Protecting your investments ––

The care and handling of Norris Sucker Rods

A four part series reprinted from the
Well Servicing magazine
Protecting your investment in
sucker rods
Part 1:
Storage and
transportation
By RUSSELL STEVENS &
SCOTT MALONE
Norris
T
he rod string is a vital link between surface
equipment and subsurface equipment in a
rod pumped well. Without this link the well
will not produce liquid. The investment in a rod
string may be significant, but failure to adequately
protect this vital link can generate substantial
expenses that far exceed the initial investment
(i.e., rig time, equipment replacement cost, lost
production, and the like). However, a rod string that
is properly designed (based upon experience),
physically handled and made-up in accordance with
the recommendations of the manufacturer, operated
within acceptable design parameters and maintained
with an effective downhole corrosion control
program should give a long, satisfactory, and
economical service life. Adhering to these
parameters makes both the initial investment and the
operating expense for a rod pumped well extremely
cost-effective as a method for artificial lift.
In order to maximize the value of your investment,
Well Servicing will publish a four-part series identifying
possible causes of failure and suggested remedies to
extend the usable service life of the rod string.
Storage and transportation
In most cases, the rod string is comprised of the
polished rod clamp, polished rod, polished rod
coupling, pony rods, rod guides, sucker rods,
stabilizer bars, sinker bars, sucker rod couplings and
subcouplings. Physically storing and transporting
these components in accordance with the
recommendations outlined below, and/or those
contained in API Recommended Practices 11BR, will
help prevent premature failures that occur due to
improper storage and transportation procedures.
Figure 1
(1) Rod string components should be inspected
upon delivery to verify quantity, size, length, type or
grade, pin size, guide size, style and/or load capacity.
(2) Protectors should not be removed from the
components while in storage, except for inspection
purposes, and then immediately reinstalled after the
visual examination is complete. Whenever a component
is observed to be without such protection, it should
be inspected and, if undamaged, thoroughly cleaned,
a suitable protective coating reapplied and the
protectors reinstalled.
(3) The components should be routinely inspected
on a quarterly basis for damage and/or protective
coating deterioration. Damaged components should
be removed and/or replaced. Rust should be removed
with a soft wire brush prior to the reapplication of a
suitable protective coating.
(4) The components should be routinely rotated
while in storage so that older inventory is used first.
Loading or unloading procedures
(5) In all handling operations, care should be
exercised to prevent the components from coming in
contact with an object that may cause mechanical
damage. Caution should be exercised with threaded
components to ensure intact thread integrity is
maintained. Care should be taken when applying or
removing the bulkheads and tie-downs used to
secure the load during shipment in order to avoid
damaging the components.
(6) Polished rods, pony rods, sinker bars, stabilizer
bars, and sucker rods should never be handled in
such a manner that may produce a permanent bend
or kink. Bent or kinked components are permanently
damaged and should be discarded.
3
 Figure 2
(7) Polished rods, sinker bars, and sucker rods
should always be handled with approved lifting
devices designed to support the sucker rod without
damage.
a. Packaged sucker rods should always be lifted and/
or laid down using a forklift and an approved spreader
bar and tee hook system that adequately supports
the full load of the sucker rod package by lifting one
package, at a time, from beneath (Figure 1).
b. Loose polished rods, sinker bars and sucker rods
should always be lifted and/or laid down one at a time
with either an approved spreader bar and nylon straps,
or by using a minimum of two individuals with each
person positioned in about 3 to 4 feet from each end.
Transportation procedures
(8) Trucks and trailers for handling rod string
components should have non-metallic floors or
supports, be in good condition that provides for
proper support to the component shipped. Trailers
should provide blockage directly under the cross-
wise supports of the package so that the sucker rods
themselves do not come in contact with the blockage.
Further, packages should be stacked so that the
bottom supports of the top package rest squarely on
the top supports of the package underneath.
a. Polished rod clamps should be placed in storage
boxes during shipment.
b. Polished rods should remain in factory protec-
tors and set level on non-metallic supports during
shipment. Nylon tie-downs should be placed in such
a position as to pass over non-metallic supports and
should be prevented from coming in contact with the
polished rod by the use of spacers.
c. Pony rods should be carefully packaged or
palletized and nylon tie-down straps should be placed
in such a position as to pass over the package supports.
