IADC/SPE 62785 New Developments in Drill Stem Rotary Shoulder Connections

Michael J. Jellison, SPE, Grant Prideco; Steve P. Hassmann, SPE, Unocal Thailand, Ltd.; Dong Cotanda Jr., Unocal Thailand, Ltd.; Doug Snapp, SPE, Grant Prideco

Copyright 2000, IADC/SPE Asia Pacific Drilling Technology This paper was prepared for presentation at the 2000 IADC/SPE Asia Pacific Drilling Technology held in Kuala Lumpur, Malaysia 1113 September 2000. This paper was selected for presentation by an IADC/SPE Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the International Association of Drilling Contractors or the Society of Petroleum Engineers and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the IADC or SPE, their officers, or members. Papers presented at the IADC/SPE meetings are subject to publication review by Editorial Committees of the IADC and SPE. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.

premium. A third development discussed in the paper is a new thread form that provides increased durability and improved fatigue life compared to standard API connections. This thread form has been successfully used on drill pipe pins and drill collar boxes. This paper discusses the engineering philosophy behind each of these new designs and details results of physical testing. Applications where the connections have been used are also presented. Design Configuration and Capabilities The eXtreme Torque (XT) is a second-generation doubleshoulder connection (see Figure 1). The XT design evolved from the design of the HI TORQUE (HT) connection. Figure 2 depicts the make-up characteristics of XT and HT. Both connections spin up freely from the stab-in to handtight position. In the hand-tight position the primary external shoulder makes contact. As the connection is made-up from the hand-tight to power-tight position the box counterbore compresses and the pin base elongates elastically and the secondary torque stop engages. The secondary torque shoulder provides the increased torsional capacity compared to a standard API rotary shoulder connection. The external (primary) shoulder is the pressure seal for the connection just as on an API connection. Since the secondary shoulder functions solely as a torque stop and not a pressure seal, minor damage to the secondary shoulder can be tolerated without adversely effecting connection performance provided there is no protruding metal that will impede contact between the shoulder surfaces. Any protruding metal on the secondary shoulder must be removed with a file or abrasive paper. Use of thread protectors when the pipe is racked back in the derrick is not required or recommended. Figure 3 shows a comparison of XT and HT. The thread taper of the XT connection is flatter than the HTs to increase the area of the secondary torque stop, resulting in increased torsional capacity. HT provides an approximate 40% improvement in working torque compared to an API connection of the same OD and ID dimensions. XT provides approximately 25% to 30% more working torque capacity than HT or an improvement in working torque of approximately 65% to 70% compared to a standard API connection of the

Abstract Harsh drilling conditions can exceed the capabilities of traditional drill string connections. As the petroleum industry moves toward more severe drilling applications - deepwater, extended reach, high-angle, short-radius and ultra-deep wells new drill string connection designs are required to safely and efficiently achieve the drilling objectives of these projects. This paper describes three new rotary shoulder connections that provide significant operational advantages for extreme drilling applications. Introduction An advanced, high-performance tool joint design provides approximately 70% more working torque capacity than standard API connections. This new design is a secondgeneration, double-shoulder connection that is optimized for each drill pipe size. The connections increased torsional strength allows for the use of a streamlined tool joint configuration. The connections can be configured with a smaller OD and larger ID compared to standard API connections without sacrificing torsional capacity. A second version of this connection incorporates a radial metal-to-metal internal pressure seal. This connection provides high torsional strength combined with gas-tight pressure sealing capability. Drill strings with the gas-tight connection can be used for drill stem testing (DST) operations, underbalanced drilling and high-pressure workover and completion operations. This eliminates the need for a separate work string saving time, money, rig space and set back capacity. This is a significant advantage in offshore operations where rig space and set back capacity are at a

