ABSTRACT

With the demand for oil and gas increased, and the development of oil and gas drilling
technology so fast, the development of global oil and gas exploration has entered a
deep well, ultra deep well and offshore deep water exploration and development era.
Land and shallow sea oil and gas exploration degree now is high, oil and gas
production has been close to the peak, therefore many country and big oil and gas
multinational companies have turned to deep water search for oil and gas resources,
and have got a series of major discovery and development.

Due to the restriction and impact of the ocean drilling platform arrangement and cost,
Offshore drilling widely used cluster well, directional well, horizontal well and large
displacement technology, all these lead to drill stem under cyclic loading, and the
working condition of drill stem become more and more bad. Due to the high cost of
offshore drilling industry, the failure accident of drill stem will cause huge economic
losses.

Oil drill stems is the main tool for exploration and development of oil and gas, the
failure accident of drill stem in oil and gas exploration will not only hindered the
drilling speed and production, but also caused huge economic loss.

The failure type of drill stem is given priority to fatigue failure, according to the
research of the drilling contractor, there are about 50~60% fatigue failure in the total
failure of drill stem. Therefore, the research of tool fatigue prediction will bring great
significance for enhance drill stem management standards, establish a whole life cycle
of drill stem, monitoring, evaluation and query, ensure the safety of drill stem quality
and drill string, and reduce drilling cost.

II
 ACKNOWLEDGEMENTS

My thesis is developed from November, 2015 to May, 2016. During the process of
preparation, I have learned a lot from the internet, research, magazine and some
Chinese books related to drill stem failure analysis.

After left Norway, I went back China and got promoted to be a operation supervisor
of operation and QHSE department of COSL Drilling. The main work for my job is in
charge of more than 40 rig's operation of COSL Drilling, during this time I worked
overtime almost every day. The drill stem management and coordination is part of
everyday work. A lot of thoughts in my thesis are from my work and colleagues.
Therefore I would like to express my great appreciation to the people who help me a
lot in my work and the process of writing this thesis.

I highly appreciate the kind help from the Professor Tore Markeset, Dr. Ing, the Head,
Dept. of Industrial Economics, Risk Management and Planning University of
Stavanger, who gave me great help in defining the structure of the thesis. With his
crucial guidance, I could have a clearer mind of writing my thesis. I also highly
appreciate the kind help from the Professor Jayantha Prasanna Liyanage, the faculty
supervisor, who gave me great help for my study in University of Stavanger.

I would like to thank my wife and daughter. They pay for a lot of things and give me a
strong support in studying abroad and writing the thesis. When I was ill in hospital,
my wife give me patient care and encouragement. I would like to thank my parents
and relatives for their unconditional love and support throughout my life. They have
been accompanied us to go through the toughest moments.

Finally, I would like to express thanks from my deep heart to COSL, thank my
company for providing me such a great opportunity of studying in University of
Stavanger, learning different culture, and learn from the best professor. Thank you for
all of your trust, and I will do my utmost to dedicate myself to the development of
COSL.

III
 Table of Content
ABSTRACT..................................................................................................................................... II
ACKNOWLEDGEMENTS ............................................................................................................ III
Section 1 Introduction ....................................................................................................................... 8
1.1 Background ............................................................................................................... 8
1.2 Scope and objective................................................................................................... 9
1.3 limitation of the project ............................................................................................. 9
1.4 Thesis structure ......................................................................................................... 9
Section 2 General situation of failure problem of drill stem ........................................................... 11
2.1 The general statistics of failure situation of drill stem ............................................ 11
2.1.1 Failure problem of drill stem in onshore drilling main oilfield of China ........ 11
2.1.2 General situation of drill stem failure in offshore drilling .............................. 15
2.1.3 Drill stem failure in foreign countries ............................................................. 17
2.1.4 Summary ......................................................................................................... 21
2.2 Failure analysis of typical drill stem cases .............................................................. 21
2.2.1 Accident background ...................................................................................... 21
2.2.2 Macroscopic observation and size measurement ............................................ 22
2.2.3 Physical and chemical properties test .............................................................. 23
2.2.4 Thickening transition zone structure analysis ................................................. 26
2.2.5 Comprehensive analysis .................................................................................. 27
2.2.6 Conclusion ...................................................................................................... 29
Section 3 Cause type and regularity of drill stem failure ................................................................ 30
3.1 Fracture failure of drill stem and its expression form ............................................. 30
3.1.1 Fatigue and corrosion fatigue fracture............................................................. 30
3.1.1 Overload fracture ............................................................................................ 31
3.1.2 Low stress brittle fracture ................................................................................ 32
3.1.3 Hydrogen embrittlement ................................................................................. 32
3.2 Puncture failure and forms of drill stem.................................................................. 34
3.2.1 Puncture of drill pipe thickening transition zone ............................................ 34
3.2.2 Puncture on drill pipe weld area ...................................................................... 37
3.2.3 Drill pipe joint thread puncture ....................................................................... 37
3.3 Drill stem wear failure ............................................................................................ 38
3.3.1 Thread sticking and wear of joint .................................................................... 38
3.4 Excessive deformation ............................................................................................ 40
3.5 Corrosion failure ..................................................................................................... 41
Section 4 Inspection and classification of drill stem ....................................................................... 42
4.1 Inspection standards of drill stem............................................................................ 42
4.1.1 API inspection standards ................................................................................. 42
4.1.2 Inspection requirement of DS-1 standards ...................................................... 44
4.1.3 NS-2 inspection standards ............................................................................... 48
4.1.4 Contrast of drill stem inspection requirements for the three standards ........... 52
4.2 Drill stem using and inspection for Chinese oil companies .................................... 54
4.2.1 Using and field inspection requirements of drill stem..................................... 54

IV
 4.3 Inspection and classification of drill stem for international oil company ............... 57
4.3.2 Shell (China) Exploration and Production Co., Ltd. ....................................... 57
4.3.2 Drill stem inspection requirements for deep water drilling ............................. 57
Section 5 New inspection technology of drill stem......................................................................... 60
5.1 Common detection methods .................................................................................... 60
5.1.3 Ultrasonic testing ............................................................................................ 60
5.1.3 Electromagnetic testing ................................................................................... 61
5.1.3 Penetration testing ........................................................................................... 61
5.2 New technology of drill stem inspection ................................................................. 62
Section 6 Discussion and conclusion .............................................................................................. 63
Section 7 References ....................................................................................................................... 64

V
 List of Figure
Figure 2-1 Drill stem failure statistics of Tarim oilfield in 1995-2005 ........................................... 12
Figure 2-2 Proportion of drill stem failure in East of Sichuan drilling company............................ 12
Figure 2-3 Ratio of drill stem failure in Jidong oilfield .................................................................. 14
Figure 2-4 Failure statistics of drill stem in Sugeli area ................................................................. 15
Figure 2-5 Failure statistics of drill stem for COSL of 2012~2014 ................................................ 17
Figure 2-6 Type statistics of frilling tool leaking ............................................................................ 17
Figure 2-7 The leaking caused by slip clamp .................................................................................. 18
Figure 2-8 Washout due to the internal coating peeling off ............................................................ 19
Figure 2-9 Washout due to the original defect ................................................................................ 19
Figure 2-10 Relationship between failure quantity and well depth................................................. 20
Figure 2-11 Macroscopic feature of sample .................................................................................... 22
Figure 2-12 piercing feature ............................................................................................................ 22
Figure 2-13 Corrosion pit morphology of the coating at the bottom of the foam ........................... 25
Figure 2-14 Metallographic structure morphology ......................................................................... 25
Figure 2-15 Internal coating profile morphology of drill pipe ........................................................ 26
Figure2-16 Sample 4 Crack surface morphology around hole........................................................ 26
Figure 2-17 Open morphology of thicken end ................................................................................ 27
Figure 3-1 Fatigue fracture morphology ......................................................................................... 31
Figure 3-2 Fracture failure morphology due to over twist and overload ........................................ 32
Figure 3-3 Morphology of low stress brittle fracture ...................................................................... 32
Figure 3-4 Hydrogen sulfide stress corrosion cracking of drill pipe (SSC) .................................... 34
Figure 3-5 Puncture morphology of drill pipe internal thicken transition zone .............................. 35
Figure 3-6 Puncture morphology of weld line ................................................................................ 37
Figure 3-7 Thread gluing morphology due to poor accuracy control ............................................. 39
Figure 3-8 Thread gluing due to improper fastening ...................................................................... 40
Figure 3-9 Thread joint expansion of female joint .......................................................................... 41
Figure 4-1 Identified windows by inspection.................................................................................. 50
Figure 4-2 Drill stem inspection requirement for direction well..................................................... 51
Figure 4-3 Drill stem inspection requirement for horizontal well................................................... 52

VI
 List of Table
Table 2-1 Relationship of drill collar and BHA for φ311.5mm Hole .............................................. 13
Table 2-2 Failure statistics of Zhongyuan drilling in Jidong oilfield in 2013 ................................. 14
Table 2-3 Leaking statistics of drill stem for the east China Sea and Bohai in the past 10 years ... 16
Table 2-4 Statistics of leakage well depth and quantity .................................................................. 22
Table 2-5 sample size measurement results .................................................................................... 23
Table 2-6 Measurement results of thorn leakage sample size ......................................................... 23
Table 2-7 Tensile and impact performance results of failure sample .............................................. 24
Table 4-1 Classification of used drill pipe (API RP 7G) ................................................................. 43
Table 4-2 Inspection frequency of different category ..................................................................... 45
Table 4-3 Classification of used drill pipe and tool joint (DS-1) ................................................. 46
Table 4-4 Recommended inspection outline of drill pipe ............................................................... 47
Table 4-5 Cumulative damage point of different design scenario ................................................... 48
Table 4-6 Classification demand ..................................................................................................... 49
Table 4-7 Inspection method for different part of drill pipe ............................................................ 49
Table 4-8 Special requirement while exceed circumstance............................................................. 51
Table 4-9 Special conditions for horizontal well............................................................................. 52
Table 4-10 Comparison of drill pipe classification ......................................................................... 53
Table 4-11 Field flaw detection item............................................................................................... 54

VII
Section 1 Introduction

In recent years, with the increase of drilling depth and the drilling technology
development of high angle wells and large displacement horizontal wells, the
performance requirement for drill stem is more and more higher. Oil drill stems is the
main tool for exploration and development of oil and gas, the failure accident of drill
stem in oil and gas exploration will not only hindered the drilling speed and
production, but also caused huge economic loss. The research of tool fatigue
prediction will bring great significance for enhance drill stem management standards,
establish a whole life cycle of drill stem, monitoring, evaluation and query, ensure the
safety of drill stem quality and drill string, and reduce drilling cost.

1.1 Background

With the demand for oil and gas increased, and the development of oil and gas drilling
technology so fast, the development of global oil and gas exploration has entered a
deep well, ultra deep well and offshore deep water exploration and development era.
Land and shallow sea oil and gas exploration degree now is high, oil and gas
production has been close to the peak, therefore many country and big oil and gas
multinational companies have turned to deep water search for oil and gas resources,
and have got a series of major discovery and development.

Due to the restriction and impact of the ocean drilling platform arrangement and cost,
Offshore drilling widely used cluster well, directional well, horizontal well and large
displacement technology, all these lead to drill stem under cyclic loading, and the
working condition of drill stem become more and more bad. Due to the high cost of
offshore drilling industry, the failure accident of drill stem will cause huge economic
losses. The studies have shown that, the fee of fixed drilling ship is about $100,000,
floating drilling ship takes one day even 2 times than fixed drilling ship, and the fee of
deep-water drilling ship (water depth > 1524 m) is about 400,000 dollars per one day
(Jenkins R W,1999). Therefore, drill stem failure will bring huge economic losses for
oil field, the failure problem of drill stem is been pay much attention for each oil field
company. The failure type of drill stem is given priority to fatigue failure, according
to the research of the drilling contractor, there are about 50~60% fatigue failure in the
total failure of drill stem. Therefore, the research of tool fatigue prediction will bring
great significance for enhance drill stem management standards, establish a whole life
cycle of drill stem, monitoring, evaluation and query, ensure the safety of drill stem
quality and drill string, and reduce drilling cost.

