SPE 117977

Impact of ERD Wells with HP/HT Downhole Conditions on Drill String

Integrity
J. Franchi and W. Gamisans, SPE, VAM Drilling, A. Baryshnikov, ENI E&P

Copyright 2008, Society of Petroleum Engineers

This paper was prepared for presentation at the 2008 Abu Dhabi International Petroleum Exhibition and Conference held in Abu Dhabi, UAE, 3–6 November 2008.

This paper was selected for presentation by an 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 Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper 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 SPE copyright.

Abstract
Continuous developments in oil and gas drilling operations have resulted in a significant increase in the application
of extended reach wells sometimes combined with HP/HT down-hole conditions.

HP/HT conditions are generally taken into account as key inputs for directional drilling equipment and casing and
tubing strings selection. Indeed, high downhole pressures and temperatures limit the selection of materials for
these equipments and also drive their design properties.

Concerning tubulars, casing and tubing strings designed for HP/HT wells incorporate heavier body walls, high
grades and special premium connections to withstand pressure levels associated with high to extreme tension or
compression.

Recent drilling operations in the North Sea have shown that drill string tubulars can also be impacted by the
combination of high levels of torque & drag associated with ERD and high temperatures. Not anticipating the effect
of such combinations in the well planning and drill string selection phases can result into severe operational issues.

This paper describes the lessons learned during recent extended reach drilling operations with HP/HT downhole
conditions and presents the key factors to be considered for appropriate drill string specification and field running in
such cases.

Introduction
Today, ERD in HP/HT wells is not anymore an unreachable target, it is a daily reality. Drilling such wells requires
planning and anticipation in particular concerning the drill string selection as these wells are, in addition to highly
complex, often deep. The drill string has to be designed with the appropriate OD and wall thickness, maybe with
ultra-high strength grade material (above API S135) and generally with proprietary high torque rotary shouldered
connections to withstand harsh drilling conditions: more than 10,000 psi (68,94 MPa), temperatures above 300° F
(149° C) and torque and drag loads at high levels.
Basically, selection of the drill string is mainly driven by torque & tension expected loads, hydraulics and pressure
levels; instinctively, impact of temperature on drill string integrity is minimized.
This paper will explain, how, from a drill pipe failure investigation, the influence of high temperature has been
highlighted, and which precautions can be recommended from this field case.

Field case
The ERD HP/HT experience which is covered by this paper is part of a complex drilling program which was
achieved in 2005 in the North Sea.

The wells drilled had the following main properties:

ƒ Downhole pressure 13,000 psi (89,63 MPa) or higher
ƒ Downhole temperature 340° F (~170° C)
ƒ Water depth 1,180 ft (360 m)
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ƒ TVD 15,100 ft (4600 m)

ƒ Inclination 40° to 60° in 12-1/4” section, 60° to 85° in 8-1/2” section

Several drilling contractors were involved in this drilling program and had selected 5” #25.60 S135 drill pipe with a
proprietary high torque double shoulder connection (6-5/8” OD x 3-1/4” ID).

While drilling this particular field, one particular drilling contractor (DC#1) experienced issues with numerous
stalling episodes at the top drive and the crew had to use the maximum torque capacity of the top drive to get un-
stucked and to resume drilling. It has to be notified that the maximum torque applied at the top drive (44.3 kft-lbs)
was significantly below the recommended make-up torque of the connections used (50 kft-lbs).

On the same field some days later, another drilling contractor (DC#2) using the same drill string specification pulled
out the drill string and observed that the majority of the connections have been over-torqued and that two of them
had provoked drill string failures (wash-out). The first hypothesis announced by the experts in charge of the
analysis was that helical buckling has occurred and led to excessive loads on the drill string downhole.

A few weeks later on the same field, the first drilling contractor (DC#1) experiences a major downhole failure. To
pull the BHA out of hole, standard fishing methods were used, but when pulling out the section of drill string
stucked, the rest of the string broke as well. At the end of the fishing operation, the initial drill string was broken in
13 pieces.
Because of this surprising situation, a comprehensive investigation was launched to determine the root causes of
such failures and potentially have a better understanding of previous overtorqued connections.

