PCPRod Hollow Rods for Progressive Cavity Pumping
Tenaris Tenaris is the leading global manufacturer and supplier of tubular products and services used in the drilling, completion and production of and gas and a leading supplier of tubular products and services used in process and power plants and in specialized industrial and automotive applications. Through our integrated global network of manufacturing, R&D and service facilities, we work with our customers to meet their needs for the timely supply of high performance products in increasingly complex operating environments. Aberdeen Nisku Prudential AlgomaTubes Dartmouth Coseley Dalmine Silcotub Almaty Bakersfield Hickman Conroe Louisville Counce Cedar Springs Westwego NKKTubes Poza Rica Guadalajara Mexico City Tamsa Dos Bocas Dammam Maharashtra TuboCaribe Barrancabermeja Puerto La Cruz Tavsa Lagos Warri Kuala Lumpur Batam SPIJ Lima Darwin Confab Rio das Ostras Broome Dampier Santiago Villa Mercedes Siderca Siat Perth Manufacturing Centers R&D Centers Sucker Rods Production Centers Service Centers Commercial Offices 2 Tenaris
Products and Services Tenaris is the only company in the world that produces sucker rods in a fully integrated way. In its plants in Argentina and Brazil, Tenaris develops special products for all kinds of needs. From the production of steel as raw material to the production of the sucker rods, the entire process takes place in Tenaris plants. Within these plants, Tenaris produces the entire line of API sucker rods, progressive cavity pumping (PCPRod ) rods and its range of premium connection products. They efficiently respond to extreme conditions such as high loads, corrosive environments and applications where tubing-rod friction control is required. The solutions offered cover from application engineering designs and failure analysis to handling procedures and installation in wells. Moreover, Tenaris also has the technical support provided by a group of specialists in technology, research and development from its Industrial Research Centers, located in its plants in Argentina, Japan, Italy, Mexico and the United States. With our permanent commitment to add value through our services, we provide our customers with: integral material packages delivered just-in-time, stock management of new and used materials, delivery and inspection at well; and the recovery of used material by means of a wide network in strategic places around the world. Products are manufactured according to API 11B Standards in Villa Mercedes facilities, San Luis, Argentina and in Moreira César Industrial Park, Brazil. The quality system bears ISO 9001:2000 and API Q1 certifications. API products are monogrammed under 11B-0020 and 11B-0067 licenses in the plants. Together with the products, associated services are offered through a team of professionals who provide specialized technical assistance during field operations as well as other related services. Some of these services are: mechanical pumping and progressive cavity pumping rod strings designs; failure analysis at laboratory, intervention integral analysis and field diagnoses; optimization of the level of field interventions and development of special products. PCPRod 1000, PCPRod 1500 y PCPRod 2500. PCPRod 3
PCPRod Hollow Rods for Progressive Cavity Pumping. In Progressive Cavity Pumping or PCP system, a rotating screw type pump is used and the rotation movement is transmitted from the surface to the pump through a sucker rod string. Standard sucker rods are manufactured under API 11B specifications, defined to work under axial loads only. This specification states that these rods should be used in other artificial lift systems, such as alternative mechanical pumping or beam pumping. Eventually, the use of these rods was implemented as standard for PCP systems drive, but the technological progress and advance in pumps produced an increase of depths and flow rates possibly reached, which submitted the rods to more requirements. These growing operating demands produced an increase of premature failures of the rods, which generated higher operating costs for the system and restrained their application field. For a long time, the industry had been waiting for a product especially designed to resist high-torsion loads. The Industrial Research Center of Tenaris developed the PCPRod hollow pumping rod, a technological breakthrough that not only increases the reliability of PCP, but also reduces operating costs. One of the alternatives that the hollow rod presents is the ability to inject a diluent into the rod for heavy and extra heavy crude pumping. This improves injection efficiency and it greatly reduces the complexity of the facilities thanks to the elimination of injection pipes and capillaries. Innovation In the creation of the PCPRod, our center based its development in customer s and PCP systems user s previous experience, in pump manufacturers and in the most common failures of conventional rods. The development was also supported by external consultants of renowned reputation in PCP systems. All this information was combined to satisfy a series of previous requirements in the design process and to develop an estimation model that would permit the definition of the requirements of the joint in different working conditions. This is how the creation of the PCPRod was achieved, the most complete solution for progressive cavity pumping. Progressive cavity pumping Drivehead.
