakeup,
makeup,properly galling.
causes
properly
of
of thread galling.
lubricating
Cleaning the
the Cleaning
threads
threads and
prior the
to threadscareful
following
makeup, prior to
properly makeup,
makeup properly
procedures
lubricating will
the threads
Fig. 13 - Tread lubricating the threads and following careful makeup procedures will
Fig. 13 - Tread Galling galling in
in Connection lubricating
prevent the threads
most problems
problems and following
with thread
thread careful makeup procedures
galling.will prevent most problems will
Fig. 13 - Tread Galling in Connection and following
prevent most careful makeupwith procedures
galling.
connection
Fig. 13 - Tread Galling in Connection prevent most problems with thread galling.
with thread galling.

Figure 14
Figure 14 is
is an
an example
example of of aa wrench
wrench square
square failure.
failure.Wrench
Wrenchsquare
square
Figure 14
failures are
failures is an example
are extremely rare of a wrench
rare and seldom square
seldom occur failure.
occur unless Wrench
unlessfrom square
frommechanical
mechanical
Figure 14 isextremely
an example of and a wrench square failure. Wrench square
failures
damage, are extremely
corrosion or rare and
manufacturingseldom occur
defects. unless
The
damage, corrosion or manufacturing defects. The example shown from
example mechanical
shownisis
failures
damage,
a wrench
wrench are extremely
corrosion
square failurerare
fromandsevere
or manufacturingseldom occur unless
defects.
mechanical from mechanical
Thedamage.
example
damage. shown
Loose oris
a square failure from severe mechanical Loose or
adamage,
wrench
sloppy
sloppy
corrosion
squareon
backups
backups on or
themanufacturing
failure
the from severe
hydraulic
hydraulic
defects.
mechanical
rod tongs
rod
Therounded
tongs have
have exampleLoose
damage.
rounded
shown
the
the oris a
wrench
wrench
sloppy
wrench backups
square The
square corner.
square corner. on
The the
failure hydraulic
fromfatigue
stress
stress fatigue rod
severecrack tongs
mechanical
crack have
beganin
began in rounded
damage.
thecorner
the the
Loose
corner of wrench
or sloppy
ofthe
the
square
wrench
backups corner.
square The
and
on the and
wrench square stress
hydraulic fatigue
progressed
rod tongs
progressed tocrack
final
have
to final began
rupturein
rounded
rupture the
or corner
fracture
or the of the
wrench square
fracture
wrench square and progressed to final rupture or
corner. The stress fatigue crack began in the corner of the wrenchfracture
Fig.
Fig. 14
14 –– Wrench
Wrench Square
Square Failure
Failure
Fig. 14 – Wrench Square
Fig. 14 - Wrench square Failure
failure square and progressed to final rupture or fracture.

Figure 15
Figure 15 isis an
an example
example ofof the
the damage
damage thatthat occurs
occursas asaaresult
resultof of
Figure 15 is
severely over-
severely an example
over- lightening theof the damage
the sucker
sucker rod that occurs
rod connection.The as a result
The example of
Figure 15 is anlightening
example of the damage connection.
that occurs as aexample
result of
severely
shown is over-
an lightening
ever-tightenedthe sucker
coupling rod
that connection.
has
shown is an ever-tightened coupling that has flared out or flared The
out example
or bulgednear
bulged near
severely over- lightening the sucker rod connection. The example shown
shown is
the contact
the an ever-tightened
contact face.
face. Slim-hole coupling
Slim-hole couplings that
couplings are has
are more flared out
moresusceptible or
susceptibleto bulged
tothis near
thistype
type
is an
the
of ever-tightened
contact face.
over-tightened coupling
Slim-hole
damage thanthat
couplings
arehas flared
are more
full-size out or bulged
susceptible
couplings. Over near
to thisthe
type
tightened
over-tightened damage than are full-size couplings. Over tightened
contact
of
full-size face. Slim-hole
over-tightened
couplings
couplings damagecouplings
on Class
on Class than
D and
D and are
are
high
high more
full-size susceptible
couplings.
strength
strength sucker to this
suckerOver
rods
rods type of
tightened
generally
generally
full-size
exhibit couplings
over-tightened
slight bulges
bulgesonand
damage Class
and thanD and
have
have are
the high strength
the full-size
concentric
concentric sucker
couplings.
deformation
deformation rods
Over generally
tightened
ridge
ridge of full-
of
Fig.
Fig. 15
15 -- Damage
Damage Due to over exhibit slight bulges and have the concentric deformation
size couplings on Class D and high strength sucker rods generally exhibit
material ridge of
Fig. 15 -Connections
tightened Damage due to over
tightened
Fig. Connections
15 - Damage Due to over material
slight bulges and have the concentric deformation ridge of material.
tightened
tightened connections
Connections
14
14
14
14
 NORRIS RODS

Figure 16 is an example of impact cracks on

couplings.
Figure 16 isThe practice of
an example of “warming up”, or
impact cracks on
Figure 16 is
hammering,
couplings. an example
The of
onpractice
couplings impact cracks
in order toup”,
of “warming on couplings.
loosen
or them
The hammering,
practicenot
should of “warming
beonallowed. up”,
couplings Thisor hammering,
in example
order shows
to loosenon how
them
couplings in
impact not
should order
damage to loosen
to a Class
be allowed. them should
ThisT example not
coupling shows be
causeshowstress
allowed.
impactThis example
fatigue damage
cracks around shows how
the Timpact
to a Class impact
couplingpointsdamage
andstress
causes
to a fatigue
Class T
acceleratedcoupling
cracks causes
localized stress
around corrosion. fatigue
the impactHammering cracks
points and on
around theSM
Class
acceleratedimpact
(spray points
metal)
localized and accelerated
couplings
corrosion. causelocalized
Hammering stress
onfatigue
cracksSM
Class
corrosion. in (spray
the hard
Hammering spray
metal)
on surface
couplings
Class and
cause
SM (spray results
stressinfatigue
metal)
coupling
cracks
couplings causefailures
in the harddue
stress to corrosion-fatigue.
spray
fatigue surface
cracksand results
in the hardin
Fig. 16 - Impact Cracks coupling
spray surfacefailures due to
and results in corrosion-fatigue.
coupling failures due to
Fig. 16 - Impact Cracks
Fig. 16 - Impact cracks corrosion-fatigue.

Figure 17 is17
Figure anisexample
an example of polished rod failures.
of polished The The
rod failures.
majority
Figure
majority of 17 allofpolished
isallanpolished
example rod
of failures
rod failures occuroccur
polished either
in thein The
rod failures.
either the
body,body,
majority just
just below ofbelow
allthe the polished
polished
polished rodrod rod clamp,
failures
clamp, or inor
occur theinpin.
either the
in pin.
the
Polished
body, just rod body
below thefailures below
polished
Polished rod body failures below the polished rod rodthe polished
clamp, or rod
in theclamp
pin.
clampresult
Polished
result from
rod the
frombody theaddition
failures of
additionbelow bending stresses.
the polished
of bending stresses. These
rod clamp
bending
result from stresses may be of
the addition imposed
bendingbyby pumpingThese
stresses. units
These bending stresses may be imposed pumping
out of alignment,
bending stresses carrier
may be bars that do by
imposed notpumping
set level, units
worn
units out of alignment, carrier bars that do not set
carrier
out bars, misaligned
of alignment, carrier load
bars cells,
that door not
incorrect polished
set level, worn
level, worn carrier bars, misaligned load cells, or
rod clamp
carrier bars, installation.
misalignedThe polished
load rod
cells, or failure on
incorrect the left
polished
incorrect polished rod clamp installation. The polished
is an
rod example
clamp of a polished
installation. rod clamp
The polished on the
rod failure onsprayed
the left
rod failure on the left is an example of a polished
portion
is an exampleof a spray metal polished
of a polished rod clamp rod.
on Spray metal
the sprayed
rod clamp
polished on rods
the sprayed
have an portion
unsprayed of a spray metal
portion of a spray metal polishedportion for polished
rod. Spray metal
polished rod. rods
rod clamp
polished Spray
placementmetal
have an polished
unsprayed rods have an
portion for polished
Fig. 17 - Polished Rod Failures
Fig. 17 - Polished rod failures unsprayed portion
rod clamp placement for polished rod clamp placement.
Fig. 17 - Polished Rod Failures

