International Journal of Fatigue 27 (2005) 13601365

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Failure analysis of IEU drill pipe wash out

Shuanlu Lua,*, Yaorong Fenga, Faqian Luob, Changyi Qina, Xinhu Wanga
a

Tubular Goods Research Center of China National Petroleum Corporation, XiAn 710065, China
b
Tarim Oilfield, Xinjiang Kuerle 841000, China

Abstract
Many 127.0!9.19 mm IEU G105 drill pipe failures of wash out occurred after 2367 h of pure drilling time and 8726 m of penetration
footage. This paper gives a detailed investigation on these failures and a systematic analysis is carried out on service and loading conditions
of the drill pipes. Measurement and inspection were performed on configuration dimensions, chemical composition, mechanical
performance, metallography, macro-fractography, micro-fractography, and corrosion products. Configuration stresses at the crack positions
of the drill pipe were calculated by FEA. Crack extending velocity of the drill pipe material under corrosion medium was also measured. It is
thought from test and analysis results that the drill pipe wash out or fracture accidents were premature corrosion fatigue failure accident. The
failure courses were as the following: corrosion pits occurred first on the internal surface at the stress concentrating area of the drill pipe, and
then fatigue cracks initiated in pit bottoms, and washed out or fractured subsequently as cracks penetrated through the wall thickness of the
drill pipe. The reasons of drill pipe wash out were related to configuration, material quality, and load condition of the drill pipe string.
q 2005 Elsevier Ltd. All rights reserved.
Keywords: Corrosion pits; Drill pipe; Pickling test

1. Introduction
Drill pipe is one kind of important tools for drilling in oil
field. Drill pipe fatigue failures often occur in oil fields
because drill pipes bear continuously changeable tension
load, torsion load, impact load, internal pressure, and etc.
during drilling. Drill pipe wash out (holes occur, and
leakage takes place) is main form that results in big
economic loss [1]. So it is very important and urgent to do
failure analysis of drill pipe wash out in order to prevent
from it. This paper reports the result of failure analysis of
drill pipes.

2. Background
2.1. Accident
Three pieces of drill pipes were washed out and broke at
the positions of the internal upset taper subject to abrupt
* Corresponding author.
E-mail address: lusl@tgrc.org (S. Lu).

0142-1123/$ - see front matter q 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijfatigue.2005.07.012

geometric change on drill pipe during normally drilling in

C1 Well.
It was found by NDT that there were defects at the
vanishing area of internal upset taper on 20 lengths of drill pipe
among 375 lengths of drill pipe used in this well. The defects
were serious on 14 lengths, and not serious on 6 lengths.
2.2. Drill pipe service history
The drill pipes without internal coating were first used at
Q1 Well, and then used at C1 Well. The service history of
the drill pipe at Q1 and C1 Wells are as the following,
respectively.
2.2.1. Drill pipe work history at Q1 well
Q1 well was straight exploratory well, and top drive
drilling was used. The well depth was 4500 m, and the
drilling time for the well was 826.75 h. The drilling
parameters were as the following:
Weight on bit was 48199 kN, rotary speed 50122 rpm,
torque 334 kN m, pump pressure 4.219 MPa, and drilling
fluid density 1.081.38 g/cm3.
2.2.2. Drill pipe service history at C1 well
C1 Well was an exploratory directional well. The well
depth was 4269.82 m and drilling time was 1541 h until drill

S. Lu et al. / International Journal of Fatigue 27 (2005) 13601365

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Fig. 1. Planned C1 Well trajectory.

Fig. 2. C1 Well trajectory.

pipe washed out. The planning of drilling was shown in

Fig. 1. The actual maximum overall angle change rate (dogleg) was 5.68/30 m, and the well trajectory was shown in
Fig. 2.
The drilling parameters were as the following:
The bit weight was 276 kN, pump pressure
2.627.6 MPa, and rotary speed 6189 rpm.
2.3. Failure analysis specimen

The failed drill pipe was opened along longitudinal

direction, and there were severe corrosion pits on inner
surface. The pits were 0.301.06 mm in depth.
The corrosion pits were obvious, and many cracks were
found on the inner surface by the washed out holes after
pickling for 1 h with 50% hydrochloric solution (Figs. 4 and
5). The internal upset shape was not regular, and the profile
presented as wave shapes.
In order to know the resistance to corrosion fatigue
cracks of the drill pipe, the comparison pickling tests

One washed out drill pipe was taken as the failure

analysis specimen and the following test was performed.

