Sucker Rod Connection Failure Reduction Using a Three-Pronged Approach

The objective of this study is to detail the improper make up related sucker rod connection failure reduction efforts of two operators in reciprocating rod pump applications. The study will give an overview of a "healthy" sucker rod connection along with their common failure mechanisms and root causes. Failure data will be shown and ultimately a three-pronged approach will be recommended for connection reliability improvement. Failure data will be analyzed using a total sucker rod connection failure metric with one operator in the Permian and another operator in the Bakken. Different forms of the three-pronged approach were carried out over time by both operators, so an analysis of the efficacy of the changes will be made to help understand the necessary operational changes required. A combination of quality assurance/quality control programs, technologies and services were used in efforts to reduce sucker rod connection failures. These efforts will be explained in detail to provide the necessary information to outline the success of the authors. The results revealed that there were three main factors that reduced the failures of the operators: 1) Rigorous QA/QC programs to rig operations, vendor facilities and transportation services of sucker rods, 2) implementing sucker rods specifically designed and manufactured to be ran without traditional thread lubricant, and 3) in-shop services of rod/coupling prep and hand-tight or torqued (buck-on) application. These three factors became the three-pronged approach. The data suggests that their simultaneous implementation is the best strategy to deliver the expected reliability improvement.