The straps should be prevented from coming in
contacting with the pony rods on the top layer.
d. Sinker bars should set level on non-metallic
supports and have nylon tie-downs that pass over the
4
Figure 3
non-metallic supports. Tie-downs should be prevented
from coming in contact with the polished rod by the
use of spacers.
e. Stabilizer bars should be carefully packaged or
palletized and nylon tie-down straps should pass over
the package supports. Tie-downs should be prevented
from contacting the stabilizer bars on the top layer.
f. Packaged sucker rods, preferably should be
handled as a packaged unit. The packaged unit should
set level with non-metallic supports under each
package support. When stacking packaged sucker
rods on top of other packaged sucker rods, the
package supports in the top package must properly
align vertically with the package supports in the
package beneath. Nylon tie-down straps should be
placed in such a position as to pass over the package
supports and should be prevented from contacting
the sucker rods on the top layer (Figure 2).
g. Loose sucker rods should be carefully placed on
five non-metallic supports. End supports should be
placed approximately 1-foot in from each end and the
other three supports should be spaced equally in the
middle. Layered sucker rods should be separated by
non-metallic spacers positioned directly above the
non-metallic supports in order to separate the top
layer from the bottom layer of sucker rods. Nylon tie-
down straps should be placed in such a position as to
pass over the spacers and should be prevented from
contacting the sucker rods on the top layer.
Storage Procedures
(9) Couplings, polished rod clamps, polished rods,
pony rods and stabilizer bars should be stored
inside, out of the elements, on shelves, pallets, racks
or sills made from non-metallic materials that are
non-abrasive to the stored component.
a. Couplings should be stored separately on pallets
in factory boxes by type, inside thread diameter, and
outside diameter (Figure 3).
b. Polished rod clamps should be stored separately
on shelves by style, size and load capacity.
 Figure 4
c. Polished rods should be stored separately on
racks or sills by type, size, length and pin size. Use
three non-metallic supports for polished rods that
are 14 feet or less in length. End supports should be
placed approximately 1-foot in from each end of the
rod and the other support spaced equal distance in
the middle. Use four non-metallic supports for
polished rods that are 20 feet or less. End supports
should be placed 1-foot in from each end of the rod
and the other two supports spaced equally along the
middle. Use five non-metallic supports for polished
rods that are 26 feet or less in length, with end
supports 1-foot in from each end of the rod and the
other three supports spaced equally along the
middle. Use six non-metallic supports for polished
rods that are 32 feet or less in length, with the
supports spaced as described above. Use seven
non-metallic supports for polished rods 32 feet or
less, with supports spaced as described above.
d. Pony rods should be stored separately by type
or grade, size and length in bins, pallets, or racks
designed to minimize metal-to-metal contact.
e. Stabilizer bars should be stored separately by
type or grade, size, pin size and guide size in bins,
pallets or racks designed to minimize metal-to-metal
contact.
(10) Sinker bars, packaged sucker rods and loose
sucker rods should be stored on racks or sills made
from non-metallic materials that are non-abrasive to
the stored components. The storage site containing
the racks or sills should have a level, firm surface
that is clear of weeds and debris with adequate
drainage to promote water runoff.
a. Sinker bars should be stored separately by
grade, size, length and pin size on racks or sills
designed to minimize metal-to-metal contact. They
should be stored loosely on a minimum of five non-
metallic supports with end supports approximately
1-foot in from each end of the bars and the other
three supports equally spaced along the middle.
Sinker bar layers should be separated by spacers
placed directly above the non-metallic supports. The
Figure 5
spacers should be thick enough to prevent the sinker
bars from coming in contacting with other sinker
bars in adjacent layers. If the spacers are not
notched, the outside sinker bar in each layer must be
chocked with blocks to prevent the sinker bars from
rolling off the spacers.
b. Packaged sucker rods should be stored
separately by type or grade and size on racks or sills
designed to minimize metal-to-metal contact. They
should be stored using non-metallic supports under
each package support and, when stacking packaged
rods, the package supports on the top package must
properly align vertically with the package supports
on the package beneath (Figure 4).
c. Loose sucker rods should be stored separately
by type or grade and size on racks or sills designed to
minimize metal-to-metal contact. They should be
stored using five non-metallic supports with each end
support placed approximately 1-foot in from each
end of the rods and the other three supports spaced
equally along the middle. Rod layers should be
separated by spacers placed directly above the non-
metallic supports. The spacers should be thick enough
to prevent the sucker rods from coming in contact
with other sucker rods in adjacent layers. If the spacers
are not notched, the outside sucker rod in each layer
must be chocked with blocks to prevent the sucker
rods from rolling off the spacers (Figure 5).
Adhering to the guidelines outlined above should
help prevent damage to components of the rod string
that result in premature failure. By proactively
preventing possible failure causes that result from
poor storage and transportation techniques, you are
protecting the initial investment in the rod string and
helping to lower operating expenses –– that just
makes good sense.
5
Protecting your investment in sucker rods
Part 2: Running and Re-Running
By RUSSELL STEVENS &
SCOTT MALONE
Norris

A
s discussed in Part 1 of this series (Well
Servicing July/August 2005), the rod string is
a vital link between surface and subsurface
equipment in a rod pumped well. A significant
monetary investment is necessary along with a
considerable amount of time. The API document,
Recommended Practices 11BR, states “…useful
sucker rod strength is limited by the fatigue perfor-
mance of a metal in a non-corrosive environment.”
