DS-1" Fourth Edition, Volume 3, Drill Stem Inspection Chapter 2 SPECIFYING THE INSPECTION PROGRAM 2.1 Scope and Definition: With the Fourth Edition of Standard DS-1°, inspection and qualification of drill string components is specified in Volumes 3 and 4. Volume 3 addresses the inspection of drill string equip- ment consisting of a single piece with no component pieces. Examples include drill pipe, drill callars, subs and pup joints. Volume 4, first published with Fourth Edition, addresses driling specialty tools, which are defined as a device that: + can be run in a drill string or casing string and perform some function + is assembled from two or more components, and; + is complete in itself with no adcitional equipment needed for its function except possibly some ‘external power or pressure source, Examples of drilling specialty tools include mud motors, MWD, LWD, underreamers and safety valves. This chapter ([rom section 2.3 onwards) gives instruc- tion on how to order an inspection program under Volume 3. Section 2.2 below provides instructions on how to specify the qualification requirements for a ariling specialty tool under Volume 4. 2.2 Qualification of Drilling Specialty Tools Using Volume 4: Unlike the drill sting equipment covered in Volume 3 of Standard DS-1, qualification of drilling specialty tools is complicated by the following: The design of drilng specialty toolsis not covered by industry standards. Therefore, the designs vary widely including the material selection, common failure modes, wear tolerances and tool function. + Designs are constantly evolving which benefits the industry. + The manufacturers are the only parties which have access to proprietary information including dimensions, stress levels, load capacities and material specifications, Considering these factors, the designer does not have the necessary information to determine the load capac ties oF develop the procedures to qualify driling spe- cialty to's. Volume 4 has been developed recognizing the limitations the designer faces and the need for the manufacturer to assume an active role in the qualifica- tion of these tools. This section describes how to specify the qualification of driling specialty tools using Volume 4, For qualification of specialty tools using Volume 4, the customer is the party that is at economic risk in the event of a tool failure. Except in a turnkey driling operation, the customer will normally be an operating company that is driling a well 2.2.1 Required actions by the customer: The customer must take the following actions when specifying qualification of driling specialty tools to Volume 4 of this standard. a. Establishaciassification. The customermustselect ‘one of the following tool classifications. Class At. The customer will accept a rental tool only if it has been completely disassembled, inspected, reassembled and function tested in accordance with Standard DS-1 Volume 4 since it was last shipped to the field. Class A1/A2. The customer will accept only 1 rental tools and tools that were previously shipped as A1 and returned unused from the field. + Class A3. The customer will accept a rental tool that was previously used, s0 long as itis function tested in accordance with Standard DS-1 Volume 4 betore itis shipped. + Class Ad. The customer will accept a rental tool so long as it meets the vendor's normal assembly, inspection and testing standards. + Class B1. The customer will accept a sale tool only ifithas been assembled and function tested in accordance with Standard DS-1 Volume 4. + Class B2. The customer will accept a sale tool so long as it meets the vendor's normal assembly, inspection and testing standards, + Shipments of classes not requested. A vendor may ship a tool of higher classification than the one the customer requested. For example, it a customer requests AS the vendor may ship 1. However, a vendor may not ship a lower classification without the customer's prior approval(TH) HILVY b. Notify the tool vendor. The customer must notify the tool vendor of the classification requirements and agree to the method for confirmation of ‘compliance. The customer may employ one or more of the following strategies. + Acceptance by statement, The customer may accept a vendor's warranty that tools are being shipped in compliance with this standard + Audit of capabilities. The customer may ‘conduct aucits to confirm that @ vendor shop has the procedures and equipment in place to fully comply with the requirements of this standard, Having confirmed that the required procedures and facilities are in place, the customer may elect to accept the vendor's warranty on future shipments. + Audit of specific performance. The customer may choose to place an authorized representative in the vendor's shop to witness and confirm thatthe requirements of Standard DS-1 Volume 4, Chapters 4, §, 6 and 7 are met on specific tools. + Confirmation of load ratings. The customer may choose to independently confirm or have confirmed the manufacturer's load ratings ‘on a specific too! model, as outlined in DS-1 Volume 4, Chapter 8 + Staged implementation. DS-1 Volume 4, Section 1.14 provides details of the ‘grandfather period for staged