8
1.2 Scope and objective

The main scope of this thesis is to study and propose the failure problem of drill stem
in China and abroad of China, and to study the inspection and class analysis of drill
stem. Also the project scope contain the reliability and utility of condition monitoring
and inspection maintenance during whole life cycle of drill stem.

The objective of this project mainly include the following several aspects:

a) Through the investigation analysis of drill stem failure situation in China and
abroad of China and the typical failure reason analysis of offshore drill stem, to
reveal the failure mechanism and failure reason of drill stem.
b) Research and identify the cause types and forms of failure, and its regularity for
drill stem.
c) Research drill tool use, inspection and testing requirements of domestic and
foreign oil companies, this include testing frequency, range, content. Research the
field and factory implementation and testing procedures of oilfield services
company.
d) Research the new detect technology of drill stem in China and abroad of China,
analysis the advantages and disadvantages of various technique;
e) Research the inspection cycle, classification of drill stem in China and abroad of
China, and study the mandatory scrapping system of drill stem in China and
abroad of China.
f) Research and study the configuration of drill stem for deepwater drilling platform
and the special inspection requirements in China and abroad of China.

1.3 limitation of the project

The research of this thesis focuses on the drill stem failure situation in China and
abroad of China and the typical failure reason analysis of offshore drill stem, analysis
the failure reason of drill stem. Also, research the inspection and grade for drill stem.
But due to limitation of founding out information and integrity of collection data,
some of the research does not contain all the condition of drill stem failure problem.

Additionally, although this paper propose some advantageous strategies regarding

drill stem management for the condition monitoring and inspection maintenance, but
does not deeply research and study the management strategies in system.

1.4 Thesis structure

This thesis is divided in to eight sections in total with the following outlines:

9
Section 1 – This section covers the introduction and scopes of the thesis. It also
describes the background information and its limitations for preparing the thesis.

Section 2 – This section is written based on general situation of failure problem of

drill stem in China and abroad of China which include offshore drill stem failure
aspect.

Section 3 – In this section, it is written about the failure cause type and its regularity
of drill stem.

Section 4 – In this section, it is written about the detection and classification research
of drill stem which include the China oil company and international oil company
aspects.

Section 5 – In this section, it will introduce the new technology for drill stem
inspection.

Section 6 – These sections draws the discussion and conclusion from the findings of
thesis.

Section 7 – It provides the list of references and sources that had been used for
preparing the thesis.

10
Section 2 General situation of failure problem of drill stem

2.1 The general statistics of failure situation of drill stem

The growing demand of the world for oil and gas resources is become more and more
huge, as the oil and gas exploration and development is increasingly thorough, the
deep well drilling scale is more and more big, the offshore oil exploration now is from
shallow sea to the deep sea. Oil drill stems is the main tool for exploration and
development of oil and gas, the failure accident of drill stem in oil and gas exploration
will not only hindered the drilling speed and production, but also caused huge
economic loss.

2.1.1 Failure problem of drill stem in onshore drilling main oilfield of China

(1) Tarim oilfield

The failure percentage of drill stem from 1995 to 2000: 35% of drill collar, 21% of
drill pipe, 16% of joint, 11% of centralizer, 8% of high weight drill pipe, 5% of shock
absorber 5%, and 4% of others. In all of the drill stem failure types, there are about 66%
of fatigue fracture, 16% of brittle fracture, 6% of stress corrosion fracture, 6% of
ductile fracture, and 6% of other types.

There has about 157 times of drill stem failure accidents happened from 2001 to 2003,
of which 121 drill pipe failure accidents occurred (Lin Yuanhua, 2007), and the most
failure problem was happened in thickening transition zone. 21 times of drill collar
failure accidents which all the problem occurred for box rupture or leakage failure.

There has total 93 times of frilling tool failure accidents happened in 2005 in Tarim
oilfield which 60 times of drill pipe leak and fracture, 14 times of drilling jar and
shock absorbers fracture, 9 times of drill collar fracture, 7 times of downhole
stabilizer fracture, and 3 times of high weight drill pipe fracture (Wang Xiyong, 2006).
Drill pipe leaks happened about 57 which the leak area failure was mainly for
thickening transition zone disappeared area.

There has total 87 times of frilling tool failure accidents happened in 2006 which
include 48 times of fracture accidents and 49 times of leak accidents. The fracture of
drill collar was highest in all the drill stem fracture accidents which accounting for
72.0% of the total number of fracture accidents. The drill stem leak location was
mainly for drill pipe thickening transition zone area, just a few for joint thread
leakage.

11
 90%
80%
70%
60%
50% 1995-2000
40%
2001-2003
30%
2005
20%
10%
0%
Drill
钻铤 collar Drill
钻杆 pipe Joints
接头 Stabilizer
扶正器 加重钻杆 HWDP Absorber
减震器 Others
其它

Figure 2-1 Drill stem failure statistics of Tarim oilfield in 1995-2005

As we can see from the statistics of drill stem failure in Tarim oil field, the failure
quantity of drill pipe is the most in all the failure accidents which followed by the drill
collar failure. And the failure types of drill pipe is mainly for thicken and transitional
area leakage.

(2) East of Sichuan drilling company

According to the statistics of the drill stem failure accident from 2011 to 2012 in east
of Sichuan drilling company, the drill stem failure accident can be roughly divided
into two kinds: (1) drill stem failure, accounts for about 62% of the total number of
drill stem failure, failure to drill collar connection thread root and compound pipe butt
welding thickening in a circumferential fracture is given priority to, it is show metal
brittle fatigue fracture. (2) the drill leakage failure, accounts for about 38% of the total
number of drill stem failure, mainly from the drill pipe thickening transition zone of
0.15 ~ 1.13 m in a circumferential pipe body pierced the failure (Chen Shaoan, 2014).

38%
fracture
钻具断裂

62% puncture
钻具刺穿

Figure 2-2 Proportion of drill stem failure in East of Sichuan drilling company

① Rule of failure position: Basic the puncture if from the drill pipe joints and pipe
butt welding thickening transition zone of 0.15~1.13 m of the tube body, it is account
12
for 64.8% of the total number of drill pipe failure; For the drill collar, it is generally in
the 2 ~ 3 buttons in a circumferential of female thread, account for 91.1% of the total
number of drill collar failure.

② Location features of failure depth：Drill collar failure is basic at the dynamic zero
stress points of weight on bit, joint rigidity transition zone of bit and drill collar, this is
nearly account for about 95.6% of the total number of drill collar failure; Drill pipe
failure in basic at the rigidity abrupt transition zone and well track changed area, it is
account for about 91.9% of the total number of drill pipe failure.

③ Formation features of failure: The failure in at the shallow hole of Shaxi temple,
artesian well, Liangao mountain, Xujia river strata, it is about account for 44% of total
failure.

④ Relationship of working condition and drill stem failure：In 2011, there has 3 wells
of well track mutation section, it is account for 3.3% of the total failure; In 2012, there
has 29 wells of well track mutation section, account for 53.7% of the total failure. It
can been see that the influence of the well track mutation for drill stem failure is on
the rise.

⑤ Relationship of drill collar and bottom hole assembly for φ311.5mm Hole in table.

Table 2-1 Relationship of drill collar and BHA for φ311.5mm Hole

Bottom Hole Assembly

φ229mm+φ203mm+φ165mm φ229mm+φ203mm+φ178mm
Year
φ165 Drill collar
Ratio φ178 Drill collar failure Ratio
failure

2011 8 wells 36.4% 4 wells 18.2%

2012 10 wells 62.5% 2 wells 12.5%

As we can see, the failure ratio of use φ165mm drill collar is 2 ~ 5 times than use
φ178mm for the bottom hole assembly of φ 311.15 mm hole, that is to say theφ165
mm drill collar is unfavorable use.

(3) Drill pipe failure statistics of Jidong oilfield

Jidong oilfield is located in the Bohai bay area which the surface is for shrimp ponds,
fish ponds and rice fields, the cost of the platform construction is high; The structure
position is located in the north basin of Huanghua depression of Bohai bay, it is a
typical complex fault block oil and gas fields.
13
The failure statistics of the drill pipe in 62 wells of Jidong oilfield which serviced by
Zhongyuan drilling company in 2013 show that the drill stem failure pattern is mainly
includes pipe body piercing, thread fastening, thorn leakage and pipe body fracture,
and so on and so forth (Hu Yulei, 2014).

Table 2-2 Failure statistics of Zhongyuan drilling in Jidong oilfield in 2013

Name and specifications Grade Quantity Position and reason

5" drill pipe Ⅰ 51 Body puncture

5" drill pipe New 1 Body puncture

5" drill pipe New 26 Threaded fastening

5" drill pipe Ⅰ 5 Body fracture

5" drill pipe Ⅰ 2 Male and female puncture

5.5" drill pipe Ⅰ 22 Body puncture

It can be seen from the table, the drill stem failure is mainly concentrated in the 5"
and 5-1/2" drill pipe, and most of the failure is for pipe body fracture and threaded
fastening. From the result of well conditions for verification of Jidong oilfield well
design, it is basically deflect at about of 500 m, the drill string is by the larger bending
stress, therefore the drill pipe is easy to fatigue at deflection area.

80 74 Failure quantity
70
60
50
40
30 26
20
10 5 2
0
Body puncture Threaded
本体刺穿 粘扣 fastening Body
本体断裂fracture Thread
内外螺纹刺漏puncture

Figure 2-3 Ratio of drill stem failure in Jidong oilfield

(4) Statistics of drill stem failure in Sugeli area

As the Chinese biggest gas field, there are total 22 drill stem failure accidents
14
occurred in Sugeli gas field area during July 3-2010 (Hua Jianjun, 2012). These
include 7 times fatigue fracture failure accidents of drill collar thread root, 6 times
fatigue fracture failure accidents of drill pipe joint thread root, 4 times fatigue fracture
failure accidents of drill pipe thickening transition zone, 2 times overload fracture
failure of drill pipe body, 1 thread tripping accident of drill collar joint, and 2 times of
other failure accidents. Among these failure accidents, the highest percentage of 3
kinds are the fatigue failure of drill pipe, thread joint fatigue invalidation of drill
collar and overload failure of drill pipe body, which are respectively for 45%, 32%
and 9% of the total drill stem failure. From the figure 2-4, we can see that the failure
accidents is mainly by fatigue failure of drill pipe and drill collar thread in Sugeli
area.

5%
9%
DP fatigue failure
钻杆疲劳失效
9% DC thread fatigue failure
钻铤螺纹接头疲劳失效
45%
DC body overload
钻杆管体过载失效
DC thread tripping
钻铤螺纹脱扣
32% Others
其它

Figure 2-4 Failure statistics of drill stem in Sugeli area

Summary: The main drill stem failure types of land drilling is the fatigue fracture or
the fatigue leakage, which the main location are drill pipe joint, drill collar joint
thread and drill pipe thickening transition zone. The well section is given priority to
dog leg serious interval.

2.1.2 General situation of drill stem failure in offshore drilling

(1) Incomplete statistics for the year 1999 ~2013

Compared with onshore drilling, offshore drilling has higher risk and higher cost. The
phenomenon of leakage from 1999 to 2013 in the part of the east China Sea and Bohai
oil field drilling can be seen in the statistics table 2-3 (Jiang Yuanwen, 2007) (Zhou
Aqi, 2014). The drill stem leakage characteristics can been show as occurred in the
female joint side of drill pipe body which about 0.5~0.7m from the mother buckle end
and located in the transition zone of drill pipe thickening. According to the above
statistics, it can be seen that the failure of drill stem in the offshore drilling is mainly
caused by the failure of drill pipe thickening transition zone in the past 10 years.