M. J. JELLISON, S. P. HASSMANN, D. COTANDA JR., D. SNAPP

IADC/SPE 62785

same dimensions. The shallow thread taper of the XT connection results in reduced clearance between the pin nose and box face during stabbing. Consequently, use of a stabbing guide is required to prevent damage to the box face or shoulder that acts as the pressure seal for the connection. With the exception of the stabbing guide requirement, eXtreme Torque handles and makes-up like a standard API connection. XT spins up freely until shouldered, then is bucked up to the make-up torque. Incorporating a stabbing guide into the make-up operation does not represent a drawback relative to using XT. Experience has shown that once the rig floor personnel become familiar and comfortable with the use of the stabbing guide, running times do not suffer and may actually improve. With the stabbing guide, rig personnel place the guide over the box tool joint and the pin can be stabbed relatively quickly into the box. Since the stabbing guide protects the sealing shoulder of the box, the pin does not need to be slowly guided into the connection. Care should still be taken during stabbing operations even with the stabbing guide, but with experience, running speeds may improve somewhat. In addition, running damage from mis-stabbing can be reduced or eliminated. Operational Capabilities. The optimized configuration of the new double-shoulder tool joint provides several significant operational advantages. High Torsional Strength. As mentioned above, the XT connection offers significantly higher torsional capacity than standard API and HI TORQUE connections. Figure 4 shows a comparison of the maximum make-up torque or working torque for API, HT and XT connections for various tool joints sizes. This additional strength provides the required torque for critical drilling applications. Streamline Profile. The increased torsional strength allows for the use of a streamline tool joint that is suitable for the pipes torsional strength. XT connections can be configured with a smaller OD and larger ID compared to standard API connections without sacrificing torsional capacity. This can allow a larger drill pipe size to be used for improved hydraulic performance. The ability to design more streamlined tool joint configurations has permitted the development of several innovative drill pipe systems. This new tool joint technology facilitated the development of a new product, 5-7/8 in. eXtreme Reach (XR) drill pipe, that represents enabling technology for Extended Reach Drilling (ERD), deep-water and other deep well applications.1 The hydraulic performance of the drill string can be a significant limitation in these applications resulting in poor hole cleaning, slower penetration rates, diminished control over well trajectory and drill pipe sticking. The 5-7/8 in. XR drill pipe provides a significant improvement in hydraulic efficiency compared to 5-1/2 in. drill pipe and does not suffer from the disadvantages associated with use of 6-5/8 in. drill pipe.

The eXtreme Torque (XT) connection design, optimized for 5-7/8 in. drill pipe, provides exceptional torsional strength combined with a streamline configuration. The XT57 tool joint OD of 7 in. permits fishing of the connection inside of 95/8 in. casing or 8-1/2 in. open hole sections with a slim-hole overshot. An XT54 connection has been designed that permits fishing of 5-1/2 in. drill pipe inside of 9-5/8 in. casing or 8-1/2 in. open hole sections using a full strength overshot. Prior to development of this second generation connection the practical minimum tool joint OD for 5-1/2 in. drill pipe was 7 in., and a slim-hole overshot was required inside of 8-1/2 in. hole sections. The XT54 connection features a 6-3/4 in. OD and 4 in. ID. The 6-3/4 in. OD permits the use of a full strength overshot inside 8-1/2 in. hole sections. This increases the pull capacity by approximately 80,000 lbf and allows for more intense jarring during fishing operations. True Flush Inside Diameter. There is no gap or change in inside diameter from the box to the pin, resulting in a recess free inside bore. This provides a smooth flow conduit with less turbulence. It also eliminates the recess in other connections where cement and solids can be trapped. Damage Resistance. The rugged XT design incorporates more steel in the critical areas of the connection resulting in less refacing and fewer recuts. Increased Wear Tolerance. Because of the increased torsional capacity, the connection extends the service life of the joint by tolerating more OD wear before the pipe must be downgraded below Premium Class (Figure 5). XT can be refaced and a portable refacing tool is also available to eliminate shipping costs to a machine shop for repair work and for use in remote areas where machine shops are not readily accessible. XT Torsional Testing. Torsional tests have been conducted on several XT configurations. The designs that have been tested are listed below: XT31 4 in. x 2 in. XT38 4-3/4 in. x 2-9/16 in. XT39 4-7/8 in. x 2-9/16 in. XT54 6-3/4 in. x 4 in. XT57 7 in. x 4-1/4 in. Other sizes were tested during the design and prototype construction process. Calculations were performed using a form of the API screwjack equation that is modified to account for the addition of the secondary torque shoulder at the pin nose.2 Finite element analysis (FEA) was also performed on some of the design configurations to allow correlation with physical test results and confirm the calculated torsional strength of the connection. The test procedure varied somewhat for the various connection configurations evaluated since information in addition to the torsional strength was desired during some tests. The basic test procedure was 1) measure and record pin