But “…the fatigue life can be dramatically decreased
by improper installation…” Many improper activities
can cause rod damage so severe that failure can
result in just a few days following initial installation.
The proper and consistent procedures of running
sucker rods into a producing well takes time and Figure 1
should not be a race against the clock. Time spent
wisely is sure to pay off in terms of longer run times
without unnecessary downtime and rod replacement.

General running and re-Running information

(1) Rod string components should be inspected
upon delivery to verify quantity, size, length, type or
grade, pin size, guide size, style and/or load capacity.
They should also be examined to verify that the
components were not damaged during the delivery
process.
(2) Protectors should not be removed from the
components until the string is ready to be installed,
except for inspection purposes, and then immediately
reinstalled after the visual examination is complete.
These protectors and packaging materials are
preserving your investment from the surrounding
environment until you can place it into the environ- Figure 2
ment for which it was designed to operate. Whenever
a component is observed to be without such Running the rods
protection, it should be inspected and, if undamaged, (5) It is extremely important that the well servicing
thoroughly cleaned and a suitable protective coating rig be correctly positioned over the wellbore. The
reapplied and the protectors reinstalled. rod hook must be positioned directly over the tubing
(3) Loose rods should be stored at the well bore in order for the sucker rods to feed into the
location in the same manner required at storage yard tubing without creating friction on the sides of the
facilities. Non-metallic supports should be used to running nipple. Any friction, undoubtedly, will rub off
ensure that rods are not bent and metal-to-metal any corrosion inhibitor film and may possibly
contact is avoided. Metal-to-metal contact is an damage the surface of the rod due to the aggressive
opportunity to damage the surface of the rod and metal-to-metal contact. The lack of corrosion protection
potentially lead to premature failure (Figure 1). and/or the work hardening of the area will create a
(4) Pony rods and couplings should be delivered small anodic area and corrosion will be accelerated
and stored on separate pallets until ready for use. in this spot and premature failure may result.
The same level of care and attention should be given (6) The rod bundles that are ready to be installed
to these accessories as is given to the sucker rods should be broken open in a safe manner that will not
(Figure 2). cause rod surface damage. This can be accomplished

6
 Figure 3 Figure 4

using side cutters or tin snips to cut the steel

banding. Axes, crescent wrenches, claw hammers, or
any other tool can easily cause damage to the rods
and may also cause injury.
(7) The rod bundles are not designed to be used as
a work surface. Do not place tools, pipe or other
equipment on the rod bundles as this will increase
the possibility of rod surface damage.
(8) Dumping the couplings out on the ground for
faster access to them may cause failure for every
coupling that retains contamination in the threads.
To properly clean the threads on couplings contami-
nated in this manner will take a great deal of time.
The threads will gall if not kept free of solid material.
(9) The pony rods are nothing more than shorter
rods and are susceptible to the same types of damage
as a regular length rod.
(10) Unscrew the rod thread protectors by hand or Figure 5
with an air impact wrench. Knocking off the thread
protectors will leave plastic remnants on the rod
threads that will damage the threads during makeup
or when they are broken out on the next pump pull.
Do not remove them until it is time to install the rods.
It is best to keep them covered and protected as long
as possible.
(11) When removing box protectors DO NOT
engage the coupling threads with the screw driver.
This action always results in thread coupling crest
damage and will more than likely fail downhole.
(12) Clean and inspect pins and boxes. “New” rod
pins are coated with corrosion inhibitor from the
manufacturer; not thread lubricant. The pins of the
rods in the derrick often have been contaminated by
wellbore fluid, unknown lubrication type and even
blowing sand. These contaminants need to be
removed and the threads re-lubricated. Figure 6
(13) The API sucker rod coupling is designed as a
rotary-shouldered, friction-loaded, fluid-free connec- such a lubricant. If no other lubricant is available use
tion between sucker rods (Figure 3). Apply a small the grease gun off the rig. Ensure that the lubricant
amount of lubrication to the pin or coupling threads has no fillers.
to help reduce the interference between the threads (15) Inspect the rod elevators regularly and repair
(Figure 4). The rod shoulder and box face contact or replace them if their use may result in damage to
requires friction to maintain proper makeup. the rods. Ensure that the seats are smooth and round
Lubrication in the friction contact area will increase in shape, that the latch opens with resistance and
likelihood of pin failure. The faces must remain clean snaps shut, and that the bail moves back and forth
and dry throughout the makeup procedure. freely. Elevators can inflict mechanical damage to the
(14) Sucker rod thread-lubricants need to be rod upset taper if seats are not smooth or the eleva-
smooth, with a grease-like consistency, and contain tors can corkscrew the entire string if they open at
corrosion inhibitors and anti-oxidants to reduce the the wrong time (Figure 5). The individual rods will be
interference-fit between the threads. Topco SRL is bent near the ends if the elevators do not pick up the

7

Figure 7
string weight in a level fashion due to their inability
to swing freely.