Failure investigation
The purpose of the investigation was to define the failure root cause. In order to consider all possible hypothesis, a
global approach was used. Each element which could potentially have played a role in the failure process was
listed and organized in a fishbone diagram, as per below below.

ENVIRONMENT MANPOWER Drilling Parameters

Hook Load

Formation hardness
Make up Torque
ROP
Make up Process
Well chemicals Qualification

Careness Thread Compound

Well shape
Rotation speed

FAILURE

Thread Surface Treatment

Thread Protectors

Thread Machining

Power Tong Pipe Heat treatment

Elevators Friction Welding (inclusion, heat treatment…)

Pipe

Handling Forging

EQUIPMENT MATERIAL

Figure 1: fishbone diagram showing all possible causes of drill string failure

When performing the failed connections analysis, all metallurgical experts agreed on a fragile failure shape (see
Figure 2). All mechanical testing on the pipes & tool joints were performed and showed a product fully compliant
with the manufacturing specification (yield strength, impact strength, hardness, micro-structure…).
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As surfaces of failures were significantly rough, a traditional cyclic bending fatigue failure could not be considered
as the right failure mode (see Figure 3). The most probable failure mode was low-cyclic fatigue with only a few
cycles prior to failure combined with high torque and tension loadings.

Figure 2: failed section of one tool joint

Figure 3: Comparison between fractured surfaces of tool joints respectively occurred in the well and after fatigue
testing.

Another possible explanation was a material embrittlement due to presence of hydrogen: a micrographic analysis
showed some similarities with a bibliographic survey from NACE or CNRS (French scientist institute). Those
hypotheses brought us to two other arms of the fishbone diagram: method and environment.

Answering to the questions raised by the environment was quite easy. It had been confirmed by both drilling
contractors and the operator concerned that they didn’t detect any kind of hydrogen in the well, coming for instance
from H2S. And even if this hypothesis could have explained the 13 failures during fishing, it couldn’t have explained
the abnormal number of overtorqued connections observed on the first well.

At that stage, the investigation group focused on the drilling parameters: what were the drilling conditions, loadings,
events, etc…? As quickly described before, in case of DC#1, some strong stalling episodes had been detected
with surface torque readings staying at peaks of 44.3 kft-lbs (60 kN.m) for almost 40 seconds. This meant that this
torque had certainly been applied to a large number of connections along the string. At the same time, in order to
free the string, an over pull up to 120 klbsf (540 kN) which could have helped transmitting torque downhole - see
figure below.
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Figure 4: drilling records showing different loadings (WOB, torque applied at surface, hookload) versus time

But even if these drilling conditions could be considered as severe, the drill pipe, thru both its body and tool joint
should have resisted to these combined loadings. One parameter was missing and we finally found it in the
“environment” arm of the Ishiwaka diagram: this parameter was temperature.

From discussions the investigation group had with one of the co-authors of this paper, it was highlighted that the
rotary shouldered connection should not have been considered as a stand-alone element but the couple threaded
connection and thread compound as the thread compound could possibly impact the connection behavior at high
temperature and under extreme stresses. That is not considered by API RP 7A1 and ISO 13 678 [1, 2] but some
combinations of tool joints and dopes have been analyzed in literature [3, 4].

Rotary shouldered connections torque-turn behavior under high temperature

This behavior a connection with dope under high stresses and temperature is hard to model, analytically or
numerically. So physical tests were launched to observe how the high torque double shoulder connection used in
drilling operations would behave when made up with copper based compound under high temperature (from 60 to
150° C).

Here is a brief description of test procedure used:

1. Apply copper based thread compound on pin & box (quantity recorded for repeatability)
2. Make up the connection (closing by hand - no torque)
3. Heat the assembly with blankets or in oven - 30 minutes of soaking time (apart last step which is a 12
hours soaking)
4. Make up the connection until recommended make-up torque (MUT) is reached using a calibrated power
tong, controlling that the tool joints assembled are still hot.
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5. Measure the final position “Pin Vs Box”. Compare it to the “reference position” which results from the
assembly at the recommeneded MUT and at room temperature (18° C).