implementation of Standard DS-1. Based on the specific operation and drilling specialty too! being considered, the customer may elect to develop project specific implementation program. For ‘example, a customer may require the vendor to implement the inspection and function testing requirements of this standard while delaying implementation of load rating and assembly requirements. Ifthe customer does not specify aimplementation timeline, then the requirements of 1.14 apply. . Operate the tool within the limits set in the operating instructions unless an authorized vendor's representative will supervise tool operation 2.3 Inspection of Equipment Using Volume 3: This and the following sections describe how to order an inspection of equipment covered under Volume 3 of Standard DS-1. For inspection of equipment using Vol- ume 3, the customer is defined as the party on whose THHill Associates, Inc. behait the inspection is being conducted. If the com- ponents are being inspected for use in a well or wells, the customers the organization at risk in the event of a failure. If the components are being inspected prior to returning them ta stock for future rental, the customer is the company owning the components. In the first case, the customer will usually be represented by the designer, who will be most familiar with the loads and anticipated operating conditions, and therefore best qualified to set the inspection program and decide is- sues that arise during inspection. 2.4 Inspection Methods: Thirty-three inspection methods are defined under the standard. (Thirty-two are to be conducted by an inspection company, and tone, Rig Floor Trip Inspection, is designed to be done by either the rig crew or inspection company.) Many of the methods are specific to a certain component type, and tools employed and procedures used in each method will vary widely. Table 2.1 lists all methods used under the Standard, and the purpose of each. Each of the 38 methods listed in table 2.1 is accompanied by ‘a specific procedure. Unless a procedure is modified by the customer, the inspection company is required to follow it exactly. 2.5 Inspection Programs: The remaining sections of this chapter provide information on setting an inspection program using Volume 3. The inspection program is set by the customer and performed by the inspection com- pany. An inspection program consists of four elements: 2.5.1 Equipment list: The customer must provide a complete list of the equipment to be inspected. ‘The list must include joint count or footage required for each component, and a complete and accurate description of each component. 2.5.2 Methods to be employed: The customer must provide precise guidelines on which of the available methods are to be used to inspect each component. Thisis usually accomplished by selecting trom one of six inspection categories (discussed further below). However the customers free to select any applicable methods he or she desires, and the procedural requirements accompanying the selected methods, are still binding on the inspection company. 2.6.3 Acceptance criteria in effect: The customer mustgive the inspection company precise instructions. about the attributes which must be met or exceeded inan acceptable component. For normal weight dil pipe, this is often done by specifying an inspection Class. Attributes of other components can not be assigned by specifying a class.DS-18 Fourth Edition, Volume 3, Drill Stem Inspection 2.5.4 Frequency of inspection: The usual practice has been to set inspection frequency on some arbitrary basis such as footage drilled or hours rotated. Such estimates are litle better than wild guesses because they don't take into account how the components in question are loaded. Neither do they consider the probable failure modes. The recommended approach for setting inspection frequency is given in paragraph 2.16. 2.6 Conducting the inspection Program per Volume Once the customer sets the inspection program, the inspection organization is responsible for conducting it, with the one exception of Rig Floor Trip Inspec- tion, which the rig crew may perform. In the conduct ‘of an inspection method, the inspection company is responsible for following the procedural requirements outlined in DS-1 Volume 3, The inspection organiza- tion is also responsible for making the customer aware of any problems in achieving the desired acceptance criteria, and for working with the customer to resoNve these problems. 2.7 Deviating from Procedural Requirements: The customer, having set the program in the first place, is free to alter any aspect of the process he or she desires. Customers are cautioned however, that deviating from the procedures in Volume 3 may negatively impact the uality of the inspection and of the accepted products. The Inspection company may not deviate from any requirement in Volume 3 of this standard without prior approval from the customer. 