Mike Ashton - Oxy
Harold Miller - ART (Automated Rig Technologies)
Sucker rod connection failures remain a critical challenge in Reciprocating and PCP Rod Pump applications. This study examines current make-up practices, associated failure mechanisms, and emerging methods aimed at improving connection integrity and reducing failures. Field observations have highlighted recurring shortcomings, including inadequate cleaning, inconsistent procedures, and ineffective or poorly maintained make-up equipment.
METHODS, PROCEDURES, PROCESS
The study provides a comprehensive perspective on sucker rod connection failures and make-up practices, incorporating insights from an operator, and a rig equipment manufacturer. Investigations included rig and equipment audits, failure analysis, data review, and sucker rod tong diagnostics using electronic circumferential displacement and torque monitoring. Mitigation strategies introduced encompass enhanced make-up procedures, improved equipment maintenance and selection, in-field services for quality assurance and feedback, and development and testing of novel equipment designs.
RESULTS, OBSERVATIONS, CONCLUSIONS
Rig operation analysis revealed significant variability in adherence to procedures and gaps in understanding proper make-up practices. Diagnostics indicated that much of the field equipment—including sucker rod tongs, hydraulic systems, and related components—often fails to deliver consistent or sufficient torque for effective make-up. Recent data has confirmed that the required torque to make up rods to proper circumferential displacement can vary widely depending on rod condition and environmental factors. Failure analysis corroborates these findings, as connection failures persist despite years of improvement efforts. Newly implemented processes and equipment have demonstrated improved consistency, and further analysis will leverage robust failure data provided by the operator.
NOVEL / ADDITIVE INFORMATION
Current make-up recommendations largely rely on best practices and engineering guidelines. This study introduces extensive field data, enabling the industry to develop targeted procedures addressing specific, observed issues. Notably, the operator data presented here supports rod manufacturer and API recommendations that rods should be made up to specified circumferential displacement. The collaborative approach of this study brings together diverse perspectives, offering actionable insights for reducing connection failures.