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fatigue tests were performed on different type of high strength available on the market, by using simple and cheaper tests
rods, in order to have better information that can be used for instead of the time and costs related to fatigue tests.
the selections process of these rods.
90 Experimental Evaluation
σ UTS For the evaluation tests, four different types of rods commonly
Sa = + 0.375 S min
80
2.8 used in our wells of different diameter and manufacturer were
70 chosen at random from bundles of new ones at the field site.
Table 1 is a summary of the rods tested, F1, F2 and F3 means
MAXIMUM STRESS (ksi)
60
three different manufactures.
σ UTS
50
Sa = + 0.43S min
3.11 Table 1. Types of rods that were evaluated.
40
ROD Classification Diameter
30
F1-M1 ASTM 4330M 3/4 in
F2-M2 ASTM 4330M 7/8 in
S a = (0.25σ UTS + 0.5625S min ) SF
20 F3-M3 ASTM 4138M 1.0 in
F1-M4 ASTM 4138M 1.0 in
10
0 All the rods tested in this study were produced with a heat
0 20 40
MINIMUM TENSILE STRENGTH (ksi)
60 80
treatment of normalized and tempered (N&T), in addition to
the fatigue tests, the following evaluations were done: tension
Figure 2. Goodman modified diagram for allowable stress and tests, chemical analysis using emission optical spectroscopy
range of stress for sucjkers rods in non-corrosive services. technique, metallographic analysis, hardness test, impact
Charpy V notch (CVN) tests and tension notch tests; each test
The steels used for high strength rods are very similar to was done following the appropriate ASTM standard. Later on,
the ones used for drill pipes, according to the API samples from the rods, except F1-M1, were under a heat
specification 5D6, there is minimum toughness requirement of treatment of quenched and tempered (Q&T) and the same
40 ft-lbs CVN (Charpy V notch impact test). Toughness is a mechanical tests were done was again. Rod F1-M1 was not
material property that quantifies the material’s resistance to fatigue tested under the Q&T condition, due to the fact there
propagation of an existing crack under slow strain conditions. were not more new rods on the field during the study, sample
The Charpy Impact resitance is a measure of the amount of from this rod were not requested directly from the vendors in
energy required to fractura a standerd ize and shape specimen order to keep them out of the study.
of a material, uing a pendulum hammer. Since Charpy tests are Fatigue tests were carried out following the standard
inexpensive and correlate well with fracture resistance, the oil ASTM E 7398, the scope of the tests can be qualified as a level
industry routinely uses Charpy impact testing as a measure of of R&D with a replication of (33-55%). To simulate the
toughness. An evaluation of the impact energy was done on corrosion pit effect on fatigue, a small hole was machined on
the material of the rods to compare the difference among them at the center of the specimens, with a diameter of 0.045 in and
(Minimum limit of 40 ft-lb). 0.020 in depth. Figure 3 is a view of machined defect on the
Most of sucker rods catalogs from different companies fatigue specimen and at the fracture surface.
imply that rods are delivered normalized and tempered. In
terms of fatigue resistance, it is well known that quenched and
tempered steels have an improved the toughness and fatigue
resistance, Sankaran7. Following the comparison with
quenched and tempered (Q&T) drill pipe, the rods were tested
in a quenched and tempered condition. Fatigue resistance and
impact CVN energy were evaluated.
In order to have a better knowledge, in addition to the
material characterization of the rods, specimens with a
superficial defect were fatigue tested under both heat
treatments. The experimental fatigue and impact results and
the effect of the superficial defect shows up important
differences among the high strength rods evaluated, that are
useful to the selection process. The used of Q&T heat
treatment gives an improvement on the impact and fatigue Figure 3. a) Small pit as a superficial defect on the fatigue
strength as compared to the N&T. specimen. b) Lateral view of the pit, SEM, 67X.