2.8 Specifying Applicable Methods: The customer may select any applicable set of methods from table 2.1. However, to simpiiy the customer's choices and at the same time allow him or her to tailor the inspec- tion program to the risks of the application, six service categories are established. These categories, and the recommended inspection programs that accompany them, are shown in Tables 2.2 and 2.3, and figures 2.7 through 2.12 2.8.1 Category 1: Category 1 applies to very shallow, very routine wells in well-developed areas, When drill stom failures occur, fallure costs are so minimal that the cost of extensive inspection would not have been justified 2.8.2 Category 2: Applies for routine driling conditions where the established practice is to perform minimal inspection and failure experience is low. 2.8.3 Category 3: Designed for mid-range driling conditions where a standard inspection program is justified, If a failure accurs, the risk of significant fishing cost or losing part of the hole is minimal. A minimum Category 3 inspection is required as a design constraint for Design Group 2. 2.8.4 Category 4: This category may be used when diiling conditions are more dificult than Category 3. Significant fishing costs or losing part of the hole ate likely in the event of a drill stom failure. 2.8.5 Category 5: This category applies to severe driling conditions. Several factors combine to make the cost of a possible failure very high. A minimum, Category 5 inspection is required as a design constraint in Design Group 3. 2.8.6 Category HDLS: Owing to the increasing tensile loads carried by landing strings, especially in deep water, a sixth service category is included. This category is designated for heavy duty lancing strings (HDLS). The customers free to institute this category whenever he or she sees fit; however, the following recommended definition of a heavy duty landing string is provided to serve as a guide. Aheavy duty landing string consists of al components {0 be used in a casing landing operation from and including the casing running tool up to and including the top drive main shaft, where either: a. The buoyed weight of the assembly exceeds one million pounds. b. Any component in the load path, other than the dril string, is loaded beyond eighty-five percent ofits rated tensile capacity. ¢. The buoyed weight of the assembly exceeds seventy percent of the drill pipe's rated tensile capacity when using conventional slips or ninety percent when using siipless technology. 2.9 Setting Acceptance Criteria: Once the inspec: tion methods have been selected, the next step is to establish the applicable acceptance criteria. Unless working to a specific Design Group, the designer may set any set of acceptance criteria that meet the design constraints. Specifying a drill pipe Class has long been the shorthand way most designers use to specify 2 complete set of acceptance criteria for normal weight drill pipe and associated connections. (A class desig- nation does not apply to other components.) Four drill pipe classes are recognized in DS-1 2.9.1 Class 1: This Class designation applies to now drill pipe and associated connections. 5(TH) HILe 2.9.2 Premium Class: The Premium Class designation applies only to used narmal weight drill pipe and associated connections. The drill pipe tube and too! joint meet the requirements in Table 3.5.1. Tool joints are approximately 80 percent as strong intorsion as new drill pipe with “standard” sized tool joints, 2.9.3 Premium Glass, Reduced TSR: Torsional Strength Ratio (TSA) isthe ratio of tool joint to tube torsional strengths. Many new and Premium Class dill pipes have too! joint aiameters that give a TSR of about 0.8, meaning that new and Premium Class {01 oints are about 80 percent as strong in torsion as the tubes to which they're attached. Premium Class, Reduced TSR allows tool joint diameters that give TSR's of approximately 60 percent, while maintaining allother attributes of DS-1 Premium Class. This class was adopted in DS-1 Second Edition to recognize long-standing industry practice of using smaller tool joint OD's in low torsion dling to gain better fishing Clearance in certain dill pipefmole diameter situations. Pipe in this class will have identical load capacities as Premium Class pipe, except fr torsional strength. Premium Class, Reduced TSR isnot recognized by API. 2.9.4 Class 2: The dill pipe tube and tool joint meet the requirements in Table 3.5.1 and are approximately 70 percent as strong in tension and torsion as new nominal drill pipe with “standard” sized tool joints. 2.9.5 Acceptance criteria for thick-walled drill pipe: Acceptance of thick walled dill pipe is usually expressed by specifying the minimum acceptable remaining wall thickness, Typical limits placed on remaining wall are 80, 90 and 95 percent of new nominal. Classification criteria for TWOP is provided in Tablo 3.5.2. 