Never put a polished rod clamp on the sprayed portion of a spray metal polished rod. The polished rod failure on the
rightput
Never
Never hasa small,
put longitudinal
a polished
polished rodrod
clamp scratches
clamponon caused
thethe
sprayed from
sprayed mishandling.
portion
portion of of a spray
a spray metal
metal polished
polished rod.
rod. The
The polished
polished rodrod failure
failure on on the
theright
righthas
has small, longitudinal
small, longitudinal scratches
scratches caused from
caused frommishandling.
mishandling.
Polished rod pin failures generally occur due to the installation of sucker rod couplings. Polished rod pins have a 9°
threadrod
Polished
Polished taperpinbetween
rod pin
failures thegenerally
failures straight-threaded
generally occur
occur tosection
duedue to the
the and the shoulder.
installation
installation Sucker
of sucker
of sucker rod rodrod couplings
couplings.
couplings. have
rodapins
Polished
Polished 30° pins
rod starting
a thread
havehave a 9°
and a deep
9° thread
thread taper
taperrecess thatthe
between
between doesn’t engage all thesection
thestraight-threaded
straight-threaded polished
sectionandrodthe
and pin threads.
shoulder.Polished
theshoulder. Sucker rod
Suckerrod couplings
rodcouplings have
couplingshave
haveaaa9°
30° starting
30°startingthreads
thread
starting
and aadeep
and profile designed
recess to properly
that doesn’t fit all
engage thethepolished
polishedrod pin.
rod pinThe shallow
threads. recessrod
Polished to couplings
the first thread
have aeasily distinguishes
9° starting threads
thread and a deep recess that doesn’t engage all the polished rod pin threads. Polished rod couplings have a 9°
polished
and rod couplings
a profile designed to from suckerfitrod
properly thecouplings
polishedandrodallows
pin. Theevery polished
shallow rodtopin
recess thread
the to be engaged.
first thread easily distinguishes
starting threads and a profile designed to properly fit the polished rod pin. The shallow recess to the first thread
polished rod couplings from sucker rod couplings and allows every polished rod pin thread to be engaged.
easily distinguishes polished rod couplings from sucker rod couplings and allows every polished rod pin thread to
be engaged. 15
15

15
 Norris
CHAMPIONX ARTIFICIAL LIFT

Norris
Corrosion-fatigue failures
Corrosion-fatigue Failures
Corrosion is one of the greatest problems encountered with produced fluids and accounts for about two-thirds of all
Corrosion-fatigue Failures
Corrosion
sucker is one ofCorrosion
rod failures.
all sucker
the greatest problems
is the encountered
destructive result of anwith produced fluids
electrochemical and accounts
reaction between fortheabout two-thirds
steel used of
in making
sucker rodsrod
andfailures. Corrosion
the operating is the destructive
environment to whichresult of an electrochemical
it is subjected. reaction isbetween
Simply put, corrosion nature’sthe
way steel used in a
of reverting
Corrosion
making is one
sucker of the
rods and greatest
the problems
operating encountered
environment to with produced
which it is fluidsSimply
subjected. and accounts
put, for about
corrosion is two-thirds
nature’s ofof
wayThe
man-made material of a higher energy state (steel), back to its basic condition (native ore) as it is found in nature.
all sucker rod failures. Corrosion is the destructive result of an electrochemical reaction between
reverting a man-made material of a higher energy state (steel), back to its basic condition (native ore) as it is found in the steel used in
elemental iron in steel combines with moisture or acids, to form other compounds such as iron oxide, sulfide, carbonate,
making sucker
nature. The rods and
elemental theinoperating
iron environment
steel combines to whichoritacids,
with moisture is subjected.
to formSimply put, corrosion
other compounds is nature’s
such way of
as iron oxide,
etc. Some form and concentration of water is present in all wells considered corrosive and most contain considerable
reverting
sulfide, carbonate, etc. Some form and concentration of water is present in all wells considered corrosive and mostin
a man-made material of a higher energy state (steel), back to its basic condition (native ore) as it is found
quantities of dissolved impurities and gases. For instance, carbon dioxide (CO2) and hydrogen sulfide (H2S) acid gases,
nature.
contain The elementalquantities
considerable iron in steel combinesimpurities
of dissolved with moisture or acids,
and gases. Fortoinstance,
form other compounds
carbon such as
dioxide (CO2) iron
and oxide,
hydrogen
common
sulfide, in most wells, are highly soluble and readily dissolve in is
water— which tends to lower its corrosive
pH. The corrosively
sulfide (H2S) acid gases, common in most wells, are highly soluble and readily dissolve in water— which tends most
carbonate, etc. Some form and concentration of water present in all wells considered and to lower
ofcontain
itsthe water
pH. The is a function
considerable
corrosively ofofthe
thewater
quantities amountis a of
of dissolvedthese two
impurities
function gases
of the andthat
amount arethese
gases.
of heldinstance,
For in solution.
two gases All waters
carbon
that with
dioxide
are held lowand
(CO2) pH hydrogen
in solution. values are
All waters
considered
sulfide
with low(H2S)
pHcorrosive
values to steel,
acid gases,
are commonwith lower
considered values
incorrosive
most torepresenting
wells, are highly
steel, greater
soluble
with lower acidity,
and
values readilyor corrosiveness.
representingdissolve in water—
greater which
acidity, tends to lower
or corrosiveness.
its pH. The corrosively of the water is a function of the amount of these two gases that are held in solution. All waters
All
Alldownhole
withdownhole environments
low pH values
environments are
arecorrosive
are considered corrosive totosome
corrosive some degree.
to steel,degree.withSome
lower
Some corrosive
values fluids may
representing
corrosive fluids maybe considered
greater
be acidity,
considered non-corrosive
or if the
corrosiveness.
non-corrosive if
corrosion penetration
the corrosion rate, recorded
penetration as milsasofmils
rate, recorded thickness
of thicknesslost perlost
year
per(mpy), is low enough
year (mpy), that it will
is low enough thatnot cause
it will problems.
not cause
All downhole
However,
problems. mostenvironments
producing
However, mostwellsareare
corrosive
producing wellstoare
plagued some
by degree.
corrosion
plagued by Some corrosive
problems
corrosionand fluids
no currently
problems may
and nobe considered
manufactured
currently non-corrosive
sucker rod can
manufactured suckerif
the
rod corrosion penetration
can successfully
successfully withstand rate, the
withstand
the effects recorded
ofeffects as
ofmils
this of
this corrosion thickness
corrosion
alone. lost per year (mpy), is low enough that it will not cause
alone.
problems. However, most producing wells are plagued by corrosion problems and no currently manufactured sucker
rod can
While
While successfully
corrosion
corrosion cannotwithstand
cannot be the effects
becompletely
completely of this itcorrosion
eliminated,
eliminated, itis ispossible alone.
possible toto control
control itsits reaction.
reaction. AllAll grades
grades of of sucker
sucker rodsrods must
must
beadequately
be adequatelyprotected
protectedthrough
throughthe
the use
use ofof effective
effective chemical
chemical inhibition
inhibition programs
programs (reference
(reference current
current editions
editions of API
of API
While corrosion Practice
Recommended cannot be completely
11BR and NACEeliminated,
StandarditRPO195).
is possible to control
Some suckerits reaction.
rod grades,Allduegrades of sucker
to different rods must
combinations
Recommended Practice 11BR and NACE Standard RPO195). Some sucker rod grades, due to different combinations of
be adequately
of alloying protected
elements, through the and
microstructures use of effectivelevels,
hardness chemical inhibition
are capable of programs (reference
longer service current editions
life in inhibited of wells
corrosive API
alloying elements, microstructures and hardness levels, are capable of longer service life in inhibited corrosive wells than
Recommended
than other gradesPractice 11BR
of either lowand NACEtensile
or high Standard RPO195). Some sucker rod grades, due to different combinations
strength.
other grades of either low or high tensile strength.
of alloying elements, microstructures and hardness levels, are capable of longer service life in inhibited corrosive wells
than other grades of either low or high tensile strength.
Figure 1818
Figure is an example
is an exampleof of
corrosion-fatigue
corrosion-fatigue from
from CO2CO2acid gas
acid corrosion.
gas corrosion.