(16) As you begin to pick up the rods, remember
that every rod must be tailed into the derrick
(Figure 6). Rods that run down the bundle damage
every rod they hit. Rods that are dragged though the
dirt have contaminated threads and may gall. These
threads must be thoroughly cleaned and inspected
for damage.
(17) Be sure to use bell nipple, a stripper or a
swage nipple for the running nipple. A piece of cut-off
tubing may damage most every rod you run.
(18) Power tongs are the recommended tools for
making up joints on virtually all sucker rod strings.
They must be set up properly to provide the
circumferential displacement specified by the
manufacturer. The displacement card must match all
four (4) characteristics of the rod (size, grade, condition
and manufacturer) to ensure accurate displacement
calibration of the power tongs (Figure 7).
Figure 9
8
Correct Incorrect Wind
Figure 8
(19) Make up the rod and coupling connections by
hand and scribe a vertical line on the coupling and
lower rod shoulder and then unscrew the lower
connection until roughly two pin-threads are left
engaged by the coupling. Note: When making these
initial connections, the rod must be hanging free in
the rod elevators squarely over the joint below.
When stabbing the rod pin into the coupling the rod
should be hanging straight and without slack to avoid
cross threading (Figure 8).
(20) Make sure the engine rpm’s are at full throttle.
Then pull the rod tongs to the connection, engage the
connection with the rod tongs using the lowest speed
possible.
(21) Maintain full engine rpm’s throughout makeup
and stall the rod tongs and do not “bump” the
connection. Back away the rod tongs and idle down
the engine rpm’s.
(22) Match the circumferential displacement on the
rod coupling connection to the proper card.
(Figure 9) Adjust the power tongs to create the
displacement necessary. Do a mechanical integrity
check of the rod tongs by checking the next 4 to 5
joints to verify the pressure adjustments are correct
and maintained. Check every 12th connection as you
go into the hole with the sucker rods and adjust the
power tong pressure accordingly.
(23) Note: Cross threaded connections are not
acceptable. Always start every connection by hand,
with at least two full threads engaged before putting
the power tongs on the joint. The tongs are capable
of cross threading the joint and the joint will fail.
(24) Pulling rods can also damage them, particularly
if you are pulling the rods and laying them down. It is
possible to lay down singles without much damage,
but it is virtually impossible to lay down doubles
without damaging the rods.
Consistently prepared joints and damage free
string installation will enhance the likelihood of long
productive sucker rod service life.
Protecting your investment in
sucker rods
Part 3:
Well Optimization
By RUSSELL STEVENS &
SCOTT MALONE
Norris
A
s discussed in Part 1 of this series (Well
Servicing July/August 2005), the rod string is
a vital link between surface and subsurface
equipment in a rod pumped well. A rod string that is
properly designed (based upon experience),
physically handled and made-up in accordance with
the recommendation of the manufacturer, operated
within acceptable design parameters and maintained
with an effective corrosion control program should
give a long, satisfactory and economical service life.
Since most failures can typically be categorized as
either man-made or well-induced, Part 1 (Well
Servicing July/August 2005) and Part 2 (Well Servicing
September/October 2005) dealt with preventing
man-made failures from improper storage, trans-
portation, running and re-running procedures. Part 3
explores design and operating conditions to optimize
the useable service life of the rod string.
Most failures in the rod string are repeat failures. In
other words, they occur as a result of the same failure
cause in a given well. Simply pulling the rod string,
replacing the failed component and re-running the
rod string will not solve the problem and will
ultimately lead to more failures. Do not replace the
rod string one component at a time. Instead, analyze
the failure cause and implement proper corrective
action based upon information gleaned from the
failure history. Failures inevitably drive costs up, so
by reducing the failure frequency, or extending the
timeframe between failures, operating expenses
(OPEX) can be kept in check. That said, the elimina-
tion of all failures in a rod pumped system is
impractical, if not impossible, and the costs associated
with the task would be astronomical! Therefore the
rod-pumped system must be optimized to effectively
manage failure frequencies, thus allowing the greatest
amount of profit to be realized from the well.
The first criterion for effective failure management
is to target problem wells. To target problem wells,
you must keep good, accurate records. Effective
failure management is data intensive and requires
comprehensive knowledge of the data from which
Figure 1
tracking measures can be developed to monitor and
measure improvements. A simple database or
spreadsheet is a good way to record and track
failures. The database or spreadsheet should record
the failure depth, failed component (pump, rods or
tubing), location of failure on the component (travel-
ing valve cage, rod body, collar, etc.), and the
root-cause of each failure (fluid pound, H2S
corrosion, inadequate makeup, etc.). During the
initial stages of an effective failure management
program, prevention costs may increase, masking the
initial effects of the improvements. However, overall
long-term cost reductions will become apparent and
improvements to operations realized resulting in
greater operating economics.