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NEW DEVELOPMENTS IN DRILL STEM ROTARY SHOULDER CONNECTIONS

length and box depth, 2) apply thread compound and 3) makeup the joint until the connection plastically deforms as indicated by a zero slope on the torque/turn curve. Strain gages were mounted on the specimens for selected tests to verify the accuracy of the finite element analysis. Results of the torsional tests are summarized in Table 1. The physical test results combined with the FEA evaluation verified the accuracy of the rating method for the connection across the product size range. XT Field History. Approximately 250,000 ft of drill pipe with the XT advanced double-shoulder connection has been manufactured. All of this drill pipe has been in OD sizes 5 in., 5-1/2 in. and 5-7/8 in. Several operators are evaluating XT for upcoming applications on smaller drill pipe sizes. Rental companies own most of the XT drill pipe. Several XT connection drill strings have been used in the field. A string of 5-1/2 in. XT55 was the first to be used. This drill string has been rented by four different operators to drill critical wells in the Gulf of Mexico. The first string of 5-7/8 in. XR drill pipe went to work for a major operator on a Gulf of Mexico project in July 1999. Two additional strings started jobs in October 1999, and a fourth string was put in service in March 2000. The second and third 5-7/8 in. XR drill strings are being used on deepwater Gulf of Mexico projects operated by two major oil companies. The fourth string is being used on a jack-up rig operated by a major independent in the Gulf of Mexico. ARCO China Inc. purchased a string of 5-7/8 in. XR drill pipe for their Yacheng ERD project in the South China Sea. Phase 2 of this project began drilling in the second quarter of 2000. The project will include two platforms with ERD wells planned from both platforms. Wells are planned with horizontal departures up to 20,000 ft and Measured Depths up to 28,000 ft (approximately 13,500 ft True Vertical Depth). The improved hydraulic performance of the 5-7/8 in. drill pipe relative to 5-1/2 in. pipe will be extremely beneficial in drilling long 12-1/4 in. hole sections to measured depths in excess of 21,000 ft. A drill string made up of 5-1/2 in. XT55 and 5 in. XT50 was manufactured earlier this year for a new build deep-water rig slated for work with a major independent in the Gulf of Mexico. Gas-Tight Seal Option A version of the advanced double-shoulder tool joint incorporating a radial metal-to-metal seal has been designed and tested. Designated the XT-M, this connection features a metal-to-metal flank seal with a configuration similar to the seal used in premium tubing and casing connectors (Figure 6). XT-M is a specialized drill pipe tool joint designed for specific critical applications. The addition of a gas-tight seal to the connection permits safe, high-pressure drill stem testing (DST) operations using the drill pipe. Consequently, one string of drill pipe can be used for drilling, workover operations and drill stem testing. This eliminates the

