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This paper was prepared for presentation at the SPE Annual Technical Conference and Exhibition held in Amsterdam, The Netherlands, 2729 October 2014.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
A properly designed sucker-rod string should provide failure-free pumping operations for an extended
period. Improper design of rod tapers can lead to early mechanical failures (rod breaks) with a complete
termination of pumping action and an inevitable loss of production. Because of its prime importance in
sucker-rod pumping technology several rod string design procedures based on different assumptions were
developed in the past. Since most sucker rod breaks are fatigue failures the mechanical design of
sucker-rod string must consider the cyclic nature of rod loading and the appropriate fatigue endurance
limit of the rod material. This is why most string designs utilize the modified Goodman diagram for
calculating the lengths of rod tapers.
Available sucker-rod string design models calculate rod taper lengths that ensure proper operation
without premature fatigue failures. Their common design problems are (a) defining the principle of taper
length determination, and (b) calculating the true mechanical stresses along the string. The universally
accepted principle of taper length calculations is to provide the same level of safety against fatigue failures
in each taper section. Mechanical loads and stresses, on the other hand, are usually found in most of the
design procedures from very approximate formulas. These loads, therefore, can greatly deviate from the
true mechanical loads that would be measured in the rod string run in the well. The paper details the main
features of available rod string designs and discusses their main characteristics; it provides a thorough
comparison of designs involving the calculation of loads and stresses predicted from the solution of the
damped wave equation. Using a predictive analysis program rod stresses are calculated that, plotted on the
modified Goodman diagram, provide a proper comparison of the merits of the different rod string design
methods.
Rod strings designed by available design procedures usually do not have identical safety included in
the different tapers. This is due to the improper calculation of rod string loads that form the basis of
calculating rod taper percentages. Based on the evaluation of the different available rod string designs the
paper introduces a novel procedure that estimates rod loads from the predictive solution of the damped
wave equation during the design process. Since loads calculated that way simulate actual loads very
accurately, the most important limitation of previous rod string design procedures is eliminated. Strings
designed using the proposed model, therefore, will have identical safeties against fatigue failures in each
taper; the new design model provides the ultimate safety over previous designs.
2 SPE-170588-MS
Introduction
The sucker-rod string is a very peculiar piece of man-made structures because its maximum diameter
(about one inch) is absolutely negligible as compared to its length of several thousand feet making it an
absolute slender bar. The weight of the string is distributed along its length and any section has to carry
at least the weight of all the rods below it. This fact suggests that the ideal shape would be an inverted
cone, continuously tapering from top to bottom. Since such a rod string is impossible to manufacture one
tries to approach the ideal shape by designing tapered strings with sections of increasing diameters toward
the surface. For shallow wells, straight rod strings made up from one rod size only are also used but deeper
wells inevitably require the application of tapered strings.
The mechanical design of tapered rod strings is highly complicated because of the type of loading the
rods are subjected to. Investigation of the possible loads that occur during the pumping cycle shows that
the following distributed and concentrated loads act on the rod string:
Weight of rods in air; it is a distributed load along the string.
Buoyancy forces oppose the rod weight and are the result of the immersion of the rods into the
produced liquid.
Fluid load on the plunger of the downhole pump is a concentrated force acting during the upstroke
only.
Dynamic loads are the results of changes in acceleration of the moving masses (rods, fluid
column).
Frictional forces are: (1) fluid friction between the rods and the produced liquid, and (2)
mechanical friction between the rods and the tubing string.
After considering the variation of these forces during a complete pumping cycle, one can easily
conclude that the rod string is exposed to a cyclic mechanical loading. During the downstroke, the string
carries the buoyant weight of the rods minus dynamic and friction forces only, while on the upstroke it
also carries the load of the fluid lifted. Mechanical stresses follow the variation of rod loads and are cyclic,
too; they are typically tension stresses with the tension level considerably increasing during the upstroke
as compared to the downstroke; the loading of the rod string can be classified as pulsating tension.
The typical failure mechanism of sucker-rod strings is the consequence of the type of loading and is
mostly fatigue failure. Fatigue failures occur at much lower levels of mechanical stresses than the tensile
strength or even the yield point of the material and are caused by the extremely high number of repetitions
of the variable loads. This type of failure is absolutely different from tensile (overpull) failures and is the
root cause of the great majority of rod string breaks. Therefore, rod string design procedures must
inevitably take into account the cyclic nature of rod loading; this is why, in order to ensure a sufficiently
long service life, the string has to be designed for fatigue endurance.
The constants A and B featuring in the Goodman Table 1Material parameters used in the Goodman formula.
Bethlehem 1953 - Fluid load plus rod weight in air - Equal max. stresses
West 1973 Rod weight in air Fluid load plus rod weight in air Mills acceleration factor SF const.
plus dynamic loads
Neely 1976 Buoyant rod Weight Fluid load plus buoyant rod weight Special formula Equal modified stresses
plus dynamic loads
Gault-Takacs 1990 Buoyant rod Weight Fluid load plus buoyant rod weight From RP 11L SF const.
plus dynamic loads
Setting the modified stresses equal in each taper means that Smin - Smax points belonging to the
different tapers, when plotted on the modified Goodman diagram (MGD), will lie on a parallel to the SF
1 line. This line, however, inevitably crosses the lines corresponding to any service factor other than
unity. Therefore, the design generates different safety factors for each taper; upper tapers are relatively
more loaded than lower ones. This situation is just the opposite of early design methods where the lower
tapers were under-designed.
Sample designs
In order to evaluate the available rod string design models an example case of a three-taper rod string is
presented. Well parameters are given here; calculated taper lengths found from each design model are
given in Table 3.