2.9.6 Acceptance criteria for drill collars: By specifying the acceptable Bending Strength Ratio (BSR) range, the designer establishes the dimensional requirements for drill collar connection OD and ID. BSR is discussed in Appendix A of this volume and Chapter 4 of Volume 2, BSR for common connection types and sizes are listed for reference in table 3.14. For convenience, the recommended ranges for BSR are repeated below. Recommended BSR Ranges Traditional Recommended Drill CollarOD BSR Range BSR Range <6 inches 225-275 1.82.5 6-7 7/8inches 2.25275 —-2.28-2.75 28 Inches 225-275 2.63.2 TH Hill Associates, Inc. 2.10 Drill Stem Inspection Order Form: A standard order form is provided at the end of this chapter. This ‘orm provides space to communicate instructions to the ingpection company. Example Problem 2.1, Ordering an Inspection: The designer needs the following equioment inspected: 7000 ft, 5-inch, 19.50 ppt, grade S, NC5O, R2 dil pipe 1000: 3.5-inch, 13.30 pot, grade S, HT38, F2 dill pipe £8000 it, 3.5-inch, 13.30 ppt, grade 8, NC38, R2 dril pipe NC50 box x HT38 pin crossover HTB box x NC38 pin crossover The designer has elected to solve certain shortcomings in her design by taking the following actions: 1. For the 3.5 inch dil pipe, tighten the minimum remaining wall tolerance trom = 80 percent of new nominal (Premium Class) to = 82 percent. This wil provide the additional tensile capacity needed atthe surface to meet the overpull design constraint 2. For the 3.5 inch section top, use 1000 fee! of 3.5 inch, grade S dil pipe with HT38 connections in place of NC38 connections. 3. Replace the weak crossover at the 2.5 inch section top. Crossover — Minimum Box OD Minimum Pin ID (in) (in) C50 b x HT38 p 698 208 HT38 b x NC38 p 458 204 (Order an inspection program on the dill string. Solution: The problem is solved in figure 2.1 on the following page. 2.11 Inspection Frequency: In addressing the ques- tion of when to inspect, the designer should consider that the problem of scheduling re-inspection is both simpler and more difficult than using rules-ot hum such as hours rotated or footage drilled. Simpler in that the dimensions governing overload failure are easily evaluated anytime the pipe is accessible on the rig. More difficult because the relationships that drive fatigue failure are far too complex to be handled with simple rules of thumb. For Design Groups 2 and 3, inspection will have been performed before the com- ponents are picked up. 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Figure 2.2 The two principal objectives of dritl stem inspection. One is easily accomplished at the rig the other requires special equipment and training. inspect thereafter must include considerations of how the components in question are used, and what is the expected failure mode, 2.12 Inspection Using Metric Units: if measuring instruments with U. S. customary units are not avail- able for use during inspection, measuring instruments with metric units can be used provided the calibration, standardization and all other applicable requirements are met. The dimensions obtained shall be converted to the appropriate U. S. customary units using Table 2.5 to determine acceptance of a component. The dimensional requirements and tolerances for verif- cation of inspection apparatuses are also allowed to be measured using metric units and converted to the appropriate U. S. cusiomary units. A reference table for ‘conversion of fractions into equivalent decimal numbers is provided as table 2.6. 2.13 Essential Objectives of Inspection: The tech- nical details of dill string inspection processes may seem daunting to someone not familiar with the tech- nology. Thus, i's very helpful to reduce inspection to its essential objectives. In most cases, setting aside issues of normal handling damage, the activities of the inspector are directed toward twa principal objec- tives. If the designer focuses on these two objectives in scheduling a follow-up inspection, the designer's estimate will be much closer to the mark than is possible with any rule-of-thumb. The two inspection objectives are 1) To ensure that adequate load capacity exists in each component, and 2) To remove components that have fatigue cracks (or are at high risk for developing them). See figure 2.2. 2.14 Inspector's First Objective: The first objective of the inspector is to ensure that each component has the load capacily required of it. This concern almost always applies to dill pipe, which usually has lower load ‘capacity than heavier BHA components, and is also subject to higher loads. For a given dill pipe size and 8 connection, load capacity is established by pipe grade, tube wall thickness, and connection OD and ID. Hitcan be presumed thal the inital inspection got these issues correct, then during future uso the designer need only be concerned about accumulated wear on tool joint boxes and drill pipe tubes (pin ID's rarely change due to wear). Mostimportanti, the two dimensions critical 0 load capacity that are affected by wear can be quickly and easily re-measured right on the rig at no cost in rig time. ‘Since the designer can readily reconfirm these dimensions when the need arises, there will rarely be a need to schedule a full r-inspection on the basis of wear considerations alone. An exception to this rule will occur when a string is about to be used in some critical situation such as a Design Group 3 or HDLS application in which design factors and projected load factors approach unity 2.15 Inspector's Second Objective: The inspector's ‘second principal objective is to identity and set aside components that contain fatigue cracks, or that are at elevated risk for forming them. Finding fatigue cracks on dril pipe is an activity requiring special equipment, best done by trained specialists who are not working under production pressures. Thus, unless rig opera- tions are to be suspended for several days, the designer should probably plan on transporting drill pipe to a location or facility where inspection can be efficiently done. A possible exception willbe inspecting BHA con- nections for fatigue cracks, which can often be done efficiently atthe rig, provided the inspector is allowed to work independentiy of rig-driven production pressure. 