requirement for a separate work tubing string on offshore locations, conserving setback capacity and valuable rig space. The XT-M connection can also be used in underbalanced drilling applications to improve the leak resistance of the drill string. Underbalanced drilling is a growing practice for exploiting hydrocarbon reservoirs. In some underbalanced applications conventional rotary shoulder tool joints provide less than adequate pressure integrity. XT-M handles and makes-up like a conventional API rotary shoulder connection, resists galling after multiple make/break cycles and provides pressure sealing typical of a premium tubing connection. XT-M Physical Testing. Two configurations of the XT-M connection have been tested. XT-M46 was tested for DST and high pressure workstring applications. XT-M39 was tested for use in underbalanced drilling operations. Durability and Internal Pressure Testing. A 6-1/4 in. x 3in. XT-M46 was tested on 4-1/2 in. 20.00 lb/ft S-135 drill pipe. This connection was designed to provide high torsional strength, tensile capacity that exceeds the pipe tension rating, a gas-tight seal capable of sealing pressures up to 12,500 psi combined with a thread form that resists galling and handling damage.3 Prior to testing finite element analysis was conducted to determine stress levels and verify that suitable dimensions, tolerances and seal interference were utilized in the design configuration. Testing was performed in the field to establish the connections ability to withstand damage from typical rig floor handling and make-up practices. Laboratory testing was conducted to establish the leak integrity of the connection with gas. Two sets of pin and box tool joints welded to two joints of drill pipe were used for make-up and breakout testing. Each joint was made-up and broken out in the vertical position for 100 cycles. A make-up torque of 45,000 ft-lbs was used. After completion of the 100 make/break cycles, the connections were visually inspected and dimensionally gauged. The seal surfaces exhibited normal burnishing and scuffing. The visual and dimensional inspection revealed no excessive wear, damage or significant galling problems. Seal integrity tests were conducted with the two sets of tool joints that were used for the make and break testing. Bypass holes were drilled in the pin near the pin nose and in the box near the box face. These holes by-passed the two shoulder seals in the connection and permitted isolated testing of the radial metal-to-metal seal configuration. The by-pass hole in the box was fitted with a 250C Autoclave connection to facilitate leak detection through use of a bubble tube. The specimens were made-up to 45,000 ft-lbs and placed in a pressure test containment pit. Pressure was applied slowly to 12,500 psi in approximately 5 minutes using nitrogen gas as the pressure medium. The 12,500 psi test pressure was maintained for thirty minutes while monitoring the bubble tube to determine if any leakage occurred. No leaks were detected with either sample.

M. J. JELLISON, S. P. HASSMANN, D. COTANDA JR., D. SNAPP

IADC/SPE 62785

External Pressure Testing. External pressure tests were also performed using four XT-M39 tool joint samples. The samples had 5 in. ODs and 2-7/16 in. IDs. The connection was evaluated for a 3-1/2 in. drill pipe underbalanced drilling application. External pressure was applied using nitrogen gas. This was believed to be the first external pressure test conducted with drill pipe rotary shoulder connections. Make-up torque for each sample was 22,500 ft-lbs. Each sample was pressure tested with nitrogen gas as follows: 500 psi - 15 minute hold time Followed by 5,000 psi - 60 minutes hold time (Note, hold time for sample #1 was 11 hours or 660 minutes.) followed by 500 psi - 15 minute hold time Samples #1 and #2 were made-up and broken out 50 times prior to pressure testing. After make-up testing, by-pass holes were drilled through the box counterbore and the pin nose of sample #1 to permit testing of only the metal-to-metal radial seal. Sample #1 held 5,000 psi for 11 hours without leakage. Two by-pass holes were drilled through the pin nose behind the metal seal in sample #2 to test the external shoulder seal of this connection. No leakage was recorded during the test. Sample #3 was made-up and broken out 100 times and pressure tested. Sample #3 held pressure, and no leakage was detected during the test. To evaluate compatibility the sample #3 pin was made-up to sample #4 box, and sample #3 box was made-up to sample #4 pin. Both connections remained leak tight for the duration of the external pressure test. No by-pass holes were used with samples #3 and #4. XT-M Field History. A major operator put a string of 4-1/2 in. 20.00 lb/ft S-135 XT-M46 in service beginning in September of 1999. The drill string is being used to perform workover, completion and drilling operations on a deep-water platform in the Gulf of Mexico. At the time of writing this paper, the string is still currently in use on the project. A string of 3-1/2 in. 15.50 lb/ft S-135 XT-M39 will be used by a major operator for underbalanced drilling operations in the North Sea beginning in the second half of 2000. Fatigue Resistant Thread Form A modified thread form that can be applied to either pin or box connections has been developed that reduces stress in the thread roots. The reduction in stress intensity provides improved fatigue endurance. The stress reduction is accomplished by machining an enlarged radius into the root of the thread (Figure 7). The modified thread form was originally designed and applied to pin threads primarily on drill pipe tool joints. When applied to pins, a second modification is introduced, where by, the pin thread body is machined on a slightly flatter taper than the box. This taper change effectively behaves like a variable pitch thread. It distributes the thread loads more evenly over the entire thread length and reduces the load at the last engaged thread by up to 40%. Results from an FEA