For the case of the double shoulder connections analyzed, here is the plot obtained:
Differencial make-up displacement - circumferential (mm)

Make-up after holding

the temperature
during 12 hours

Reference position
corresponding to make-up
at room temperature

Figure 5: make-up tests of rotary shouldered connection at different temperatures

To obtain the “reference position”, a make-up at room temperature has been performed (18° C – 0 mm
circumferential make-up). A significant change of behavior is observed after 110° C (230° F). At 150° C (302° F),
the additional circumferential distance is 60 mm, and when instead of 30 minutes, the soak time is 12 hours,
distance becomes 65 mm.

Now, it is important to understand the consequence of such overturn on the connection. At 150° C (302° F), the
additional turn is 60 mm in circumference, so approximately 0.1 turn (the OD of the connection was 6-5/8”). Due to
the thread lead, this additional rotation will induce 0.7 mm of axial displacement, which corresponds to the
additional make-up torque of 35.4 kft-lbs (48 kN.m). The following figure helps to figure out the consequences of
such over-turn.
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Double shoulder high torque connection

140
Connection torsional yield
limit at room temperature
120
Make-up torque (kN.m)

100 Zone of permanent

deformation
80 Connection recommended make-up torque
at room temperature

60

40

20

0
0 0,05 0,1 0,15 0,2 0,25 0,3
Turns
Torque-turn diagram at room temperature
Position reached at recommended make-up torque and room temperature
Position reached at recommended make-up torque and 150° C
Torque-turn diagram at 150° C

Figure 6: torque-turn diagram of rotary shouldered connections at ambient and high temperature (150° C)

The blue plot represents a typical torque-turn diagram for the high torque connection considered in this paper. The
yield torque is close to 120 kN.m. A permanent deformation is observed after 0.17 circumferencial turn from the
first contact between the torque shoulders (origin point on the X axis). The recommended make-up torque for such
connection is 67,8 kN.m (50 kft-lbs) which is reached after 0.1 turn at room temperature.

If the connection had been heated at 150° C, it will take more than 0.2 circumferencial turn to reach the same
torque: torque versus turn graph confirmed observation made on the circumferential displacement in the previous
paragraph. If we compare the same rotation under room temperature, the torque would be close to 120 kN.m. This
is clearly in the yielding area and without any tension applied.

Because of the impact of temperature, an overturn occurs which induces an axial displacement of the pin inside
the box. This displacement increases dramatically stresses inside the connector. To assess the type and the
quantity of additional stress, Finite Elements Analysis (FEA) has been run.

Here is a comparison between a connection made up with 0.1 circumferencial turn and a connection made with 0.2
turn.

Figure 7: strain status after 0.1 circumferencial turn

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Figure 8: strain status after 0.2 circumferencial turn

Areas colored in grey are considered as “permanently yielded”. As expected, both shoulders face serious
damages. And even if such deformations had been observed in the field, they were not the first reason of the
failures.

When analyzing the failed connections, the origin of cracks had been identified at the root of the first engaged
thread in the box, which determines the box critical cross section. This section faces also high deformation, as
shown by the FEA analysis and from such a stress situation any extra solicitation, like strong pulling to unstuck the
pipe or alternative bending will open cracks and destroy the connection.

This simple test and evaluation had demonstrated the most probable root cause of the failures.

High Thread compound behavior

temperature changing
Overturn
Applied torsion
60 kft-lbs in stuck pipe condition

Additional static or cyclic tension

(bending) applied

Box critical cross

Failure
section overloaded
Aggravating causes (hydrogen)

Figure 9: tool joint failure process

One fact confirmed this hypothesis: the break-out torque of the strings used by the drilling contractors DC#1 and
DC#2 when they were pulled out of hole. There was no record of break-out torque both contractors confirmed that
most of connections required high break out torque. To confirm, we have observed marks done by the tong dies,
and they were deep enough to witness the high torque involved. Indeed, the heating of the connections had
caused extra overturn downhole while applying regular torque at surface, but after cooling down and with the
compound getting its normal properties back, unscreawing the connections required very high torque.
8 SPE 117977

