Development and Field Experience of a New Concept in Sucker Rods Technology

Abstract

Abstract The Cerro Drag?n oilfield, operated by Pan American Energy, has producing oil wells that use rod pumping systems with average depths of 2,440 m (8,000 ft) and fluid rates as high as 200 m3/d (1,300 bfpd). In this oilfield, the pulling operations exhibited a high incidence of pin breaks, generally located in the 22.23 mm (7/8 in) OD taper that we concluded to be the weakest part of the entire string, as we will show. In order to solve this problem, a new sucker rods design was developed by creating a new non- API 22.23 mm (7/8 in) sucker rod with ends of 25.4 mm (1 in) in order to reinforce the string. This technical work describes the development of this technology, as well as the experience in the field, with excellent results p to the present. Introduction erro Drag?n is an oilfield located in the Golfo San Jorge Basin (see Figure 1). This field has 1,800 oil producing wells, with 1,642 wells lifted by rod pumping systems. Average pump depths are 2,440 m (8,000 ft) with oil producing rates as high as 200 m3/d (1,300 bfpd). In 1988, a secondary recovery project was started. The water injection rate was raised (Figure 2), resulting in higher production rates and consequently higher loads to all of the components (rods, pumping units, etc.) of the lift system. Associated with this increase in the production rates, an increase in failure rates was observed. It was determined that the main cause of this failure rates increase was connection failures; in particular, the 22.23 mm (7/8 in) pin failures. Approximately 18% of the failures were caused by 22.23 mm (7/8 in) pin breaks. As a result, a team was established between the rod supplier and the operating company to work together to improve the fatigue resistance of the 22.23 mm (7/8 in) connection. The result of this teamwork was a new non-API sucker rod with a 22.23 mm (7/8 in) diameter and a threaded connection of 25.4 mm (1 in). Currently, there are 60 rod strings installed, the oldest ones with an operating service life of about four years, and there has been just one failure (the oldest one failed after 1,499 days in service). The installation of the improved sucker rods in 160 wells (thosewith the higher failure rates) will result in savings of almost US$2 MM/year. This paper describes the development of the rods, as well as the experience in the field. Failures History Due to the increase in the IPA (index of interventions per well per year) for wells lifted by rod pumping (Figure 3), work was conducted to understand the different causes of the failures. The first conclusion was that the sucker rod failures were growing at a constant rate, corresponding to the increment in the production rates.