Say Goodbye to Drill string failure

 Drill Pipe Fatigue

 BHA connection Fatigue
 Tension
 Torsion
 Sulphide Stress cracking
 Split box
 Connection Leak
 Mechanical
 Collapse
 Welding related
 Combined tension/ torsion
 Burst
 Raising the awareness level
• Domino effect.
• Mud corrosion Level
• Drill string history is unknown.
• Vibration /wobble.
• Doglegs are present.
• Hole enlargement.
• Torque and drag are erratic.
• Jarring.
• OD wear and abrasive
formations.
• High angle holes.
• Back reaming.
• Unfamiliar equipment.
• Drill stem tests.
 BASIC DRILL STRING KNOWLEDGE
OBJECTIVES
Identify the various types and grades of drill
pipe used on rigs, and know how to
determine the operating limits for each.

Demonstrate a knowledge of the following :

Drill Pipe Ranges,Grades and Terminology.

API and Numbered Connections Tool Joint Upsets.

Pipe Identification.

Drilling Tubular Function.

Fatigue Failures.

Tension and Torsion Failures.

 Basic Principles
DRILL PIPE RANGES

Drill pipe comes in three ranges or lengths:

Range API length (ft)

1 18 - 22

2 27 - 32

3 38 - 45

PIN RANGE 1 NOW OBSOLETE BOX

 GRADES
The grade of a pipe is commonly given by its minimum yield
strength expressed in units of 1,000 pounds per square inch.

Grade D-55 has a minimum yield strength of 55,000 lb/in2

Grade E-75 has a minimum yield strength of 75,000 lb/in2

Grade X-95 has a minimum yield strength of 95,000 lb/in2

Grade G-105 has a minimum yield strength of 105,000 lb/in2

Grade S-135 has a minimum yield strength of 135,000 lb/in2

Tensile strength of new pipe is the minimum yield strength x cross sectional
area of pipe body

5” OD S-135 19.5 lbs/ft has a cross section area of

5.2746 in2.
135,000 x 5.2746 = 712071 lbs
5.2746 in2
 DRILL PIPE TERMINOLOGY

Example
5” OD E grade IEU NC50 drill pipe
Nominal Size

5”OD

Nominal Weight

Nominal Weight 19.5 lb/ft

Approximate Weight.

PIN Approximate Weight 20.89 lb/ft BOX

 API AND THE NUMBERED
CONNECTION (NC)

Some Examples of NC interchange

NC 26 - 23/8 IF or 27/8 SH
NC 31 - 27/8 IF or 31/2 SH
NC 38 - 31/2 IF, 31/2 WO or 41/2 SH
NC 40 - 4 FH
NC 46 - 4 IF, 41/2 XH or 4 WO

NC50 41/2 IF
5 XH
41/2 WO

Flat
Crest Designated as V-0.038R
.065” and mates with the V-
V Thread Form .038” 0.065 thread form.
Round
Root
 TOOL JOINTS AND UPSETS

THE PIPE BODY IS OF SEAMLESS CONSTRUCTION

EXTERNAL UPSET ( EU )

INTERNAL UPSET
( IU )

INTERNAL-EXTERNAL UPSET
( IEU )

Pins usually have 350 tapered shoulders Boxes usually have 180 tapered shoulders

PIN BOX
 IDENTIFICATION

TONG AREA HARDFACING

TONG AREA

1. TOOL JOINT MANUFACTURERS SYMBOL.

2. MONTH WELDED.

G 6 95 B E 3. YEAR WELDED.
SAMPLE MARKINGS
AT BASE OF PIN. 4. PIPE MANUFACTURERS SYMBOL.

5. DRILL PIPE GRADE.

 IDENTIFICATION
STANDARD WEIGHT
STANDARD WEIGHT STANDARD WEIGHT HEAVY WEIGHT GRADE E75 DRILL PIPE
GRADE X95 DRILL PIPE GRADE S135 DRILL PIPE GRADE E75 DRILL PIPE

SLOT
NO MARKINGS

ONE GROOVE THREE GROOVES

SLOT
GROOVE

ONE WIDE SLOT GROOVE

TWO GROOVES GROOVE

STANDARD WEIGHT HEAVY WEIGHT HEAVY WEIGHT HIGH STANDARD WEIGHT HIGH
GRADE G105 DRILL PIPE GRADE G105 DRILL PIPE STRENGTH DRILL PIPE STRENGTH DRILL PIPE
 DRILLING TUBULAR
CLASSIFICATION AND CONDITION
Tool Joint Condition Bands

Classification bands for drill pipe and tool joints

Stencil marking for permanent classification.

