SUCKER RODS Reducing Rod String Failuresapergycdn.5thring.co.uk/NorrisRodsSuckerRods1.pdf ·...

SUCKER RODS

Reducing Rod String Failures

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Elevating the Potential of Artificial Lift Production.

Dover Artificial Lift, part of Dover Energy, offers a comprehensive line of artificial lift equipment, accessories and services strategically designed to drive the operational excellence of each of our clients. We provide industry-leading systems and components engineered to enhance the profitability of gas lift, plunger lift, rod lift, progressing cavity pump applications and surface production, as well as state-of-the-art software and products in the well automation, analysis, and optimization space.

As an organization dedicated to the needs of our clients, we place a consultative service and support approach at the forefront of our operations. Driven by a team of veteran artificial lift experts, our mission is to deeply understand the complex production challenges faced by well operators on a daily basis, and provide them the exact set of tools needed to meet them as efficiently and effectively as possible.

Strengthened by the vast global footprint and tradition of excellence of our parent company, the Dover Corporation, we are able to ensure that the products we provide – and more importantly – the people who make up our organization, are the best in the artificial lift industry.

DOVER ARTIFICIAL LIFT

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Lower Total Cost of Ownership. Increased Profit. Peace of Mind.

Since its inception, Norris has operated with one strong set of cohesive goals - to provide the rod lift industry the most durable, long-lasting and effective sucker rods available on the market.

Premature rod failure is primarily caused by two forces, operational stress and downhole corrosion. In a direct effort to alleviate these issues, Norris has adopted a number of industry-unique production methods, which result in rods that last longer and offer more corrosion resistance than any competitive product on the market. Combined with the fact that our rods are 100% manufactured from US domestic steel, we’re confident enough to offer our customers a “Norris Zero Defect Guarantee.” That’s how strongly we stand behind our

product and its ability to help enhance the operational profit of our customers. With an expansive global footprint that includes all of the world’s prime oil and gas producing regions, and a firm commitment to offering the industry’s most customer-focused service experience, Norris is proud to offer close, expert-driven support, no matter our customer’s location. From initial rod selection to the end of your well’s lifespan, you can feel confident knowing that Norris is behind you through every rod-related stage of your operation’s production.

INCREASED OPERATIONAL PROFITBy drastically reducing the need for rod replacement, well downtimes and maintenance, Norris rods are engineered with the customer’s bottom line in mind. Leveraging long-lasting rods increases production uptimes, while reducing the labor costs associated with well maintenance and rod replacement.

ENHANCED ROD LIFENorris’s unique NOR-PEENING® and quality processes greatly enhance rod strength, and corrosion tolerance resulting in a rod that lasts longer than any competitor alternative, greatly prolonging the time needed between rod replacement.

LOWEST TOTAL COST OF OWNERSHIPNorris rods offer the industry’s lowest total cost of ownership. Designed to significantly outlast any other rods on the market, Norris rods provide the greatest lifetime value available in the industry today.

NORRIS

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MANUFACTURING QUALITY

OUR COMMITMENT TO STRICT QUALITY ASSURANCE ALLOWS US TO OFFER:

The Norris Zero Defect Guarantee - Due to our strict quality and internal inspection standards, we’re proud to offer our customers complete peace of mind with a zero defect guarantee on each of the rods we sell. Should a 3rd party inspection service ever determine one of our rods is not in compliance with API 11B, we will completely cover all of the costs associated with its replacement.

CHALLENGES ADDRESSED:

Premature Rod Failure

Increased Downtimes

Thread guaging is one of various stages within our stringent inspection proces that ensures each and every rod is manufactured to exceed API requirements.

Our Manufacturing ProcessNorris rods offer the rod lift market the industry’s longest lasting and reliable rod solution. Through a combination of superior and carefully selected, domestic steel alloys, advanced manufacturing processes, and stringent quality control standards, we provide well operators a product engineered to ensure a maximum return on investment and enhanced operational efficiency.