Numerous combinations of depths, tubing sizes,
fluid volumes, pump sizes and configurations, unit
sizes and geometries, stroke lengths, pumping
speeds and sucker grades and tapers are available to
the system designer. Most designs are optimized
for conditions existing at the time of the initial
installation. However as the well matures, gas and/or
water production may increase or decrease, resulting
in changes to load requirements and fluid
corrosiveness. A good initial design may become a
poor design if well conditions change. The system
may need periodic re-evaluation to insure all
components are operating effectively. Develop a
systematic approach to well optimization by
monitoring actual operating parameters with reliable
diagnostic equipment. Always verify that conditions
are optimal for the well after any change in operating
conditions (production volumes, fluid level, pump
size, stroke length, strokes per minute, chemical
treatment, etc.) as these changes can severely impact
the total rod-pumped system. This allows better
control of operating conditions such as rod loading,
pump fillage, corrosion, solids and the like, that
enhance the useable service life of your equipment.
9
 Figure 2
Have you ever heard the phrase, “If it ain’t
bumping, it ain’t pumping!”? Bumping, a.k.a. pump
tagging, allows the reciprocating top valve rod
bushing to impact the stationary valve rod guide of
the downhole rod pump at or near the end of the
downstroke. The force of the impact between the
two pump components rattles the traveling valve ball
off its seat and allows a load transfer from the rod
string to the tubing to take place. At the same time, a
shock wave is generated throughout the rod-pumped
system by the sudden impact of these two
components “tagging” each other. The impact
damages the clutches on the bushing and guide
(Figure 1) and the shock wave creates rod buckling,
rod-on-tubing contact and excessive wear. Bumping
also elevates the possibility of damage to the gear
reducer of the pumping unit.
Bumping the pump is a band-aid solution that
attempts to correct symptoms created by erratic
valve action in the downhole rod pump. Erratic valve
action is a problem that may be caused from solids
and/or gas interference. Careful review of pump tear-
down reports will indicate problems from solids, i.e.
sand cut plungers (Figure 2), scored barrels, and
such. Solids can significantly increase pump friction,
reducing rod loads on the downstroke and “pushing”
rod buckling further up the well. Solids trapped
between the barrel and the plunger will also increase
loads on the upstroke. Using alternate pattern balls
and seats (Figure 3), with increased flow areas, may
help alleviate some of the symptoms commonly
associated with this phenomenon.
Designing pumps with high compression ratios is
another way to effectively deal with gas interference.
The compression ratio of the pump is equal to the
swept volume of the plunger stroke plus the unswept
volume of the plunger stroke divided by the unswept
volume of the plunger stroke. The pump discharge
pressure is equal to the pump intake pressure times
the compression ratio. If the pump discharge pressure
is not equal to or greater than the hydrostatic fluid
load on the traveling valve, gas interference or gas
locking will occur. Heavy wall, stroke-thru barrels
(RHBC & RHAC) are examples of pumps that develop
10
Figure 3
relatively low compression ratios due to the area of
the unswept volume in the lower extension and are
prone to more problems with gas interference and
gas pound (Figure 4) if not properly designed.
Many wells produce gas along with the well fluids.
The presence of free or break-out gas at the pump
can interfere with the efficiency of the pump action,
thereby reducing the amount of fluid produced. This
interference can result in a gas pound and, when
extreme, it can result in a completely gas-locked
pump. During the pumping unit upstroke, the pump
barrel is filled with fluid and free gas, usually in a
frothy condition. On the downstroke, the rod and
fluid loads above the plunger must compress this gas
until the pressure above and below the traveling
valve are equalized to allow the traveling valve to
open and discharge the gas and fluid into the tubing.
At this time, a pound or shock wave similar to that
produced by fluid pound, only cushioned more,
travels through the entire system. Some control can
be maintained if gas separation is possible before the
gas enters the pump, but where gas breaks out of
solution during the pressure drop within the pump,
only partial control can be achieved. In a situation where
gas completely fills the pump barrel the pump gas
locks, which means that not enough discharge pressure
can be built within the pump to open either the
traveling or standing valve and production will cease.
A great many pumping wells pound fluid, either
intentionally or unintentionally, and any well is
subject to pounding depending on many pumping
conditions. A “fluid pound” (Figure 5), as experienced
in rod-pumped wells, is caused by the pump not
completely filling with fluid on the upstroke. As the
downstroke begins, the entire fluid and sucker rod
load move down through a void until the plunger hits
the fluid level in the pump barrel. The traveling valve
opens, suddenly transferring the load to the tubing,
causing a sharp decrease in load which transmits a
shock wave through the entire rod-pumped system.