TheFigure
Thesize
size18of
of isthe
the an example
pit,pit,
asas asof
farfar corrosion-fatigue
when
as whenit becomes
it becomes from CO2 acid
detrimental
detrimental toto
thegas
the corrosion.
sucker
suckerrod, rod,
depends on three factors—load, material type and hardness.
depends on three factors—load, material type and hardness. Class K sucker Class K sucker
The
rods size
may ofdevelop
the pit, deeper
as far asandwhen it becomes
larger pits than detrimental
aa Class DD to therod
sucker sucker
before rod,
rods may develop deeper and larger pits than Class sucker rod before
depends
it becomes ondetrimental
three factors—load, material
to the sucker rod. type
Classand hardness.
D sucker rodsClass K sucker
may develop
it becomes detrimental to the sucker rod. Class D sucker rods may develop
rods may
deeper anddevelop
larger deeper
pits than and larger
a high pits than
tensile a Class
strength D sucker
sucker rod before
rod before it
deeper and larger pits than a high tensile strength sucker rod before it becomes
it becomes
becomes detrimental
detrimental toto
thethe sucker
sucker rod.
rod. Classmaterials
Softer D sucker with
rodslower
may develop
rod stress
detrimental
deeper and to the
larger sucker rod. Softer materials with lowerrodrodbefore
stress ittolerate
Fig.
Fig.18
18- -CO2
CO2Acid Gas
acid Corrosion
gas corrosion tolerate larger pits pits
thanthan a high
do harder tensile
materials strength sucker
with higher rod stress. Therefore,
Fatigue larger pits
becomes than do harderto the materials with higher rod stress.
withTherefore, small
stresspits
fatigue small pits detrimental
can be detrimental sucker rod.
to higher Softer
tensile materials
strength sucker lower
rods rod
as opposed
Fig. 18 - CO2 Acid Gas Corrosion can
tolerate
to be
a softer detrimental
larger pitsrod
sucker to
than higher
dodoes
that tensile
harder strength
notmaterials sucker
with higher
have as much rods as opposed to
rod stress. Therefore,
rod stress. a softer
Fatigue sucker
small pitsrodcanthat does not have
be detrimental as much
to higher rod stress.
tensile strength sucker rods as opposed
to The
a softer
left-most rod in Figure 19 shows an examplerod
sucker rod that does not have as much stress.
of acid corrosion of a
sucker rod.
The left-most rod in Figure 19 shows an example of acid corrosion of a
The left-most rod in Figure 19 shows an example of acid corrosion of a
sucker
Service rod.
companies use acids for well stimulation and cleanout work. All acid
sucker rod.
work should have an effective inhibitor mixed with the acid before injection into
Service companies use acids for well stimulation and cleanout work. All acid
Service
the well.companies
Spent acids use
areacids for well stimulation
still corrosive to steel and andthecleanout work.
well should beAll“flushed”
acid
work
work should
should havehave an effective
an effective inhibitor
inhibitor mixed with the acid before injection into
long enough to recover all spent acid. Inmixed with the acid
rare instances, somebefore injection
produced into
waters
thethe well. Spent
well.organic
contain Spent acidsacids
acidsare are still
thatstill
have corrosive
corrosive to
formedtodownhole,steel and
steel and such the
the wellwell should be
shouldhydrochloric
as acetic, “flushed”
be “flushed”
andlong enough
long sulfuric
enoughacids. to recover
to recover all spent
all spent
Corrosion fromacid.acid. In
acidInisrarerare instances,
instances,
a general some
some
thinning produced
of produced
metal, leaving waters
waters
Fig. 19 - Acid Corrosion thecontain
contain
surface organic
organic theacids
withacids that
that have
appearance have offormed
formed downhole,
downhole,
sharp, featherysuch orsuchasas acetic,
acetic,
web-like hydrochloric
hydrochloric
residual metal
andand
nodules. sulfuric
sulfuric acids.
acids.
Metallic Corrosion
Corrosion
scale will notfromfrom
be acidisisaina
acid
formed general
general
the thinningofofmetal,
thinning
pits. metal,leaving
leaving
Fig.
Fig. 19 19 -Corrosion
- Acid Acid corrosion thethe surface
surface with
with thethe appearance
appearance of of sharp,
sharp, feathery
feathery or or web-like
web-like residual
residual metal
metal
16 nodules.
nodules.Metallic
Metallicscale willwill
scale notnot bebeformed
formed ininthethepits.
pits.

16
16
 Sucker rod failure analysis
NORRIS RODS

Chloride
Chloridecorrosion
Corrosion
Sucker rod failure analysis
Chlorides contribute to the likelihood of an increase in corrosion-related sucker rod failures. The corrosivity of water
Chloridesascontribute
increases to the likelihood
the concentration of chlorides of an increaseCorrosion
increase. in corrosion-related
inhibitors have sucker
morerod failures.
difficulty The corrosivity
reaching of
and protecting the
water increases as the concentration of chlorides increase. Corrosion inhibitors have more
steel surface of sucker rods in wells with high concentrations of chlorides. Corrosion, from water with high concentrations difficulty reaching and
Chloride Corrosion
ofprotecting
chlorides, has the steel surfacetoofbe
a tendency sucker
more rods in wellstowith
aggressive highsteel
carbon concentrations
sucker rodsof chlorides.
than to alloyCorrosion,
steel sucker from water
rods. with
Chloride
high concentrations of chlorides, has a tendency to be more aggressive to carbon steel
corrosion tends to evenly pit the entire surface area of the carbon steel sucker rod with shallow, flat-bottomed, irregular sucker rods than to alloy steel
Chlorides
suckerpits.contribute
rods. to the likelihood of an increase in corrosion-related sucker rod failures. The corrosivity of
shaped PitChloride corrosion tends
shape characteristics to evenly
include steep pitwalls
the entire surface
and sharp pit area
edges.of the carbon steel sucker rod with shallow,
water increases asirregular
flat-bottomed, the concentration
shaped pits.ofPitchlorides increase. Corrosion
shape characteristics include inhibitors
steep wallshave
and more
sharp difficulty
pit edges.reaching and
protecting the steel surface of sucker rods in wells with high concentrations of chlorides. Corrosion, from water with
high concentrations of chlorides, has a tendency to be more aggressive to carbon steel sucker rods than to alloy steel
CO2 Corrosion
CO2 corrosion
sucker rods. Chloride corrosion tends to evenly pit the entire surface area of the carbon steel sucker rod with shallow,
CO2 acid gas corrosion combines with water to form carbonic acid—which
flat-bottomed,
CO2 acid gasirregular
corrosion shaped
combines pits. Pit shape characteristics include steep walls and sharp pit edges.
lowers the pH of the water. Carbonicwith acidwater
is very to aggressive
form carbonic acid—
to steel and
which lowers the pH of the water. Carbonic acid is very aggressive to
results in large areas of rapid metal loss that can completely erode sucker rods
CO2 Corrosion
steel and results in large areas of rapid metal loss that can completely
and couplings. The corrosion severity increases with increasing CO2 partial
erode sucker rods and couplings. The corrosion severity increases with
pressure and temperature. CO2 corrosion pits are round-based, deep with
CO2increasing CO2 partialcombines
acid gas corrosion pressure withand temperature.
water to formCO2 corrosion
carbonic acid—pits
steep walls and sharp pit-edges. The pitting is usually interconnected in long
are round-based, deep with steep walls and
which lowers the pH of the water. Carbonic acid is very aggressive to sharp pit-edges. The pitting
lines
is andbut will
usually occasionally be
interconnected insingular
long linesandbutisolated.
willloss The pit bases
occasionally will be filled
be singular
steel results in large areas of rapid metal that can completely
with iron
andsucker carbonate
isolated. Theand scale, a loosely
pit couplings.
bases will be adhering
filled gray
with iron deposit
carbonate that is a by-product
scale, awith
erode rods The corrosion severity increases Fig. Fig.
20 - 20
CO2- Corrosion on
ofloosely
CO2 acid gas corrosion.
adhering gray deposit that is a by-product of CO2 acid gas CO2 corrosion on
increasing CO2 partial pressure and temperature. CO2 corrosion pits Couplings
corrosion. couplings
are round-based, deep with steep walls and sharp pit-edges. The pitting
is usually interconnected in long lines but will occasionally be singular
Figures 19 and
and isolated. pit 20 showwilltypical examples of CO2 acid gas corrosion.
Figures The 19 and bases
20 show be filled
typical with iron
examples of carbonate
CO2 acid gas scale, a
corrosion. Fig. 20 - CO2 Corrosion on
Figure 20 is an example of CO2 acid gas corrosion on a coupling and
looselyFigure
adhering
20 is gray
an depositof
example that
CO2 is acid
a by-product
gas of CO2
corrosion on acid
a gas and
coupling
Figure 21 is an example of CO2 acid gas corrosion on rod bodies. Couplings
corrosion.
Figure 21 is an example of CO2 acid gas corrosion on rod bodies.