Lessons learnt and recommendations

The investigation to understand the reasons of the drill string failures in this HP/HT ERD program helped us
become aware of the following:
- HP/HT conditions combined with ERD wells can lead to un-expected loads and stresses on the drill string;
- These conditions and their impact on drill string mechanics should be carefully analyzed prior to start drilling.
Ideally they should be investigated soon enough in order to specify and supply the right drill string solutions (for
example tool joint and thread compound combined);
- Safety factors used to specify torsional resistance of drill strings for such wells should be higher than for more
“standard” drilling operations;
- The thread compound and its friction properties can play a huge role in the safety/efficiency/cost of the drilling
operations; Corresponding API/ISO standards shall require from thread compound manufacturers to provide
compound friction properties under temperature (for instance under 150° C).
- As modeling the behavior of a connection with a given thread compound is difficult, pre-testing should performed
in a testing facility in order to determine the appropriate friction factor to be applied in the field;
- Rotary shouldered connections behavior above the normal operating envelope shall be tested in order to assess
the nature of the failure mode. In this specific case, the manufacturer of the high torque double shoulder
connection decided to upgrade the design of the existing product for the size concerned in order to take advantage
of the lessons learned. The new connection design, in addition to bringing similar or higher torsional capacity, has
been specially tested under high temperature and guarantees both extended mechanical safety margins and a
progressive failure mode; it also brings additional value to the user by providing quick rig make-up.
- The rig crews should be trained on this specific matter in order to pay attention to make-up, break-out operations
of the drill string;
- Simple observations should be made on the rig floor such as break-out torque, die marks on tool-joints, etc…
which could indicate signs of excessive stresses or loads on the connections;
- When possible, quick inspection kits for rotary shouldered connection should be used after specific drilling events
such as severe stick & slip and when tripping out of the hole. This can prevent from using a potentially overtorqued
product;
- More frequent inspection should be performed on drill strings used to drill HP/HT ERD wells.

Future developments
Anticipation clearly plays a role when addressing HP/HT ERD operations. Indeed, forecasting torque and tension
loadings, selecting the drill string with proper safety factors will certainly maximize chances to meet the safety,
quality and cost targets associated with these programs.

But what could be the next step? It could probably be designing a connection which is not sensitive to high
temperature. Regarding the study made, the main player involved is the thread compound. As of today, thread
compounds have sensitive to temperature and their friction factors change with slopes depending on the
termperature range and the type of threaded connection.

Would it be possible to eliminate this factor? Maybe if materials or surface treatments which enable to make-up
safely and extensively rotary shouldered connections without any thread compound can be found.

New projects based on alternative tool joints materials are close to be launched. New materials, such as beryllium-
copper or copper-nickel alloys, provide very good anti-galling properties when tool-joints are assembled without
any thread compound. Therefore sensitivity to temperature could be eliminated. Also, on an environmental
standpoint, it could bring new horizons.

Conclusion
ERD wells are more and more common, as well as HP/HT conditions. The combination of the two which is
described in this field case has shown that drill string integrity can be severelly affected if proper analysis, design
and selection of drilling tubulars are not largely anticipated. This is mainly due to the incidence of temperature
generally above 235° F (110° C) which deeply impacts thread compound properties and therefore the mechanical
behavior of rotary shouldered connections, either standard or high torque.
Before the industry develops solutions with are less sensitive to temperature, higher safety margins should be
considered in the selection of drilling tubulars in order to achieve successful operations with such characteristics.

The authors hope that this paper can assist drilling engineers responsible for planning HP/HT ERD programs in
planning ahead and making the best product selection in order to minimize risks and maximize efficiency.
9 SPE 117997

Bibliography
1) API RP 7A1, Recomended practice for testing of thread compound for Rotary Shouldered Connections
2) ISO 13 678, Evaluation and testing of thread compounds for use with casing, tubing and line pipe
3) A. Baryshnikov, F. Donati and G. Toffolo, ENI-Agip and P. Ferrara, Recommendations could improve the
serviceability of drillstring components, WO, July 1998
4) J.J. Maney, Unocal Geothermal Div., and C.A. Strozier, Jet-Lube Inc, SPE 19554, High-Temperature
Performance of Rotary-Shouldered Connections, 1989