15
Table 2-3 Leaking statistics of drill stem for the east China Sea and Bohai in the

past 10 years

Oil-Gas Well Occurrence Leaking

Specification and grade
field number time quantity
PH B6 1999.2~1999.3 4 φ127mm, S135 drill pipe
φ127mm, 1 joint for G105, others
PH B1 1999.6~1999.7 24
for S135
PH A6 1999.8~1999.9 19 φ127mm,G105
φ127mm, 11joints for G105,
PH BA6 2001.3~2001.4 14
others for S135
PH Aa5 2002.11~2003.2 3 φ127mm, S135

LD LD5-2 2006.2 2 φ127mm, G135

CFD XFD11-1A 2006.5 2 φ127mm, height weight drill pipe

BZ BZ25-1C 2006.6 1 φ127mm, S135

BZ BZ25-1C 2006.26-29 3 φ127mm, S135

PL PL19-3A 2007.5.28 1 φ127mm, S135

PH BA6s 2012.11~2013.2 18 φ127mm, S135

(2) Failure statistics of drill stem for COSL (China Oilfield Services Limited)
2012~2014

According to the drill stem failure statistics of COSL 2012 ~ 2014, the drill sting
leakage failure occurred about 42 cases. Among them, as shown in Figure 2-5, there
are 38 times of drill pipe leaking which accounted for the total failure of 90.5% and 4
times of drill stem fracture failure which accounting for only 9.5%.

In the total number of puncture failure, there are about 26.3% for the male connector
end thickening transition zone, about 47.7% the female connector end thickening
transition zone, about 13.2% for the body leakage and about 13.2% for the joint
puncture leakage. It can be seen from figure 2-6 that the drill stem puncture is mainly
at the disappear area of thicken transition zone and slip bite area which accounting for
about 73.7% of the total leakage failure accidents.

Drill pipe leakage accident is mainly located near the KOP (Kick Off Point) of the
well, and the dogleg neat the KOP is larger, even some reach to 3 degrees /30m. In
addition, some of the leakage failure happened in rotary table area, which may be

16
related to the rock or bumps of drilling rig. When the drilling rig is swinging or
pitching, some of the derrick is inclined, the upper end of the drill string is not vertical,
and the drill pipe under some distance from the rotary table is still vertical, therefore
the drill string is bent. Because the stiffness of drill pipe is much smaller than kelly, so
most of the bending occurs on the first drill pipe the side of the kelly. In the vicinity of
the rotary table, the drill pipe is easy to leak due to bending fatigue.

25
Drilling tool failure

20
15
10
5
0
刺漏
Leaking 断裂
Fracture
2012 9 1
2013 23 3
2014 6 0

Figure 2-5 Failure statistics of drill stem for COSL of 2012~2014

Failure statistics of drilling tool leaking

14
12
Failure quantity

10
8
6
4
2
0
Male公端过渡带
transition zone Female
母端过渡带 transition zone
接头台肩或螺
Thread 本体body
Pipe
纹
2012 4 3 0 2
2013 5 13 2 3
2014 1 2 3 0

Figure 2-6 Type statistics of frilling tool leaking

2.1.3 Drill stem failure in foreign countries

(1) Failure analysis and research results of the International Association of

Drilling Contractors

According to the IADC (International Association of Drilling Contractors) and failure

analysis of drill pipe survey results, the failure occurred at thicken transitional zone of
17
drill pipe body is accounted for 70% of drill pipe failure accidents, the drill pipe
thicken transitional zone is the "weak link" of drill pipe.

(2) Failure of drill stem in North oilfield of Norway

J.V.Bjune of University of Stavanger and K.A.Macdonald of Norway DNV (DET

Norske Veritas) done the drill stem failure research of the North Sea for nearly 10
years (1996-2006) (K A Macdonald, 2007), it was found that most of the drill stem
failure occurred mainly in the thicken transition zone area and the threaded
connection area, rarely occur in the body of the drill pipe. They also listed the three
typical cases to represents the drill tool leakage failure trends and types of cause:

① Slip bite caused. In the course of tripping, the area of slip clamp holding
larger tension load, stress concentration caused by slip bite marks, this can
lead fatigue crack initiation, finally cause fatigue leaking. The fatigue crack
can been usually observed at the bottom of the slip bite area.

Figure 2-7 The leaking caused by slip clamp

② Drill pipe internal coating peeling off. Internal coating not only reduce the
friction of drilling fluid, but also play a role in corrosion protection. After the
internal coating is partially detached, corrosion fatigue is easy to occur, which
causes the initiation of fatigue cracks at the bottom of the corrosion pits.
Internal coating peeling is usually due to the combination decline of the
coating and the body which caused by the poor construction quality and
placed too long time of the drill stem. When split the leaking hole, the
blistering and shedding phenomenon can be seen in the internal coating,
sometimes also observed the morphology of thorn crack which expansion
from the inside to outward of the hole.

18
 Figure 2-8 Washout due to the internal coating peeling off

③ Drill pipe manufacturing defects. The small original quenching crack and
folding defects existed in the drill pipe, and does not detected, this will
become a source of fatigue crack during the drill pipe service process, and
finally washout or fracture due to the crack extension in the drill pipe.

Figure 2-9 Washout due to the original defect

(3) General situation of drill stem failure in Iran national South Oil Company

S.Moradi and K.Ranjbar researched drill stem failure analysis to statistics 30 years of

19
 the National Iranian South Oil Company (S Moradi, 2009) , it established database
which contains 92 wells of drill stem failure. The statistics show that more than 750
cases of drill stem failure types are thorn leakage and overload fracture, and the thorn
leakage is the most common form of failure. Although the overload fracture appear
less frequently, but usually cause huge losses. Based on the failure database, they also
studied the discipline of well depth, casing for drill stem failure. According to the data
analysis, the following conclusions are obtained:

1) About 93% of the failure occurred at the top of the well (casing diameter
466.78mm, 444.5mm of the hole), only 6% occurred in the 311.2mm of well diameter
section. As the figure shown below, the failure occurred in 18-5/8" casing section is
more, when access to 13" casing, the failure number of failure is reduced to 0. It is to
say that the probability of buckling and vibration of drill stem can be reduced due to
reduce the diameter of the borehole.
Failure quantity

Failure quantity

Well depth Well depth

Figure 2-10 Relationship between failure quantity and well depth

2) 95% of the failure is the puncture and leakage of tube, and the rest is reverse
fracture.

3) 65% failure accident occurred for drill pipe, and most of them located in slip
holding area. About 22% failure accident occurred for drill collar, and most of the
failure pipe is near the bottom hole assembly.

4) The failure drill pipe comprises new drill pipe and old drill pipe.

5) The most failure accident occurred when use three cone bit to drill the well.

Summary: The results of typical oil field research in foreign countries show that the
main failure modes of drill stems are puncture and overload, and the puncture is more
common.

20
2.1.4 Summary

It is found that the drill stem failure situation of China and foreign onshore and
offshore drilling are as below:

(1) In all types of drill stem failure, the fatigue failure is the main form which include
drill pipe thicken transitional belt and slip clamp area of the thorn leakage failure,
joint thread fatigue thorn leakage and fracture failure.

(2) The drill pipe thicken transitional belt and slip clamp area of the thorn leakage
failure is more prominent for offshore drilling, thorn leakage wells occurred in the
well section with high dogleg.

2.2 Failure analysis of typical drill stem cases

In order to further understand the cause of the failure of offshore drilling, a well drill
stem in the east China sea thorn leakage situation are analyzed.

2.2.1 Accident background

The well type was been designed for directional well in the east China sea which the
well depth is 4788 m, the water depth is 88.88 m, the rotary table height is 46.62 m,
and the side tracking window is located in the well depth of 855 m ~ 860.7 m. The
drilling fluid performance as follows: 1.70 ~ 2.53 g/cm3 density, fluid loss 14.0 ml ~
18.0 ml, 47.0 ~ 51.0 s viscosity, pH value of 10. The ROP (rate of penetration) is
average about 77-81 RPM.

The total drill pipe thorn leakage of the well is 20 joints, these including 18 joints of 5
" S-135 drill pipe and 2 joints of 5" height weight drill pipe. The drill pipe thorn
leakage of well depth and quantity statistics are shown in table 2-4. From the statistics
we can see that the quantity of drill pipe thorn leakage in 600 ~ 1000 m hole are 14
joints (include 2 joints height weight drill pipe) and in 1000 ~ 1500 m hole are 6
joints even most are old pipe.

Analysis the two samples of S-135 drill pipe leakage, thorn leakage location are the
thickening transition zone disappear area of female joint. Sample number are 8-1 and
8-4 which the corresponding pipe number are SZAR258 and S0398 respectively. The
specifications of drill pipe is for Ф 127 mm x 9.19 mm which thick form for internal
thicken and drill pipe manufacturers for Grant Drill stems Limited Company.

21
 Table 2-4 Statistics of leakage well depth and quantity

Thorn of well depth/mm Drill pipe number/root

600-1000 14
1000-1500 6
Note: 2 joints of height weight drill pipe in 14 joints

2.2.2 Macroscopic observation and size measurement

The macroscopic sample analysis is shown in figure 2-11 which the outer wall of 2
samples is corrosion serious. Sample 8-1 piercings as shown in figure 2-12 (a) which
the piercings hole bigger and present oval shaped. Sample 8-4 piercings as shown in
figure 2-12 (b) which present circular. The specific size parameter of measurement
results are shown in table 2-5.

Sample 8-4

Sample 8-1

Figure 2-11 Macroscopic feature of sample

（a）Sample 8-1 （b）Sample 8-4

Figure 2-12 piercing feature

22
 Table 2-5 sample size measurement results

Distance Distance Tube

between between Piercing size/mm diameter
Sample piercings and piercings Welding neck of
number internal thread hole and diameter/mm piercing
joint sealing weld Lateral lengthways position
surface /mm line/mm length length /mm
8-1 550 152 38 12 129.2,129.1 127.8
8-4 530 143 12 11 128.8,129.0 127.1

After open the sample 8-1, it is found that the internal wall coating has been damaged
which as shown in figure 2-13 (a), and the internal coating of thickening transition
zone was serious peeling off, the tube coating spraying of thickening transition zone
and its near position of the tube was uneven and presented ring shaped distribution.
After observation, there are sparkling falls off phenomenon around the piercings
coating as shown in figure (b) 2-13, the coating spraying uneven phenomenon also
exist in other parts of this sample, and the junction between the coating and coating
has been sparkling fall off as shown in figure (c) 2-13. Sample 8-4 cut open after wall
The morphology of sample 8-4 as shown in figure 4 when cut open the sample, we
can see that almost all internal coating was corrode and felled off.

When measure the internal thickening area size of the two samples, the results are
shown in table 2-6. From the results, we can say that the internal upset parallel length
of Liu and internal thickening transition zone length of Miu are all conform to API
Spec 5 DP - 2009 standard.

Table 2-6 Measurement results of thorn leakage sample size

Internal upset parallel Internal thickening

Sample number length of Liu transition zone length of
/ mm Miu / mm
8-1 96.5 91.5
8-4 96.5 100.5

API Spec 5 DP standard 95.25~146.05 ≥76.20

The macroscopic morphology observation results show that the leakage hole of two
samples are located in a thickening transition zone disappeared area, and the crack is
originated in inner wall, also the internal coating spraying of drill pipe is uneven,
foaming, falls off.

2.2.3 Physical and chemical properties test

23
(1) Chemical composition analysis

Respectively sampling around piercings of sample of 8-1 and 8-4, using direct reading
spectrometer to analysis the chemical composition in accordance with the standard of
ASTM E415-08, results show that the chemical composition of the two failure
samples are in accordance with API Spec 5 DP - 2009 standard's requirement for drill
pipe body.

(2) Tensile and impact properties

According to ASTM A370 standard, respectively take samples in sample 8-1 and 8-4
by plate tensile and 7.5 mm x 10 mm x 55 mm impact test at room temperature which
the results as shown in table 2-7. It is showed that the yield strength, tensile strength,
elongation and impact energy of failure samples are in accordance with API Spec 5
DP - 2009 standard's requirement.

Table 2-7 Tensile and impact performance results of failure sample

Tension property Impact property

Performance
Tension strength Yield strength Rt Elongation
Single Average
Smple Rm / MPa 0.7/MPa /A%
8-1 1064.5 1001.6 20.0 80,80,76 79
8-4 1017.9 966.4 20.8 76,74,76 75
API Spec
≥1000 931~1138 ≥13 ≥38 ≥43
5DP-2009

(3) Rockwell hardness

Take annular specimen near the piercings and carry out Rockwell hardness test in
accordance with the ASTM A370, the results showed that the Rockwell hardness of
failure samples piercings near to relatively homogeneous.