It is this shock wave that damages the components of
the pumping system. A fluid pound is always
undesirable and rod-pumped system controls should
be used to monitor and detect this condition. If fluid

Figure 4 and Figure 5
pound is suspected, changes need to be made to the
rod pumped system to eliminate or reduce the
pound. The worst fluid pound condition is when the
pound occurs at or near maximum polished rod
velocity and the resulting shock wave is greatest.
Properly designed and operated rod-pumped
systems will not allow the rod string to come in
contact with the inside of the tubing. Poorly
designed rod strings, excessive strokes per minute
and solids in the pump can retard the plunger fall
causing the rod string to “stack out” and buckle. It is
difficult to predict where rod-on-tubing contact and
wear will occur so it is advantageous to eliminate or
reduce factors that retard plunger fall. Rod-on-tubing
contact and wear will typically accelerate any other
processes that are acting to reduce the usable service
life of the rod string. The rod string needs to operate
in tension and the tubing should be properly
anchored at the lowest possible depth in the well.
Properly anchoring the tubing is always recommended
–– justify any decision made that doesn’t include a
tubing anchor!
Wear is defined as the progressive removal of
surface metal by contact with the tubing. Wear
causes failures by reducing the cross-sectional area
of the metal component, exposing new surface metal
to corrosion, and causes connection failures in the
rod string from impact and shoulder damage. Angled
wear patterns indicate rod strings that are
aggressively contacting the tubing at an angle,
usually as a result of fluid pound, gas interference,
pump tagging, and/or unanchored (or improperly
anchored) tubing. Tubing-slap wear (Figure 6) is the
result of the rod string “stacking out” during the
downstroke. This extremely aggressive coupling or
rod-on-tubing contact is the direct result of severe
fluid pound, unanchored (or improperly anchored)
Figure 6
Figure 7
tubing, sticking (or stuck) pump plungers, or any
combination of the preceding.
Wear that is equal in length, width and depth
usually suggests a deviated or crooked well bore
(Figure 7). For a deviated or crooked well bore, it
may be necessary to use injection molded rod guides
to manage the sideloads that occur due to the dogleg
severity. For deviated or crooked well bores, a
properly designed injection molded rod guide system
will allow the rod guide to become the sacrificial
component in the rod string and prevent rod-on-tub-
ing contact and wear. A wellbore deviation survey is
recommended for proper placement of the rod
guides in areas suspected of having high sideloads.
When using rod guides, rod rotators are always
recommended to extend the service life of the rod
guide by distributing wear around the entire outer
circumference of the component.
This article is by no means all inclusive of every
design and operating condition encountered in every
type of rod-pumped system available. It is intended
as a reference guide to help optimize wells. Where
design and operating conditions are concerned, there
are no absolutes. But, by recognizing unfavorable
operating conditions through proper failure manage-
ment and well monitoring techniques, optimization
practices can be implemented that will make more
wells economically advantages to produce.
11
 Protecting
Protecting your
your investment
investment
in
in sucker
sucker rods
rods
Part 4: Corrosion-fatigue induced failures
By RUSSELL STEVENS &
SCOTT MALONE
Norris
K
eeping with the theme presented in the
previous three parts of this series, the rod
string is a vital link between the surface
equipment and the subsurface equipment in a rod
pumped well. To optimize the service life of the rod
string, it must be properly designed (based upon
experience), physically handled and made-up in
accordance with the recommendations of the manu-
facturer, and operated within acceptable design
parameters with an effective corrosion control
program. An effective corrosion control program that
is properly designed, implemented and optimized
using accepted monitoring techniques, is a critical
constituent that helps extend the economical service
life of the rod string. Since most failures can usually
be categorized as either man-made or well induced,
Part 1 (Well Servicing July/August 2005), Part 2 (Well
Servicing September/October 2005), and Part 3 (Well
Servicing November/December 2005) of this series
dealt with preventing man-made failures and
recognizing acceptable design parameters. Now in
Part 4, we will attempt to explore some of the more
commonly recognized design, implementation and
monitoring techniques for an effective downhole
corrosion control program.
Corrosion defined
Corrosion is defined by NACE International as
“… the deterioration of a substance (usually a metal)
or its properties because of a reaction with its
environment.” For the steel components in the rod
string, corrosion is the electrochemical reaction
between the steel and the corrosiveness of the
produced fluids. This electrochemical reaction will
turn your investment, in the rod string, into a worth-
less solution of corrosion byproducts (i.e., iron oxide,
iron sulfide, iron carbonate, etc.). Some form and
concentration of water (H2O) is present in all wells
12
considered corrosive and most contain considerable
quantities of dissolved impurities and gases. For
instance, carbon dioxide (CO2) and hydrogen sulfide
(H2S) acid gases, commonly found in most wells, are
high soluble and readily dissolve in H2O –– which
lowers its potential of hydrogen (pH). The corrosivity
of the produced fluid is then a function of the amount
of these two acid gases that remain in solution, the
pH of the fluid, wellbore temperature and pressure.