3. Visual examination and dimension measurement

3.1. Visual examination
There were three wash out positions at the drill pipe
(Fig. 3). The wash out positions were 495, 497, and
503 mm far from pin seal shoulder, respectively. The
washed out holes were 21, 33, and 35 mm in
circumference direction.

Fig. 3. Washed out morphology on the drillpipe.

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S. Lu et al. / International Journal of Fatigue 27 (2005) 13601365

that the total length of internal upset taper (Miu) is in

accordance with API SPEC 5D [2], but the internal upset
taper is irregular, and presents wave shapes with different
radius.

4. Material tests
4.1. Chemical analysis
The chemical composition analysis result of the drill pipe
material was in accordance with API SPEC 5D.
Fig. 4. The morphology on inner surface of failed drill pipe after pickling
test.

4.2. Mechanical tests

The test result of mechanical performance was in
accordance with API SPEC 5D.
4.3. Metallography

Fig. 5. The contrast between failed drill pipe and the compared drill pipe for
streamline metal after pickling test (the failed drill pipe is beneath).

between failed drill pipe and the compared drill pipe were
done for 1 h with 50% hydrochloric acid solution. The test
result indicated that resistance to corrosion of the failed drill
pipe was worse than that of the compared drill pipe, and the
resistance to corrosion by the inner surface of the failed drill
pipe was worse than that by the outer surface (Fig. 5).
It is shown from wash out morphology analysis and
pickling tests that the wash out positions are all limited to
the internal upset taper, and there are severe corrosion pits in
this area, and the cracks bud from corrosion pits stemming
from internal surface.
3.2. Main dimension measurement
The main dimension measurement result of the failed
drill pipe was shown in Table 1. It is indicated from Table 1

The metallography result is shown in Figs. 68. It was

indicated from metallography result that there were severe
corrosion pits and cracks at the vanishing area of internal
upset taper, and cracks were 1.257.33 mm in depth
(Figs. 68). The microstructure was tempered S, and
inclusions were A1.0, B0.5, and D1.0.
It is known from metallography that cracks initiated from
corrosion pits, and featured corrosion fatigue cracks. Some
crack tops extended along rolling direction.

5. Micro-fractography and corrosion product analysis

5.1. Micro-fractography
The cracks opened were hemicycle flat area with black
color originating from corrosion pits on inner surface. There
were corrosion pits and deposits on the origination area and
extending area of cracks. There were fatigue striations on
the flat area front (Fig. 9).
It is clear from the micro-fractography result that cracks
originated from corrosion pits on inner surface, and there
were fatigue striations on the fracture, and corrosion
deposits contain Cl, S, K, Ca, and etc., and the crack nature
is corrosion fatigue crack.

Table 1
The main dimension measurement result (mm)
Item

Pipe body

Upset area

Dou

dou

Miu

Internal taper shape

Result

127.1

108.6

129.7

88.0

113

543

API SPEC 5D [2]

C1:3
127:0K
0:6

131:8C3:2
K0:8

90.5

R76:2

Wave shape, and radiuses

were 181, 209, 53 and
128 mm, respectively

S. Lu et al. / International Journal of Fatigue 27 (2005) 13601365

Fig. 6. The corrosion pit morphology on inner surface by wash out hole.

1363

Fig. 8. The crack top morphology (the main crack was vertical to the rolling
direction, and branch cracks were parallel to rolling direction).

5.2. Structure identification of corrosion deposits

The components of corrosion deposits were Fe, Cl, Cr,
Mn, S, and Si per Energy Dispersive Analyzer.
The structure identification results of corrosion deposits
are shown in Table 2 per XRD.
It is known from Table 2 that oxides occupy high
proportion among the corrosion deposits. The oxides are
produced frequently per electrochemistry corrosion because
drill pipes are dunked in drilling fluid with oxygen during
drilling.