With all these experimental data, a sensitivity analysis was
done to generate a correlation that allows estimating the According to standards ASTM E 466, and ASTM E 468
expected fatigue of the rod material, based on the tensile the fatigue curves were determine, a stress ratio of zero (R=0),
properties and the impact energy. This correlation will help in cycling load applied at a frequency of 60 Hz, and a run out of
the selection process among different rod manufactures 5 millions cycles. Equation 1 is used to calculate the fatigue
concentration factor; it is the ratio of the fatigue endurance
SPE 102211 3
with a notch and the fatigue endurance of the material without Table 4. Impact energy CVN tests, at as-received condition.
a superficial defect. Rod Sample CVNave.
σ manufacture CVN (lb-ft) (lb-ft)
Kf = e (1) F1-M1 21.70, 20.23, 18.39 20.10
σ ed F2-M2 29.79, 28.32, 27.95 28.69
F3-M3 16.18, 13.24, 15.08 14.83
Experimental results F1-M4 11.04, 13.24, 13.61 12.63
Chemical composition. The results of the four rods are
presented in Table 2. According to the alloy elements, the rods
were classified following AISI specifications. The AISI Table 5. Notch tensile strength tests results.
classification agrees well with the manufacturer rod Rod Ys σs σs / Ys NSR
HBN
specifications. The letter M is an indication of the presence of sample (ksi) (ksi) NSR (average)
microalloys vanadium, Titanium, Niobium. According to the F1-M1.1 134.84 234.06 1.74
1.71 335.6
specialized literature, these alloys increase the mechanical F1-M1.2 134.69 227.01 1.69
strength of the steel without affecting its toughness. F2-M2.1 119.02 227.12 1.91
1.90 310.2
Table 2. Chemical composition of the rods, %wt. F2-M2.2 120.48 228.70 1.90
F3-M3.1 105.08 198.83 1.89
Element F1-M1 F2-M2 F3-M3 F1-M4 1.89 287.0
F3-M3.2 104.60 196.77 1.88
Fe 94.92 95.10 96.89 96.73 F1-M4.1 119.81 212.98 1.78
1.71 312.0
C 0.341 0.318 0.405 0.410 F1-M4.2 121.45 199.04 1.64
Mn 0.833 0.848 1.065 1.256 HBN: Hardness Brinell Number.
Si 0.210 0.230 0.273 0.288
Cu 0.260 0.270 0.311 0.143
Ni 2.047 1.922 0.067 0.000 Table 5. Results of inclusion and microstructure analysis at as-
Cr 0.940 0.877 0.594 0.722 received condition.
V 0.064 0.097 0.095 0.059 Sample Inclusion analysis Microstructure
Mo 0.248 0.236 0.255 0.309 Ferrite, perlite, carbides
Ti 0.002 0.001 0.002 0.004
Al 0.042 0.005 0.003 0.027 Coarse type 1½ and
Nb 0.008 0.007 0.006 0.045 fine type 1 globular
F1-M1
AISI –SAE 4330M 4330M 4138M 4138M oxide, and slim
sulfides type ½.
Mechanical properties. Table 3 shows the results of the
tension and hardness tests of the rods at as-received condition
Ferrite, perlite, carbides
(N&T). Tables 4 and 5 give the results of the impact CVN and
the notch tensile strength tests, respectively. These tests were
carried out at ambient temperature. Fine globular oxides
F2-M2 type 1, and fine
Table 3. Tension tests results, at as-received condition (N&T). sulfides type 1 and 2.
Rod Manu- Specim σys UTS %e
σys/UTS
facture ent (ksi) (ksi) (50 mm)
M1.1 134.81 153.83 15.20 0.88 Ferrite, perlite, carbides
F1-M1
M1.2 134.66 154.85 20.60 0.87 Coarse type 1 and
M2.1 118.99 140.86 16.60 0.85 fine types 1 and 1½
F2-M2
M2.2 120.45 142.26 16.80 0.85 F3-M3 globular oxides and
M3.1 105.06 133.23 15.16 0.79 types 1 ½ and 2
F3-M3
M3.2 104.58 132.72 14.26 0.79 sulfides.