Regardless of the steel grade or type, effective
corrosion inhibition is necessary in any well
considered corrosive. Some steel grades or types
may offer enhanced performance in certain aqueous
environments, but effective inhibitor programs must
be maintained to adequately protect the steel from
corrosion. In order to be effective and provide a
protective barrier against corrosion, the inhibitor
must be allowed to contact the surface of the steel it
is to protect. The preceding statement acknowledges
that, for effective corrosion inhibition, it is best to
start out with clean equipment. Another aspect of
corrosion is the steel and its potential to corrode.
New steel introduced into an corrosive environment
typically has a higher potential to corrode –– thus
steel components in the rod string must be
adequately protected from corrosion. NACE Task
Group T-1D-3 has prepared recommendations for the
corrosion control of steel sucker rods and these
recommendations are published in the API
Recommended Practice 11BR. These recommenda-
tions set forth standard guidelines for application
methods, inhibitor selection and treatment program
evaluation.
Type and method of treatment
Fluid compatibility, fluid volumes, completion
methods and reservoir compatibility determine the
type and method of treatment that is available for
 Figure 1
each well. Fluid analysis is critical to the evaluation of
treating chemicals for compatibility with the fluid
produced by the well. Selection criterion includes
using chemicals that do not create stable emulsions.
Selection criterion also includes using treating
chemicals that are not so tenacious as to develop
undesirable precipitates or “gunk” when injected
downhole. Prior to their application, chemical
companies should test their chemicals with
produced well fluid in order to prevent operational
problems related to the chemical treatment program.
An effective corrosion inhibitor will create a
protective barrier between the steel rod string and
the corrosive well fluids, but will not create additional
problems with operating the well. Improper selection
of a corrosion inhibitor may result in increased
subsurface pump failures, rod failures and problems
with surface production facilities.
Batch treating
Batch treating down the casing/tubing annulus is a
common method of applying corrosion inhibitors.
Batch treating involves “pre-flush” water to wet the
casing/tubing, a high concentration of corrosion
inhibitor, and “flush” water, of a determined volume,
that helps disperse the chemical treatment down-
hole. A calculated quantity of corrosion inhibitor is
added to the casing/tubing annulus at regular
intervals to help promote the continued repair of the
protective inhibitor film until the next treatment
cycle. A basic rule-of-thumb for corrosion inhibitor
concentration is to start at 25 ppm (parts per million),
based on the total fluid production volume between
treatments, and to increase the concentration as
deemed necessary by results obtained from accept-
able monitoring techniques. (Use a minimum volume
of 2 quarts corrosion inhibitor per 1,000' of well
depth). Flush volumes will be determined by the well
depth and the dynamic fluid level in the casing/
tubing annulus.
Batch treatments are sometimes re-circulated for
several hours. A relatively large volume of corrosion
inhibitor is deliberately re-circulated from the
casing/tubing annulus to the production stream and
back again. Batch and circulate treatments help
ensure all downhole production equipment surfaces
in the well make contact with the corrosion inhibitor
more than once.
Figure 2
Continuous treatment
Continuous treatment is another method commonly
used to apply corrosion inhibitors. Continuous treat-
ment involves a chemical-feed pump used to inject
corrosion inhibitor at the surface or below the sub-
surface pump via a capillary string. A small volume of
produced fluid is continuously circulated to help
flush the inhibitor down the casing/tubing annulus.
Prior to putting the well on continuous injection, a
pre-treatment application, typically consisting of five
to 10 gallons of concentrated corrosion inhibitor, is
injected into the casing/tubing annulus. The basic
rule-of-thumb for corrosion inhibitor concentration is
to start at 25 ppm (parts per million), based on total
fluid production, and to increase the level of
concentration as deemed necessary by results
obtained from acceptable monitoring techniques.
Squeeze treatments
Although not a common practice, corrosion
inhibitor squeeze treatments can be effective and
long-lasting. Squeeze treatments involve pumping
large volumes of corrosion inhibitor, diluted with
solvent, into the producing formations under high
pressure. The inhibitor in the formation desorbs over
time to help maintain the inhibitor film on the down-
hole production equipment. A basic rule-of-thumb for
corrosion inhibitor concentration is to start with 50
to 75 ppm (parts per million), based on the total fluid
production for the expected treatment life. Because
inhibitor compatibility with the formation fluids and
the formation rock is a concern, squeeze treatments
are generally not used when other treatment
methods are possible.