evaluation showing the distribution of force along the length of the threads for a standard API NC46 connection and an NC46 connection with the modified taper are shown in Figure 8. The modified thread form with the taper change has been applied to drill pipe for use in regions throughout the world to enhance the fatigue endurance of the pin tool joints. It has been used extensively in the Middle East, where the presence of H2S is a significant concern. Recently, the modified thread form has been applied to drill collar box connections. In this case, the taper change is not included to simplify dimensional inspection and allow the use of standard box thread gauges. An FEA study comparing the modified thread form applied in the box connection to a standard thread form was performed. No stress relief features (API stress relief groove or API boreback box) were utilized on the pin or box connections of the modified thread form model. The modified thread form model was compared with the following box connection types: standard box with no stress relief feature box with API stress relief groove box with API boreback feature All models were based on an API 6-5/8 Regular connection with an 8 in. OD and a 3 in. ID. Each model included a make-up torque of 50,700 ft-lbs and was evaluated with bending loads equivalent to a 10 deg/100 ft and a 20 deg/100 ft dogleg. The results of the FEA are shown in Table 2. The modified thread form results in a significantly lower stress level at the last engaged thread of the box compared to the standard API thread form. The modified thread form also compares favorably to the box with the API stress relief groove and the API boreback box. At a 10 deg/100 ft dogleg the stress level with the modified thread form is 17% lower than a standard box with no stress relief feature, 11% lower than a box with an API stress relief groove and 14% lower than a box with an API boreback box. With a 20 deg/100 ft bending load, the stress level with the modified thread form is 18% lower than a standard box with no stress relief feature, 11% lower than a box with an API stress relief groove and 13% lower than a box with an API boreback feature. A major advantage of using the modified thread form on drill collar boxes instead of the API box stress relief groove or API boreback box feature relates to the amount of material lost from re-machining the connection. Both the API box stress relief groove and the API boreback feature significantly add to the length of material that must be removed to effectively remachine a worn or damaged connection. The modified thread form provides a larger reduction in stress level and better fatigue life than either the API stress relief groove or the boreback feature. In addition, using the modified thread form reduces the length of material that must be removed to remachine the connection by approximately an inch or more. The modified thread form has been successfully used on drill collars to enhance the box fatigue life in well applications

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NEW DEVELOPMENTS IN DRILL STEM ROTARY SHOULDER CONNECTIONS

in Canada. Since drill collars are often scraped when they are too short to re-machine the connections, the modified thread form can increase the overall life of the collar. Conclusion Continued advancements in technology are essential to meet the challenges our industry faces today and in the future. Three advanced rotary shoulder connection designs have been developed for harsh conditions and improved performance. The second-generation double shoulder tool joint connection provides increased torsional capacity, promotes more streamline geometric configurations and tolerates more tool joint wear than standard API rotary shoulder connections. A version of this double-shoulder connection is available with a gas tight metal-to-metal radial seal to allow drill stem testing , high pressure workover operations and enhanced sealing in underbalanced drilling applications. A modified thread form that improves fatigue life has been developed for use on drill pipe pins and drill collar boxes. Use of this modified thread form on drill collar boxes can permit more re-machining of the connections and, consequently, a longer service life than possible with traditional API stress relief features. The authors hope that these new developments can assist engineers to implement creative solutions to challenging drilling problems.

Acknowledgement The authors thank the management of Grant Prideco and Unocal Thailand for their support and encouragement in publishing this paper. References
1. Jellison, M.J. and Payne M.: New Drill Pipe Size Improves ERD and Deepwater Drilling, World Oil (January 2000) 113. API Recommended Practice 7G, Recommended Practice for Drill Stem Design and Operating Limits, sixteenth edition, American Petroleum Institute, Washington, D.C., (August 1998). Bailey, E.I., Petrella, J. and Smith, J.E.: Development of Gas Tight Seal for Tool Joint, paper SPE 49202 presented at the 1998 SPE Annual Technical Conference and Exhibition. New Orleans, September 27-30.

2.

3.

SI Metric Conversion Factors ft x 3.048* E 01 = m in. x 2.54* E + 00 = cm lb x 4.448 222 E + 00 = N psi x 6.894 757 E + 00 = kPa
* Conversion factor is exact.