Figures 19 and 20 show typical examples of CO2 acid gas corrosion.

Dissimilar Metals
Figure 20 is an example of CO2 acid gas corrosion on a coupling and
Dissimilar
Figure 21 is anmetals
example of CO2 acid gas corrosion on rod bodies.
An extremely rare failure, dissimilar metals corrosion may result when
An extremely rare failure, dissimilar metals corrosion may result when joining
joining two metals with differences in solution potentials together in the
two metals with differences in solution potentials together in the same
same solution. One metal has a marked tendency to corrode in preference Fig. 21 - CO2 Corrosion on Rods
Dissimilar Metals
solution.
other,
One metal
to the other,
and under
has a certain
and under
certain
markedfluid
fluid
tendency to corrode
conditions,
conditions, the less
in preference
the less
noble metal
noble metalto the
corrodes at a
corrodes at a higher rate. Dissimilar metals corrosion is
higher
usuallyrate. Dissimilar
greatest nearmetals
the corrosion
joining of theis usually
two greatest
metals. Since
An extremely rare failure, dissimilar metals corrosion may result near
most the joining
sucker
when rodofmaterials are compatible, this failure is
seldom
the
joining two seen
twometals.
metalsinSince
the
withrod
moststring.
sucker in
differences rodsolution
materials are compatible,
potentials this
together infailure
the is
seldom
same seen in
solution. Onethemetal
rod string.
has a marked tendency to corrode in preference Fig. 21 - CO2 Corrosion on Rods
Fig. 21 - CO2 corrosion on rods
H2S Corrosion
to the other, and under certain fluid conditions, the less noble metal
corrodes at a higher rate. Dissimilar metals corrosion is
usually
H2Sgreatest
acid gas near the joining
corrosion resultsofinthe twobased
round metals. Since
pits that most
may be sucker
deep rodwithmaterials
beveled pitareedges.
compatible,
Sometimethisthese
failure is
pits
H2S corrosion
seldom
may seen in the
be small, rod string.
random and scattered over the entire surface of the sucker rod. A second corrodent generated by H2S
H2S acid gas corrosion results in round based pits that may be deep with beveled pit edges. Sometime these pits may
acid gas corrosion is iron sulfide scale. The surfaces of both the sucker rod and the pit will be covered with the tightly
be small, random and scattered over the entire surface of the sucker rod. A second corrodent generated by H2S acid gas
adhering black scale. Iron sulfide scale is highly insoluble and cathodic to steel. This tends to accelerate corrosion
H2S Corrosion
corrosion is iron sulfide scale. The surfaces of both the sucker rod and the pit will be covered with the tightly adhering
penetration rates. A third corroding mechanism is hydrogen embrittlement, which causes the fracture surface to
black
havescale. Ironor
a brittle sulfide scale
granular is highly insoluble
appearance. A crackand cathodic
initiation to may
point steel.orThis
maytends
not beto visible
accelerate
and corrosion penetration
a fatigue portion may rates.
H2S acid
A may
gas
thirdnot
corrosion
corroding
results
mechanism is
in round
hydrogen
based pits that
embrittlement,
may
which
be deep
causes
with
the
beveled
fracture
pit edges.
surface to
Sometime
have a
these
brittle or
pitsor
granular
be present on the fracture surface. The shear tear of a hydrogen embrittlement failure is immediate during
may be small, random and scattered over the entire surface of the sucker rod. A second corrodent generated by H2S
appearance.
fracture due A to
crack
the initiation
absorptionpoint may or may
of hydrogen andnot
thebeloss
visible and a fatigue
of ductility portion may or may not be present on the
in the steel.
acid gas corrosion is iron sulfide scale. The surfaces of both the sucker rod and the pit will be covered with the tightly
fracture surface. The shear tear of a hydrogen embrittlement failure is immediate during fracture due to the absorption of
adhering black scale. Iron sulfide scale is highly insoluble and cathodic to steel. This tends to accelerate corrosion 17
hydrogen and the loss of ductility in the steel.
penetration rates. A third corroding mechanism is hydrogen embrittlement, which causes the fracture surface to
have a brittle or granular appearance. A crack initiation point may or may not be visible and a fatigue portion may or1 7
may not be present on the fracture surface. The shear tear of a hydrogen embrittlement failure is immediate during
 Although a relatively weak acid (when
compared with CO2 acid gas), any
CHAMPIONX ARTIFICIAL LIFT
measurable trace amount of H2S acid gas
is considered justification for chemical
Althoughinhibition programs
a relatively when
weak acid any measurable
(when compared
with CO2trace
acidamount of water
gas), any (H2O) is
measurable alsoamount
trace
A