One punch mark = Premium Class
Two punch marks = Class 2
Three punch marks = Class 3

* Colour bands on the pipe are for presentation purposes only and do not represent a class or condition.
DRILLING TUBULAR FUNCTIONS

The Drill String

(1) Transmits rotary torque to the bit.

(2) Provides a conduit for circulating fluid to reach

the bit.

The BHA

(1) Prevents buckling the drill pipe by keeping it in

tension.
(2) Allows weight to be applied to the
bit.
(3) Help stability of the bit.
(4) Minimise directional control
problems.
 DRILLING TUBULAR FATIGUE
FAILURES
Drill Pipe Drill Collars

Near Slip Damage,

Mashes or Dents

Near Internal
Upsets

Near Last Engaged

Thread Roots
 DRILLING TUBULAR FATIGUE
FAILURES
HOW FATIGUE HAPPENS

Compression

Tension

Pipe Buckles Due Collars Buckle

To Excessive When Weight Is
Pipe Bends Due
Weight Being Applied To Bit
To Hole Shape
Applied
 DRILLING TUBULAR TYPES OF
FATIGUE FAILURES

SLIP CUTS, MASHES AND DENTS CAN LEAD TO PREMATURE FAILURE

Notch in pipe focuses Fatigue crack starts at Crack propagates through

and accelerates fatigue bottom of notch pipe until failure occurs
 Bending Stress Ratio

Box should be 2.5 times stiffer than pin

 DRILLING TUBULAR TYPES OF
FATIGUE FAILURES
INTERNAL UPSETS CAN LEAD TO PREMATURE FAILURE

100

80 Box End

% 60

40

20 Pin End

0
0 8 16 24 32 40 48
Distance From Box and Pin Ends (Inches)
 DRILLING TUBULAR TYPES OF
FATIGUE FAILURES
BOTTOM HOLE ASSEMBLY CONNECTION FAILURE

SOLUTION
Stress Relief
Groove on Pin

Bore back on
Box

PROBLEM

Stress Concentrator Areas Cold Rolling Thread Roots

 DRILLING TUBULAR TYPES OF
FATIGUE FAILURES
BOTTOM HOLE ASSEMBLY STIFFNESS RATIO
5” OD x 3” ID 8” OD x 3” ID

Abrupt changes in OD Selecting the correct

and ID of collars. combination of pipe sizes
reduce stress levels.

9” OD x 3” ID
9” OD x 3” ID
For routine drilling or very low failure rate experience, keep (SR) below 5.5
For severe drilling or significant failure rate experience, keep (SR) below 3.5
Drill Pipe Fatigue Failure

What Happens? • Causes

Slips/cuts
Damage Washouts / Twist offs
accumulates Corrosion
as soon as the Bending and buckling
pipe goes into Back Reaming
service.

Cracks form by
fatigue and grow Fatigue is the
with each greatest cause
revolution
of drill string
failure
 TENSION FAILURE TORSION FAILURE
DRILLING TUBULAR FAILURE

Simultaneous Tension
Reduces Torsional Yield DRILLER STARTS
Strength in Pin Weak ROTATING PIPE.
Connections
DRILLER STARTS
PULLING ON PIPE.

EXCESSIVE TORQUE
CAUSES PIN TO BE
SCREWED INTO BOX
PIPE IS TORN UNTIL IT FAILS IN
APART WHEN PULL TENSION.
EXCEEDS LOAD
CAPACITY.
Simultaneous Torsion
Reduces The Drill Pipe
Tube Tensile Capacity

TENSION FAILURE TORSION FAILURE

 DRILLING TUBULAR
FAILURE
EXCESSIVE SPLIT/BELLED BOX PIN STRETCH
TORQUE EXCESSIVE
TORQUE

EXCESSIVE
TORQUE

Belled
Split
Thread Profile Gauge Box
Box

Stretched Threads
DRILLING TUBULAR FAILURE

CONNECTION WASHOUTS

Leak at Seal Area

Helical Pathways in
Thread Root.
Washouts
Fatigue Failure
 DRILLING TUBULAR
CORROSION

ACIDS: Corrode metal by lowering the pH and dissolving protective films.

DISOLVED SALTS: Chlorides, Carbonates and Sulphates increase electrical

conductivity of the drilling fluids. This increases electrochemical reactions and may result
in higher corrosion rates.

HYDROGEN SULPHIDE: Is weaker and less corrosive than Carbonic Acid when
dissolved in water. However a more significant problem is the effect known as Hydrogen
Embrittlement or Sulphide Stress Cracking.