PCPRod 1000 internal flush joints. Comparative Advantages of PCPRod Eliminates premature failures due to rod pin breakage caused by over torque during the well operation. Allows the operation of high flow rate pumps (over 100 m3/d 600 bpd) reliably at high depths (over 1,200 m/ 3,600 ft). Reduces friction between rods and tubing due to the design of its flush joint. The localized friction in connections and tubing of the conventional sucker rods produces important increases in operating costs due to failures in production pipes. This does not occur with PCPRod, since the sudden change of geometry in the rod joints is eliminated and this allows a better friction loads distribution. The use of these hollow rods reduces the initial installation costs by 30-50%, necessary to pump identical flow rates in mechanical or electro-submergible pumping systems (ESP). Reduces the installation and operating costs for the injection of diluents in the production of heavy and extra heavy crude. Increases the effectiveness of corrosion inhibition. Reduces handling problems: the PCPRod does not require any special tools for its installation and they can be rapidly installed: a 1,000 meters string requires approximately from 3 to 5 hours. Accessories Tenaris offers a complete line: Pup joints to adjust string length. Combination crossover between API conventional thread and PCPRod thread. Polished and chromium-plated hollow rods. Joints for diluent injection. Slotted PCPRod (flow diverter nipple) that allows fluid injection into the tubing. Safety-check valves. Technical Service Tenaris provides total support through its Technical Assistance Service, which, among other things, will help you choose the best string configuration and design according to your well conditions. Additionally, technical assistance is provided for the well completion. If further information is needed to verify availability of new applications or to request a complete version of Handling Practices and Recommended Torque Guide, please contact Sucker Rods Technical Assistance Department specified in the website: www.tenaris.com Reduces backspin effect; this makes the re-dimensioning of the surface head easy. For instance, a 1,000 m string of 1 1/8 sucker rods accumulates 41 turns of elastic deformation. The column acts as a spring and when the pump stops, it turns in reverse until it releases such energy. On the other hand, a PCPRod 1000 string accumulates only 8 turns of elastic deformation due to its higher torsional stiffness. This also means a more effective and constant torque transmission. PCPRod 5
PCPRod Main Features This special product was developed to work under rotating loads in PCP and to withstand fatigue through infinite life. This product includes a pipe with box-box ends and a nipple connector that allows an external flush joint (with no variation of the diameter in the joint area), which minimizes turbulence and loss of localized loads. The flush connection significantly reduces friction between the tubing and the rod string and therefore produces savings as a result of the reduction of failures and the decrease in tubing and rod consumption. The range of products with PCPRod thread includes three models of connections to work with torques up to 1,000; 1,500 and 2,500 lb.ft depending on the model. Other Characteristics External and near flush joint. Higher reliability for PCP systems. PCPRod tapered thread with 8 hpp trapezoidal-like tooth and differentiated tapering between pin and box. Joint with torque shoulder. Diluents, corrosion inhibitors or other fluids can be added through a hollow joint. Temperature and pressure sensors can be lowered down the string. Manufactured from a hot rolled seamless pipe, using hard alloy steel with a maximum tensile strength of 140,000 psi. Handling and Installation For