SPE-170588-MS 5
Design Fundamentals
The solution of the problem i.e. finding a taper combination with identical service factors is surely an
iterative process. To reach the final rod string design one has to calculate rod loads and stresses in many
SPE-170588-MS 7
This formula represents the relationship between the length of the taper, l, and the service factor, SFi,
which can be calculated from the maximum and minimum stresses along the taper. It will be used in the
design procedure to investigate the effect of changing the length of the taper for a fixed service factor. For
that reason, lets solve Eq. 6 for the taper length, denoted Li:
7
This equation forms the cornerstone of the rod string design procedure developed in this paper because
it allows one to calculate the required length Li of any taper based on the required or assumed service
factor (SF) value. As will be shown later, taper lengths during the iteration process will be changed
according to this formula, while considering the actual values of the variables involved.
8 SPE-170588-MS
Calculation procedure
Although the developed design can handle any
number of tapers, calculation steps are detailed for
the case of a three-taper rod string in the following.
The description of the design procedure is accom-
plished with reference to Fig. 4.
At the initial conditions (iteration number J 0)
the total rod string length is divided into three equal
parts and the following taper lengths are calculated:
8
10
11
Using the modified taper lengths, the wave equation is solved again and the distribution of minimum
and maximum loads in taper two is utilized to find the parameters of the best-fitting lines, a2 . . . d2.
The second iteration step (J 2) starts with the adjustment of the length of the second taper and
keeping the length of the first taper. The third taper length is adjusted also and the relevant formulas are:
12
13
14
SPE-170588-MS 9
in ft - ft - ft -
Sample design
The developed rod string design procedure was applied to the example problem presented previously
assuming a C-456D-256-120 pumping unit and three different rod materials. Calculated taper lengths
along with the service factors valid in tapers are presented in Table 4. As shown, Grade D rods are quite
heavily loaded since the average value of the service factors is SFavg 0.843. Use of stronger materials
(high-strength rods and rods with Tenaris premium connections) resulted in much lightly loaded strings
with average service factors of SFavg 0.534 and SFavg 0.494, respectively.
The merits of the string design procedure introduced in this paper are easily seen in Fig. 5, where
minimum and maximum rod stresses in the tapers are plotted in a dimensionless form of the modified
Goodman diagram. For every kind of material used the three points belonging to the three tapers fall on
lines representing the average service factors in the string. This proves that all tapers have the same service
factor, consequently the same safety included in their design. In comparison to other designs available
today, rod loads during the whole design procedure were found from the solution of the wave equation.
Since the wave equation predicts rod loads with the highest possible accuracy the design developed in this
paper can be considered as the ultimate tool for designing sucker rod strings.
10 SPE-170588-MS
Conclusions
Based on the detailed evaluation of the available procedures for rod string design and the development of
a new design model the following conclusions were drawn:
Available rod string design procedures estimate rod loads from approximate formulas which result
in loads that are not a true measure of the actual conditions. Since estimated loads are used in the
design procedures, calculated strings do not meet the basic requirement of reaching identical safety
in each taper.
The ultimate rod string design model presented here calculates rod loads from the solution of the
one-dimensional wave equation and, therefore, results in strings with a much enhanced safety
against fatigue failures as compared to previous designs.
Nomenclature
ai . . . di parameters of the best-fitting lines in Eqs. 3 and 4
l taper length, ft
Ai metal area of the rod in the ith taper, sq in
A, B empirical constants specific for the rod material, -
Fmin i minimum load in the ith taper, lbs
Fmax i maximum load in the ith taper, lbs
Li,j length of the ith taper in the jth iteration, ft
Ltotal total required length of the string, ft
Sa fatigue endurance limit (allowable stress), psi
Smax maximum rod stress, psi
Smin minimum rod stress, psi
Smod modified stress, psi
SF service factor, -
T minimum tensile strength of the rod material, psi
Acknowledgement
The authors used data from their previous publications at the 60th and 61st Annual Southwestern
Petroleum Short Course when preparing this paper; permission from SWPSC is gratefully acknowledged.
References
1. Recommended Practice for Care and Handling of Sucker Rods. API RP 11BR, 9th Ed.,
American Petroleum Institute, Dallas, Texas 2008.
2. Sucker Rod Handbook. Bethlehem Steel Company, Bethlehem, Pennsylvania 1953.
3. Design Calculations for Sucker-Rod Pumping Systems (Conventional Units). API TL 11L 5th
Ed. American Petroleum Institute, Washington, D.C., 2008.
4. Eickmeier, J. R.: Diagnostic Analysis of Dynamometer Cards. JPT January 1967, 97106.
5. West, P. A.: Improved Method of Sucker Rod String Design. Proc. 20th Southwestern
Petroleum Short Course, 1973, 15763.
6. West, P. A.: Improving Sucker Rod String Design. PE July 1973, 68 77.
7. Neely, A.B.: Sucker Rod String Design. PE March 1976, 58 66.
8. Gault, R. H.: Rod Stresses from RP 11L Calculations. Proc. 37th Southwestern Petroleum Short
Course, 1990 292301.
9. Takacs, G.: MODERN SUCKER-ROD PUMPING. PennWell Books, Tulsa, Oklahoma, 1993.
SPE-170588-MS 11
10. Gault, R. H. - Takacs, G.: Improved Rod String Taper Design. Paper SPE 20676 presented at
the 65th Annual Technical Conference and Exhibition of the SPE in New Orleans, Louisiana.
September 23-26, 1990.
11. Gibbs, S. G.: Method of Determining Sucker Rod Pump Performance. US Patent 3,343,409
(1967).
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Rods. SPE PF February 1995, 4145.
13. Takacs, G. Gajda, M.: Critical Evaluation of Sucker Rod String Design Procedures. Proc.
60th Annual Southwestern Petroleum Short Course, 2013, 213222.