(4) Metallographic structure analysis

Respectively take samples of 8-1, 8-4 on the blistering place of sample coating to test
the metallographic specimen, corrosion pit can been observed at the bottom of coating
which as shown in figure 2-13. Along the lateral to take metallographic specimen for
microstructure observation, the metallographic structure of the samples are tempered
sorbite which the results as shown in figure 2-14. Along the longitudinal to take
metallographic specimen for non-metallic inclusion rating analysis, the inclusion
content of the organization are within the normal range.

24
 (a) Sample 8-1 (b) Sample 8-4

Figure 2-13 Corrosion pit morphology of the coating at the bottom of the foam

(a) Sample 8-1 (b) Sample 8-4

Figure 2-14 Metallographic structure morphology

(5) Internal coating rating of drill pipe

Due to the coating of sample 8-4 has already erosion fall off and cannot evaluate
coating. Take longitudinal metallographic specimen in tube coating uneven area of
sample 8-1 to observe the coating section which the results are shown in figure 2-15.
From the figure, we can seen that the coating within a small amount of bubbles and
the thickness of coating spraying is not uniform, That is to say the internal coating
thickness of the sample does not conform to SY/T 0544-2010 oil drill pipe internal
coating technology conditions.

25
 Figure 2-15 Internal coating profile morphology of drill pipe

(5) Micro analysis

The piercings fracture of sample 8-1 is mud flushing traces, the original crack surface
have been damaged. When observed the original crack surface morphology of sample
8-4 by scanning electron microscope piercings, the result as shown in figure 2-16.
From the result we can say that it is mainly for the mud corrosion morphology, after
the original crack formation, mud seeping into the crack.

Figure2-16 Sample 4 Crack surface morphology around hole

2.2.4 Thickening transition zone structure analysis

Drill pipe upset end thickening transition zone is the transition region of drill pipe and
tube body, is the area of section size changed. There is an obvious stress concentration
in use process for drill pipe thickening transition disappeared zone, this is mainly
related to transition zone length Miu and transition radius R. There are no relevant
provisions in API Spec 5 DP standard for pipe body and the transition zone at the
junction of the transition radius, but the related data show that the longer the Miu and
26
R, the smaller the stress concentration factor of the tube body and the transition zone.

Thorn leakage of sample 8-1, 8-4 internal thicken of Miu is 91.5 mm and 100.5 mm
respectively, and the good internal thicken sample of other manufacturers of Miu is
135 mm, which compares as shown in figure 2-17. From the figure we can see that the
failure samples internal thicken straight section and the transition angle of transition
zone is bigger, the transition is not flat.

inwall

ektexine
The length Miu of sample 8-4 is 100.5 mm
inwall

ektexine
The length Miu of sample 8-1 is 91.5 mm

inwall

ektexine
The length Miu of compared sample is 135 mm

Figure 2-17 Open morphology of thicken end

2.2.5 Comprehensive analysis

The well for directional well, and total of 20 root thorn leakage happened. The
analyzed of sample thorn leakage location are internal thickening transition disappear
zone. According to the well conditions, accumulative total drilling time of piercing
pipe is about 127 h ~ 400 h. The essence of the drill rod thorn leakage failure is the
result of fatigue crack propagation through, the physical and chemical test results
show that the chemical composition, mechanical properties of the failure drill pipe are
in accordance with API Spec 5 DP - 2009 standards. The main reason of thorn leakage
of the failure drill pipe are the quality of drill pipe internal coating, the structure of
thickening transition zone, the rate of borehole whole angle and other factors. The
following will one by one to analysis.

(1) The quality effect of drill pipe internal coating

Drill pipe internal coating not only can improve hydraulic conditions, but also can
effectively prevent the pipe inside corrosion. Part foam peeling of drill pipe internal
coating is a main cause of corrosion fatigue. According to the observation, coating
samples of 8-4 inside coating almost completely washed off, and the sample 8-1
inwall spray coating quality is poorer, uneven thickness, the thickness of the local area
27
is only 100 um, it does not conform to the stipulations of the ST/T0544-2010 standard.
In addition, the part of coating section also found that there are air bubbles, it may
cause foaming coating fall off, this is also a reason why it cause corrosion fatigue of
the drill pipe.

When drill pipe has been used, the uneven coating of stress concentration area foam
and fall off firstly, then the exposed body of drill pipe and the electrochemical
corrosion of drilling fluid will generate pitting corrosion pit, and then form the fatigue
initiation fatigue crack source. And the formation of pitting corrosion pit is further
exacerbated the partly stress concentration, also accelerate the process of the whole
pipe corrosion fatigue. When the fatigue crack penetrates the whole wall thickness
eventually, the drill pipe thorn leakage failure will happen.

(2) The structure effect of drill pipe internal thickening transition zone

In the thickening transition zone as the section size change area of the drill rod, the
stress concentration is more obvious. Drill pipe failure in thickening transition
disappear area of the hole formed position as the severe stress concentration area.
Finite element simulation results show that under the effect of composite load, the
longer of length Miu of the internal thicken transition zone, the more relax of the
stress distribution, and the low level of the stress.

Relevant data show that drill pipe thickening transition area within a thorn leakage is
most occurred inside the nipple end, and rarely occurred in the male connection end
of the drill pipe. From the perspective of the structure size of drill pipe joints, drill
pipe external thread for fluid contraction joint end, and drill pipe internal joint thread
end for fluid diffusion section. The spread of the fluid is much more complicated than
fluid contraction, it have some impact in the process of diffusion vortex on the wall
erosion and initiation of crack. From the result of flow field analysis of the failure
samples, the total pressure of internal flow field for thickening transition zone is
bigger than inner and outer thickening type, due to the thickening transition zone of
the failure sample is not flat, the vortex reflux formed near the transition zone, this
cause certain impact to the lining, and have further denudation for initiation of
corrosion pit, fatigue crack, and so on.

(3) The effect of borehole whole angle rate

Drill string on borehole angle rate all overweight or too big section will bear the
additional bending load, drill pipe puncture caused by fatigue. According to drilling
data, the drill pipe thorn leakage failure of the Well are mainly distributed near the
wellhead of 600 m ~ 1500 m sections which the borehole whole angle change rate is
too high section, but the borehole whole angle rate of other hole section is low which
without pipe thorn leakage failures occur.

Generally, if it is more close to the wellhead, the requirements of the borehole whole
28
angle rate of change is smaller. Therefore, if drill pipe is near the wellhead, it will
under bigger tensile load, fatigue damage will more occure. If the drill pipe wiht
better quality of coating and internal thickening transition zone at borehole whole
angle rate changed larger section, it can reduce the probability of thorn leakage failure
of drill pipe in certain degree.

To sum up based on the analysis, drill pipe thorn leakage failure of the well is mainly
caused by three reasons: (1) internal coating quality of thickening transition zone area
is not well, bubbles off of the coating on uneven areas cause drill pipe corrosion
fatigue; (2) internal thickening transition disappear zone is high form fatigue crack. (3)
the borehole whole angular rate in 600 m - 1000 - m sections is changed bigger, drill
pipe under rotating bending load will cause fatigue crack in stress concentration area.

2.2.6 Conclusion

(1) The physical and chemical properties of drill pipe failure samples are comply with
the requirement of API Spec 5 DP - 2009 standard.

(2) The internal coating of drill pipe failure samples spraying uneven, and local
thickness does not conform to the stipulations of the SY/T0544-2010 standard.

(3) The spraying quality of the drill pipe internal coating is unevenly, internal
thicken transition region is not smooth, overall smooth of surface roughness is poor,
all these are the reasons of drill pipe leakage failure. Also the "dog leg" of the well in
600 m ~ 1000 m section is too large, it is the main reason which lead to the drill pipe
thorn leakage.

29
Section 3 Cause type and regularity of drill stem failure

Drill stem service environment is poor, and the stress state is very complex which
include torsion, bend, tension and compression load, and also impact by the
environmental media, such as drilling fluid, H2S, CO2, temperature, pressure, etc..
For a long time, the failure statistics and analysis results show that the main forms of
drill stem failure include: fracture failure, failure of puncture and leakage, corrosion
failure, wear and deformation. The reason and regularity of drill stem failure are as
follows (Li Helin, 1990).

3.1 Fracture failure of drill stem and its expression form

Fracture failure mainly include fatigue and corrosion fatigue fracture, overload
fracture, low stress brittle fracture, hydrogen embrittlement failure etc..

3.1.1 Fatigue and corrosion fatigue fracture

Fatigue fracture failure of drill stems is the sudden brittle fracture under the
alternating stress of the fatigue limit of the metal. Drill stem in the hole to produce
buckling or in the well section of "dogleg" will produce serious alternating bending,
these will occur fatigue because the drill string is under alternating stress (Lin
Yuanhua, 2004). During the rotation, the side of the curved drill string is subjected to
cyclic tension / compression alternating stress in the axial direction. When the stress
at the root of the crack reaches a certain value, the crack will continue to expand at a
certain rate until the rest of the section is not enough to bear the fracture.

Fatigue fracture generally occurs in drill pipe joint, drill collar and adapter threaded
part or section mutation region, or surface damage caused by the stress concentration
zone.

The form of fatigue fracture: drill joint thread fatigue fracture, crack source area is
relatively flat, the fatigue crack can be observed in the vicinity of the bottom. If the
fracture surface is relatively intact, the fatigue zone can be observed in the fatigue
fracture zone by scanning electron microscope.

30
 (a) Fatigue fracture of drill collar thread (b) Fatigue fracture of drill pipe body

Figure 3-1 Fatigue fracture morphology

In fact, because of the special drilling environment, the drill stem has less failure due
to fatigue, usually failure in the presence of corrosion and fatigue. Drill pipe corrosion
fatigue fracture failure is caused by the corrosive medium (mud and formation of
harmful gases and other media) and bending alternating stress.

Drill string corrosion fatigue mechanism: under the action of alternating stress, the
slip occur between the metal lattice, this destroy the protective film of metal surface.
Due to the electrochemical corrosion, micro corrosion occurs at the sliding point,
micro corrosion forms a corrosion pit under the alternating stress. Under the common
action of the alternating stress and the anodic dissolution process of the crack tip, the
crack continuously develops and the leakage or fracture occurs finally.

Expression form: The fracture surface of corrosion fatigue is similar to the fatigue
fracture surface, the area of the crack is fan shaped and the fracture surface is
relatively flat.

3.1.1 Overload fracture

According to the types of loads, overload fracture can be divided into tensile overload
fracture and torsional overload fracture. Tensile overload is the drill string tensile load
greater than the yield load, and torsional overload is caused by the torque of the drill
string in the bottom of the well greater than the yield torque.

Overload fracture is generally by sticking, free stick, milling and other un normal
operation which generates a larger drill yield torque or tensile load, fracture occur in
weak link of the drill stem.

Expression form: There will be a large number of plastic deformation and "thin neck"
phenomenon in the vicinity of the tensile overload fracture. This is due to the plastic
deformation exist which is often accompanied by the tensile overload. There is a
certain fracture flanging. Due to the good toughness of drill pipe material, the fracture
31
surface of the over twist area usually presents a cup cone shape.

Figure 3-2 Fracture failure morphology due to over twist and overload

3.1.2 Low stress brittle fracture

Low stress brittle fracture is refers to drill stem which in bear is much lower than the
nominal yield force load and suddenly brittle fracture.

Expression form: low stress brittle fracture is flush, no obvious plastic deformation,
section exist herringbone extended lines (Gong Danmei, 2014).

Low stress brittle fracture caused by (1) heat treatment of drill pipe material is
improper, toughness is low, these resulted in the brittle fracture of the thread; (2)
cracking because welds exist in large gray spots area; (3) quenching crack exist
because of tubes heat treatment etc..

Figure 3-3 Morphology of low stress brittle fracture

3.1.3 Hydrogen embrittlement

Hydrogen embrittlement is mainly due to hydrogen atoms into the steel organization,
brittle fracture occurred under the tensile stress. Hydrogen sulfide stress corrosion

32
cracking is caused by hydrogen in oil and gas well which contain hydrogen sulfide,
hydrogen sulfide stress corrosion cracking is a kind of hydrogen embrittlement.