present.
of H2S acid gas is considered justification for
B
as
chemical inhibition programs when any measurable
Figures 22 and 23 are examples of H2S
ble trace amount of water (H2O) is also present.
acid gas corrosion. The three rod body
A AA Figures 22 and 23 are examples of H2S acid gas Fig. 2
BB samples on the left (22 A, B and (pitting)
B corrosion. The three rod body samples on the left
C C
C and the two rod body samples on the
D DD (22 A, Bon and (pitting)
the right (22andD the
andtwo rodexamples
E) are body samples
of general thin
E
E on the 18
E is Fig. 22 - H2SofCorrosion
an example Fig.due
a pin failure 23 to
- H2S
hydrogen embrit
Fig. 22 - H2S Corrosion Corrosion on the right (22 D and E) are examples
Fig. 23 - H2S Corrosion
ig. 22 - H2S Corrosion
Fig. 22 - H2S corrosion Fig.
Fig.23
23- H2S
- H2S Corrosion
corrosion of general thinning corrosion from scale-deposit
Microbiologically Influen
of general thinning corrosion from scale-deposit corrosion. The sample in Figure 23corrosion. The sample in Figure 23 is an example of
thinning
drogen corrosion from
embrittlement scale-deposit
where corrosion.
a flat, brittle fracture shown. in Figure 23 a pin failure
Theissample
surface Figuredue24toshows
hydrogen embrittlement
several examples of where
microbiologica
brittlement where a flat, brittle fracture surface is shown. a flat, brittle fracture surface is shown.
microscopic life form is present in essentially every
celled organisms capable of living in all sorts of con
Influenced Corrosion
Microbiologically (MIC)
influenced corrosion (MIC) referred to as bacteria or “bugs”. Bacteria are classi
enced Corrosion (MIC)
Figure 24
microbiologically shows several
influenced examples
corrosion (MIC) of
onmicrobiologically
rod bodies. Some influenced
amount of
aerobic (req
corrosion (MIC) on rodOfbodies. Some amount of microscopic lifethe
form Some bacter
entially every producing well. primary concern to the rod string are single
ogically influenced corrosion (MIC) on rod bodies. Some amount of soluble iron
l sorts ofisconditions
present in and
essentially every
multiplying producing
with well.
incredible Of primary
speed. This isconcern
commonly
ery producing well. Of primary concern to the rod string are the single
eria are classified according to their oxygen (O2) requirements:
to the rod string are the single celled organisms capable of living in
conditions and multiplying with(does
incredible speed. MIC is very a
aerobic all
(requires
sorts ofO2), anaerobic
conditions not require
and multiplying O2)This
andisfacultative
with incredible
commonly
speed. This(either).
is
AA
assified according to their oxygen (O2) requirements: B
B environmen
Some bacteria generate H2S, produce organic acids or enzymes, oxidize
commonly referred to as bacteria or “bugs”. Bacteria are classified CC continuously
requires O2),inanaerobic
soluble iron (does or
produced water, not require
any O2) and
combination facultative
of the preceding.(either). D
according to their oxygen (O2) requirements: Fig. 24 - MIC on Sucker D dilution tech
cteria generate H2S, produce organic acids or enzymes, oxidize E
E
Rodaggressive
Bodies aerobic (requires O2),grades
anaerobic the number
on
MICinisproduced
very water, orall
and any combination
sucker rod the(does
ofcorrode not require
preceding.
rapidly O2)
in downhole Fig. 24 - MIC on Sucker Rod
and facultative (either). Some bacteria generate used on all s
environments containing bacteria. Suspect fluids shouldH2S, produce organic
be monitored Bodies
Fig. 24 - MIC on sucker rod
acids or
continuously
ry aggressive by
andenzymes,
sampling,
all suckeroxidize
rodsoluble
gradesiron
identifying and in produced
counting
corrode the water,
bacteria.
rapidly or any
The
in downhole extinction
bodies
dilution
ments techniquebacteria.
combination
containing is of
commonly used fluids
the preceding.
Suspect to culture
shouldbacteria for an estimation of
be monitored Acid-Producing Bacteria (APB)
the number of bacteria present in the well. Bactericide or biocide should be Corrosion pitting due to Acid-Producing Bacteria (A
usly by sampling, identifying and counting the bacteria. The extinction
used on all suspect fluids to control bacteria populations. corrosion. Corrosion pitting from APB has a cavern
echnique MICis is very aggressive
commonly used to andculture
all sucker rod grades
bacteria for ancorrode rapidlyof
estimation in downhole environments containing bacteria.
usually striated or grainy. The pit will not contain sc
Suspectpresent
ber of bacteria fluids should
in thebewell.
monitored continuously
Bactericide by sampling,
or biocide should identifying
be and counting the bacteria. The extinction
dilution
all suspect fluidstechnique
to control is commonly used to culture bacteria for an estimation of the number of bacteria present in the well.
bacteria populations. Sulfate Reducing Bacteria (SRB)
ng BacteriaBactericide or biocide should beshape
(APB) has the same basic pit used on characteristics of CO2
all suspect fluids acid gas
to control bacteria populations.
Figure 24 C and E show Sulfate Reducing Bacteria.
has a cavernous appearing pit-wall with sharp pit edges and the pit-base is
SRBs probably cause more problems to downhole
ot contain scale deposits.Bacteria
Acid-Producing This is shown
(APB) in figure 24 B and D.
to SRBs have the same basic pit shape characterist
a (APB) has the same
Corrosion pittingbasic
due pit shape characteristics
to Acid-Producing Bacteria of CO2has
(APB) acidthegas
same basic pit in
shape characteristics of CO2 acidthe
gaspit-edges (pits
the pit-base, tunneling around
ernous appearing pit-wall with sharp pit edges and the pit-base is
corrosion. Corrosion pitting from APB has a cavernous appearing pit-wall with splotches sharp pit edges
on theand the
steel pit-base
surface). is usually
The multiple crackin
ncing Bacteria.
scale deposits.Sulfate Reducing
striated orThis is shown
grainy.
Bacteria’s,
The pit in
willfigure
(SRBs),
24 B and
not contain
are those that produce H2S.
scaleD.deposits. This is shown in figurethe 24 bacterial
B and D. lifestyle. This not only corrodes the ste
to downhole equipment than do any other type of bacteria. Corrosion due
e characteristics of H2S acid gas corrosion, often with multiple stress cracks
pit-edgesSulfate Reducing pit
(pits- within-pits), Bacteria
clustering(SRB)and/or unusual anomalies (i.e. shiny
eria. Sulfate Reducing
Figure 24 C and Bacteria’s,
E show (SRBs),
Sulfate are those
Reducing that produce
Bacteria. Sulfate H2S. Bacteria’s,
Reducing 18 (SRBs), are those that produce H2S.
ultiple cracking in the pit-base results from the hydrogen sulfide by-product of
ole equipment
rrodes SRBs
the than
steelprobably
but candocause
any other
embrittlemore type
theproblems
surfaceof bacteria.
to the
of downhole
steelCorrosion thedue
equipment
under than do any other type of bacteria. Corrosion due to SRBs
colony.
ristics ofhave
H2Sthe acid gasbasic
same corrosion, often
pit shape with multiple
characteristics stress
of H2S acid cracks
gas corrosion, often with multiple stress cracks in the pit-base,
pits- within-pits), pit clustering
tunneling around and/or
the pit-edges unusual
(pits- anomalies
within-pits), (i.e. shiny
pit clustering and/or unusual anomalies (i.e. shiny splotches on the steel
cking insurface).
the pit-base results from the hydrogen sulfide by-product
The multiple cracking in the pit-base results from the hydrogen of sulfide by-product of the bacterial lifestyle. This
steel but
notcan
onlyembrittle
corrodes the thesteel
surface
but can of the steel under
embrittle the colony.
the surface of the steel under the colony.

