Remanufactured Sucker Rods
When TRC was formed, our Board of Directors challenged our managers to redefine the sucker rod reclamation industry. They told us to find better methods and more reliable ways to inspect each rod; not for the purpose of increasing the reject rate, but to give our inspectors the confidence needed to do a proper inspection job. They wanted the old saying “when in doubt, kick it out” eliminated from our vocabulary.
Once the good sucker rods had been identified, they told us to find a way to decrease the residual stresses which had built up in the rod. The mission was to significantly increase the life of each rod that passed inspection. Before TRC entered the sucker rod reclamation business, the goal of the industry was to extend the useful life of a used sucker rod string by inspecting each rod to determine if it was fit for use. If not, the rod was eliminated from the string and the balance was re-run downhole. Over time, the reject rate climbed. It was not uncommon to see reject rates of 60% to 70%.
Through its proprietary shot peening method and by developing other new, innovative processes, TRC is continually improving the industry. Years of testing have proven that TRC’s remanufacturing processes extend the typical fatigue life of your rods by 50% to 100% by reducing the amount of residual stress in the rods. TRC’s historical, weighted average, recovery rate stands at 61%.
TRC’s Remanufacturing Process
While TRC was founded to inspect sucker rods, our continual innovations over the years, have led to our ability to remanufacture sucker rods.
Anyone can purchase and use shot peening equipment. However, the “recipe” is the critical element to achieve predictable and consistent, beneficial results. Through today, TRC’s recipe has continually evolved since 1974 when our founder invented the sucker rod inspection process. In 2016, we achieved a new milestone whereby our processes demonstrated in tests the repeated ability to increase a used sucker rod’s fatigue life to a level exceeding the fatigue life of newly manufactured sucker rods. These test results showed that, on average, a used sucker rod processed by TRC had a 50% increased fatigue life versus a new sucker rod that was shot peened by the original manufacturer!
TRC’s processes restore your sucker rods to a level that exceeds the Original Equipment Manufacturer’s performance specifications. And, they carry a 30-month warranty, exceeding the OEM’s original warranty.
Today, we are remanufacturing sucker rods in two of our Midland plants and are currently retrofitting our other plants to enable them to be able to remanufacture sucker rods in the near future.
TRC’S REMANUFACTURING PROCESS INCLUDES:
▸ Perform a NORM (Naturally Occurring Radioactive Material)
▸ Inspect load and documentation to generate work order number
▸ Cleaning of contaminates
▸ Rod guide removal
▸ Rod straightening
▸ Coupling removal
▸ Pin cleaning
▸ Shot peening
▸ Thread gaging and parallelism check
▸ EMI inspection of the rod body
▸ Wet magnetic particle inspection of the end area
▸ Demagnetization of the rod
▸ Immersed in corrosion inhibitor
▸ Thread lubricant applied and thread protectors installed
▸ Palletized and color coded according to steel grade and API inspection classification
▸ Inspection report itemizing recoveries and rejects
▸ 30-month written warranty
Shot peening is the
The only similarity between shot blasting and shot peening is that each process involves propelling media at a high velocity to strike a surface. Shot peening, however, requires control over a consistent size and shape of media, a consistent velocity of media, a consistent volume of media striking the surface area, and for a consistent length of time. Careful controls yield consistent and repeatable results that are not measurable visually. Shot blasting is ordinarily less controlled, therefore less expensive, and results can usually be assessed visually.
Shot peening can be measured using several means, both destructively and non-destructively. The most widely accepted non-destructive, commercially acceptable measurement involves the use of the Almen method, which is the method used at TRC. All treatments are carefully controlled and documented like a recipe for reliable, consistent, and repeatable results.
TRC shot peens the rods as compared to all other rod service companies that only shot clean their rods. This process is the cornerstone difference between TRC and our counterparts. They reclaim your used sucker rods while we remanufacture your used sucker rods. Our remanufacturing process will reduce the residual stress build up in your rod and will
The Shot Peening Process
Shot peening of sucker rods is a cold working process in which the surface is bombarded with small spherical media called
Benefits of Shot Peening
Benefits obtained by shot peening are the result of the effect of the compressive stress and the cold working induced. Compressive stresses are beneficial in increasing resistance to fatigue failures, corrosion fatigue, stress corrosion cracking, and hydrogen assisted cracking (Hydrogen Embrittlement).
Shot peening is effective in reducing sucker rod fatigue failures caused by cyclic loading. These failures usually originate in surface areas under tension load, and cracks propagate from a surface defect or other stress risers. Shot peening prevents suck failures by inducing an even, compressive stress layer in the surface of the sucker rod, permitting an increase in service life or the allowable stress level. As a shot peened sucker rod is loaded, its critical surface area will not develop tensile stresses until the peen induced compressive stresses are first
Stress Corrosion Cracking
Stress corrosion cracking is defined as failure by cracking under
Atomic hydrogen is extremely mobile and able to easily penetrate and interact with metal, greatly reducing ductility and its ability to withstand cyclic loads. Shot peening has been shown to be effective in retarding the migration of hydrogen through metal.
Shot peening improves the surface integrity of the sucker