The mechanism of hydrogen sulfide stress corrosion cracking (SSC) is mainly

considered as the mechanism of hydrogen induced cracking stress corrosion. H2S
soluble in water and ionization and acidic gradual occur, which describe by the
following corrosion process:

 H2 S → HS − + H + (2-1)
 HS − → S 2− + H + (2-2)

The electrochemical reaction occurred on the surface of the steel:

Anodic reaction:

 Fe → Fe2+ + 2e (2-3)

Cathodic reaction:

 2H + + 2e → [H] + [H] (2-4)

Hydrogen atoms adsorbed on the surface of the steel, partially formed for hydrogen
and diffusion in the solution, and some of the hydrogen atoms will diffuse into the
steel, forming lattice hydrogen.

Corrosion products formed by anode:

Fe2+ + S 2− → FeS（2-4）

Hydrogen atom diffusion into the internal steel and then aggregate in steel defect,
such as surface defects, dislocations and the three dimensional stress area. The
binding strength of these defects and hydrogen is strong, the hydrogen has been
captured by these defects and cannot spread. The hydrogen atoms in a trap combined
for hydrogen molecules, when the accumulation of hydrogen is in very high pressure,
plus stress or residual stress will urged to make steel crack formation in the defect
site.

Expression form: The fracture is brittle fracture in macroscopic and intergranular

morphology in microscopic.

33
 Figure 3-4 Hydrogen sulfide stress corrosion cracking of drill pipe (SSC)

3.2 Puncture failure and forms of drill stem

According to the puncture position of drill pipe, the puncture failure can be divided
into drill pipe body thickening transition zone, drill pipe weld puncture, drill pipe
joint puncture. The failure mechanism, the form of expression and the rule of the
puncture are as follows.

3.2.1 Puncture of drill pipe thickening transition zone

(1) Mechanism and process of drill pipe puncture

The leakage position of drill pipe internal thicken transition zone is the most common
form of puncture. According to statistics, it accounts for about 70% of the failure of
drill stems. Puncture mechanism and process (Lv Shuanlu, 2006): Corrosion occur
and pit corrosion develop after drill pipe inner wall coating damaged. Due to stress
concentrated, corrosion fatigue crack initiate and crack propagate and penetrate the
thick wall, then drill mud pierced erosion from internal to outside, and finally formed
puncture. Most fatigue crack of thorn leakage position of drill pipe internal thickening
transition zone originated from the inner surface, a handful of fatigue crack of thorn
leakage position of drill pipe internal thickening transition zone originated from the
defect area of outer surface (such as slip bite marks, corrosion, wear, etc.).

(2) Expression form

The leakage position of drill pipe internal thicken transition zone is generally from
female joint sealing surface about 0.5~0.7m, the circular or elliptical distribution
along the circumferential direction is shown in figure 1. When opened the fracture,
there is no more than half circle around the fatigue crack growth in the hole, and the
origin of the crack can be judged according to the plane of the original crack. The
circular arc faces to outer wall, the crack plane is in wide and narrow shape, it can be
considered that the crack originated from the inner wall. If the original fatigue crack
plane is not completely destroyed, fatigue can be observed at the front of the crack
growth sector.
34
 （a） （b）

（c） （d）

(a) Puncture macroscopic morphology (b) Fatigue crack extend from inner wall
(c) Puncture macroscopic of pipe body (d) Crack extend from out wall to inner wall

Figure 3-5 Puncture morphology of drill pipe internal thicken transition zone

(3) Regularity of puncture

1) Structure of drill pipe thicken transition zone

The puncture of drill pipe thicken transition zone is mainly occurred in the transition
with female connector end, little occurred in male joint end. The thicken transition
zone is the area of the section size changed, the stress concentration is more obvious,
therefore the fatigue crack initiation is more easily. From the structure size aspect of
the drill pipe joint, the joint end of the drill pipe male connection is a fluid contraction
section, and the joint end of the drill pipe female adapter is a fluid diffusion section.
The diffusion of fluid is much more complicated than contraction of the fluid, and
some impact vortices generated during the diffusion process can be used to the wall
erosion and promote the initiation of fatigue crack.

2) Well section regularity of drill pipe puncture

According to the statistics of drill stem leakage in the Tarim Oilfield, the drill pipe
puncture and leakage in the 0~1500m well section is accounted for 68.8%. This is
mainly related to the force of the drill pipe. The tension of the drill pipe is mainly

35
from the weight of the drill pipe during the normal use. The drill pipe which near the
wellhead will get greater pull stress. In addition, borehole has certain whole angle rate,
the more the drill pipe near the wellhead of the well, the worst of the whole angle rate
damaged on drill pipe.

3) Well depth regularity of drill pipe puncture

Statistics show that there are 92.5% of the puncture occurred in the depth of
2001~5000 m section, which indicates that the stress condition is harsh in the well
(Lv Shuanlu, 2006). The size of 311.2 mm and 215.9 mm drill bit had been used in
the 2001~5000 m depth range of the field, that is to say the force conditions of drill
pipe is quite seriously within the size of the hole and the well body structure and the
assembly conditions.

4) The influence of rotary speed on the puncture of drill pipe

The statistical results show that with the increase of rotary speed, the number of drill
pipe puncture is increased. High speed will increase the centrifugal force and
additional bending stress for the drill string, and high speed will produce violent
vibration load which damaged the drill string seriously; high speed will increase the
composite stress for the drill string which leading to fatigue crack initiated and
propagation speed increased and piercing the drill pipe finally.

5) Whole angle change rate influenced on drill pipe puncture

The whole angle change rate is too big to make the drill string bear additional bending
load, and prone to accidents of drill pipe piercing. Pinghu 6As well which located in
China East Sea had 20 joints of drill pipe thorn leakage which are located close to the
large section of wellhead whole angle changed rate. There are three points of whole
angle changed rate in the vicinity of 4°~ /30m, maximum up to 4.81°/30m. Thus, the
change rate of whole angel has great influence on the life of drill pipe.

6) Effect of drill pipe aging

The grade II of drill pipe is not allowed to be used in parts of harsh onshore drilling
and offshore drilling. The fatigue cumulative damage of the drill pipe aging should be
paid attention. According to the statistics of the Tarim Oilfield, the grade II drill pipe
is in the drill pipe piercing for 65.3%. Drill pipe piercing through corrosion, fatigue
crack initiation and propagation stages, drill pipe piercing is the result of fatigue
accumulation. The deeper the well is, the more severe the drilling condition is, the
shorter the fatigue life of the drill pipe is. The grade II drill pipe is generally used for
a long time, and the fatigue accumulation is relatively serious. The proportion of
grade II drill pipe piercing is mainly related to the aging of the drill pipe. This
requires to develop a reasonable lift testing period. If we can predict the time of drill
pipe to generate fatigue crack, we can determine the reasonable flaw detection period,
36
and finally reduce and prevent drill pipe puncture and fracture accident effectively.

3.2.2 Puncture on drill pipe weld area

(1) Drill pipe weld puncture mechanism

The thickness of drill pipe weld zone is about 2 times than the pipe wall thickness,
weld leakage is mainly caused for welding of gray leaf spot (Yu Shijie, 2011). Drill
pipe friction welding does not produce large areas of gray leaf spot generally, but
because the surface quality control is lax before welding and weldment shortening is
insufficient which may cause welding gray spots flaw.

(2) Expression form

Drill pipe washout puncture occurred in friction welding, open the thorn hole will
found the cross section around the hole is flat and thorn.

（a） （b）
weld line

(a) Weld line of puncture area (b) Fracture appearance of puncture

Figure 3-6 Puncture morphology of weld line

3.2.3 Drill pipe joint thread puncture

Joint thorn leakage often occurs in the thread and sealing surface, the rate of joint
thorn leakage occurred in the drill pipe joint is bigger than occurred in the drill collar
thread (Gong Danmei, 2014). The joint thread leakage may be due to: (1) joint torque
is insufficient which resulting in seal shoulder surface contact pressure drop, and the
sealing performance failure; (2) joint thread is for the stress concentration region.
Under the effect of alternating load condition, it will prone to fatigue crack, when the
crack penetrate the wall thickness, joint thorn leakage; (3) when the original flaw or
the original crack exist in the thread parts, it also can lead to joint puncture early.

37
3.3 Drill stem wear failure

The wear failure of drill stem is mainly includes: joint thread sticking and pipe body
friction and wear.

3.3.1 Thread sticking and wear of joint

(1) Reason of sticking

Drill stem joint sticking and wear is due to the internal and external thread with metal
friction interference which make the surface temperature rise sharply, so that the
internal and external thread surface bonding (Lv Shuanlu, 2011). Because, internal
and external thread surface circumferential displace even often accompanied by
gluing metal migration in the process of make-up and break out. Sticking is usually
adhesive wear, but if there are gravel, iron and other hard particles sandwiched
between inner and outer thread, it also can form sticking wear.

(2) Influence factors and performance of sticking

① Quality of design and processing

1) Thread surface roughness. Inner and outer thread easy sticking when the rotate if
the machining thread with rough surface. The surface roughness of the screw thread is
related to the precision and performance of the lathe.

2) Taper mismatch. In the case of big taper of inner thread but small taper of external
thread, with the internal and external thread joint, the small end will get big contact
force which makes it easy to stick. In the case of small taper of inner thread but big
taper of external thread, with the internal and external thread joint, the bid end will get
big contact force which makes it easy to stick.

3) Thread pitch mismatch. When the inner joint thread pitch is greater than the
external thread joint pitch, the contact pressure on the guide surface of joint big thread
and bearing surface of joint small thread is high which can prone to stick. when the
inner joint thread pitch is less than external thread joint pitch, the contact pressure on
the guide surface of joint big thread and bearing surface of joint small thread is high
which can prone to stick.

4) Tight pitch of thread. In the case of the other single parameter with small deviation,
the thread tight pitch is mainly reflects the diameter of the thread. If the external and
internal thread tight pitch is both too large, the thread will exposed if make up with
normal torque; but if increase torque of making up to no exposed thread, it will easy
to gluing.

38
 Figure 3-7 Thread gluing morphology due to poor accuracy control

② Influence of thread surface treatment quality

Influence of surface treatment quality. The surface treatment of drill stem joint thread
are copper plating and phosphating. Surface treatment failure can easily lead to thread
gluing, such as : a, surface treatment is not thick enough which can easy to wear off in
use; b, the strength and toughness of surface treatment layer is insufficient which can
easy to broken off in use; c, the surface treatment layer is not dense, with holes,
defects such as trachoma which can easy to rust in placing and use; d, surface
treatment layer off, the base metal will direct contact in the process of making up and
break out which can easy lead to thread gluing.

③ Effect of thread grease

The main role of thread grease is to lubricate the surface of thread, reduce friction,
prevent sticking and rust and so on. If the quality of thread grease is poor, mixed with
debris (sand, bits of iron, etc.) , it will easy to make the oil casing thread joints rust,
even gluing.

④ Improper fastening

In the process of connect drill string, too quickly making up speed can make the joint
subjected to impact loads which can damage thread. If make-up thread with deflection
which the drill string center shaft line and the into hole drill pipe axis ling are not
properly aligned, large deviation will exist which produced a larger tilt angle when the
thread in the screwing process. Therefore, easy to gluing.

Feature of thread gluing: It is very easy to cause serious thread gluing which the entire
thread teeth have been worn out, and if the thread gluing is serious, the appearance of
the "secondary hardening martensite" can be formed.

39
 Figure 3-8 Thread gluing due to improper fastening

⑤ The fast make up speed lead to deviation of drill pipe joint

If make up speed fast, especially in the guide button process, the external thread
haven't reached normal engagement, tooth of male and female thread will interfere
with each other, this will result in extrusion wear in the thread surface, and caused
plastic deformation, eventually led to wrong button and a stick (Yu Shijie, 2011). In
addition, the high making up speed will cause the thread surface heat not easy to
distribute, the friction surface temperature will rise sharply so that the friction surface
of the metal to soften and flow, this will also easy lead to thread gluing.

⑥ Thread gluing caused by over torque

Over torque of making up is easy to cause thread gluing. To ensure that the internal
and external threads to achieve the best fit, the making up torque of joint must be
moderate. If the torque is too large, it will resulting in plastic deformation in the
surface of the internal and external thread , and finally cause thread gluing.

