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CASING
Objectives
On completion of this module you will be able to: Indentify different types of Drill String failure Understand the factors that influence the life of Drill String components Describe the prevention measures to prevent DS failure and extend its life
Introduction
Premature and unexpected failures of drill strings cause great losses in time and material. Reducing drill string failures will improve rig operating performance and reduce expenses
* TH Hill
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Failure Types
Mechanisms which can cause failures: Tension Torsion Sulfide Stress Cracking Fatigue Other Causes
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DS Failure Mechanisms
Group 1 Mechanisms (Overload failures):
Acts only if stresses in a component exceeds some fairly high stress threshold
Tension Torsion Collapse Pressure Burst Pressure Combined Tension and Torsion Combined Tension and Collapse
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DS Failure Mechanisms
Group 2 Mechanisms: Can occurs at low stress level
Fatigue Split Box Sulfide Stress Cracking (Corrosion failure) Stress Corrosion Cracking (Corrosion failure)
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Failure Study
Fatigue Failure Mechanism Torsion SSC/SCC Tension Other 0% 20% 40% % of All Failures 60% 80%
Fatigue
Damage that accumulates when a component undergoes cyclic stress. At some point, cumulative damage results in the formation of a fatigue crack which can grow under continuing stress cycles until failure occurs.
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Tensile Failures
Tensile failures occur when the tensile load exceeds the capacity of the weakest component in the drill String. Occasionally the pin will fail if the connection was made up beyond recommended torque.
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Tensile Failure
Appearance : Jagged and Necked down Orientation: 45 deg to pipe axis
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Torsional Failures
API Standard tool joints are 80% as strong in torsion as the tube to which they are attached. Therefore in all cases, torsional failures will occur in tool joints.
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Torsional Failures
Torsional stress limit is exceeded. Failures occur in form of stretched pin or belled box (swelling). Torsional failures usually occur in the tool joint.
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Combination of Tension/Torsion
These failures are most likely to happen while fishing or pulling on stuck pipe.
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Wear
If during drilling significant wear is expected then tools can be run to measure wall thickness reduction. Collapse and burst pressures will be determined by the thinnest part of the wall, tensile strength by the remaining cross sectional area.
Burst strength
Determined by minimum wall thickness
Tensile strength determined by remaining area.
Wear Prevention
Reducing side force by minimizing DLS (especially high up in the hole) and using drillpipe protectors. Using drilling fluids containing solids (weighted) Always using sharp tong dies Minimizing rotating hours (use down-hole motors) Run a casing friendly hardbanding material on tool joints
Group 2 Mechanism
Can occur at low stress levels: Fatigue Split box Sulfide Stress Cracking Stress Corrosion Cracking
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Stress Concentrators
Stress concentrators.The accelerators of fatigue:
Stress concentrators focus and magnify the cyclic stress at local points. These points become the origin of fatigue cracks, which act as their own concentrators, to speed crack growth to ultimate failure. Internal upsets, thread roots, slip cuts and corrosion pits are the most common stress concentrators
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Fatigue
Under cycle loading, microscopic damage at high stress points A microscopic crack forms The crack grows under continuing stress cycles until a failure occurs.
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Fatigue in connection
Shape and Appearance:
Flat planar shape. Maybe accompanied by ragged area where component parted in tension
Location
BHA ConnectionsNear last engaged thread roots
Orientation
Perpendicular to the pipe axis
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Slip cuts
Upsets
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Corrosion
Corrosion occurs due to electrochemical reactions with corrosive agents. Corrosion rate increases when: Higher temperature. Rates double for each 31 C. Higher flow rate, especially if abrasive solids present. Higher concentration of corrosive agents (O2, H2S, CO2). Corrosion rate decreases when: Reducing dissolved O2 Reducing dissolved CO2 Increasing pH to > 9 Add coatings and inhibitors
Corrosion
Corrosion reduces the wall thickness of tubular.
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Elemental hydrogen (H +) migrates into steel and collects at high stress points
2H + + 2e H 2
Preventing Corrosion
Corrosive attention usually falls into one or more of the areas below: OXYGEN pH CO2 AND CHLORIDES HYDROGEN SULFIDE BARRIERS and INHIBITORS
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Inspection Methods
Ultrasonic (wall thickness) Magnetic Particle (cracks in thread roots and stress relief features) Liquid (Dye) Penetrant (thread roots and stress relief features) Electromagnetic (DP) Visual
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References
API RP 7G Drill String Design and Op Limits API SPEC 7 Specifications for Rotary Drilling Elements API SPEC 5D Specifications for Drill Pipe SLB Drill String Design manual TH Hill DS-1 Drill String Design