Rod and tubing wear is a major challenge in rod-lifted wells, particularly in corrosive environments. It occurs when the relative motion between these components, under dynamic loading and harsh downhole conditions, gradually degrades both. This issue represents a significant portion of rod-lift operating expenses (OPEX) in US unconventional operations, shortening component run life and driving more frequent interventions.
To address this challenge, Tenaris developed an integrated approach over three years of collaborative research and field implementation, combining root cause analysis, full-scale laboratory testing, material innovation, optimized string design, and operational practices. Two laboratory protocols, the Tribocorrosion Sliding Test and the Abrasive Sliding Test, were developed to replicate real downhole wear conditions. This enables controlled evaluation of environmental factors, loads, and fluid or abrasive constituents across a wide range of products and materials commonly used in oil-producing wells.
Laboratory testing demonstrated significant reductions in wear compared to conventional materials used in rod-lift applications. Field trials in the Williston Basin confirmed these findings, showing measurable improvements in run life and reductions in wear-related failures in rod-lifted wells. Results also demonstrate that combining advanced materials with optimized string design and operational adjustments provides a holistic and replicable strategy for reducing OPEX and improving reliability in challenging unconventional environments.
Tenaris experts will share these insights at the Artificial Lift Conference & Exhibition 2026 (ALCE), taking place August 25–27 in The Woodlands, Texas. Esteban Oliva, Technical Sales Regional Senior Manager; Jordan Anderson, Sales Manager; Ricardo Pulido and Francisco More, Technical Sales Managers; and Guillermo Ghione, Product Engineer, together with Bryan Weaver, Senior Production Engineer at ConocoPhillips, will deliver a technical presentation titled "Integrated approach to mitigate rod and tubing wear: Full-scale testing, advanced materials, and field results" on Thursday, August 27, from 1:30 to 2:00 p.m. at Waterway 4.
At Booth #515, Tenaris will showcase technologies and engineering capabilities focused on enhancing reliability, extending equipment life and supporting higher production rates in demanding rod-lift applications.
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