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MEGALEXCarbon fiber sucker rods
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MEGALEXCarbon fiber sucker rods
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Presenter
Mitchell Hale, P.E.
Professional
• Professional Engineer, California
• US Patent #4869322 Sequential Hydraulic Fracturing of a Subsurface Formation 1989
Education
• BS Petroleum Engineering, Louisiana State (LSU)
• MBA, University California Los Angeles (UCLA)
Experience
• Mobil Oil, Production Engineer (5 yrs)
• Darco/LS, Vice President (8 yrs)
• LS Petrochem Equipment, Director (14 yrs)
• Lone Star ALS, President (3 yrs+)
• Megalex, LLC founder
MEGALEXCarbon fiber sucker rods
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Megalex® Carbon Fiber Sucker Rods
High strength Light weight
Small diameter High temperature
Fatigue resistant Corrosion resistant
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MEGALEXCarbon fiber sucker rods
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Megalex Rod Specifications
Rod Body Diameter in 5/8
Rod Area in2
0.3068
API pin size in 3/4
Diameter of end Fitting in 1-5/8
Rod Length ft 37.5
Total Weight w/ one coupling lbs 12.61
Weight per ft. w/ one coupling lb/ft 0.336
Lengths of pony rods ft 18, 9, 6, 3
Ulitmate Tensile Strength psi 235,000
Modulus of Elasticity psi 23.6 x 106
Speed of Sound ft/sec 32,488
Working Load lbs 36,500
Proof Load lbs 40,000
Temperature Rating °F 273
Stress Range Diagram MLX Megalex
End Fitting Steel KD 4340
Dimensional Properties
Mechanical Properties
MEGALEXCarbon fiber sucker rodsCustomer Benefits
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Production
from Deeper Depths
Drilling, Completion,
and Capital costs
Operations and
Maintenance costsWell Life and
Ultimate Recovery
MEGALEXCarbon fiber sucker rods
Greater Production from Deeper Depths
8Steel & FG data from Fiberflex marketing material. Megalex maximum production vs. depth information based on 1” diameter Mega lex rods
Customer BenefitPr
Op Rv
Dr
MEGALEXCarbon fiber sucker rods
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Customer BenefitPr
Op Rv
DrLonger stroke unit can increase production without
gearbox over-torque due to light-weight rods
Max
stroke
168”
Max
stroke
192”
MEGALEXCarbon fiber sucker rods
Reduced Drilling, Completion & Capital costs
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5-1/2" Well 4-1/2" Well
2-7/8" tubing 2-3/8" tubing
20" @ +/- 40' 16" @ +/- 40'
13-3/8" @ +/- 1,550' 10-3/4" @ +/- 1,550'
8-5/8" @ 6,000' 7-5/8" @ 6,000'
TD 9,450' 5-1/2" @ 9,450' TD 9,450' 4-1/2" @ 9,450'
Hole: 13-1/2"
Hole: 9-3/4"
Hole: 6-3/4"
Hole: 17-1/2"
Hole: 12-1/4"
Hole: 7-7/8"
Customer Benefit
Megalex rods
enable drilling slim-
hole well for same
production
EX) Andrews County, TX
Well Depth: 9,450 ft
Savings: $254,000drilling 4-1/2” well instead of 5-1/2”
Savings Double for
12,000 ft. well
Pr
Op Rv
Dr
MEGALEXCarbon fiber sucker rods
Reduced Operations and Maintenance costs
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Smaller pumping unit
Less corrosion
inhibitor
Lower
electrical
cost
Customer BenefitPr
Op Rv
Dr
MEGALEXCarbon fiber sucker rods
Reduced Operations and Maintenance costs
• Megalex rods enable the use of poly-lined tubing
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Poly-lined tubing reduces
frequency of tubing failures
caused by rod-tubing wear
Poly-lined tubing increases
tubing life 10x
5/8” Megalex rods have the
endurance strength of 1”
HS steel with the coupling
OD of ¾” steel
Customer BenefitPr
Op Rv
Dr
Photo courtesy of Western Falcon
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Megalex rods easily fit inside poly-lined tubing
Customer BenefitPr
Op Rv
Dr
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Customer Benefit
Low Bending Stiffness = Low side-wall loading
5/8” Megalex rods are
88% LESS STIFF as
1” steel rods, resulting
in low side-wall
loading around bends
and dog-legs
Pr
Op Rv
Dr
Ideal for multi-well
pad-drill-site wells
MEGALEXCarbon fiber sucker rods
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Megalex: 4 fewer loss-of-displacement opportunities over a 75 ft. stand of steel rods
Megalex has 57% less risk for
loss-of-displacement compared to steel
37.5 ft.
1 2 3
Megalex
37.5 ft.
1 2 3 4 5 6 7
Steel
25 ft. 25 ft. 25 ft.
Pr
Op Rv
Dr
MEGALEXCarbon fiber sucker rods
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Megalex: 2 fewer loss-of-displacement opportunities over a 75 ft. stand of fiberglass rods
37.5 ft.
1 2 3
Megalex
37.5 ft.
1
Fiberglass
37.5 ft. 37.5 ft.
2 3 4 5
Megalex has 40% less risk for
loss-of-displacement compared to fiberglass Pr
Op Rv
Dr
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Customer Benefit
Better Fatigue resistance than Steel or FG
Excerpt from SPE 28523, 1994 Delmonte, J., “Properties of Carbon/Graphite Composite%” 1987, published by Kriager Publishing Co.