Fig. 9. The fatigue striations on crack front.

6. Corrosion fatigue simulation test

Streamline metal on failed drill pipe was obvious due to
severe inclusions precipitated. Theoretically, if there were
severe inclusions in metal material the corrosion fatigue life
of the drill pipe will be reduced. In order to quantitatively
analyze the effect of inclusions precipitated on corrosion

fatigue life of the drill pipe the contrast test between the
failed drill pipe and the compared drill pipe without
inclusions precipitated were carried out to confirm the
extending speed of corrosion fatigue crack. The test
condition and result are as follows.
6.1. Test condition
The full thickness specimens were taken from internal
upset taper area of the failed drill pipe (1#) and the
compared drill pipe (2#), respectively. The specimen was
120 mm in length, and 6 mm in width. The specimen
thickness was different along internal upset taper.
The corrosion fatigue test was carried out on GD test
machine, and the stress ratio was 0.5, and stress breadth was
sin wave type. The test solution was 3.5% NaCl at 14G2 8C.
Table 2
Identification results of corrosion deposits

Fig. 7. The crack morphology initiated from corrosion pits at vanishing area
of internal upset taper.

Molecular formulary of corrosion deposits

Content (%)

FeO(OH)
FeFe2O4
Ca2SiO4

7.96
82.24
9.80

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S. Lu et al. / International Journal of Fatigue 27 (2005) 13601365

Fig. 10. The relation of crack expending speed (da/dn) versus stress
intensity parameter (DK) at crack top. Note that the crack growth rate of the
sample made from the failure pipe material is 1.72.3 times the crack
growth rate of the comparison sample that do not show corrosion fatigue in
service.

The extending speed of crack was inspected with

microscope (error of G0.005 mm).
6.2. Test result
The test result on relation of crack extending speed
(da/dn) versus stress intensity parameter breadth (DK) is
shown in Fig. 10. It is seen from Fig. 10 that the extending
speed of corrosion fatigue crack of 1# is higher than that of
2#, The former is 1.72.3 times of the latter.

pure drilling time is 2367 h, and total penetration footage is

8769 m. The normal penetration footage of a drill pipe is 90,
000 m according to drilling experience in this oil field. The
working life of failed drill pipe is only 9.6% of its normal
life. So the drill pipes are abnormal failures. According to
the research results of Dale [3] and Joosten [4] that the drill
pipes are also premature corrosion fatigue failures.
It is indicated from test result that the drill pipes were
failed because of corrosion fatigue cracks. The failure
process is as the following:
Corrosion pits brought on the inner surface of the drill
pipe/fatigue cracks originated from corrosion pits/
cracks extended/washed out (as depth of cracks penetrated through wall, or approached wall).
The corrosion fatigue cracks of the drill pipe are caused
by the stress of alternating change and corrosion medium.
The failure of drill pipes is affected on corrosion, stress
condition, and the stress concentration of drill pipe
structure.
It is known from test result that the corrosion fatigue
cracks originated from corrosion pits, and cracks and pits
are severe at the locations of internal upset taper subject to
abrupt geometric change. The corrosion pits possess the
feature of pinhole corrosion (Fig. 6), i.e. tiny batteries with
Fe anode are formed first at the discontinuous positions of
metal microstructure, such as inclusions, carbide, and
outcrop of streamline metal etc., and the structural
discontinuity, such as abrupt structure change and roughness at the internal upset taper area. Fe dissolves and
corrosion origination is formed. Fe ions hydrolyze as the
following:

7. FEA
Fe C 2H2 O/ 2HC CFeOH2
FEA was carried out with MSC/NASTRAN software,
adopting axes symmetry cell of linearity static state, and
applying axial tension load. The FEA result is shown in
Table 3.
It is known from Table 3 that the stress concentration is
less with more Miu and R. As internal upset taper is irregular
with different R the maximum stress concentration locates at
an area of r30.