2.16 Considerations for Scheduling Re-inspection: Given that the initial inspection was correctly done, the factors that should determine when re-inspection is needed are accumulated fatigue and accumulated wear. 2.16.1 Fatigue: Accumulated fatigue damage on drill pipe tubes should determine when to schedule a re-inspection for crill pipe fatigue cracks. The dificuty here is that fatigue damage can accumulate at vastly different rates in different parts of the string. This is, illustrated in figure 2.3. Here, a hole section is to be drilled from the tangent point (C) to section TD (0). With the bit rotating atthe tangent point, fatigue cycles begin accumulating on drill pipe that is within the build section. However, as drilling progresses, pipe moves from the build section into the straight tangent section, and from the straight section above the kickoff point into the build section. Also, if the tangent section is not horizontal, tension in the build section increases with each foot of new hole. This increases the Curvature Index and accelerates the rate at which damage accumulates on pipe in thebuild section. Figure 2.3 shows the accumulated damage when drilling the hole section is complete. While pipe immediately above TD andin the straight section above the kickoff point have accumulated little or no damage, other sections, like the pipe at and immediately above the tangent point, will have significant damage. Other locations will have intermediate amounts of damage. 2.16.2 Load capacity: Load capacity will be affected by wear on tool joints and tube bodies. Therefore, scheduling inspections for overioad considerations should be done on the basis of cumulative wear 2.17 Estimating Cumulative Fatigue Damage: To simplify the problem, the designer can separate the string into more than one section, then estimate ac- cumulated fatigue damage on each, using formula 2.1 Though this manuel estimate will be very crude, it will be more useful for setting inspection frequency than any rule-of-thumb. The estimate is made by accumu- lating "damage points’ on various sections of the drill string. Using this information, the designer can rotate component locations in the string to try to equalize damage, and schedule inspections based on the sum of accumulated damage points. The estimate takes into account average Curvature Index and number of cycles. Cyeles+Cl _ 60+CI+RPM-Footage DP= ROP«A0® 10° (2A) secTIONTD FATIGUE DAMAGE LMT ——, . Figure 2.3 Fatigue damage will accumulate unevenly over the length of a drill string. DS-1° Fourth Edition, Volume 3, Drill Stem Inspection Where: DP = Fatigue "damage points" trom one episode Cl = Average Curvature Index during episode RPM = Average string rotation speed during episode {revimin) Footage = Footage drilled during episode (It) ROP = Avorage rate of penetration during episode (IU) 2.18 Inspection scheduling: Inspection for fatigue cracks willbe indicated when total cumulative damage points for a section reach a predetermined threshold. Limited data is presently available to set these thresh olds. However, based on the hind cast of several failure analyses, the recommended beginning estimate would be to inspect when total accumulated damage points reach 500 for “eiical" applications. Less critical situ- ations could be handled with higher limits on damage points, such as shown on the table below. Inspection Trigger (Design Group) (Cumulative Damage Points) 3 500 2 600 1 700 ‘The designer should remember that this manual estimat- ing method is very crude. However, itis an improvement ‘over counting footage drilled or hours rotated, as it takes into account the relative severity of the driling condi- tions. More accurate estimates can be obtained using ‘a computer program designed for the task. Example Problem 2.2, Scheduling Inspection for Fatigue Cracks: The designer dis the hole section in figure 2.3 from the tangent point to section TD in 10 ppg mud. Heuses Brinch, 19.50 ppt, grade S, premium class dil pipe. The wellbore kicks off at 3,000 feet and builds to 60 degree hole angle at a3 degrees per 100 feet build rate. In this scenario, each joint of oil pipe that traverses the build section travels 2,000 feet within the build section where ‘combined tension and bending are imposed while rotat- ing. The join of pipe that enters the build with tho bit 2,000 feet from TO will experience the largest combined tension and bending while traversing the build section Based on a torque and drag estimation, assume this 2,000 foot section experiences an average tension of 120,000 Ibs. and is subjected to an average rotating speed of 120 RPM and an average ROP of 50 feet per hour. 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