Carbon Fiber60% of tensile strength
Steel40% of tensile strength
Fiberglass<20% of tensile strength
Pr
Op Rv
Dr
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Modified Goodman Diagram
T = 235,000 psi
Megalex superior fatigue strength
Megalex
141,000 psi
120,000 psi
UHS Steel 80,000 psi
50,000 psi
Megalex Stress Range Diagram
T .
1.96
T .
1.66
T .
2.8
T .
1.75
MEGALEXCarbon fiber sucker rods
Greater well life and greater ultimate recovery
Drill-Deeper wells produced on SRP
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5-1/2” casing
2-7/8” tubing
5-1/2” casing
4” liner
2-3/8” tubing
Cement
squeeze
Customer BenefitPr
Op Rv
Dr
MEGALEXCarbon fiber sucker rods
Greater well life and greater ultimate recovery• Gas well dewatering: SRP brings Liquid level below perfs.
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Reduced Pressure @ perfs.
Maximum drawdown
Greater Ultimate Recovery
4” casing
0
psig.
Gas
H2O
2-3/8” tubing
200
psig.
Gas
H2O
4” casing
2-3/8” tubing
High pressure @ perfs.
Limited drawdown
Reduced Ultimate Recovery
Plunger Lift Sucker Rod Pump
Customer BenefitPr
Op Rv
Dr
MEGALEXCarbon fiber sucker rods
Why Sucker Rod Pumping (SRP)?
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High Efficiency
Gas Lift 60-70%
Hydraulic Pump 70-75%
ESP & PC Pump 75-85%
Sucker Rod Pump >90%
Greatest
well drawdown
Norm Hein, “Hi Vol. Sucker Rod Lift”, Sucker Rod Pumping Workshop, Sep.2009
50% - 60% Efficiency
90% Drawdown
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Megalex Comparison with Fiberglass & UHS Steel
Unit 5/8" MEGALEX 1-1/4" Fiberglass 1" UHS Steel
Rod Body Diameter in 0.625 1.225 1
Rod Body Area in2
0.307 1.179 0.785
Standard Rod length ft 37.5 37.5 25
Avg. Wt. per Ft. w/ coupling lb/ft 0.336 1.412 2.900
Wt. of rod w/ one coupling lbs 12.6 52.9 72.5
Wt. of one 75' stand of rods lbs 25.2 105.9 217.5
Wt. 5/8" Megalex as % of 1-1/4" FG & 1" Steel - 24% 12%
API Pin Size in 3/4" 1" 1"
Max Diameter (End fitting/coupling) in 1.625 2.000 2.000
Modulus of Elasticity (stretch capability ) psi. 23.6 x 106 6.9 x 106 30 x 106
Ultimate Tensile Strength psi. 235,000 90,000-115,000 140,000
Temperature Rating °F 273 240 no limit
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Megalex Installation
February 2015
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MEGALEXCarbon fiber sucker rods
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MEGALEXCarbon fiber sucker rods
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MEGALEXCarbon fiber sucker rods
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MEGALEXCarbon fiber sucker rods
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MEGALEXCarbon fiber sucker rods
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MEGALEXCarbon fiber sucker rods
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MEGALEXCarbon fiber sucker rods
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Megalex Installation
March 2016
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Megalex Results
ft. of
Megalex
Pump
Depth, ft.
PPRL , lbs.
before
PPRL , lbs.
after
Avg. Rod
% before
Avg. Rod %
after
GB torque
% before
GB torque
% after
Denbury CC 2,680 8,650 35,700 24,500 77% 63% 107% 84%
Denbury ELOB 2,800 8,400 25,000 25,000 86% 67% 104% 92%
Well #3 4,400 9,800 43,700 26,500 85% 62% 93% 56%
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MEGALEXCarbon fiber sucker rods
Summary
Optimal Use
In “Ditch” wells: D-T-C-H
D Deep
T Tight
C Corrosive
H Hot
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Deep
Optimal in wells with TVD
10,000 ft. and deeper (challenging for
fiberglass due to rod stretch, and steel due to rod weight)
Enabling technology to rod
pump deeper than 16,000 ft. (considered the technological limit for sucker rod pumping)
MEGALEXCarbon fiber sucker rods
Tight
Allow deep rod pumping in 2-3/8”
tbg.
Operate within poly-lined tubing w/o
sacrificing rod strength
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MEGALEXCarbon fiber sucker rods
Corrosive
Same resistance to H2S and CO2
as FG
End fittings are Grade “KD” material
Enable use of corrosion resistant
API Grade “C” rods on bottom
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MEGALEXCarbon fiber sucker rods
Operational Advantages
Smaller pumping unit
Lower electrical / chemical costs
Reduced tbg. leaks (poly-lined tbg.)
Easy to space pump
Set pump below perfs
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MEGALEXCarbon fiber sucker rods
Hot
Max operating temp: 273º F
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MEGALEXCarbon fiber sucker rods
Economic Advantages
Drill cheaper slim-hole wells
Lift oil instead of steel rods
Lower cost artificial lift system
Enable drill-deeper
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MEGALEXCarbon fiber sucker rods
Enabling Technology
Marginal reserves become economic
De-water deep gas wells
Sucker rod pump deeper than
technologically possible before
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Contact: Mitchell Hale
Email: [email protected]
Tel: 713.210.9031