M4.1 119.78 147.28 15.22 0.81
F1-M4
M4.2 121.43 148.34 15.00 0.82 Ferrite, perlite, carbides
Coarse type 1 and
Metallographic analysis. Table 5 is the compendium of the fine types 1 and 1½
inclusion and metallographic analysis of the rods at as- F1-M4 globular oxides and
received condition (N&T). Table 6 are the results of phases types, and fine
present, size of the previous austenite grain, ferrite grain sulfides
evaluated using the scanning electronic microscope
4 SPE 102211
Table 6. Austenitic and ferritic grain size of the rods at as- Fatigue tests. Figures 4, 5, 6 and 7 are the fatigue curves of
received condition. the four rods tested, F1-M1, F2-M2, F3-M3, and F1-M4,
Austenitic grain size Ferritic grain respectively.
Rod sample
N° ASTM (µin) size (µin)
F1-M1 8 (0.89) 0.74 F1-M1
F2-M2 4 – 6 (2.5) 0.56 90
Rod σys UTS %e σs σs / Ys Figure 4. Fatigue results of rod F1-M1, only two
manuf. (ksi) (ksi) (2 in) (ksi) NSR conditions were evaluated for the N&T.
131.5 142.3 16.28 226.99 1.72 F2-M1
F2-M2
136.5 147.2 16.34 222.08 1.63 100
F1-M4 70
141.9 152.5 13.42 236.2 1.67
60
Sample CVNaverage 40
Rod CVN (lb ft) (lb ft)
30
F2-M2 80.88, 84.56, 86.03 83.22 N&T AS RECEIVED
F3-M3 72.06, 68.38, 69.49 70.00 20
N&T WITH DEFECT
F1-M4 58.82, 55.88, 58.82 57.84 10 Q&T WITHOUT DEFECT
Q&T WITH DEFECT
0
Table 9. Metallographic analysis of the Q&T rods. 10000 100000 1000000
CYCLES
10000000 100000000
F2-M2 70
ALTERNATING STRESS (ksi))
60
50
Tempered martensite 40
30
F3-M3 20
N&T AS RECEIVED
10 N&T WITH DEFECT
Q&T WITHOUT DEFECT
0
1000 10000 100000 1000000 10000000
Tempered martensite CYCLES
70
notch tensile strength. From the impact energy test results,
60
there is an importance difference among the rods in the N&T
50 condition. Figure 8 is a summary of the mechanical tests and
40 the fatigue behavior of the N&T rods.
30
N&T AS RECEIVED
20 N&T WITH DEFECT 250
230,53 227,91
10 Q&T WITHOUT DEFECT
206,01
Q&T WITH DEFECT 197,8
0 200
10000 100000 1000000 10000000
CYCLES
ksi, ft-lb
150 141,56
conditions were evaluated. 134,74
119,72
132,98
120,61
104,82
Table 7. Summary of the fatigue tests. 100
CONDITION F1-M1 F2-M2 F3-M3 F1-M4 65
σe N&T 65.0 58.0 51.0 55.0
58
51 55
w/o defect 50
28,7
σ e 20,1
N&T 14,8 12,6
f 34.0 30.8 27.8 32.5
with defect 0
F1-M1 F2-M2 F3-M3 F1-M4
Kf (N&T) 1.91 1.88 1.83 1.69
σe Q&T Yield strength Ultimate strength
NA 39.5 65.0 62.5 Notch strength Endurance limit
w/o defect CVN
σ ef Q&T
NA 26.3 NA 37.5 Figure 8. Comparison of the mechanical test results among
with defect the rods in the as-received condition (N&T).