3.4 Excessive deformation

The failure of excessive deformation of drill stem is mainly shown as the extension of
drill pipe female joint and the part extension of drill pipe outer thread joint. The main
common is the internal thread joint expansion. Within the expansion morphology of
internal thread joint is for trumpet shaped, seal regional with serious deformation
organizations. The process of deformation and swell of drill pipe joint generate a large
amount of friction heat which makes the phase transition occurs in the surface
microstructure, and finally the formation of white bright layer "secondary hardening
martensite" can been see as below.

40
 Figure 3-9 Thread joint expansion of female joint

The main reason for the joint expansion is (Lv Shuanlu, 2008):

(1) Bottom hole torque is too large. On the one hand, a large hole drilling make the
drill string under large torque. Failure analysis data shows that, the drill string bear
large torque if drilling in large hole. On the other hand, bouncing or sticking will
increase torque for drill string. It will make the rotary torque increases instantaneous
when bit bouncing or sticking, and the drill string will bear double of torsion load.

(2) The torque for drill pipe is insufficient. The insufficient of drill pipe connection
torque make the shoulder sealing surface of drill pipe joint does not have enough
contact surface pressure. In the drilling process, the drill pipe joint will self make up
which caused by variety of over torsion and out of control of downhole factors. So
that the contact surface pressure of shoulder sealing of tool joint increase and exceed
the material yield strength, ultimate failure by plastic deformation and swelling
damage.

(3) The size of external thread joint does not meet the standard requirements. For
example, the chamfer diameter of outer thread joint shoulder surface is smaller than
internal thread joint shoulder surface, even a larger extent beyond the tolerance range
of the standard requirements. This will make the chamfer diameter of internal thread
sealing shoulders small which will make the bearing stress shift to the inner wall.

3.5 Corrosion failure

The corrosion failure is most for the drill pipe internal coating destruction which
environmental media and various factors that caused drill pipe inner wall corrode. The
corrosion failure types are mainly as CO 2 corrosion, oxygen corrode, salt mud drilling
corrosion, etc.

41
Section 4 Inspection and classification of drill stem

4.1 Inspection standards of drill stem

The international old drill stem inspection common standards is mainly used for: the
"API RP 7G. Recommended practice for drill stem design and operating limits" the
third chapter drill stem of "DS-1 (API, 1998). Standard DS-1 chapter 3 drill stem
inspection", the "NS-2 (T H Hill, 2012). Drill string inspection standard NS-2"
(Procter Group Fearnley, 2005). In China the old drill stem inspection is mainly
according to the oil industry standard "SY/T5824-93 Drill grading and inspection
method" and "GB/T 24956-24956 Oil and gas industry drilling string design and
operational limits".

In fact, "GB/T 24956-2010 standard" is equivalent to translate the API RP 7 G, 16

edition, 1998, and the grading requirement in the SY/T5824-93 standard requirements
is basically the same with the API standards. For the inspection of drill pipe, API 7 G
inspection standard is basically the same as the test requirements of class 3 of
"Standard DS-1"; the category 5 of "Standard DS-1" inspection is basically equivalent
to "Drill string inspection standard NS-2". The following will introduce and compare
the inspection grading requirements of the standard.

4.1.1 API inspection standards

API standard is mainly on the basis of residual wall thickness of pipe and corrosion
pit depth which divided used drill pipe into 3 class: classⅠ, class Ⅱ and class Ⅲ.
The sub class is based on minimum diameter of drill pipe joint, minimum shoulder
thick of eccentric wear female joint which divided sub intoⅠand Ⅱ. The detail of
classification data are as follow standard.

The minimum wall thickness of class Ⅰ drill pipe is about 80% of the nominal wall
thickness, and the minimum wall thickness of class Ⅱ drill pipe is about 70% of the
nominal wall thickness. The rules of classification are in the following table.

42
 Table 4-1 Classification of used drill pipe (API RP 7G)

Class Ⅰ (Premium
Class Ⅱ Class Ⅲ
Pipe condition class)
Yellow Bands Orange Bands
Two White Bands
1.Exterior
condition
A. OD wall wear
Wall Remaining wall not less Remaining wall not less than
thickness than 80% 70%
B. Dents and Not over 3% of OD
mashes reduction Not over 4% of OD reduction
Crushing, Not over 3% of OD Not over 4% of OD reduction
necking reduction
C. Mechanical
damage of slip area Bite mark not over the 10% Bite mark not over the 20% of
Bite mark, scratch of average wall thickness average wall thickness
Over the dents and
D. Stress induced mashes of Class
Not over 3% of OD
diameter variations Ⅱdrill pipe
reduction Not over 4% of OD reduction
（1）Stretched
Not over 3% of OD Not over 4% of OD reduction
（2）Shortened
reduction
E. Corrosion,
incision, bruise
Remaining wall not less Remaining wall not less than
（1）Corrosion
than 80% 70%
（ 2 ） Cuts and
bruise
Remaining wall not less Remaining wall not less
than 80% than70%
Longitudinal
Remaining wall not less Remaining wall not less than
transverse
than 80% 70%
F. Fatigue craxks None None None
2.Interior
conditions
A. Corrosive pitting Remaining wall not less Remaining wall not less than
Wall than 80% measured from 70% measured from base of
thickness base of deepest pit deepest pit
B. Erosion and
wear
Remaining wall not less Remaining wall not less than
Wall
than 80% 70%
thickness
C. Fatigue cracks None None None

No matter which class of drill pipe, once found that fatigue crack or leak, it should not
43
use. For drill pipe joint, we generally according to the standard table 4-1 to determine
the minimum diameter of drill pipe joint to divided classⅠ and class Ⅱ.

4.1.2 Inspection requirement of DS-1 standards

(1) Inspection methods of drill pipe

The latest standard of DS-1 category (4th edition, 2012) stipulated 33 kinds of drill
pipe inspection methods. These methods including 32 kinds which must be conducted
by the inspection company and one kind may be done by the drilling crew or
inspection company. There are total of 16 kinds of 33 kinds of testing method is
suitable for drill pipe inspection.

(2) Inspection category

DS-1 standard make 6 kinds of service category according to the drilling risk and
failure costs which the different service category corresponds to the different
inspection requirements. The 6 categories are as below:

Category 1: suitable for shallow well and conventional well of developed area. When
the drill string failure occurs the failure loss is very small, so that a large number of
inspection fee is not economical.

Category 2: for conventional drilling conditions, the failure rate is low, the existing
practice is a small amount of inspection.

Category 3: designed for moderate drilling conditions, the inspection standard outline
the most reasonable. If failure occur, the fishing cost or loss well risk is lower.
Category 3 is the minimum design requirements of category 2.

Category 4: this type can be used for more demanding drilling conditions than
category 3. When drill string failure, it may have higher fishing costs or losses.

Category 5: this type is suitable for very demanding drilling conditions. Many factors
lead to very high cost of possible failure, category 5 is the minimum design
requirements of category 3.

Category HDLS：Due to the tensile load increase especially in deep water, adds
category 6 in the third edition of service category. This type is design for HDLS
(Heavy Duty Landing strings).

(3) Inspection frequency

According to the different use categories, DS - 1 standard make recommendations

inspection frequency of drill pipe as table 4-2.

44
 Table 4-2 Inspection frequency of different category

Service category
Component
1 2-3 4-5 HDLS
Drill pipe Put out of hole Put out of hole Before trip in （Note 2）

Note 2：If used before any other operations, such as drilling or jar, or the tensile load
more than 90% of tensile strength, inspection should be done before every time
operation, otherwise, inspect while operation 3 times.

(4) Inspection equipment

DS-1 standard has detailed regulations and requirements for inspection equipment,
these regulations and requirements are not contained in API RP 7G.

(5) Drill pipe classification

Regulate classification of drill pipe is a shortcuts which most users used to formulate
drill pipe and its sub receiving criterion. DS - 1 standard stipulated 4 classification of
drill pipe.

① ClassⅠ: This class code applies to new drill pipe and tool joint. It is
equivalent to new drill pipe.

② Premium class：Drill pipe body and tool joint meet the requirements of table
3.5.1. Tool joint torsional strength is about 80% of new drill pipe body which with
"standard" specification of tool joint.

③ The premium class of drill pipe which reduced torsional strength ratio:
torsional strength ratio (TSR) refers to the tool joint and the ratio of the torsional
strength of drill pipe body. The torsional strength ratio of new pipe and premium class
drill pipe is about 80%. The torsional strength ratio of premium tool joint of drill pipe
which still reduced the torsional strength ratio is about 60% while in keeping all the
other properties of the DS-1 standards. In addition to the torsional strength, the
bearing capacity for this pipe and premium class drill pipe is the same. The class of
this drill pipe has not been recognized by API.

④ Class Ⅱ： Drill pipe body and tool joint meet the requirements of table 4-3.
The tensile strength and torsion strength is about 70% of new drill pipe body which
with "standard" specification of tool joint.

45
 Table 4-3 Classification of used drill pipe and tool joint (DS-1)

Class
Condition premium class class Ⅱ
Component
Remaining wall ≥80% ≥70%
Slip bite mark and ≤3% of average border ≤20% of average border
groove upon upon
Outer diameter
Pipe body ≤3%×stipulate OD ≤4%×stipulate OD
reduction
Outer diameter
≤3%×stipulate OD ≤4%×stipulate OD
increase
Cracks None None
≥80% of premium class ≥80% of class Ⅱ pipe
Torsional strength
pipe body body
External thread ≤0.006”（within in the ≤0.006"（within in the scope
Tool joint elongation scope of 2"） of 2"）
As the standard
As the standard requirement
Other size requirement of table
of 3.7.1-3.7.17
3.7.1-3.7.17

(6) Recommended inspection outline

DS-1 category standards goal is to build the inspection standard procedure of old drill
stem components. These inspection procedure aimed to ensure that every component
has the appropriate bearing capacity, and to replace fatigue crack (or high risk)
component.

In accordance with the standards of DS-1 category inspection, the inspection

procedure should be consists of 4 parts: equipment table, use method, effective
receiving criterion and inspection frequency. For ordinary drill pipe (that is, the
ordinary drill pipe), its effective receiving criterion is usually stipulate service class to
divide inspection class. DS-1 standard specified 6 classes in the different degree of
risk for drilling service. The inspection procedure as show in table 4-4.

46
 Table 4-4 Recommended inspection outline of drill pipe

Class Service classification

Component 1 2 3 4 5 6
Tool joint
Tool joint
Tool Tool joint Tool joint Tool joint visual
visual
Tool joint joint visual visual visual Size 2
Size 1
visual Size 1 Size 1 Size 2 Black light
Black light
Retroactivity
Pipe body
Pipe Pipe body
Pipe body Pipe body visual
body visual
visual visual OD calipers
visual OD calipers
Pipe OD OD calipers FLUT2
Drill pipe OD EMI2
body calipers Wall thickness Slips/Thicken
body calipers Slips/Thicken
visual Wall UT EMI1 MPI
Wall MPI
thickness Slips/Thicken Slips/Thicken
thickness Slips/Thicken
UT EMI1 MPI UT
UT UT
Retroactivity
Receiving class Premium Premium
class Ⅱ Premium class Item standard
criterion Ⅱ class class

(7) Consideration factor while set out inspection frequency

When set out inspection plan for old drill pipe, the cumulative fatigue damage of drill
pipe body shall be determined. But the difficulty is the fatigue damage may be in
accumulation in different rate in different parts of drill stem. In addition, the change
of bearing capacity which caused by tool joint and pipe body should be considered.

The standard recommended the method of the estimation cumulative fatigue damage.
In order to simplify the problem, drill stem designer divided the drill stem into several
parts, then apply the follow formula to estimate the cumulative fatigue damage of
each part. By accumulating the "damage" of drill stem sections to estimate, the
location of the components in the rearrangement of drill string can be used to try
balance the damage, and according to the total cumulative damage to set out
inspection plan.

60 × CI × RPM × Footage
DP =
ROP × 106
In the formula：
DP—the fatigue "damage" of accumulated;
CI—the average bent index;
RPM—the average rotary speed of drill stem (Revolution/minute)；
Footage—the consideration drilling footage (ft);
47
 ROP—the average drilling speed of consideration (ft/h).