No matter how advanced the process, rod manufacturing is a dynamic procedure with a number of variables. As a result, even the most advanced techniques can result in rods with discontinuities, sub-optimal fatigue life and corrosion resistance. This is why we inspect every rod we produce above and beyond API requirements, and at various points during the manufacturing process. From eddy current inspection of our unfinished bar stock, to a close, manual inspection of every rod before it’s shipped, we do our due diligence to ensure each of our customers only receive durable, long-lasting equipment.

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Premature Rod Failure

MANUFACTURING QUALITY

Norris’s value-adding NOR-PEENING® process ensures that our rod’s boast the artificial lift market’s best notch sensitivity, as well as its highest fatigue life, fatigue strength and corrosion tolerance. While several competitors may also claim to peen their rods, our unique approach achieves the highest shot intensity and rod coverage area in the industry.

NOR-PEENING® BENEFITS

Generating permanent, residual compressive stress - The impact of each piece of shot causes a permanent compression at the point of impact. This compressive stress remains in the rod until failure, lowering the amount of applied stress placed on it during use.

Eliminating surface defects - Peening the rod’s surface helps reduce the chance of cracks developing and helps eliminate surface defects. These types of imperfections are typically where corrosion begins, and their absence prevents it from occurring.

Avoid Corrosion Damage

During the NOR-PEENING® process, thousands of small steel spheres are carefully and precisely shot at the rod to cause a permanent compression at the sites of impact. This benefits the rod in various ways, all of which provide a significant and tangible effect on the durability of a rod.

Corrosion


Stretched Surface

Compression

Premature rod failure

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NOR-PEENING®

Bold claims are meaningless without the facts to back them up. That’s why we put our rods through rigorous, controlled 3rd party testing procedures to ensure our unique approach to manufacturing is leading to true results. The following two studies show exactly how much our processes are enhancing the life of our rods, and ultimately, the operational efficiency of our customer’s wells.

The University of Tulsa performed a study on life cycle rates of Norris Type 97 Pony Rods before and after the NOR-PEENING® process. The data showed a remarkable increase in expected product life span.

The Effects of NOR-PEENING®

NON-SHOT PEENED TEST RESULTS

Force Stress Amplitude

Number of Test

Average Life Cycles

90 lbs 89.64 ksi 2 27,515

80 lbs 83.12 ksi 2 50,782

70 lbs 76.60 ksi 3 114,787

60 lbs 70.08 ksi 5 170,005

50 lbs 63.56 ksi 6 139,482

NOR-PEENED TEST RESULTS

Force Stress Amplitude

Number of Test

Average Life Cycles

90 lbs 89.64 ksi 2 62,946

80 lbs 83.12 ksi 2 164,748

70 lbs 76.60 ksi 3 498,713

60 lbs 70.08 ksi 3 7,702,305

50 lbs 63.56 ksi 1 21,696,977 (no failure)

PERCENT INCREASE

Force

129%

224%

334%

4,431%

INFINITE

129%increase

High Stress Conditions 334%

increase

Moderate Stress Conditions Effective

InfiniteLifespan

Low Stress Conditions

Prevent Premature Rod Failure


Inadequate fatigue life

Frequent rod replacement

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NOR-PEENING®

As a direct result of our NOR-PEENING® and quality processes, our rods are engineered specifically to last longer than any other on the market. The following case study excerpts shows how the life of our rods stands up to the competition.

Norris Rod’s Enhanced Fatigue Life

Rod Performance Testing - Millions of Cycles to Failure Gray area represents competitor average.

0

400

800

1200

1600

2000

Norris 96Norris 97 MFG ASpecial

1

MFG ASpecial

2

MFG ASpecial

3

MFG ASpecial

4

MFG BSpecial

MFG CSpecial

Cyc

les

to F

aiur

e (0

00s)

66% life span increase over next closet manufacturer

75% life span increase over next closet manufacturer

High Strength Rod Fatigue Performance

0

1000

2000

3000

4000

5000

Norris 78 MFG AAPI D 1

MFG AAPI D 2

MFG AAPI D 3

MFG BAPI D 1

MFG BAPI D 2

MFG BAPI D 3

MFG CAPI D

Cyc

les

to F

ailu

re (0

00s) 350% life span increase over next closet manufacturer

API Grade D Rod Fatigue Performance

Rod Performance Testing - Millions of Cycles to Failure. Gray area represents competitor average.

