Sperry-Sun
HALLIBURTON
Basic Drill String Design
1.1.1 Introduction
Drill strings are subjected to forces of tension, torsion and bending when drilling a well. Designing
a drill string to accommodate these forces requires knowledge of the physical characteristics of the pipe
and the terminology used to identify these characteristics.
1.1.2 Objectives
Applying sound engineering criteria to the selection of tubulars can help prevent failures as oil
wells become deeper and environments more harsh.
The strength of tubulars, such as drill pipe is defined by a combination of pipe grade, weight, size
and condition.
Grade indicates the yield strength of the drill pipe. There are four commonly used grades of drill
pipe. These are:
E-75
X-95
G-105
S-135
There are four grades not in general use. These are:
D-55
N-80
C-75
V-150
The grade of drill pipe can be specified with or without the number following the letter. For
example, either "Grade E" or "Grade E-75" is correct.
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Basic Drill String Design
The numbers in the pipe grade specifically refer to the yield strength of the pipe. For example,
grade G-105 pipe has a minimum yield strength of 105,000 lb/in² (psi).
The pipe weight must be considered, as it is part of the hook load on the derrick. This effects the
depth a rig is capable of drilling to safely. It is important that the specific weight of drill pipe is referred to.
Drill pipe is listed under three different weight titles. These are nominal weight, plain end weight
and approximate weight.
Nominal Weight
Drill pipe is purchased and referred to by its nominal weight. The nominal weight is the pipes
"given name" and refers to the wall thickness of the pipe it does not refer to its actual weight.
Plain end weight is the weight per foot of a non-upset, non-threaded and non tool-jointed piece of
pipe.
Approximate Weight
This is the average weight per foot of a joint of complete drill pipe. It includes the non-upset
section, the upsets and both tool joints. The approximate weight depends upon the size and type of tool
joints on a piece of pipe. This is the value used in hook load calculations.
Weight Comparisons
The following table shows the weight comparisons for a 5" G-Grade drill pipe with a nominal
weight of 19.5 lb/ft, a 0.362" wall thickness and H-90 connections
API drill pipe is designated in terms of its outside diameter on the non-upset sections. There are
eight different sizes. These are: 2 3/8", 2-7/8", 3-1/2", 4", 4 1/2", 5", 5-1/2" and 6-5/8"
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Basic Drill String Design
Once drill pipe has been used, normal wear and other use related defects cause the pipe to
loose some of its original strength. API has developed inspection criteria to determine the extent of
damage. These criteria are used to assign the pipe to "classes" according to the extent of the damage.
The inspection examines the following conditions with all the criteria having to be met for a drill pipe to
gain the specific class.
OD wall wear
Dents and mashes
Slip area mechanical damage. Crushing, necking, cuts and gouges
Stress induced diameter variations. Stretched or shot.
Corrosion cuts and gouges, longitudinal and transverse.
Fatigue cracks
Internal corrosion and pitting
Internal erosion and wear.
Internal fatigue cracks.
Any evidence of fatigue cracks or washouts and the pipe is designated as scrap.
There are five classes of drill pipe indicating the amount of wear a joint of pipe has sustained
during its lifetime.
New
Premium or class 1
Class 2
Class3
Scrap
All new drill pipe becomes premium class as soon as it is used. New drill pipe indicates it is
directly from the manufacturer and has never been used. As soon as a joint of new pipe is picked up for
use on a rig it is re classified as premium or class 1 pipe. Interestingly this allows the manufacturers a
broader set of tolerances with the pipe having to conform to the requirements for Premium grade rather
than the new specification.
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Basic Drill String Design
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Basic Drill String Design
Figure 4 illustrates the changes in dimensions and mechanical properties of 5" G-105 pipe with
H-90 connections according to the different class specifications.
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Basic Drill String Design
2.2.1 Introduction
This section covers the theory of the mechanical limits of drill pipe.
2.2.2 Objectives
Define the terms limit of elasticity, limit of plasticity, and yield strength, tensile strength and torsional
strength as they relate to drill pipe.
Explain the effect tensile load has on torsional yield strength.
Explain the causes of drill pipe fatigue failure.
Define the term endurance limit as it relates to drill pipe fatigue.
Explain the effect of yield strength, surface finish, environment and tension have on the endurance
limit of the drill pipe.
2.2.3 Tension
Drill pipe is designed to lower, support and raise large loads. The application of a load, which
must be supported causes tensile stresses in the pipe.
2.2.4 Elasticity
One important property of steel is that, under certain conditions of loading it is elastic in nature
and can be stretched and once the load is removed it will return to it's original size and shape.
The elastic nature of steel is difficult to measure without the aid of instruments.
The elastic behaviour of steel is extremely important when designing and load bearing steel
structure or part.
If a bar of steel L cm long and A square cm in cross sectional area is fixed at one end and a load
P applied to the free end the bar will stretch or elongate a small amount, e. If the load P is removed, the
bar will return to its original length.
This type of non-permanent deformation is called elastic deformation and elasticity is the
property which permits a material to deform under a load and return to it's original shape once the load
is removed.