OXYGEN: Causes rusting and pitting leading to washouts, twistoff’s and fatigue failure.

CARBON DIOXIDE: When dissolved in water forms a weak solution of Carbonic Acid
that corrodes steel in the same manner as other acids. When present with Oxygen
corrosion rate is higher than the individual corrosion rates.
 Corrosive Environment

THE PROBLEM IS :
 Expose to air.
 H2s, chloride, CO2.
 Corrosive fluids.
 Nicks and gouges.

PREVENTION:
 Keep the pipe clean.
 Use wipers on trips.
 Keep all set back areas clean.
 BHA Connection Fatigue

Causes of Failure:
• Poor make up.
• Over or under torque.
• Over size hole can cause
buckling.
• Thread and shoulder
damage, stabbing and
handling.
 Tension Failure
Causes:

• Over pull.
• Jarring
• Weight indicator not
calibrated properly.
• Wrong pipe
specifications for well
conditions.
• Inattention by crew.
 Example Calculation

• 5” 19.5 lbs/ft G-105

premium class DP
• Minimum cross sectional
area 4.15sq in.
• Minimum yield strength:
105 .000Ibs/sq in.

Answer:
• Load capacity =

• 4.15x 105,000lbs =
436l,150Lbs
Frictional Torque
Buckling Behaviour
 Torsion Failure
Look for:

• Stretched pins.
• Swollen boxes.
• Thread damage.
• Key points.

• OD and ID determine torsional

capacity.
• Back reaming with high drag.
• Under gauge hole.
• Poor lubricant selection in
relation to pipe make up.
 Sulphide Stress Cracking
Causes:

• Low Ph.
• No corrosion scavengers
in
the mud.
• Failure occurs in high
tensile components.
• Protection required
especially around tool
joint areas.
 Split box failure
Causes:

• Over facing can cause

wedging.
• Buckling forces force the
pin sideways.
• No bevelling.
• Over torque on make up.
 Connection Leak Failure
Causes:

• Under torque.
• Improper doping.
• Shoulder damage/
handling.
• Improper cleaning.
• Miss match on
connections.
 MECHANICAL FAILURES

MUD
JARS MOTORS
BITS

HOLE IBOP’s
OPENERS

SAFETY
VALVES

OTHERS
MWD
TOOLS
SHOCK UNDER
REAMERS
SUBS
 Mechanical Failure
Components at risk:

• Safety valves
• Kelly cocks
• Hole openers
• Jars
• MWD tools
• Mud motors

Causes of failure:
• Improper maintenance
• Poor operation practices
• Not correctly rated
 DRILLING TUBULAR FAILURE

COLLAPSE AND BURST PRESSURE

EXTERNAL PRESSURE INTERNAL PRESSURE

EXTERNAL LOAD EXCEEDS INTERNAL LOAD EXCEEDS

TUBE YIELD STRENGTH AND TUBE YIELD STRENGTH AND
PIPE COLLAPSES PIPE SPLITS
 Collapse Failure
• External Load pressures
exceed collapse rating of
the pipe.

Causes:
• Torquing up on pipe
body.
• Running to bottom
without fill.
• Maximum pipe pulling
with pipe empty.
 Welding Related

Causes of failures:

• Ledges.
• Under gauge hole.
• In adequate design in the
weld procedures.
 DRILLING COMPONENT
FAILURES
WELDING

Hole Openers Under reamers Welded Blade

Stabilizers
Rebuilt Tool
Joints
 Burst Failures

Causes:

• Incorrect pop off settings.

• Pressure, plugged pipe.
• DST tests with too high a
pressure.
 SOME OF THE BAD PRACTICES THAT PEOPLE
GET UP TO
Using Wrong Thread Protectors
Using Rotary To Make-up or
Breakout

Not Spacing Pipe On Deck

Correctly

Using One Tong Instead Of Two

For Make-up or Breakout
Picking Pipe Up By Hooking
Ends

Setting Slips Before Pipe

Removing Thread Protectors Movement Stops
Early

No Visual Inspection And Correct Riding Slips On Pipe

Doping Before Making-up

Incorrect Stabbing (Hitting Jacking Pipe With Tools Not

Shoulder or Rolling Pin Into Box) Designed For Job ie.(Stilson)
 DRILLING TUBULAR FAILURE PREVENTION

BALANCING AREAS THAT ARE WITHIN OUR CONTROL

Very
Low
Environment Design
GOOD Handling FAILURE Inspecting GOOD
SCALE

Very
High

Design FAILURE
Inspecting SCALE
BAD
Environment
Handling