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TECHNICAL SERVICES

Our full “cradle-to-grave” technical service approach helps ensure that our customers are getting the greatest return on investment from our rods. From the time you make first contact with our staff, to after your rod has reached the end of its life, we make our team of experts accessible to you at every step along the way. With full life cycle support from pre-purchase well optimization consultation to rod failure tracking and analysis, our mission is to directly help your operation reach its long-term goals.

In addition to our Theta-driven rod string design services, we also offer comprehensive well optimization training programs led by our team of veteran artificial lift experts. These courses are designed to help your personnel better understand the unique characteristics of their wells, and how to approach them in order to achieve maximum operational efficiency. From proper in-field procedures to diagnostic analysis and automation methods, these training programs covers the entire scope of well optimization techniques.

Assisted by Theta, and its RODSTAR software, we use the industry’s most advanced rod string design tools to provide clients with custom rod suggestions and pump configuration schematics.

Supplied with only a few key well data points and a list of the pumping equipment you currently have access to, we can determine which of our rods is ideal for your unique application. This helps your operation achieve optimal production, as well as minimize pump and rod maintenance costs.

Well Optimization Services

Failure Tracking and Analysis

Our failure tracking and analysis program offers our customers a method to ensure continuous improvement of their operation’s production. By first identifying the exact cause of your rod string failure, our experts are then able to provide recommendations that address and alleviate the current challenges posed by your well.

RODSTAR offers both vertical and horizontal well operators a simple-to-use tool to design optimized pump and rod configurations, and accurately predict future pump production performance. Pictured: RODSTAR output illustrating a 3D plot of a deviated well.

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TRAINING SERVICES

In order to ensure that you’re reaching your production goals efficiently, we offer a number of training services – both on and off site – to ensure that your personnel are equipped with the knowledge they need to help your operation succeed. Led solely by our staff comprised of the industry’s foremost artificial lift experts, we’ll teach your team how to get the most of your equipment throughout its entire life span. Our training programs cover everything from proper rod installation and maintenance procedures to ideal storage conditions and reconditioning techniques.

Our Operator Training Services

Operator Training Topics

Reduce well safety risks Help prevent environmentally damaging spills

Lower maintenance time and costs Enhance production and operational efficiency

ROD STRING DESIGNWithout understanding and catering to proper rod string design parameters, your operation risks increased maintenance costs and a loss in production up-times.

ROD SELECTION CRITERIAIdentifying the ideal rod that directly addresses your well-specific challenges and production goals is often one the most difficult aspects of rod-driven production.

PROPER STORAGE & TRANSPORTATION

Damage during the transportation or warehousing of a rod can cause operational inefficiencies before the equipment is ever put into use.

CORRECT MAKEUP METHOD

Ensures your field personnel and contract rig crews understand exactly how to build a rod string without stripping threads or causing damage to equipment.

RUNNING RODS DOWNHOLE

Optimal production starts with proper rod installation. This part of our technician training course is designed to help your production process start correctly.

FAILURE ANALYSISBeing able to identify and analyze the specific reasons for rod failures is integral in your operation’s ability to continuously improve its performance.

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1. Tensile strength and yield strength values are the only steel sucker rod and pony rod physical requirements in API Specification 11B. All other physical properties are expected values only and may deviate from the listed values shown above.

Type 30 40 54 75 78 90 96 97

AISI Series C-1536-M A-4621-M C-1541-VM A-4330-M A-4142-M A-4320-M A-4138-M A-4330-M

API Grade C K D Carbon D Special D Alloy D Special - -

Chemical Properties % 30 40 54 75 78 90 96 97

Aluminum (AI) 0.35 Max. 0.35 Max. 0.35 Max. 0.35 Max. 0.35 Max. 0.35 Max. 0.35 Max. 0.35 Max.