18
 Sucker rod failure analysis
NORRIS RODS

Sucker rod failure analysis

Oxygen-Enhanced
Oxygen-enhanced Corrosion
corrosion
Oxygen-enhanced corrosion will be most prevalent on couplings, with a few instances found on rod upsets. This type
Oxygen-enhanced corrosion will be most prevalent on couplings, with a few instances found on rod upsets. This
of corrosion is rarely seen on the rod body. In fact, aggressive oxygen-enhanced corrosion can erode couplings without
Oxygen-Enhanced Corrosion
type of corrosion is rarely seen on the rod body. In fact, aggressive oxygen-enhanced corrosion can erode couplings
harming the sucker rods on either side.
without harming the sucker rods on either side.
Oxygen-enhanced corrosion will be most prevalent The on The
couplings,
raterate of with a few
corrosion
of corrosion is isinstances found on rod
directlyproportional
directly proportional upsets.
tothe
to the This
dissolved
dissolved
type of corrosion is rarely seen on the rod body. In fact, aggressive
oxygen (O2) oxygen-enhanced
concentration, chloride corrosion
content can erode couplings
oxygen (O2) concentration, chloride contentofofthetheproduced
produced
without harming the sucker rods on either side. water and/or presence of of
other
water and/or presence otheracidacidgases.
gases.Dissolved
DissolvedO2 O2can can
The
causerate of corrosion
severe corrosion is directly
at extremelyproportional
low to the dissolved
concentrations and
cause severe corrosion at extremely low concentrations and erode
oxygen
erode (O2) amounts
large concentration,
of metal. chloride
Pitting content of the
is usually produced
shallow,
large amounts of metal. Pitting is usually shallow, flat- flat-
bottomed
water
bottomedand/or
andpresence
broad-based of other withacid
the gases.
tendency Dissolved
of one O2 can
pit to
and broad-based with the tendency of one pit to combine with
cause
combine severe
with corrosion
another. Pit at extremely low concentrations
shape characteristics may include and sharp
another. Pit shape characteristics may include sharp edges and
erode
edges large amounts
and steep sidesofif metal. Pitting isby
accompanied usually
CO2 or shallow,
broad,flat-smooth
steep sides
bottomed and ifbroad-based
accompanied by CO2
with or broad, of
the tendency smooth
one pit craters
to
craters with beveled pit-edges if accompanied by H2S. Corrosion
with
combine beveled pit-edges
with another. if accompanied
Pit shape by
characteristics H2S. Corrosion
may include rates
rates increase with increased concentrations of dissolved O2.sharp
increase
edges
Figuresand with
steep
25 and increased
26sides concentrations
if accompanied
are examples of dissolved
by CO2 or broad,
of oxygen-enhanced O2. Figures
smooth
corrosion.
25
craters and 26 are
with beveled
The coupling examples
on the leftpit-edges of
in Figure oxygen-enhanced
if accompanied
25 is an example corrosion.
by H2S.of the The
Corrosion
effects
coupling
rates increaseon with
of oxygen-enhanced the left in Figure
increased
CO2 25 iscorrosion.
an example
acidconcentrations
gas ofslim-hole
the effects
of dissolved
The O2.of
Fig. 25 – Oxygen Enhanced oxygen-enhanced 26 areCO2
Fig. 25on
- Oxygen enhanced corrosion Figures
coupling 25
inand
the middle andacid
examplesthe gas corrosion.
of oxygen-enhanced
full-size couplingTheon slim-hole
the rightcoupling
corrosion.
Corrosion Couplings
The
areincoupling
the middle
examples on
of the the
and left in Figure
full-size
effects of 25 is anon
coupling
oxygen-enhanced example
the right
H2Sofare
theexamples
acid effects
gas
on couplings
of oxygen-enhanced
of the effects
corrosion. The sucker CO2
rod acid
of oxygen-enhanced
samplesgas corrosion.
in H2S acid
Figure The
26gas
showslim-hole
corrosion. Theof
the effects
Fig. 25 – Oxygen Enhanced
coupling in the
oxygen-enhanced middle and the full-size coupling
sucker rod samples in Figure 26 show the effects of oxygen- and
CO2 acid gas corrosion near on
the the
upset right
(left)
Corrosion on Couplings
are examples
on enhanced
the rod body of the
CO2 effects
(right).
acid of oxygen-enhanced
gas corrosion near the upset H2S acid
(left) andgason the
corrosion. The sucker rod samples in Figure 26 show the effects of
rod body (right).
Stray Current Corrosion
oxygen-enhanced CO2 acid gas corrosion near the upset (left) and
on the rod body (right).

Stray
Rarely seen current corrosion
in most wells, stray current corrosion refers to the
Stray
induced,
Rarelyor
Current
stray,
seen in electrical
most wells,
Corrosion
currents that flow
stray current to or from
corrosion thetorod
refers the
string. Stray or
induced, current
stray, corrosion can be caused
electrical currents by grounding
that flow electrical
to or from the
Rarely seento
equipment in the
most wells, stray
wellhead, current
casing or fromcorrosion
nearbyrefers to the
cathodic
rod string. Stray current corrosion can be caused by grounding
induced, orsystems
protection stray, electrical currents
(pipelines). that flow tofrom
Arcs originating or from the rod
the rod string
electrical equipment to the wellhead, casing or from nearby
string.aStray
leave deep,current
irregularcorrosion
shaped can be caused
pit with smoothbysides,
grounding
sharp electrical
pit-
cathodic protection systems (pipelines). Arcs originating from
equipment
edges and atosmall
the wellhead,
cone in the casing
baseor offrom nearby
the pit. Arcs cathodic
originating from
the rod string
protection systems leave a deep, irregular
(pipelines). shapedfrom
pit with smooth
the tubing leave deep pits with Arcs
smooth originating
sides and the edges
sharp rod string
that
are sides,
leaverandomsharp
a deep, pit-edges
inirregular
dimension and irregular
shaped
and apitsmall
with cone
smooth in the
in shape. base
sides,
Stray of the
sharp pit-pit.
current
Fig. 26 - Oxygen-Enhanced Arcsand
edges
corrosion originating
a small
pits frominthe
cone
are usually thetubing
baseand
singular leave
of the deep pits
pit. Arcs
isolated in withdown
smooth
aoriginating
row from
one
Corrosion thesides
side tubingand
of the leavesharp
sucker edges
deep
rod pits that
the are
nearwith random
smooth
upsets. in and
sides dimension and that
sharp edges
areirregular
random in in shape.
dimensionStrayand
current corrosion
irregular pits Stray
in shape. are usually
current
Fig. 26 - Oxygen-Enhanced corrosion
singularpits
and are usuallyinsingular
isolated and isolated
a row down one sideinof
a row down one
the sucker rod
Fig. 26 - Oxygen-enhanced corrosion
Under-deposit Corrosion
Corrosion sidenear
of the
thesucker
upsets.rod near the upsets.

Scales such as barium sulfate, calcium carbonate, calcium sulfate, iron carbonate, iron oxide (rust), iron sulfide, and
Under-deposit Corrosion
strontium sulfate should be prevented from forming on sucker rods. Although scale on a sucker rod slows down the
Under-deposit
corrosion penetrationcorrosion
rate, it also reduces the effectiveness of chemical inhibitors. Severe localized corrosion, in the
Scales
Scales
form of such
such as barium
as
pitting, barium sulfate,calcium
resultssulfate,
anytime calcium carbonate,
carbonate,
the scale is cracked calcium
calcium sulfate,movement
sulfate,
by a bending ironcarbonate,
iron carbonate, ironoxide
iron
or removed oxide (rust),iron
by (rust),
abrasion. iron sulfide,
sulfide, andand
strontium sulfate should be prevented from forming on sucker rods. Although scale on a sucker rod slows down thethe
strontium sulfate should be prevented from forming on sucker rods. Although scale on a sucker rod slows down
corrosionpenetration
corrosion penetrationrate,
rate, it also
it also reduces
reduces thethe effectiveness
effectiveness ofof chemical
chemical inhibitors.
inhibitors. Severe
Severe localized
localized corrosion,
corrosion, in the
in the form
form of pitting, results anytime the scale is cracked by a bending movement or
of pitting, results anytime the scale is cracked by a bending movement or removed by abrasion.removed by abrasion. 19

