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Case Study: API Box Boreback Stress Relief With Truncated Threads Can
Cause Premature Connection Fatigue Failure
Michael B. Gerdes, P.E., Dr. Kang Lee, SPE, T H Hill Associates, Inc.
Copyright 2010, IADC/SPE Drilling Conference and Exhibition
This paper was prepared for presentation at the 2010 IADC/SPE Drilling Conference and Exhibition held in New Orleans, Louisiana, USA, 24 February 2010.
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 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 does not necessarily
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Abstract
A rotary shouldered connection (RSC) can be modified
with two stress relief features to improve its fatigue
performance: 1) A stress relief groove on the pin and/or 2)
A boreback feature on the box, commonly called a box
boreback. Both are API approved stress relief features,
whose only purpose is to mitigate stress concentration
caused by unengaged threads in the connection. However,
under certain operating conditions the box boreback
feature as traditionally machined can actually reduce the
fatigue life of the connection. Prompted by recognition of
unique failure locations in the box of numerous BHA
connection types, the authors performed finite element
analysis to better understand the fatigue mechanisms
driving the failures.
In a typical API box boreback, the crests of the last four or
five threads are cut short, resulting in truncated threads.
Regarding the box boreback feature, API Specification 7-2
(API, 2008) controls for three primary dimensional
variables by connection type & size: 1) Cylinder diameter
2) Depth to last thread scratch 3) Depth to end of cylinder.
A machined boreback will be technically acceptable
adhering to these dimensional requirements, which allow
for truncated threads, but this method is not optimal. The
approach does offer two commercial advantages for the
tool owner as it is both simpler to execute and leaves
greater material behind for future recuts. API 7-2 also
allows for a box stress relief groove, but this feature is
rarely used commercially for similar reasons. To quantify
the impact of the box boreback on fatigue life, the authors
modeled a failed NC46 drill collar connection with the
feature and compared with hypothetical configurations of
the same connection.
Introduction
Rotary shouldered connections typically fail from fatigue
in the last engaged thread root of either the box or pin,
determined by the member weaker in fatigue and the
operating conditions impacting the connection. To improve
IADC/SPE 128931
BB with Truncated
Threads
BB with Full-Height
Threads
Figure 1 - The truncated threads version of the API box boreback is generally preferred by machinists because of the
ease of manufacture. The cutter is set at the boreback diameter, then pulled straight out of the box connection.
Crack Location
4"
Length to Crack
2 11/16"
Worn Threads
IADC/SPE 128931
The models showed that the last four box threads at the
back of the box did not engage the pin threads, and further,
that the wear on the threads was sufficient to cause a loss
of contact with the mating pin threads. CFI analysis was
used to evaluate the impact of this loss of contact on the
fatigue life of the failed connection. CFI is based on an
application of the Morrow strain-life model (Dowling,
1993), which considers both the crack initiation and
propagation phases in determining fatigue life. Connection
features and loading conditions are modeled using a finite
element analysis program, which gives a prediction of
fatigue life in the form of cycles to failure. Details of the
process used to calculate CFI can be found in Appendix A
and IADC/SPE 112105 (Ellis, 2008). Figure 6 displays the
FEA results for the example failure, and Figures 7-9
represent alternative hypothetical connection configuration
options holding inputs constant, except as noted.
IADC/SPE 128931
SRF
NC46
BB
th
4 thread
worn
17(2.0)
12(2.8)
5(4.8)
NC46
No SRF
22(7.2)
18(1.0)
10(3.0)
NC46
API SRG
25(1.0)
20(1.5)
12(3.5)
SRF
BB
NC46
no worn
23(1.4)
18(2.3)
11(1.1)
thread
BB
st
NC46
1 thread
21(1.4)
16(2.1)
8(7.9)
worn
BB
th
NC46
4 thread
17(2.0)
12(2.8)
5(4.8)
worn
Table 2 CFI fatigue performance values for different NC46
BB thread contact geometries.
BB w/ full
thread
24(4.7)
19(6.9)
12(1.7)
height
Table 1 CFI fatigue performance values for different NC46
stress relief feature geometries.