When totally cumulative damage point of certain section of drill stem reached certain
degree, the fatigue crack inspection should be execute. According to the results of
several failure analysis, the standard recommend that the inspection should be execute
while the initial estimate total cumulative reached to 500.

Table 4-5 Cumulative damage point of different design scenario

Drilling condition Inspection trigger point

(Design scenario) (Cumulative damage point)

3 500

2 600

1 700

This artificial estimate is very rough, but is more useful for insure inspection
frequency than any experience methods. This method takes into account the relative
punitive of drilling condition, it is an improved method than only consider simple
footage or rotate time, and better than traditional experience method which according
to estimation of rotation time or penetration.

4.1.3 NS-2 inspection standards

NS-2 standards focuses on the North sea drill stem which belong to the European oil
drill stem standard, also known as the standards of the Shell or the North Sea. The
inspection scope of NS-2 standards covers all of the inspection and repair of drill stem
components for North Sea drilling. NS-2 standards include some content what no
included API, DS-1 standards, such as high twist joint connection, special drilling
equipment, automatic thread detection, received new drill pipe inspection, fishing and
milling tool; detailed inspection frequency guidance, inside coating, etc.

The standards has strict requirements for inspection equipment, inspection personnel
and inspection method. For some non API thread tool joint, it also has detailed
inspection requirements. Therefore, NS-2 standard is the most strict inspection
standards for offshore drill stem.

(1) Classification of used drill pipe and tool joints

To the North Sea drilling, in addition to new drill pipe, only the premium class drill
pipe is acceptable. The classification as show in follow table：

48
 Table 4-6 Classification demand

Drill pipe body Demand

Minimum remaining wall 80%
Slip bite mark and nick 10% of average critical wall
(maximum depth) thickness
Diameter reduction 3% of stipulate OD
Diameter reduction 3% of stipulate OD
Fatigue crack None
Tool joints Demand
Torsional strength 80% of premium class pipe body
Male end elongation Elongate 0.006 inch/every 2 inch
Other size Note
Fatigue crack None

Note：Other sizes include API tool joints diameter, shoulder width, WT joints, the
relevant requirements size of DS tool joints.

(2) Basic requirements of drill pipe inspection procedure

For API drill pipe, the inspection method is as follow:

Table 4-7 Inspection method for different part of drill pipe

1. Fluorescent magnetic particle flaw

detection;
Tool joints and thread 2. Macroscopic observation;
3. Dimension inspection;
4. ATI（ACFM）electromagnetic testing.
1. Fluorescent magnetic particle flaw
detection;
2. Macroscopic observation;
Slip area and upset area
3. Dimension inspection;
4. Ultrasonic pipe body inspection;
5. MIU length and profile inspection.
1. OD inspection;
2.Ultrasonic inspect wall thickness;
Pipe body, slip area and upset area
3. Macroscopic observation;
4. Pipe body electromagnetic.

49
(3) Inspection frequency guidance of the North Sea drill stem

In order to minimize the possibility of drill stem failure, periodically inspection or

replace in accordance with inspection stage should be comply. See figure 4-1.

Standard thinks that in the past drill stem inspection which based on drill stem
rotating time or drilling footage to determine whether need to inspect is arbitrary.
According to the experience of a region or the used time of a component is like guess.
Whether or not to inspect drill stem should be depends on the harsh degree of drilling
environment rather than used time.

New component Identified windows by

Crack origin inspection method

Thread tripping
The minimum crack size Washout
which can be detected

Detect by pressure gage

Figure 4-1 Identified windows by inspection

The inspection outline of the standards using WS-INSPECT computer program, this
program is developed from the specific failure analysis date of Shell Expro (Shell)
exploration wells. WS-INSPET assumes that each component of drill stem existed
micro cracks, the micro cracks is very small and was not detected in the latest
inspection. After drill stem service, the program follow up drill stem position and
estimate the propagation rate of the crack. When the program calculated the
component is close to the final failure curve, it will alert users to arrange inspection.
For some strict Wells (larger slope angle), when harsh service environment beyond
the scope of the following outline requirements, WS-INSPET can provide accurate
crack propagation analysis and generate detailed drill stem inspection procedure. The
inspection frequency requirement which the standards outline is as follows:

1) Vertical well

 According to contract to inspect before drilling the first well;

 Inspect after the accumulative drilling footage reach to 10668 m, (Every half
year to inspect if there is no record footage);
 For single well, inspect after accumulative drilling footage more than 6096
m.

2) Directional well

50
  According to contract to inspect before drilling the first well
 Inspect after the accumulative drilling footage reach to 9144 m, (Every half
year to inspect if there is no record footage);
 For single well, if the total well depth exceed to 4114.8 m, inspect the drill
pipe which well depth exceed 4114.8 m or rotate at the build zone. That is, if
the depth of directional well is more than 4114.8 m, the inspection should be
done for the drill pipe which at the build zone (A) and the adjacent area (B)
of the length is 4114.8 m to the total depth.

4114.8m

Figure 4-2 Drill stem inspection requirement for direction well

But, If the drilling plan or operation practice exceed any of the following
circumstances, the WS - INSPECT should be used to generate the follow inspection
frequency program in detail.

Table 4-8 Special requirement while exceed circumstance

Drilling rate Average less than 3 m/h below 4114.8 m of well depth

Wellhead rotate speed Average exceed 150 rpm below 4114.8m of measured depth

Rate of build Average exceed 3°/30 m at upper build zone

Total vertical depth (TVD) Exceed 3200m

3）Horizontal well

 According to contract to inspect before drilling the first well

 Inspect after the accumulative drilling footage reach to 9144 m, (Every half
year to inspect if there is no record footage);
51
  For single well, if the total well depth exceed to 4114.8 m, inspect the drill
pipe which well depth exceed 4114.8 m or rotate at the lower build zone.
That is, if the depth of horizontal well is more than 4114.8 m, the inspection
should be done for the drill pipe which at the lower build zone (A) and the
adjacent area (B) of the length is 4114.8 m to the total depth.

Figure 4-3 Drill stem inspection requirement for horizontal well

But, If the drilling plan or operation practice exceed any of the following
circumstances, the WS - INSPECT should be used to generate the follow inspection
frequency program in detail.

Table 4-9 Special conditions for horizontal well

Permeation rate Average less than 6 m/h below 4114.8 m of well depth

Wellhead rotate speed Average exceed 60 rpm below 4114.8m of measured depth

Rate of build Average exceed 5°/30 m at upper build zone

It's worth noting that the guidance outline of the standards did not mention detailed
requirements for upper build zone or kick off point of horizontal well, and did not set
inspection frequency for remaining drill stem, also did not make up clear drill stem
life-cycle management method.

4.1.4 Contrast of drill stem inspection requirements for the three standards

Based on the above explain, the main difference and relation of drill pipe inspection
requirements of API 7G, DS-1 and NS-2 standards are as follows:
52
(1) The main difference

API RP 7G：(1) only as recommend; (2) drill stem design and operation limit; (3) the
explain is more general and no specificity; (4) choose with limit.

DS-1 standards：(1) the accept and rejection standard of used drill pipe; (2) the drill
stem inspection include many component; (3) the specific procedure and method； (4)
flexible choose; (5) training and qualification; (6) calibration and compulsive
requirement; (7) summarize of quality control and measure for equipment and
procedure.

NS-2 drill stem inspection standards: (1) inspection personnel qualification; (2)
requirement for inspection and repair equipment; (3) detailed inspection, testing and
repair procedure; (4) defective evaluate; (5) detection and repair procedure; (6)
accepted detection requirement for new drill stem; (7)service limitation; (8) other
recommend, such as the drill stem inspection frequency outline。

(2) Comparison of drill pipe classification

From the table which contain drill pipe classification requirements of 3 standards we
can see that the acceptable and criterion standard for premium class pipe is the same.
But the acceptable standard of class Ⅱ is the same for API 7G and DS-1. The API
7G even retain the divide of class 3. Under the premium class circumstance of drill
pipe body and tool joints, DS-1 standards added the premium class which reduce the
torsional strength rate between the premium class and class Ⅱaccording to the
decline degree of torsional strength rate, but this has not been accepted by API. NS-2
standards only class premium class pipe after inspect because the North Sea drilling
only accept above quality of class Ⅱ drill pipe.

However, in quality control aspect, DS-1 standards and NS-2 standards both have
clear and strict requirements for equipment, using and inspection procedures.

Table 4-10 Comparison of drill pipe classification

Classification Class Ⅰ Premium - Class Ⅱ Class

(API RP 7G) (New drill pipe) class Ⅲ
Classification Class Ⅰ Premium Premium class Class Ⅱ -
(DS-1 standards) (New drill pipe) class which reduce
the torsional
strength rate
NS-2 standards - Premium - - -
class

(3) Comparison inspection procedure

53
DS-1 standards divide 6 classes according to rigor drilling environment, each class
has different inspection requirements. Under class 3 and below, the premium class and
class Ⅱ drill pipe are essentially the same as API standards. But considering the
harsher drilling problems in application, DS-1 standards increase the class 4, and class
5 inspection. For landing string applications, especially in deep water condition, DS-1
standards added HDLS class due to the tensile load increased.

4.2 Drill stem using and inspection for Chinese oil companies

According to research, the specific classification and inspection standards of Chinese

domestic oil company such as Petro China Tarim Oilfield Company, Sinopec
Northwest Branch Company, Petro China Great Wall drilling Company, Western
Drilling Company, Sinopec Jianghan Drilling Oilfield and other drilling services
company are in according with API RP7G and the "SY/T5824-93 Drill Classification
Test Method". Each company set out inspection cycle for themselves which the cycle
is roughly the same and generally inspect after the new drill pipe using for half year.
The following will explain the using and inspection requirements of Chinese domestic
oil companies such as Petro China Tarim Oilfield Company and Sinopec Northwest
Branch Company.

4.2.1 Using and field inspection requirements of drill stem

4.2.1.1 Petro China Tarim Oilfield

(1) Field flaw detection of drill stem:

Drill stem field flaw detection items are shown in the following table:

Table 4-11 Field flaw detection item

Drill stem Heavy weight Stabilizer, Downhole

Drill pipe Kelly
name drill pipe crossover sub tool
Flaw detection Welding Welding line, Welding line,
Thread Thread
item line thread thread

Under normal operating conditions, perform field flaw detection in accordance

with the following period:

① Drill pipe field flaw detection period:

A: The rotation time of the new drill rod is 250±100 hours;

B: The rotation time of the Class Ⅰ drill pipe is 600±100 hours;

54
 C: The rotation time of the Class Ⅱ drill pipe is 500±100 hours.

② Drill collar, crossover sub and stabilizer field flaw detection period:

A: 8-1/2" and above the well hole rotation time is 475±25 hours;

B: 6" and the below well hole rotation time is 275±25 hours.

③ Heavy weight drill pipe field flaw detection period:

A: 8-1/2" and above the well hole rotation time is 475±25 hours;

B: 6" and the below well hole rotation time is 275±25 hours.

④ Kelly field flaw detection period:

Rotation time is 1000±100 hours.

After special operations (such as accident treatment, underground complex problem,

etc.), the user can apply early detection for engineering and technical department.

(2) Plant inspection

After drill stem out of service more than 3 days, the engineering and technical
department should be informed to recover the drill stem. The follow drill stem
detection in the factory should be done:

① To further clean inner and outer surface of drill pipe and screw thread in time.

② In accordance with the requirements of SY/T5824-93, the "Drill pipe

Classification Inspection Method", SY/T5369-94 the "Management and Using of
Petroleum Drill Stem, Kelly, Drill Pipe, Drill Collar", and Q/CNPC-TZ 52 -2004 the
"Drill Stem Maintenance and Screw Thread Repair Specification" to execute the
inspection. After inspection, the drill pipe should be marking in accordance with drill
pipe class mark.

③ The inspection results should be accurate and record, so that to provide single
drill pipe inspection report to user.

After test finished, the drilling tool which need to repair should be done:

(1) Specific carry out the standard of Q/CNPC-TZ 52-2004 the "Drill Stem
Maintenance and Screw Thread Repair Specification".

(2) The drill stem which has been repaired should mark code to ensure the traceability.

55
(3) Strictly carry out 3 classification inspection for repaired drill stem to ensure the
repair quality reach to 100%.