Within the elastic range of a material, if a load P is applied to the bar the bar will elongate a small
amount. If more weight is added to the load P, the increase in elongation will be proportional to the
weight added. For any successive increase in load, there will be a corresponding proportional increase
in elongation (Hookes Law).
So, for each increase in stress, there will be a corresponding proportional increase in strain, and
when the stress is removed the strain disappears and the bar returns to its original length.
The maximum stress that the bar can take without becoming permanently deformed is known as
the elastic limit.
2.2.5 Plasticity
The elastic condition has a limit and at some point of loading when the load is removed the bar
will not return to its original length but will be longer than it was originally. The bar is then permanently
deformed or plastically deformed. The amount of deformation is referred to as the permanent set.
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Basic Drilll String Design
Plasticity is the ability of the material to assume permanent deformation without breaking.
The plastic limit is the point of highest stress the material can withstand before failure occurs
this is also the tensile strength of the material.
L A
e
e
P Permanent
Set
P
The proportional limit is the greatest stress a material is capable of sustaining without deviating
from the law of proportionality of stress to strain (Hookes Law). In metals, the elastic limit and the
proportional limit practically coincide.
The yield point is the stress at which a material exhibits a specified limiting elongation. For Oil
field tubulars this elongation is 0.2%. This is the value referred to in the drill pipe grade G-105 pipe has a
minimum yield strength of 105,000 psi. It is also referred to as the yield strength.
As a material enters the plastic range, exceeding the elastic limit, the material becomes
stronger from work hardening. This means a higher stress is required to further deform the material.
This continues until the maximum stress the material can withstand is reached. This is referred to as the
Tensile strength. Once the tensile strength of a material is exceeded the material will rupture.
When drilling a well the main concern is how much can we pull on a string of drill pipe. The yield
strength and tensile strength then become very important. From the previous discussion it is obvious
that the stress must be kept below the materials tensile yield point. This point is referred to as the tensile
yield strength or maximum allowable hook load for the drill pipe.
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Basic Drill String Design
B A - Proportional Limit
or Elastic Limit
S
T A B - Yield Point or
R 0.2% Permanent Set Yield Strength
E
S C - Tensile Strength
S
D - Elastic Range
E - Plastic Range
D E
STRAIN
The Following formula is used to calculate the tensile yield strength, the yield point for a purely
tensional load on the drill pipe.
Pt = YmA
Where:
Pt = minimum tensile yield strength - pounds
Ym = Minimum unit yield strength - psi
A = Pipe cross sectional area - in²
For API 5", G-Grade 19.5 lb/ft, premium grade drill pipe.
Then:
Solution:
P = 436,150 lb.
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Basic Drill String Design
2.2.11 Torsion
One of the functions of the drill pipe in addition to supporting load is to rotate the bit and BHA.
Rotation causes torsional stress to be imparted to the drill string. Wall friction, stabiliser hang up and
other down hole conditions will increase the torque required to rotate the tube. If the torque becomes too
great, the tube may fail.
The torsional yield strength of a drill pipe is defined as the resistance of the tubular to failure by a
twisting torque or force. The torsional yield strength is based upon the shear strength equal to 57.7% of
the minimum yield strength (figure 1).
When the drill string is not under any tensile load the following formula is applied.
0.096167 J Ym
Q = D
Where:
For API 5", G-Grade 19.5 lb/ft, premium grade drill pipe.
Then:
Ym = 105,000
J = ( / 32) (4.85524 - 4.2764 )
Solution:
= 45199 ft/lb
When a joint of drill pipe is subjected to a combined load of torque and tension, its ability to resist
torsional failure is reduced, as part of the strength of the drill pipe must go to supporting the tensional
load. In this case, as would be seen during normal drilling operations the following formula is used.
Where:
For API 5", G-Grade 19.5 lb/ft, premium grade drill pipe supporting a tensile load of 100,000 lbs.
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Basic Drill String Design
Then:
Solution:
= 0.4305 x 102202.88
= 43995 ft / lbs
For API 5", G-Grade 19.5 lb/ft, premium grade drill pipe supporting a tensile load of 200,000 lbs.
= 40167 ft / lbs
For API 5", G-Grade 19.5 lb/ft, premium grade drill pipe supporting a tensile load of 300,000 lbs
= 32808 ft / lbs
For API 5", G-Grade 19.5 lb/ft, premium grade drill pipe supporting a tensile load of 400,000 lbs
= 18017 ft / lbs
For API 5", G-Grade 19.5 lb/ft, premium grade drill pipe supporting a tensile load of 430,000 lbs
= 7563 ft / lb
For API 5", G-Grade 19.5 lb/ft, premium grade drill pipe supporting a tensile load of 436149 lbs
= 81 ft / lbs
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Basic Drill String Design
2.2.14 Fatigue
Usually a drill string is designed for its capability to withstand tensile loads under static
conditions. This takes into account yield strength, tensile strength and maximum hook load.
Most failures occur not through tension failure but through fatigue failure.
Fatigue is failure resulting from the progressive growth of irregularities to major cracks caused by
the repetitive cycling of stresses.
