Rod Testing Under Torsion, Tension & Bending

Paul Skoczylas, C-FER Ross Pliska, Alberta Oil Tool

Objective

Why are failures in the field different from lab test results?

In the coupling (lab tests fail in the rod body) At lower torque

Outline
Strength of rod body vs. connection in torsion/tension testing Field conditions vs. laboratory conditions Effect of make-up procedures Effect of bending Conclusions

Rod Test Procedure (Tension/Torsion)

1. Thoroughly clean pin and coupling 2. Apply lubricant as per manufacturers recommendation 3. Make-up connection hand-tight 4. Increase torque until make-up is reached (either torque or circumferential displacement criterion) 5. Drop to zero torque 6. Apply axial load (and keep constant for duration of test) 7. Increase torque at constant rate until failure For rod body test with no connection, start at step 6.

1 Rod Body, No Connection

7000 6000 5000 Torque (ftlb) 4000 3000 2000 1000 0 0 0.2 0.4 Turns 0.6 0.8 1

1 Modified Pins on 2 Rod

7000 6000 5000 Torque (ftlb) 4000 3000 2000 1000 0 0 0.2 0.4 Turns 0.6 0.8 1

Connection vs. Body

1 Rod body fails at ~2000 ftlb, yields at ~1000 ftlb 1 Modified pin with 1 slimhole coupling fails at 5500-7000 ftlb, yields at 2000-5000 ftlb Rod body should always fail first

Field vs. Laboratory Conditions

Lab:

Connections cleaned thoroughly prior to makeup Precisely-controlled make-up (either torque or circumferential displacement) Failures in rod body Connections may not be thoroughly cleaned Make-up is not usually precise Failures occur in connections and body

Field:

Why the Difference?

An investigation is ongoing Two factors considered so far:

Make-up procedures! Rods are often run in deviated wellsdoes this affect loading on couplings?

Make-Up Tests
Performed with 1.5 Grade 97 rods with 1.125 pins, and regular High Strength (HS) couplings Published torque rating is 3750 ftlb at 90,000 lb axial load All tests had 90,000 lb axial load applied after make-up

Test #1, 2

Thread lubricant applied to threads and torque shoulder (over-lubrication) Made-up by vendor using field practices Connection failures at 2910, 3108 ftlb (below torque rating)
3500 3000 2500 Torque (Nm) 2000 1500 1000 500 0 0 0.5 1 1.5 Turns 2 2.5 3 3.5

Test #1 Test #2

Tests #3, 7, 8

Connections made-up by vendor, with proper lubrication, using field practices Connection failure at 4830, 5496, 5296 ftlb (above torque rating)
6000 5000

4000 Torque (Nm) Test #3 Test #7 Test #8

3000

2000

1000

0 0 1 2 Turns 3 4 5

Tests #4, 6

Test #4

Made up and broken out by vendor Cleaned and properly lubricated by test lab Rod failure at 5899 ftlb Cleaned and properly lubricated by test lab Two make-breaks before test to failure Slight galling noticed on make-breaks Rod failure at 6178 ftlb

Test #6

Tests #4, 6
7000 6000 5000 Torque (Nm) 4000 3000 2000 1000 0 0 0.5 1 1.5 Turns 2 2.5 3

Test #4 Test #6

Tests #5, 11
Pins cleaned at test lab Coupling containing anti-corrosion lubricant (off the shelf) used without cleaning Connection failures at 2850 & 3000 ftlb

3500 3000 2500 Torque (Nm) 2000 1500 1000 500 0 0 0.5 1 1.5 Turns 2 2.5 3 3.5

Test #5 Test #11

Test #9, 10
Cleaned and properly lubricated by test lab In test #10, Moly-based lube was used Failure in rod at 5848 & 5901 ftlb

7000 6000 5000 Torque (Nm) 4000 3000 2000 1000 0 0 1 2 Turns 3 4 5

Test #9 Test #10

Summary of Make-up Tests

Cleaned by test lab:

5848, 5899 (M-B), 5901, 6178 (M-B) ftlb Rod body failures

Cleaned by vendor and made up with field practices:

4830, 5296, 5496 ftlb Connection failures 2910, 2850, 3000, 3108 ftlb Connection failures

Not cleaned and/or over-lubed:

Make-up

Properly clean BOTH pins AND coupling

Minimumwipe all faces and threads Best practiceuse degreaser

Apply only recommended amount of lubricant

Effect of Bending
A large portion of torque resistance is from friction on the torque shoulder In bending, contact force is increased on one side and decreased on other sidewill this affect the torque resistance? Tests were conducted with 1.25 Grade 75 Rods (torque rating 2100 ftlb at 50,000 lbs axial load) Test procedure was similarbending is applied after make-up, before axial load

Test Apparatus Capacity

2x10 rods (Std. tests are 2x2) 12,000 ftlb 300,000 lb axial >200/100ft bending in connection region, via specially designed bearings

Results

Maximum Torque

Straight:

3163, 3476, 3137 ftlb 3113, 3155, 3105 ftlb

10/100ft:

All failures in rod body

No significant difference in maximum torque

Results
4000 3500 3000 Straight 1 Torque (ftlb) 2500 2000 1500 1000 500 0 0 2 4 Turns 6 8 10 Straight 2 Straight 3 Bent 10/100ft 1 Bent 10/100ft 2 Bent 10/100ft 3

What Happens During/After Make-up?

2500

2000 Straight 1 Torque (ftlb) 1500 Straight 2 Straight 3 1000 Bent 10/100ft 1 Bent 10/100ft 2 Bent 10/100ft 3 500

0 0 0.1 0.2 0.3 Turns 0.4 0.5

What Happens During/After Make-up?

Incremental make-up occurs at a torque that is less than the make-up torque

Cause axial load unloads shoulder Straight: 1480, 1530, 1600 ftlb 10/100ft: 1285, 1350, 1480 ftlb

This occurs at:

There may be a small effect of bending from 0-10/100ft, but it is not statistically significant

Conclusions
Properly cleaned, lubricated, and installed, connections are stronger than the rod body! If connectionsboth pin and couplingare not properly cleaned and lubricated, low torque capacity results Bending does not reduce torque capacity