19
19
 Norris
CHAMPIONX ARTIFICIAL LIFT

Manufacturing Defects
Manufacturing
Manufacturing defects
Defects
Failures due to a manufacturing defect seldom occur. Manufacturing defects are easily recognized and it
Failures due tothat
is important a manufacturing
you understand defect
whatseldom occur. Manufacturing
these defects look like if you defects areaccurate
are to file easily recognized
claims for and it is important that
warranty
Failures
you due to awhat
understand
reimbursement. manufacturing
The these defects
original defect
steel mill seldom
lookor like
supply occur.
if you arethe
and Manufacturing
to file defects
accurate claims
manufacturer are
for
of sucker easily
warranty recognized
rods and and
reimbursement.
couplings it Thebe
cannot original
is important
steel that
mill orfrom
excluded supplyyou
theand understand what
the manufacturer
possibility these
of defects in defects
ofmaterial
sucker rods look like if you
and couplingsThe
or workmanship. are to
cannotfile accurate
be excluded
following claims
examplesfromfor warranty
the possibility
include defects of defects
reimbursement.
from several The original
different steel
manufacturers. mill or supply and the manufacturer of sucker rods
in material or workmanship. The following examples include defects from several different manufacturers. and couplings cannot be
excluded from the possibility of defects in material or workmanship. The following examples include defects
from several different manufacturers.
Mill
Mill Defects
defects
Figure 27 is an example of mill defects. Mill defects occur along one side of the rod body and these discontinuities
Mill Defects
Figure 27have
normally is anlongitudinally
example of mill defects.
tapered Mill defects
bottoms occur
and sharp alongwith
edges oneindications
side of theof rod
thebody and these
longitudinal seamdiscontinuities
in the base of
normally have longitudinally tapered bottoms and sharp edges with indications of the longitudinal seam in the base
the discontinuity.
Figure
of the 27 is an example of mill defects. Mill defects occur along one side of the rod body and these discontinuities
discontinuity.
normally have longitudinally tapered bottoms and sharp edgesThe with indications
example onthe of the
the far leftlongitudinal
left and the the rod seam
rod body in the base
The example on far and body third third from
from
of the discontinuity. theleftleft are
are examples
examples of of aa sliver.
sliver. (In(In the example third from
the
The
theexample
from left,
thethe on
thethe
left,protrusion far folded
protrusion left and the rod
against
folded the
againstbody third
fracture
the from
surface
fracture
the
surface
duringleft are examples
during
“fishing”). Theof
“fishing”).rod aThe
sliver.
body rod (In the second
body
second example
from thefrom thirdthe
right is
from
right the left,
is an example
an example the protrusion
of a scab.of aAscab. folded
sliverAissliver against
a smallis a loose the
small or fracture
loose
torn
surface
or torn during
segment and a“fishing”).
segment and aisscab
scab aThe
large rod
is bodyor
aloose
large second
loose
torn or from
torn the
segment of
right
segment is an example
of material of a scab.
longitudinally A sliver is
rolled a small
into loose
the surface
material longitudinally rolled into the surface of the bar.
or
of torn
theend segment
bar. and a scabsliver is a large loose or torn
One ofOne
the end
sliveroforthe or scab
scab is normally ismetallurgically
normally
Fig. 27 - Examples segment of material longitudinally
metallurgically bonded into the rod body while rolled into thethesurface
Fig. 27 of Mill Defects
- Examples of mill defects bonded into the rod body while the remaining end is rolled
of the bar. One
remaining end is end of the
rolled into sliver or scab and
the surface is normally
physically
into the surface and physically
Fig. 27 - Examples of Mill Defects metallurgically bonded into the rod body while the
Fatigue failures, which result from slivers or scabs, will have aremaining piece of loose material protruding over
end is rolled into the surface and physically the fatigue
Fatigue
portionfailures, which result
of the fracture from
surface. Theslivers or scabs,
rod body secondwillfrom
havethe a piece
left is of anloose
example material protruding over
of rolled-in-scale. the fatigue is a
Rolled-in-scale
Fatigue
portion failures,
surfaceofdiscontinuitywhich result
the fracture caused from
surface.when slivers
scale
The rod or scabs,
(metal
body will
oxide),
second have
fromformed a piece
the left during of loose
is anaexample material
prior heat, of has protruding over
not been removed
rolled-in-scale. the fatigue
Rolled-in-scaleprior to bar is a
portion
rolling. of
The the fracture
rod body surface.
on the farThe
rightrod
is body
an second
example offrom
a the
rolling left
lap. is an
Rolling example
laps of
are
surface discontinuity caused when scale (metal oxide), formed during a prior heat, has not been removed prior to bar rolled-in-scale.
longitudinal Rolled-in-scale
surface discontinuities is a
surface
that have
rolling. discontinuity
Thethe caused
rodappearance
body on theoffarwhen
a seam scale
right isfrom(metal oxide),
rolling, with
an example formed
of asharp during
rollingcorners
lap. Rolling a prior
folded laps heat,
overareandhas not been
rolled intosurface
longitudinal removed prior
the bardiscontinuities
surface to bar
rolling.
without The rod body on
metallurgical the far right is an example of a rolling lap. Rolling laps are longitudinal surface discontinuities
bonding.
that have the appearance of a seam from rolling, with sharp corners folded over and rolled into the bar surface without
that have the appearance of a seam from rolling, with sharp corners folded over and rolled into the bar surface
metallurgical bonding.
Forging Defects
without metallurgical bonding.
Figure 28 is an example of forging defects. The
Forging
Forging Defects
defects fracture begins internally below a forging crack
Figure
Figure
in 28isisan
28
the upset an
area example
example
and is of offorging
forging
brittle defects.in
defects.
or granular The
The
fracture
fracturebegins
appearance. begins internally
internally
A crack below
below
initiation aaforging
site may orcrack
forging cracknot
may in the
in
be the
upset upset
area
visible and area
and a is and is brittle
brittleportion
fatigue or
or granular granular
may in in
orappearance.
may not
appearance.
be present
A crack onA crack
initiation thesite initiation
fatigue site may
may fracture
or may or visible
surface.
not be mayThenot
and
be visible
examples and a
on the left
a fatigue portion fatigue
mayand portion
in the
or may may
notmiddleor may not
occuron
be present as the
a
be present
result of lowon the
forging fatigue fracture
temperatures.
fatigue fracture surface. The examples on the left surface.
The The
example
examples
on lefton the left and in theand middle example
occur as a
andthein the is from
middle a cold-shut
occur as a resultthe of low forging
result
in the of low forging
middle isThe
from temperatures.
a forging The example
temperatures. example oncrack.
the leftThe fracture
is from a cold-
on the left is from a cold-shut and
on the right is a failure caused by a subsurface the example
shut and the example in the middle is from a forging
in the middleseam
longitudinal is from a forging
located nearcrack.
the end Theoffracture
the raw
crack. The fracture on the right is a failure caused
on the right is a failure caused by
bar. During the forging process, the orientation ofa subsurface
by a subsurface
longitudinal seamlongitudinal
located nearseam
the located
end of thenear
raw
Fig. 28 - Examples of Forging Defects this discontinuity was changed transversely.
the end of the raw bar. During the
bar. During the forging process, the orientation of forging process,
Fig. 28 - Examples of Forging Defects the discontinuity
this orientation ofwas this changed
discontinuity was changed
transversely.
20 Fig. 28 - Examples of forging defects transversely.

20
20
 Sucker rod failure analysis
NORRIS RODS

Sucker
Sucker
rod
rod
failure
failure
analysis
analysis
Figure 29 is an example of incipient grain boundary
Figure 29 is an example of incipient grain boundary
melting. This is an extremely rare manufacturing
melting. This is an extremely rare manufacturing
defect. This condition is caused by forging the upset
defect.
Figure
Figure 29 This
29
is an
is condition is caused by forging the upset
end ofan example
theexample
rod at of of
incipient
too incipient
highgrain
a grain boundary
boundary
temperature for the
end ofThis
melting.
melting. the rod
This
is an
is at
an too high arare
extremely
extremely temperature
rare
manufacturing for the
manufacturing
steel. Unfortunately, no inspection exists that will
defect.
defect.
steel.This This
condition
condition
Unfortunately, isnocaused
is inspection
caused bybyforging
forging thethe
upset
upset
catch this before the rod isexists
shipped.that will
Fortunately,
endendof of
the
catchthese the
rodrod at
this before at
too too
highhigh a temperature
a temperature for for
thethe
brittlethepinsrodusually
is shipped.snap Fortunately,
off during makeup
steel.
steel.Unfortunately,
theseso Unfortunately,
brittle no noinspection
inspection exists
existsthat
thatwillwill
failure typically does not occurmakeup
pins usually snap off during downhole. No
catch
catch this
this
before
before thetherod rod is shipped.
is shipped. Fortunately,
Fortunately,
so failure
crack typically
initiationdoes pointnot occur
is off downhole.
visible and noNo fatigue portion
these
these brittle
brittle
pinspins
usually
usually snapsnap off during
during makeup
makeup
crackwillinitiation
be point ison
present visible
the and no fatigue
fracture portion
surfaces.
sosofailure
failuretypically
typicallydoesdoes notnot occur
occurdownhole.
downhole. NoNo Optical
willinitiation
crack
crack be present
pyrometers
initiation on the
point
pointis fracture
onvisible
isforging
visibleand surfaces.
equipment
andnono fatigue Optical
fatigue have
portion
portion virtually
Fig. 29 - Incipient Grain Boundary Melting pyrometers on
willwill
bebe eliminated
present
present onforging
on this
thethe equipment
problem.
fracture
fracture have
surfaces.
surfaces. virtually
Optical
Optical
Fig. 29 - Incipient grain boundary melting pyrometers
pyrometers
eliminatedon on
forging
this forging
equipment
problem.equipment
have
have
virtually
virtually
Fig.Fig.
2929
- Incipient
- Incipient
Grain
Grain
Boundary
Boundary
Melting
Melting
eliminated
eliminated
this
this
problem.
problem.