Table 1 - XT Connection Torsional Strength Test Data

Test Results Torsional Strength Connection Type OD (in.) ID (in.) Number of Tests Actual Material Calculated Torsional Rating Yield Strength Based on Actual Material Yield (ksi) Strength (ft-lb) Calculated Torsional Rating Based on 120 ksi Yield Strength (ft-lb) Minimum (ft-lb) Maximum (ft-lb)

XT57 XT54 XT39 XT38 XT31

7 6 3/4 4 7/8 4 3/4 4

4 1/4 4 2 9/16 2 9/16 2

5 3 1 2 4

N/A 132.9 129.4 129.4 137.5

N/A 95,915 38,935 35,852 23,987

94,340 86,605 36,107 33,248 20,934

98,571 90,000
1

119,085 127,197 N/A 48,632 34,100

49,523 33,283 28,100

1 - Torque test machine inadvertantly set to dump at 90,000 ft-lbs (connection did not yield).

Table 2 Summary of Connection FEA Results Stress Intensity at Last Engaged Box Thread Root (psi) Model Description Standard Box API Stress Relief Groove Box API Boreback Box Modified Thread Form 10 deg/100 ft 171,734 160,528 165,394 142,441 20 deg/ 100 ft 240,087 220,717 226,047 196,487

M. J. JELLISON, S. P. HASSMANN, D. COTANDA JR., D. SNAPP

IADC/SPE 62785

Figure 1 eXtreme Torque is a second generation double shoulder drill pipe connection. XT provides increased torsional capacity, promotes more streamline configurations and tolerates more tool joint wear than standard API rotary shoulder connections.

Primary Shoulder Box Pin Pin base Box Counterbore Secondary Shoulder

Figure 2 eXtreme Torque and HI TORQUE in the power-tight make-up postion. The secondary torque stop increases the torsional strength compared to a standard API tool joint connection.

HT

XT
Figure 3 Comparison of eXtreme Torque and HI TORQUE. The flatter taper of XT increases the secondary shoulder area resulting in more torsional capacity.

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NEW DEVELOPMENTS IN DRILL STEM ROTARY SHOULDER CONNECTIONS

Make-up Torque (ft-lbs)

90,000 80,000 70,000 60,000 50,000 40,000 30,000 20,000 10,000 0

7X4 8X5 3-1/2 X 1-3/4 4 X 2-5/32 6-1/4 X 3-1/4 4-3/4 X 2-9/16 5-1/4 X 2-13/16 6-5/8 X 3-1/2

XT vs. API Tool Joint Diametrical Wear Comparison

XT38 3-1/2" 13.30# S-135 NC38 0.188 0.770 4" 14.00# S-135 NC40 0.312 0.850 4-1/2" 16.60# S-135 0.469 0.812 5" 19.50# S-135 NC50 XT55 5-1/2" 21.90# S-135 5-1/2 FH
0.000 0.200 0.400

0.531 0.344 in. difference (183% increase)

API HT XT

XT40

0.458 in. difference (147% increase)

Co nn XT46 ec tio NC46 n

XT50

0.381 in. difference (81% increase)

0.500 in. difference (160% increase)

0.313 1.297 0.563

0.600 0.800 1.000 1.200 1.400 1.600 1.800 2.000

0.735 in. difference (131% increase)

Allowable Diametrical Wear from New to Premium Class (in.)

Tool Joint Dimensions (in.)

Figure 4 Maximum make-up torque or working torque comparison for API, HT and XT connections with various tool joint sizes.

Figure 5 XT vs. API Tool Joint Diametrical Wear Comparison

Note Some XT diameters may not be achievalbe due to connection dimensional constraints (minimum box face thickness requirement)

Seal Threads Pin Box Pin Nose

Figure 6 Metal-to-metal radial seal provides gas-tight pressure integrity.

Enlarged Thread Root Radius

API Thread Form

Figure 7 - The enlarged root radius of the modified thread form reduces the stress concentration at the thread root.

Figure 8 - The slightly flatter taper of the modified pin distributes the thread loads more evenly over the entire thread length and reduces the load at the last engaged thread by up to 40%.