NC46
IADC/SPE 128931
Stress at last
engaged
thread
Connection
SRF
NC46
BB
no worn thread
166.29
NC46
No SRF
19.11
NC46
API SRG
29.07
BB
NC46
w/ full thread
29.719
height
Table 3 Last engaged thread contact stress for different
NC46 thread geometries.
Connection
SRF
NC46
BB
no worn thread
166.29
NC46
BB
st
1 thread worn
133.36
NC46
BB
th
4 thread worn
69.23
IADC/SPE 128931
IADC/SPE 128931
Appendix
For the analyses to be discussed herein (taking plastic
strain, stress, and fatigue into account), the Morrow strainlife model2 is used. The Morrow strain-life model was
chosen as it accounts for the fatigue crack initiation phase,
not just the crack propagation phase. This is important as
the connection geometry (thread design or stress relief
groove width) heavily influences fatigue performance.
Using a fatigue model such as the Forman model, which
assumes an initial crack size, would not capture the effects
of connection geometry. Equation 1 is the Morrow strainlife equation used to calculate fatigue life.
a =
f m
E
(2 N ) + ( )(2 N )
b
mp
...
(1)
Where:
f
m
= Strain amplitude
= Material fatigue constant determined
experimentally
= Mean stress (psi), when
m > mys
m = mys
E
Nf
b
f
mp
mp
, set
m mys
, set
=0
= Material fatigue constant determined
experimentally
Application of MUT
Applying torque to a computer generated model of a rotary
shouldered connection is much more difficult than loading
an actual connection into an iron roughneck and pressing
the GO button.
Successfully modeling a threedimensional connection (getting a convergent solution) can
be a daunting task because of the amount of sliding contact
between the thread flanks, the helical nature of the thread
path, and the boundary conditions. As a result, rotary
shouldered connections are most easily modeled in two
dimensions. Two dimensional axis-symmetric models
with asymmetric (bending) loads must be created. MUT is
approximated by either assuming a certain amount of
thread and shoulder overlap, or by applying a thermal
gradient (to expand the material thereby creating thread
flank and shoulder interference) to the pin and/or box. The
bulk stresses induced from applying MUT to an actual
connection are known or calculable in three key areas
IADC/SPE 128931
References
API Specification 7-2, Specification for Threading and
Gauging of Rotary Shouldered Thread Connections, first
edition, American Petroleum Institute (June 2008).
Dowling, Norman E., Mechanical Behavior of Materials:
Engineering Methods for Deformation, Fracture, and
Fatigue. Prentice Hall, 1993, ch. 9 & 14.
Ellis, S., Wadsworth, T., Lee, K., Gerdes, M., Altizer, S.:
Connection Fatigue Index (CFI): An Engineered Solution
for Connection Selection and a Replacement for BSR,
SPE/IADC 112105 (2008)
Bending Load
Axial loads and pressure are generally simple to apply.
Applying a bending load to a two dimensional axissymmetric asymmetric model generally requires the use of
a special element type. When modeling bending in a
rotary shouldered connection, it is important to bend the
connection multiple times in order to generate the best
approximation of the stress state at the thread roots.
During connection make up, the last few engaged pin
threads, any remaining unengaged pin threads, and some
areas of a stress relief groove (if present) are usually
plastically deformed. Since the stresses are plastic,
bending the connection once will not give accurate stress
and strain values. The connection must be bent multiple
times to allow for the effects of stress relieving and stress
redistribution. In an actual connection made up and run
down hole, this will occur once the connection is rotated
more than one revolution while bent or buckled.
CFI Calculation
CFI is expressed as a numeric representation of the relative
fatigue life. The relative fatigue life is determined by the
inputting the stress and strain values determined from FEA
into the Morrow Strain Life equation. These resulting
values are often expressed as a logarithmic value. CFI is
represented by a simplified expression of the logarithmic
value. The exponent of the base 10 multiplier is displayed
as the first number and the coefficient is displayed in
parenthesis. The exponent value affects the fatigue life far
more than the coefficient. By displaying the relative
fatigue life in this manner a quick and easy comparison can
be made.
25600000 = 2.56 x 107 = 7(2.56)