Carbon (C) 0.3/0.39 0.18/0.25 0.36/0.45 0.3/0.34 0.38/0.45 0.18/0.24 0.36/0.45 0.28/0.35

Chromium (Cr) 0.3 Max. 0.25 Max. 0.3 Max. 0.8/1.0 0.8/1.1 0.7/0.9 0.52/0.88 0.7/1.0

Copper (Cu) 0.35 Max. 0.35 Max. 0.35 Max. 0.35 Max. 0.35 Max. 0.35 Max. 0.35 Max. 0.35 Max.

Manganese (Mn) 1.1/1.4 0.6/0.8 1.35/1.65 0.8/1.0 0.8/1.0 0.8/1.0 0.88/1.52 0.7/1.0

Molybdenum (Mo) 0.06 Max. 0.15/0.25 0.06 Max. 0.2/0.3 0.15/0.25 0.2/0.3 0.25/0.35 0.2/0.3

Nickel (Ni) 0.35 Max. 1.65/2.0 0.35 Max. 1.65/2.0 0.45 Max. 1.15/1.5 0.3 Max. 1.65/2.0

Niobium (Columbium) (Nb) - - - - - - 0.02/0.045 -

Phosphorus (P) 0.04 Max. 0.035 Max. 0.04 Max. 0.035 Max. 0.035 Max. 0.025 Max. 0.035 Max. 0.035 Max.

Silicon (Si) 0.15/0.35 0.15/0.35 0.15/0.35 0.15/0.35 0.15/0.35 0.15/0.35 0.2/0.35 0.15/0.35

Sulfur (S) 0.045 Max. 0.035 Max. 0.04 Max. 0.04 Max. 0.035 Max. 0.025 Max. 0.04 Max. 0.04 Max.

Vanadium (V) 0.02/0.07 0.02/0.07 0.04/0.09 0.04/0.09 0.02/0.07 0.04/0.09 0.04/0.09 0.04/0.09

Physical Properties1As Normalized & Tempered

30 40 54 75 78 90 96 97

Tensile Strength

ksi 90/115 90/115 115/140 125/140 120/140 120/140 140/150 140/150

Mpa 621/793 621/793 793/965 861/965 827/965 827/965 965/1 034 965/1 034

Yield, 2% Offset

ksi 60 Min. 60 Min. 85 Min. 100 Min. 95 Min. 95 Min. 115 Min. 115 Min.

Mpa 414 Min. 414 Min. 586 Min. 689 Min. 655 Min. 655 Min. 793 Min. 793 Min.

Elongation, 8” 15 Min. 16 Min. 15 Min. 10 Min. 10 Min. 10 Min. 10 Min. 10 Min.

Reduction, % 45 Min. 55 Min. 50 Min. 45 Min. 45 Min. 45 Min. 45 Min. 45 Min.

SUCKER ROD SPECIFICATIONS

NOTE: The selection guide is not intended as design criteria. Call Norris for specific rod string design recommendations.

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ROD SELECTION GUIDE

Type 30 Steel Series

API Grade

CAISI C-1536-M

Carbon

For Shallow-to-Medium Depth Wells

Not suited for Progressing Cavity Pump (PCP) applications


API Grade

KAISI A-4621-M

Nickel-Chromium-Molybdenum Alloy Steel

For Shallow-to-Medium Depth Wells

Suited for some Progressing Cavity Pump (PCP) applications


API Grade

Carbon

DAISI C-1541-M Carbon Steel

For any depth not exceeding the maximum allowable stress rating



AISI A-4330-M Nickel-Chromium-Molybdenum Alloy Steel


Suited for Progressing Cavity Pump (PCP) applications

API Grade

Special

D


API Grade

Alloy

DAISI A-4142-M

Chromium-Molybdenum Alloy Steel


Suited for Progressing Cavity Pump (PCP) applications





API Grade

Special

D


SpecialService

High Strength

AISI A-4138-M Chromium-Molybdenum Alloy Steel







SpecialService

High Strength

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