In many industries where fatigue failures limit the life of equipment, industry standards have been
established which permit the design of equipment to operate at stress levels, which assure indefinite life
free from fatigue failure. Additionally equipment can be designed to operate at certain stress levels for a
finite period before failure occurs. These designs will incorporate various periods of peak loading above
the average stress level.
Very little statistical data concerning the nature of failures in drill pipe has been accumulated and
published. Reports made to the AAODC confirm the consensus of personal observations from many in
the industry that failures occur in the following manner:
1) Most failures in drill pipe occur while rotating or when picking the pipe up off bottom immediately
after drilling rather than when pulling on stuck pipe.
2) Most failures occur within 4 ft of the tool joint at either end of the pipe.
3) Failures are frequently associated with severe pitting on the inside of the pipe, and these cracks
appear to have started from the inside. Multiple cracks are frequently observed in severely pitted
pipe failures. Progressive crack growth is indicated.
4) Failures that appear to originate from the outside of the pipe are usually associated with slip marks
or surface damage. Progressive crack growth is indicated
5) Even when failure occurs as a result of pulling on stuck pipe failure frequently occurs in a location
where fatigue cracks have developed but not progressed to failure.
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Basic Drill String Design
Any metal part subjected to a cyclic variation is stress will fail through the progressive growth of
small irregularities to larger cracks and fractures even when the average stress is less than the yield
strength of the material. This type of failure is a high-cycle, low-stress fatigue failure. Characteristically
the fatigue failure shows concentric semicircular marks illustrating periodic growth in the crack.
If we look at a round bar that is held in a bend when it is rotated, we find that every fibre of the
bar is stretched in tension and then compressed. If there are any irregularities when they reach the
tensile side of the bend it is opened up and forced to grow. If the stress level at the base of the
irregularity is large enough the irregularity will enlarge progressively until the remaining solid material is
too weak to support the total load and a failure occurs. This failure will be instantaneous.
In the oil industry, a great deal of testing has been performed on full size drill pipe and tool joint
specimens. The results are plotted as stress vs. the number of cycles.
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Basic Drill String Design
From these plots, the stress level below which failures do not occur is called the endurance
limit. At stress levels above the endurance limit failure will occur at a predictable period in the life of
part.
Tests with notched specimens show a sharp decrease in the endurance limit when compared to
the same material that was tested without notches.
In drill pipe steels, increases in yield strength are obtained without relative increases in ultimate
strength from published data the following properties can be seen.
Comparing the endurance limits for these materials there is even less improvement from grade
E-75 to S-135. The endurance limit for grade E-75 specimens was 26,000 psi, 89% of the 29,000 psi
value obtained for S-135 specimens.
The type of surface finish effects the endurance limit of drill pipe. Improvements in the endurance
limit can be seen from an "as forged" state to "hard rolled" to "machined" to "ground".
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Basic Drill String Design
The continuous immersion in a corrosive fluid while undergoing cyclic stressing is extremely
damaging to steel. Conducted tests indicate a severe reduction in the ability of S-135 pipe to withstand
bending fatigue when immersed in seawater. No endurance limit is indicated for specimens run in
seawater.
Referring to the earlier example of a bending drill pipe Figure 9 we noted each fibre is alternately
in tension and compression. If a high tensile load is added to the pipe the stresses can vary from
maximum tension to minimum tension without the pipe ever becoming compressed. The addition of this
tensile stress reduces the ability of the pipe to withstand cyclic stresses.
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Basic Drill String Design
Additional factors are the sharpness of the bend the pipe is rotating in and the amount of tensile
load on the specific area of the drill pipe. The sharper the angle and the greater the tension the faster
the drill pipe fatigues.
It is worth noting that all fatigue experienced by a piece of drill pipe is cumulative. If exposed to
high stress bending in a sharp dogleg the joints are damaged by this although it may be of short
duration, shortening their effective life. The life of the pipe depends upon its cumulative history at
various stress levels, a short period of stress can significantly shorten the life of a joint of pipe. This
damage cannot be detected by any current field method until cracks develop.
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Appendix
Pipe Grade Sigma Sigma Min Minimum Fatigue Stress M. Elasticity Density Poisson's
Steel Ultimate (psi) Tensile Yield (psi) Endurance Limit (psi) (psi) lb/gal Ratio
E 100000 75000 22000 30 x 10^6 65.4 0.3
G 130000 105000 25000 30 x 10^6 65.4 0.3
S135 160000 135000 31000 30 x 10^6 65.4 0.3
S165 175000 165000 33000 30 x 10^6 65.4 0.3
Sperry-Sun HALLIBURTON
Sperry-Sun / Brazil
Appendix
Sperry-Sun HALLIBURTON
Sperry-Sun / Brazil
Appendix
Sperry-Sun HALLIBURTON
Sperry-Sun / Brazil
Appendix
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Sperry-Sun / Brazil
Appendix
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Sperry-Sun / Brazil
Appendix
Used Maurer points on S-N curve and solved for exponent b from Eq. 2 to
approximate single equation curve for cycles between 100,000 and 1,000,000.
6. API RP7G:
Schematic representation of S-N curves for ferrous and non ferrous materials.
Sperry-Sun HALLIBURTON
Sperry-Sun / Brazil