Falcon Engineering Application – Oil Production Sucker Rod Guiding

Falcon Engineering Application – Oil Production Sucker Rod Guiding

In the world of oil and gas production, sucker rods play a crucial role in ensuring the efficient and effective extraction of resources from deep within the earth. These mechanical components serve as the link between the surface pumping unit and the rod pump deep within the well bore. There are several types of sucker rods, each with its own specialized role; these rods can be constructed of different materials to optimize strength-to-weight ratios for well depth and oil properties, such as density and viscosity.

When it comes to designing sucker rods, material selection is key. Historically, the industry has used glass-reinforced PA66, PPA, PPS, and Nylon 46 in oil production sucker rod guiding. However, these materials are known to cause wear on the production tubing. Additionally, the high drag and coefficient of friction (COF) of the materials used in the well casing of sucker rods and centralizers can reduce the efficiency of the well as it requires more power to pump the oil or gas to the surface.

At PolySource, we’re known as “The Fixers” for a reason. Together with Falcon Engineering, a company dedicated to enhancing the lifespan of oil field rods and tubulars by minimizing friction in drilling and production, we embarked on a mission to discover and create the optimal material needed to produce strong and high-performing sucker rods.

Steps to the PolySource Solution

To determine the ideal material for the job, we started from square one by delving into the intricate mechanical property needs and critical-to-quality outputs (CTQs). These application requirements were multifaceted: wear, COF, dimensional stability, chemical resistance to common NORSOK fluids, heat and abrasion resistance, toughness, and fatigue and creep resistance. The suitable material had to exhibit dimensional stability equivalent or superior to the current material while providing low wear and COF against metal production tubing. By thoroughly understanding these necessities, we could devise, evaluate, and authorize material solutions with remarkable efficiency and efficacy, ultimately saving the customer valuable time and money. In collaboration with Falcon Engineering, PolySource succeeded in developing a customized material solution that satisfied all CTQs, ending complaints, field failures, and replacements.

Polyketone: A Practically Perfect Option

Providing hands-on technical and processing assistance during the developmental stages, PolySource developed INTEGRA™ POK FALCON GEN 1, GEN 2, and GEN 3. Developed and tested in-house in a controlled environment, these polyketone (POK) compounds were also validated in-house before field use and include INTEGRA™ POK 9060 and INTEGRA POK wear and friction grades. These offer additional wear and COF performance and meet the application requirements for heat, chemical, and abrasion resistance, toughness, dimensional stability, and fatigue and creep resistance. With strong, proven technical expertise, PolySource was able to respond quickly to meet aggressive developmental timetables.

INTEGRA™ FALCON GEN 1, GEN 2, and GEN 3 showed an improved production tubing lifetime performance and uptime of two to three times that of what was used previously; all three compounds also reduced the number of workovers. With wells running longer and fewer workovers, customers saw significant cost savings in addition and improved performance.


PolySource and Falcon Engineering’s collaboration revolutionized sucker rod design and production and led to improved efficiency, reduced costs, and increased production. Falcon Engineering became the first in the industry to use polyketone, installing the first POK sucker rod guides in the Permian basin in February 2017. PolySource and Falcon Engineering’s partnership serves as an example of how companies can work together to solve industry challenges and drive innovation.

PolySource is committed to providing customized solutions that meet the specific needs of our customers, and the development of INTEGRA™ POK GEN 1, GEN 2, and GEN 3 is no exception. Ready to optimize production and reduce costs with our solutions?

Contact The Fixers today to learn more.