Processing Defects
Processing
Processing
Processing
Figure Defects
Defects
defects
30 shows examples of processing defects. The example is a casehardened sucker rod and the other example
is a coupling
Figure 3030shows that has been
examples processeddefects.
through a example
grindingisoperation to reduce the diameter. In both examples,
is a a
Figure
Figure30 shows
shows examples
examplesofofof
processing
processing
processingdefects.
defects.The
TheTheexample is aisacasehardened
example acasehardened
casehardened sucker
sucker
suckerrod
rod and
rod
andandthe
the other
the
other example
other
example
example
difference
iscoupling thatin
aiscoupling
a coupling the
has
that
that
hasmaterial
been
has
been
been hardness
processed
processed
processed has
through a resulted
throughgrinding
througha grindingin preferential
operation
a grinding to reduce
operation
operation corrosion
to to
reduce
reduce attack.
the diameter.
thethe In both
diameter.
diameter. examples,
In In
both
both a difference
examples,
examples,a a in
difference
differencein in
thethe
material
material
hardness
hardness has
has
resulted
resulted
in in
preferential
preferential
the material hardness has resulted in preferential corrosion attack. corrosion
corrosion attack.
attack.

Fig.
Fig.
30-
Fig. 30-
Processing
30- Processing
Defects
Processing Defects
Defects Fig.Fig.
3131
- Fig.
Mill
- Mill
and
31and
- Machining
Machining
Mill Defect
Defect Defect
and Machining
Fig. 30 - Processing defects Fig. 31 - Mill and machining defect

Figure
Figure3131shows
shows examples
examples of of
a mill
a mill
defect
defect
andanda machining
a machining defect.
defect.
The The
lower
lower example
example (31(31A) A)
is aisfailure
a failure
duedue
Figure 31 shows examples of a mill defect and a machining defect. The lower example (31 A) is a failure due
Figure
to to 31 internal,
a large, shows
a large, examples
internal,
nonmetallicof ainclusion
nonmetallic mill defect
inclusionin and
in
thethea machining
pin.pin.
TheThe defect.
fracture
fracture Theinternally
began
began lower example
internallyandand
the(31
the A) is a surface
fracture
fracture failure due
surfaceis is
to a large, internal, nonmetallic inclusion in the pin. The fracture began internally and the fracture surface is
brittle
brittle
or or
granular
granular in in
appearance.
appearance. A crack
A crack
initiation
initiationsite
site
maymayor or
maymaynot not
be be
visible
visible
andanda
to a large, internal, nonmetallic inclusion in the pin. The fracture began internally and the fracture surface is fatigue
a fatigueportion
portionmaymay
orbrittle
or
maymay or
not granular
not
be be
present inonappearance.
present on
thethe
fracture
fracture A crack
surfaces.
surfaces.initiation
TheTheupper site
upper may or
example may isnot abe visibledefect
and afrom
fatigue portion may
brittle or granular in appearance. A crack initiation site may orexample
may not (31(31
B) visible
be B) ais“ran-twice”
“ran-twice”
and a fatigue defect from
portion rolling
rolling
may
or
thethemay
pin pin not
threads betwice.
threads present
twice. onthe
Rolling
Rolling the
the fracture
threads
threads surfaces.
twice
twicehas has The upper
flattened
flattened thethe example
pin
pin (31 B)
thread-crest
thread-crest is
andanda “ran-twice”
will
will
notnot
bebe defect
capable
capable from rolling
of of
or may not be present on the fracture surfaces. The upper example (31 B) is a “ran-twice” defect from rolling
the pin
achieving
achieving threads
thethe
correcttwice.
correct Rolling
connect
connect the
preload
preload threads
required
required twice
forfor has
makeup. flattened
makeup. the pin thread-crest and will not be capable of
the pin threads twice. Rolling the threads twice has flattened the pin thread-crest and will not be capable of
achieving the correct connect preload required for makeup.
achieving the correct connect preload required for makeup.

21

2121
 CHAMPIONX ARTIFICIAL LIFT

The bottom line

Your initial investment in sucker rods is substantial. Moreover, the costs related to replacing damaged sucker rods
generally outweigh the original cost of the new rod string. Protecting your investment and getting the maximum service
life out of your sucker rods just makes good sense. It is important to diagnose rod failures accurately and to implement
corrective action measures to prevent future failure occurrences.

This photo essay is intended for use as a reference guide in sucker rod failure analysis. It explains how rod failures
occur and expounds methods for identifying the characteristics of the failure mechanisms. Where sucker rod failures
are concerned, there are no absolutes and no two failures look exactly alike in appearance.

But, by recognizing the visual clues and identifying characteristics of the different failures, corrective action measures
can be taken to prevent sucker rod failures, thus allowing the operator to produce marginally profitable wells more cost-
effectively.

Failure sample support

Please ship failure samples to the most applicable location listed below and contact the service
center in advance to advise that you will be shipping a sample for analysis.

CANADA USA
Alberta Oil Tool CALIFORNIA, ROCKIES, & BAKKEN REGIONS
6939-68 Ave. NW 200 Carver Street
Edmonton, AB T6B 3E3 Shafter, CA 93263
Canada Attn: Technical Services
Attn: Technical Services Telephone: +1 661-399-0628
Telephone: +1 780-434-8566
MID CONTINENT, SOUTH TEXAS & NORTHEAST
INTERNATIONAL REGIONS
4801 W. 49th Street 7902 West I-20
Tulsa, OK 74107 Midland, TX 79706
Attn: Technical Services Attn: Technical Services
Telephone: +1 918-445-7600 Telephone: +1 432-561-8107

22
 NORRIS RODS

Unsurpassed customer support

Our relationship with the oilfield operator does not end when our rod-lift products enter the wellbore.
In fact, that relationship will continue to grow over the product’s complete life-cycle, with our highly
trained Technical Service and Sales staffs just a phone call or email away should you require any
assistance, from system design to troubleshooting to completing a product’s delivery and installation.

6939-68 Ave. NW 4801 W. 49th St. 4801 W. 49th St.

Edmonton, AB T6B 3E3, Canada Tulsa, OK 74107 Tulsa, OK 74107
Phone: +1 780-436-8566 Phone: +1 918-445-7600 Phone: +1 918-445-7611
Fax: +1 780-436-4329 Fax: +1 918-445-7632 Fax: +1 918-445-7632
Email: AOT_Sales@championx.com Email: nor.sales@championx.com Email: UPC_Sales_PO@championx.com

23
Norris Rods The safety of our employees, customers, shareholders, and communities is vitally important. From the
way we operate, to the products we develop, to how we partner with customers, our goal is zero: zero
4801 W. 49th Street accidents, zero incidents, and zero environmental releases.
Tulsa, OK 74107
Telephone: +1 918-445-7600
Goal Zero is an ongoing initiative at ChampionX Artificial Lift designed to reinforce our safety culture,
championX.com based on the fundamental belief that all accidents are preventable.

This document is provided on an “as is” basis without warranties of any kind. ChampionX Artificial Lift DISCLAIMS ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, IMPLIED
WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR SUITABILITY FOR ANY PURPOSE, TITLE, AND NON-INFRINGEMENT. While reasonable care has been taken in the
preparation of this document, ChampionX Artificial Lift does not represent or warrant that the contents of this document are accurate, complete, reliable, current or error-free.

©2022 ChampionX Artificial Lift, All Rights Reserved. 03092022_NOR