megalex - artificial lift alrdc seminar for new artificial lift... · •megalex rods enable the...

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


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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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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


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

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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”


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

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Reduced Operations and Maintenance costs

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Smaller pumping unit

Less corrosion

inhibitor

Lower

electrical

cost

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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

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Photo courtesy of Western Falcon


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Megalex rods easily fit inside poly-lined tubing

Customer BenefitPr

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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

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Ideal for multi-well

pad-drill-site wells


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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

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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

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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

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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


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

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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

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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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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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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)


Tight

Allow deep rod pumping in 2-3/8”

tbg.

Operate within poly-lined tubing w/o

sacrificing rod strength

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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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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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Hot

Max operating temp: 273º F

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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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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

mailto:[email protected]

megalex - artificial lift alrdc seminar for new artificial lift... · •megalex rods enable the...

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