FeOH2 C OHK/ FeOH3

Fe(OH)3 deposits at corrosion pits and covers pitheads, so
that PH will decrease because of HC, and Fe will dissolve
quickly. On the other hand, ClK in mud enters the pits from
pitheads in virtue of ionization, and chemical reaction
appears as the following:
ClK C HC/ HCl

8. The analysis on cause of drill pipe washed out

Pure drilling time is 826.75 h, and penetration footage is
4500 m for these drill pipes in Q1 well. Pure drilling time is
1541 h, and penetration footage is 4269 m in C1 well. Total

So that PH reduces, and solution accelerates. i.e.

catalyzing itself action takes place.
The pickling test results showed that there were severe
streamline metal on longitudinal section and the streamline
metal at area closing with internal surface was more severe

Table 3
FEA result
Item

Length of
internal taper
(Miu), mm

Radius at vanishing area (R),

mm

Small radius at position

of 58 mm far from start
position of Miu (r), mm

Stress coefficient of pipe

body, so

Maximum stress coefficient

and position, smax

smax/so

Result

80
110

300
647

30

1.591
1.591

1.828 (at r30 position)

1.62 (Miu vanish point)

1.149
1.018

S. Lu et al. / International Journal of Fatigue 27 (2005) 13601365

than that at the region near outer surface; but there was no
obvious streamline metal for compared drill pipe. Hence
there must be discontinuous microstructure (such as
bandings, inclusions, carbonizations, and etc.) and discontinuous configuration in micrography for failed drill pipes.
There were severe corrosion pits on the internal surface of
the drill pipe. The more severe pits of the area were, the
more severe fatigue cracks of that area were.
There were dissolved oxygen, ClK and etc. in the mud,
so that corrosion concentration occurred at locations of the
internal upset taper subject to abrupt geometric change.
Corrosion fatigue test showed that the crack extending
speed of the failed drill pipe was 1.72.3 times by that of the
compared drill pipe. I.e. the drill pipe failure is related with
the material impurity separated out that makes the drill pipe
life reduction of 41.256.5%.
In order to prevent drill pipes from corrosion, the internal
surface coating is an effective method. Severe corrosion
must take place on the internal surface of drill pipe without
internal coating at locations subject to abrupt geometric
change because drill pipes were dunked in the mud
containing dissolved oxygen and ClK during drilling.
As the corrosion pits are formed, the stress concentration
becomes more severe, and the corrosion fatigue cracks will
nucleate and extend. It is clear from the test result that the
cracks are limited to the locations of internal upset taper
subject to abrupt geometric change. This indicates that the
section of internal upset taper is weak position, and the
abrupt geometric changes of the configuration accelerate
corrosion fatigue cracks budding and extending, which are
verified by failed drill pipes and FEA.
On the other hand, C1 Well is a slanted well with obvious
tilted angle and dog-leg, so that the drill pipe must have
borne high stress, and budding and extending of fatigue
cracks must be accelerated.

1365

To summarize, the drill pipes were premature failures

due to the working condition and the drill pipe quality.
Considering working condition, there were severe corrosion
medium, and the drill pipes had borne large load in this well.
Thinking over the pipe quality, the internal upset tapers
were irregular configuration with severe corrosion and stress
concentration, and the material resistance to corrosion was
low.

9. Conclusion and suggestion

(1) The drill pipes were premature failures due to corrosion
fatigue cracks.
(2) The main reason of drill pipe washed out was bad
quality of drill pipes with irregular internal upset taper
configuration subject to abrupt geometric change and
low material resistance to corrosion, and rigor condition
of the well with severe corrosion medium and obvious
tilted angle and dog-leg.
(3) Use of drill pipes with internal coating, and improving
internal upset taper configuration and material quality
of the drill pipe were recommended.

References
[1] Lu Shuanlu. Investigation and analysis of drill pipe wash out accident.
Oil drilling and production technology, 2005.
[2] API SPEC 5D, Specification for drill pipe, API, Washington, DC.
[3] Dale BA. Inspection interval guidelines to reduce drill string failures.
SPE17207, 1988.
[4] Joosten MW. New study shows how to predict accumulated drill pipe
fatigue. World Oil, October 1985.