Kf (Q&T) -- 1.50 -- 1.67
The rods with a superficial defect showed an importance
decrease in the fatigue endurance limit, the Kf factor is around
Result Analysis 1.90 for all the rods, this implies the high sensitivity of these
Chemical composition effect on fatigue. The steel alloys high strength steels to the presence of small superficial
evaluated belong to the grades AISI-SAE 4330M ( Cr–Ni-Mo defects.
steel) and 4138M (Cr – Mo steel), the rods agreed well with Figure 9 is the Goodman diagram for the rods evaluated.
the manufacture specifications. In terms of chemical Manufacture of the rods F1-M1 and F1-M4 specified,
composition, the N&T rods F1-M1 and F2-M2 (4330M) graphically in the catalogue, the same allowance limit (dash
showed higher fatigue endurance limits as compared to the line) for both rods, Equation 2 was generated from the graph.
other (4138M); the difference is related to: the hardening Rods F2-M2 and F3-M3 from different manufactures have the
grade related to the elements chromium, nickel, and Equation 3 as a reference to calculate the allowance limit.
molybdenum, the refining of the austenitic grain due to the
presence of aluminum and vanadium, also the refining of the ⎛ T ⎞
ferritic grain caused by silicon, vanadium and niobium. Rod SA = ⎜ + 0.43 S MIN ⎟ SF (2)
F1-M1 had the higher fatigue limit; this is probably related to ⎝ 3.11 ⎠
a smaller austenitic grain size due to the presence of 0.042% ⎛ T ⎞
of aluminum. The letter M on the steel classification is an SA = ⎜ + 0.375 S MIN ⎟ SF (3)
indication of the presence of microalloy elements such as
⎝ 2.8 ⎠
vanadium, titanium and niobium. According to the specialized
The vertical axis of the diagram corresponds to a stress
literature, these alloys increase the mechanical strength of the
steel without affecting its toughness, perhaps this is the reason ratio of zero (R=0, σmin=0)9, the fatigue results with a without
of using these steels in the normalized and tempered condition defect are shown on this line. For R=0, the maximum stress is
with the benefit of decreasing the producing costs. twice the endurance limit, see Equation 49, and following the
recommendation of API 11 BR the maximum stress is derated
Mechanical properties effect on fatigue. Three of the N& T by a factor of two. As can be seen, the experimental fatigue
rods evaluated by the tension tests were in agreement with the limit (without defect) for rods F1-M1 and F1-M4 are above
manufacture specification, only the rod F3-M3 gave the limit specified by the manufacture, the same happens to
6 SPE 102211
compared to the N&T. The values were over the 40 ft-lb 200
as specified for steels used in drill pipe6. 156,9
- The fatigue limits increase approximately of 10 ksi as 146,89 142,61
150
compared to the N&T rods. Rod F2-M2 was an exception 127,61
with very low values as expected. On this rod, the fracture
surface of some specimen shows that the fatigue crack
ksi, lbs-ft
100
69,98
started on a big inclusion located close to the surface, see 58
62,5 64,16
Figure 10. 50
- Rod F1-M4 with very high yield and tensile strength and
low toughness gives a lower fatigue endurance limit as 0
compared to the F3-M3 rod; both rods are 4138M steel. F1-M4 F3-M3
Figure 11 is a summary of the experimental results of
Yield strength Ultimate strength
these rods.
- The metallographic microstructure corresponds to a Notch strength CVN (lb-ft)
tempered martensite. This microstructure is in agreement Limit endurance
to the higher toughness and fatigue resistance as it was
Figure 11. Mechanical properties of the rods F1-M4 and F3-
expected.
M3 with the Q& T heat treatment condition.
Conclusions
- In the N&T condition the steel 4330M has higher fatigue
strength as compared to the steel 4138M; the same
behavior was observed on the toughness of these
materials.
- The rods had showed to have fatigue limit well over the
limit specified by the manufacture, at exception of the F3-
M3 rod, which was just on the limit.