4.2.1.2 Sinopec Northwest Branch Company

The recovery drill stem should be inspect according to the Sinopec Northwest Branch
Company standard to carry out, below the Class Ⅱ drill pipe prohibit to use.

Under normal operating conditions, the drill stem inspection cycle is required to
execute the normal standard. If the drill stem used for special operations such as
drilling tool failure processing, downhole complex problem like percussion drilling,
serious limp drilling, sticking, corrosion of hydrogen sulfide and carbon dioxide etc.,
the special detection should be established before the normal flaw detection.

According to the requirements of drill stem classification, nondestructive detection

item and inspection period, the drill pipe should be sent to tube plant workshop for
classification, detection if the using time reaching inspection period; other drill stem
should be send to tube plant workshop or in the field for classification and detection.

(1) Field flaw detection requirements

 Detection requirements:

The field detection of drill stem include appearance inspection, dimensional

measurement and nondestructive flaw detection (including ultrasonic testing,
magnetic particle detection and liquid penetration testing), etc.. The detection process
should pay more attention to the crack defect of drill stem threaded connection
location, drill pipe upset transition disappear zone and drill collar operating groove
area.

 Detection frequency:

The drill stem field nondestructive flaw detection period shall be determined
according to drill stem working time, classification, used time, geological condition,
drilling technology, drilling parameters and the area drill stem failure analysis
condition. For BHA (bottom hole assembly), each trip should execute crack detection.
In the process of gas drilling, the field detection period is about 20%~40% of
common drilling.

If the drill stem used for special operations such as drilling tool failure processing,
downhole complex problem like percussion drilling, serious limp drilling, sticking,
corrosion of hydrogen sulfide and carbon dioxide etc., the suitable detection method
should be choose for drill stem flaw detection.

After the failure of drill stem has be treated, the inspection of drill stem which near
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the fault position should be done.

(2) Inspect after drilling tool recovery

After the drilling is finished, the drill stem should be recovered inspection or field
inspection in timely, the inner and outer surface thread and pipe body shall be cleaned.
The inner and outer surface and the thread part of the recovery drill stem should be
cleaned and checked in time. The inspection contents include: quantity, specification,
steel grade, pipe body coating, joint type, thread, wear-resistant belt and other
information.

The recovery drill stem should be determine class based on the detection data, classify
place according to drill pipe classification, and classified record.

If the inspection is disqualified and does not meet the drill stem scrap standards, it
should be repaired and recorded according to the requirements.

4.3 Inspection and classification of drill stem for international oil

company

According to the research for drill stem inspection company, the results show that
generally for deepwater drilling the NS-2 or DS-1 of the fifth class inspection should
be conduct, and for shallow water drilling the DS-1 fourth class inspection should be
conduct.

4.3.2 Shell (China) Exploration and Production Co., Ltd.

Shell Exploration Company in China unconventional gas projects is mainly for

Sichuan Fushun shale gas project, Shaanxi Changbei tight gas project, Sichuan Jinqiu
and Zitong tight gas project. In these projects, Yulin Changbei tight gas project require
inspection in accordance with the NS-2 standards which can be equivalent to the class
5 of DS-1 standards. But in the shale gas projects of Sichuan, Shall also in accordance
with the requirements of the class 5 of DS-1 standards when lease Shenzhen Far East
drill pipe for operation.

4.3.2 Drill stem inspection requirements for deep water drilling

The research of Texaco drilling company and oil and gas leasing service corporation
as early as 1999 in offshore drilling with 5.5" drill pipe operation show that it is
respectively using the DS-1 4 and 5 class for drill stem inspection.

The Ocean star rig of Texaco drilling operations in Mexico Green Valley. The water
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depth is about 1219m, and the depth of the well is about 8387m. The drilling duration
of this project was about 18 months, after successful drilled 2 wells, the drill pipe was
divided into two stages to inspect.

(1) Initial detection procedure

The half of the drill pipe had been transported to plant to carry out the strict inspection.
Set out a detailed inspection procedure before inspect, and in accordance with the 5
class of DS-1 standards to inspect which including:

① Macroscopic, outside diameter measurement ； ultrasonic thickness

measurement, electromagnetism detector pipe body.
② Macroscopic and size measurement for external thread.
③ Ultrasonic detection in thickened area.
④ Magnetic particle inspection and size measurement for external threads.
⑤ Magnetic particle inspection for thickened area and thread.

Test results: rejected or scraped for 70 internal thread joints, 70 external threaded
joints and 7 whole length of joints.

(2) Final detection procedure

According to the initial detection results, using class 1 of oil leasing services
company's standard to inspect the rest of the drill pipe, the results are as shown in
below.

① Macroscopic ； outside diameter measurement ； ultrasonic thickness

measurement, electromagnetism detector pipe body.
② Macroscopic and size measurement for external thread.
③ Ultrasonic detection in thickened area.
④ Magnetic particle inspection and size measurement for external threads.
⑤ Magnetic particle inspection for thickened area and thread.

After completed the inspection of remaining half drill pipe, the rejection of the joint
for 8 internal threaded joints, 17 external threaded joints and 1 full length of the joint.
It can be seen that deepwater drilling at least use the 4 and 5 class of DS-1standars to
inspect drill stem.

The Chinese domestic oil companies have not yet been strictly implement the
inspection in accordance with the NS-2 standards. But in case of key exploration
projects, they will inspect old drill pipe based on NS-2 standards, such as Shell in the
South China Sea project and Sichuan unconventional gas projects. Most European
58
companies, such as the Norway National Petroleum Corporation, British National Oil
Company are implement the NS-2 standards to inspect drill pipe. Due to the special
risks and expensive costs of offshore drilling, the inspection of drill stem is in
accordance with the NS-2 and fourth or fifth categories of DS-1 standards to
implement. But in fact the inspection of slip clip area and thicken zone of category
fifth of DS-1 standards is less than of NS-2 standards, for most internal upset
transition area of drill stem failure, this is particularly important. Therefore, as can be
seen from the above analysis, the advanced experience and commonly method of
international oil company for drill stem inspection of offshore drilling is based on
NS-2 standards, and only using new drill pipe and the high quality grade drill pipe.

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Section 5 New inspection technology of drill stem

After long time using, it is necessary to carry out nondestructive testing for drill stem.
The choice of nondestructive testing methods of drilling tools is usually selected
according to the standard of inspection, the inspection methods and equipment
requirements for different parts of the drill pipe, DS-1 standards and NS-2 standards
are described in detail. The commonly NDT inspection methods include: ray detection,
ultrasonic testing methods, eddy current testing, magnetic particle testing, penetration
testing and other methods. These commonly used inspection methods has some
common characteristics: ① the requirements of inspection space and environmental
are not very strict; ② the body harm for test people is less, without using special
protection measures; ③ the required devices are easy to carry which is conducive to
carry out on-site inspection work; ④ using the rechargeable battery, without
requiring using industrial power supply.

With the requirement of drill stem system management in oil field, several inspection
methods have emerging in recent years, such as acoustic emission testing, magnetic
memory testing, ultrasonic phased array testing and so on.

5.1 Common detection methods

The five conventional detection of nondestructive detection include: ultrasonic testing,

radiographic testing, magnetic particle testing, eddy current testing. And the
additional detection methods are ultrasonic testing, electromagnetic testing (magnetic
particle testing, magnetic flux leakage testing) and penetration testing.

5.1.3 Ultrasonic testing

Ultrasonic flaw detection is a method that using ultrasound to penetrate the depths of
the metal material, and using the interface occurs reflection characteristic at the edge
of the interface while ultrasound from one cross section to enter another section.

The advantages of ultrasonic flaw detection include thickness detection, high

sensitivity, fast, low cost, harmless to the human body, localization and quantification
of defects characters. However, the technology for ultrasonic testing technology is
difficult, it can be influenced by the subjective and objective factors, also the testing
results is difficult to be preserved. This detection method is commonly used for drill
pipe inside and outside body upset transitional belt, tube body and joint weld, pipe
body thickness and drill collar thread damage detection.

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5.1.3 Electromagnetic testing

The electromagnetic testing method is using the characteristics which generated at

defect area or no defect area of the magnetic field generated by the current, or the
current generated by the changed magnetic field to detect the internal state of drill
stem (Lu Mingjong, 2004). The electromagnetic testing include magnetic particle
testing method magnetic flux leakage testing method.

For Magnetic particle testing, it is commonly used for Chinese domestic, the detection
result of this method is intuitive, the testing operation is simple, the testing cost is low
and the detection efficiency for surface and near surface defect is high. But it is
unable to know the depth of defect and it is only suitable for test the surface and near
surface of ferromagnetic material, the degree of testing automation is low, it is easy
affected by human factors.

For magnetic flux leakage testing, it is mainly for detection of drill pipe body, this
method have the advantages of simple structure, convenience in signal processing,
detection capability, high sensitivity, it is especially with positioning, objectivity and
recording advantages which is not only suitable for detection of oil drill pipe, also
suitable for the rough surface of tubes. Meanwhile, this detection method has higher
requirements for magnetic flux leakage testing equipment, detecting probe and
magnetization technology.

5.1.3 Penetration testing

Penetration testing is not limited by magnetic, shape, size, structure, chemical

composition and defects of the workpiece, and a single operation can check the
defects in each direction. Penetration testing operation is simple, and does not require
complex equipments, the testing cost is low, the defect is easy display and has very
high sensitivity. Due to the penetration detection has the unique advantage, it is
throughout application in various fields of modern industry. The international research
shows that the detection probability of penetration testing for surface and linear defect
is higher than magnetic particle testing, and it is one of the most effective surface
detection methods.

But penetration testing also has its own limitations as show in the following three
aspects:

(1) It can only detect the open surface defects;.

(2) It does not apply to test for porous material made of the workpiece and rough
surface materials.

(3) The penetration testing can only detect the distribution of surface defects, it is
61
difficult to determine the depth of defect and to make quantitative evaluation for
defects. The detection result is affected by the operator. For drill stem damage
detection, it is mainly applicable to detect the internal and external threads none
magnetic drill collar.

5.2 New technology of drill stem inspection

At present, the new technology of drill stem nondestructive testing is mainly include
magnetic memory testing, acoustic emission technology and ultrasonic phased array
testing technology. For this research, due to the limitation of material collection and
ability of myself, this paper will not research and discuss so much.

62
Section 6 Discussion and conclusion

With the increase of drilling depth and the drilling technology development of high
angle wells and large displacement horizontal wells, the performance requirement for
drill stem is more and more higher. Oil drill stems is the main tool for exploration and
development of oil and gas, the failure accident of drill stem in oil and gas exploration
will not only hindered the drilling speed and production, but also caused huge
economic loss.

The failure type of drill stem is given priority to fatigue failure. It is found that for all
types of drill stem failure, the fatigue failure is the main form which include drill pipe
thicken transitional belt and slip clamp area of the pricking leakage e failure, joint
thread fatigue thorn leakage and fracture failure. Also the drill pipe thicken
transitional belt and slip clamp area of the thorn leakage failure is more prominent for
offshore drilling, thorn leakage wells occurred in the well section with high dogleg.

The physical and chemical properties of drill pipe failure samples are comply with the
requirement of API Spec 5 DP-2009 standard. The internal coating of drill pipe failure
samples spraying uneven, and local thickness does not conform to the stipulations.
The spraying quality of the drill pipe internal coating is unevenly, internal thicken
transition region is not smooth, overall smooth of surface roughness is poor, all these
are the reasons of drill pipe pricking leakage failure.

Drill stem service environment is poor, and the stress state is very complex which
include torsion, bend, tension and compression load, and also impact by the
environmental media, such as drilling fluid, H 2 S, CO 2 , temperature, pressure, etc..
The failure statistics and analysis results show that the main forms of drill stem failure
include fracture failure, pricking leakage failure, corrosion failure, wear and
deformation. And the fatigue and corrosion are the frequently-occurring failure.

Using the general failure analysis methods to analysis the drill stem failure, it can not
only beneficial to find the failure reason, mechanism, but also can out forward the
prevention measures for the failure forms and behavior characteristics of drill stem.
The general failure analysis methods is difficult to find out he failure reason when
analysis the individual failure problem, this need special analysis for special
environment and special problems.

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