Program performance
Once a corrosion inhibition program is designed
and effectively applied, it is important to monitor the
performance of the program and optimize the
inhibitor type or concentration level before failures
occur. An effective chemical inhibition program is
fairly expensive and may be subject to cutbacks if
justification for this huge expense cannot be made.
Non-effective corrosion inhibition programs allow the
system to become contaminated and may require
extensive cleaning in order to re-establish an
effective maintenance film. By reducing an effective
inhibition program, it will become difficult to
continue operating the well economically due to the
13
 Figure 3
Figure 5
potential damage incurred by the downhole
production equipment. In the long run, most wells
will be more economical to operate with effective
corrosion inhibition programs versus those without.
Monitoring techniques
NACE International recommends using several
monitoring techniques simultaneously, if possible ––
and recommends never relying on any single method
for monitoring corrosion! Some of the tools typically
used to measure the effectiveness of chemical
inhibition programs include: (1) water and gas analysis;
(2) weight loss coupons; (3) pH measurements;
(4) H2S content; (5) C02 content; (6) O2 content;
(7) chloride content; (8) iron count measurements;
(9) copper ion displacement (CID); (10) corrosion
inhibitor residuals; (11) linear polarization; (12)
bacterium cultures; (13) bottomhole temperature
measurements; (14) bottomhole pressure measure-
ments; (15) fluid level measurements; and (16) visual
water quality.
Designing and implementing an effective corrosion
inhibition program is a complex subject that is
difficult to cover due to the numerous combinations
of corrodent concentration levels, temperatures,
pressures, compatibility issues, production volumes,
and completion methods –– to name a few. Proper
selection of the corrosion inhibitor type and
concentration level, application method and
monitoring techniques should help prevent most
corrosion related failures. However, this article is by
no means all inclusive on the subject of corrosion
induced failures. Chemical companies that specialize
in the design and treatment of corrosion inhibition
programs are the best source for up-to-date informa-
tion about programs recommended for your
particular application.
14
Figure 4
Figure 6
Types of corrosion
Acid corrosion is a uniform thinning of the metal
surface, leaving the component with the appearance
of sharp, feathery, or web-like residual metal nodules.
Corrosion deposits will not be formed in the pits or
on the surface of the component (Figure 1).
Acid producing bacteria (APB) has the same basic
pit shape characteristics of CO2 acid gas corrosion
except for the cavernous appearing pit-wall and the
striated or grainy appearing pit-base. The pit will not
contain scale deposits (Figure 2).
Carbon dioxide (CO2) acid gas corrosion forms
round-based pits with steep walls and sharp pit-edges.
These pits are usually interconnected in long lines
but can occasionally be singular and isolated. The pit
base will be filled with iron carbonate scale –– a corro-
sion byproduct of CO2 acid gas corrosion (Figure 3).
Chlorides contribute to the likelihood of an
increase in corrosion related failures in wells with
small amounts of CO2 and/or H2S acid gas corrosion.
Plain carbon steel tends to pit in produced waters
containing high chlorides. The pitting is usually
spread over the entire surface of the component with
flat-bottomed, shallow, irregular shaped pits that
exhibit steep walls and sharp pit-edges.
Dissimilar metals corrosion may be apparent
when the less noble metal has a tapered or leeched
appearance toward the more noble metal.
Hydrogen blistering is the formation of blisters on
or near the metal surface from the absorption of
hydrogen into the metal lattice creating excessive
internal pressure in the steel (Figure 4).
Hydrogen embrittlement usually leaves the fracture
surface halves with a brittle, granular appearance
due to the immediate shear tear that occurs as a
result of the absorption of hydrogen into the metal
lattice and the loss of ductility in the steel (Figure 5).
 Hydrogen sulfide (H2S) acid gas corrosion pits are
round-based with beveled walls and pit-edges. Pits
are usually random and scattered over the entire
surface of the component. Both the surface of the
metal and the pit-base will be covered with iron
sulfide scale –– a corrosion byproduct of H2S acid gas
corrosion (Figure 6).
Oxygen (O2) enhanced corrosion pits are broad-
based, smooth-bottomed with the tendency for one
pit to combine with another. Pit shape characteristics
may include steep pit-walls and sharp pit-edges with
CO2 acid gas corrosion or beveled pit-walls and Figure 7
pit-edges with H2S acid gas corrosion (Figure 7).
Stray current corrosion generally leaves deep,
irregular shaped pits with smooth sides and sharp
pit-edges.
Sulfate Reducing Bacteria (SRB) has the same basic
pit shape characteristics of H2S acid gas corrosion,
often with multiple transverse cracks in the pit-base,
tunneling around the pit-edges (aka pits-within-pits),
pit clustering, and/or unusual anomalies (i.e. shiny
splotches) on the surface of the component
(Figure 8).
Figure 8

15