- It was observed the expected effect of toughness on
fatigue properties on the rods; in addition to the well
Figure 9. Goodman diagram for the rods evaluated, the know influence of the ultimate tensile stress.
arrows on the vertical axis indicate the locations of the - There is an increase in the toughness in the Q&T rods as
experimental data for the rods with and without defects. compared to the N&T ones, which will improve the
fatigue behavior of these high strength steels. This higher
SPE 102211 7
toughness will increase the fatigue life of the rods under Acknowledgement
the presence of superficial defects. We thank ECOPETROL S.A. for the permission to publish
- A correlation equation was developed that allows a this paper. We also thank our fellows Javier Mateus,
preliminary qualifying the expected fatigue behavior of Alexander Perez, Martin Lizcano and Rafael Gomez for the
rods of different manufactures, in a selection process, lab support.
using simple and inexpensive test such as tension and
CVN tests. Bibliography
1. API Recommended Practice 11B, “Specification for Sucker
Rods”, American Petroleum Institute, 1998.
Recommendations 2. API 11BR “Recommended Practice for Care and Handling of
- To experimentally generate the allowance stress limit for Sucker Rods”, American Petroleum Institute, Washington, 1989
3. Varillas de Bombeo, Catalogo General de Productos API y
the Goodman diagram is an expensive and time Premium, Siderca Tenaris Group.
consuming process. Every manufacture should be 4. Changes in EL and XD Rod Stress Loading Calculations, Theta
requested to develop and provide this information for Newsletter, A. de la Cruz, June 1999.
everyone of the rods. This experimental information in 5. Theta Enterprises Newsletter - May, 1998, www.theta-ent.com
combination with the field experience will help in the 6. API 5D, “ Standard specification for drill pipe”, last edition,
selection process of rods and improve the sucker rod American Petroleum Institute, Washington, 2002.
string design. 7. S. Sankaran, High cycle fatigue behavior of a multiphase
- Since high strength rods are sensitive to superficial microalloyed medium carbon steels: a comparison between
defects; special care must be taken during handling and ferrite – perlite and tempered martensite microstructures,
Materials science and Engineering A 362 (2003).
running in the well and the application of corrosion 8. Norma ASTM E 739, “Standard Practice for Statistical Analysis
inhibitors when they are used in corrosive sweet of Linear or linearized Stress – life (S-N) and Strain Life (e-N)
environments. fatigue Data”.
- More experimental data is needed in order to 9. G. Dieter, Mechanical Metallurgy, Mc Graw Hill, 1986.
establishment an impact CVN energy limit for the rods, as 10. Jaimes, A., “Correlacion Impacto fatiga: Optimización de
a minimum requirement of toughness. criterios de selección de materiales para varrillas de pozo” MSc
thesis, 2005, Universitad Industrial de Santander, Colombia.
11. Atlas of fatigue, Edited by Boyer, H. E., American Society of
Metals, Second printing, 1986.
Nomenclature
12. Bellow, D.G. and Smuga-Otto, I. Corrosion - Fatigue of Oilfield
σy = yield strength (ksi) Sucker Rods” Canadian Region Western Conference, 1991.
σu = ultimate tensile strength (ksi) 13. Lampman, S.R et al, Fatigue and Fracture, volume 19, ASM
σs = Notch tensile strength (ksi) handbook, ASM International, Ohio, 1996.
Smax= maximum allowance stress (ksi) 14. Martinez, A., et al “Evaluación del comportamiento de varillas
Smin= minimum allowance stress (ksi) de alta resistencia de sistemas de bombeo mecánico en
CVN = Impact energy Charpy V notch (ft- lb) ambientes corrosivos por CO2”, X Congreso Colombiano del
NSR= Notch strength ratio Petróleo, 2003.
σe = fatigue endurance limit (ksi)
σed = fatigue endurance limit with superficial defect (ksi) Metric Conversion Factor
Kf = fatigue defect factor ft x 3.048 E-01 = m
σmax = maximum tensile stress (ksi) in x 2.54 E-02 = m
σmin = minimum tensile stress (ksi) lb x 4.448222 E 00 = N
σmax, exp = expected fatigue endurance limit (ksi) lbs - ft. x 1.355818 E 00 = J
ksi x 6.8947 E 00 = MPa
ksi=103 psi