handling and transportation of PCPRod hollow sucker rods, the same specifications for conventional sucker rods must be followed. Installation at well site is simple, as no special accessories are needed, such as stabbing guides. Running 1,000 meters of PCPRod takes between three and five hours. Elevators Conventional sucker rods elevators are used with a 1 x 2 feet pony rod and a crossover to adjust the PCPRod end when elevating. Power Tong The use of standard hydraulic pipe tongs with adapted clamps for an outer diameter of 1.66 or 1.9 is recommended. The installation torque for each pipe diameter is indicated in the Adjustment Torque Table for Hollow Rods. No special tools are required. For better performance, an electronic torque control device is suggested. Hanging Slips Pneumatic slips are used for conventional pipes adapted to outer diameters of 1.66 or 1.9. ADJUSTMENT TORQUE FOR HOLLOW RODS TABLE PRODUCT Min. torque ft.lb Optimum torque ft.lb Max. torque ft.lb PCPRod 1000 900 950 1000 PCPRod 1500 1400 1450 1500 PCPRod 2500 2400 2450 2500 TECHNICAL SPECIFICATIONS PRODUCT PIPE OUTER Ø Pipe thickness Upset outer Ø Max. working torque * Metric weight without nipple Metric weight with nipple Length range Joint min. int. Ø PCPRod 1000 48,8 mm 6,7 mm No upset 1.000 ft.lb 6,95 kg/m 7,1 kg/m 9,35 to 9,75 m 20 mm PCPRod 1500 42,2 mm 5,0 mm 50 mm 1.500 ft.lb 4,6 Kg/m 4,7 kg/m 8,53 to 9,20 m 17 mm PCPRod 2500 48,8 mm 6,7 mm 60 mm 2.500 ft.lb 6,95 Kg/m 7,2 kg/m 9,35 to 9,65 m 20 mm *Tenaris recommends using a 0.9 safety factor to maximize resistance to fatigue. 6 Tenaris
Well Installation with PCPRod Well configurations Rotating joint / Swivel swivel (for fluid injection) Nipple connection for hollow polished PCPRod use Well with injection Injected fluid PCPRod with box-box ends Wellhead for PCPRod Hollow polished rod Flow line Torque shoulder Hollow nipple connector with pin-pin ends External flush joint PCPRod hollow polished rod (for fluid injection) Well with Internal PCPRod Oil Production PCPRod pup joint (for adjusting well depth) PCPRod with box-box ends PCPRod Hollow Rods Torque shoulder Hollow nipple connector with pin-pin ends Near flush joint PCPRod slotted pup joint (for diluent injection) Crossover connection to pump (API thread combination with PCPRod thread) Standard well Tag bar PCPRod with box-box ends Torque shoulder Hollow nipple connector with pin-pin ends Near flush joint PCPRod 7
www.tenaris.com SUCKER RODS Argentina Alejandro De la Serna (011) 4018 2582 tel (011) 4018 9280 fax adelaserna@tenaris.com Brazil Robson Silva 55 (12) 3644 9614 tel 55 (12) 3644 9027 fax rosilva@confab.com.br Canada Juan Pablo Martín (1) 403 2670347 tel (1) 403 2670351 fax jpmartin@tenaris.com Colombia Ramiro Esquiroz (57) 1 321 1010 ext 4431 tel (57) 1 321 1103 fax resquiroz@tenaris.com Mexico Eduardo I. Martínez Albarrán (54) 229 989 4431 tel (54) 229 989 1119 fax ealbarran@tamsa.com.mx United States Fernando Labaronne (1) 713 585 3089 tel (1) 713 767 4444 fax flabaronne@tenaris.com Venezuela José Jaime García (58) 212 600 3999 tel (58) 212 600 3691 fax jgarcia@tenaris.com Other countries Ezequiel Fernández (54) 3489 5353 tel (54) 3489 5366 fax efernandez@tenaris.com Version 06 / May 2009 Tenaris Marketing Communications Tenaris and its member companies have produced this catalogue for general information only. Tenaris does not assume any responsibility or liability for any loss, damage, injury resulting from the use of information and data herein. Warranties, indemnities and any other obligations will result only from the respective contracts of license or sale, as the case may be. Please contact a Tenaris representative for more complete information, and for information on other Tenaris products not shown here which are also available upon request. Tenaris 2009. All rights reserved.