This document discusses drill string design procedures. It covers selecting drill collar diameter and connections, determining bottom hole assembly (BHA) and drill pipe section lengths, and performing tension, torsion, burst pressure, collapse pressure, buckling, and other calculations. Design factors are applied to material strengths to account for uncertainties. The procedures begin by selecting the BHA components and working upward through successive drill pipe sections. Special considerations are discussed for extended reach wells. Proprietary software can now perform the detailed calculations described.
This document discusses drill string design procedures. It covers selecting drill collar diameter and connections, determining bottom hole assembly (BHA) and drill pipe section lengths, and performing tension, torsion, burst pressure, collapse pressure, buckling, and other calculations. Design factors are applied to material strengths to account for uncertainties. The procedures begin by selecting the BHA components and working upward through successive drill pipe sections. Special considerations are discussed for extended reach wells. Proprietary software can now perform the detailed calculations described.
This document discusses drill string design procedures. It covers selecting drill collar diameter and connections, determining bottom hole assembly (BHA) and drill pipe section lengths, and performing tension, torsion, burst pressure, collapse pressure, buckling, and other calculations. Design factors are applied to material strengths to account for uncertainties. The procedures begin by selecting the BHA components and working upward through successive drill pipe sections. Special considerations are discussed for extended reach wells. Proprietary software can now perform the detailed calculations described.
DRILL STRING DESIGN 1.4.1 INTRODUCTION When designing a drill string the aim is :- Keep the maximum stress at any point in the drill string less than yield strength derated by a design factor. Select components and configure assemblies to retard fatigue as much as economically practical. Provide equipment that is resistant to Hydrogen Sulphide (H2S) if H2S is expected. This Topic covers simple drill string design steps for vertical and directional wells, including some considerations for extended reach drilling. Loads applied by tension, torsion, combined tension and torsion, burst pressure, collapse pressure, slip crushing and stability forces are considered. It does not cover techniques for vibration analysis, torque and drag modelling, hydraulics design, directional control or jar placement. Proprietary software programs for performing the calculations described in this Topic is now available in most OUs. As always, however you should be aware of what data they are using and what they are doing with it. 1.4.1.1 DESIGN ASSUMPTIONS For simplicity, the assumptions outlined below are built into the calculations in this section. Tension is approximated using the "Buoyed Weight" method when doing manual calculations. Although this method ignores the effects of circulating pressure on tension, it continues to be very popular for tensile design. This is no doubt due to the following: o It's the way we've always done it (Tradition!), o It's simpler than the more exact "Pressure-Area" method, which is used by Torque/Drag software such as Well plan for Windows, and o The error that it causes is easily compensated when selecting the Margin of Overpull (MOP). Buckling is assumed to occur only below the point where buoyed string weight equals weight on bit. This point will be called the "Neutral Point". This assumption ignores some pressure forces in order to simplify design calculations. In fact, unless the drill pipe is stuck, the neutral point will never be above this point except temporarily when pump rate is increased with the bit on bottom. Increasing hole angle at the BHA reduces the fraction of BHA weight available for bit weight. Tension calculations assume the string is hanging vertically. For high angle and extended reach drilling, this assumption will be modified as it would otherwise result in too conservative a design. Material yield strength is the specified minimum for the component being considered. Drill pipe tube wall thickness is the minimum for the stated drill pipe class. Connection torsional strength and makeup torque are calculated using the A.P. Farr formula from API RP 7G.
(2) DRLG STRG DESIGN 11:54 AM 7/13/2007 M A-Mohsen 1.4.1.2 DESIGN FACTORS Design factors are numbers that are used to derate the load capacities of components and assemblies. Design factors provide an extra margin of capacity to take care of inexactness in our assumptions about material properties, loads and hole conditions. For drill strings, the following design factors will be used: For Tension (DF T ): This factor is divided into a component's maximum tensile load capacity to determine the maximum allowable load that we're comfortable applying to that component. Design Factor for tension (DF T should be 115, based on SIEP recommendations. Margin of Overpull (MOP): This is excess tensile capacity above the normal hanging or working load (P w ) to account for factors such as hole drag. MOPs may vary from 50,000 to 150,000 lbs, depending on hole conditions. For excess BHA weight (DF BHA ): This factor is multiplied by desired weight on bit (WOB) to determine minimum buoyed BHA weight. This excess weight in the BHA provides an extra margin to keep the neutral point below the top of the BHA. The recommended value for DF BHA is 115. For Torsion: Applied torsion is limited to tool joint makeup torque. Standard makeup torque is either 60% or 50% of tool joint torsional yield strength, according to the Class of the pipe, and tool joints are almost always weaker in torsion than the tubes to which they're attached. Therefore a design factor in torsion isn't necessary for drill string design. For Collapse Pressure (DF C ): Collapse pressure capacities are first derated to account for the effect of any simultaneous tension, then the derated capacity is further reduced by dividing by the collapse design factor. DF should be 1125. For Burst Pressure (DF B ) Burst pressure loading is rarely a concern in drill string design because surface pressures rarely approach the burst capacities of most drill pipe. The design factor for burst is divided into a component's burst pressure capacity to give the maximum permissible burst pressure that may be applied to that component. DF B should be 1176. Burst capacity is increased by simultaneous tension, but this benefit is normally ignored in drill string design. 1.4.2 DESIGN PROCEDURE Design is a multi-step process which usually begins at the bottom of the hole and works upward. The following is a discussion of a simple tension and torsion design. These steps and considerations will be present in most design situations. Special considerations for extended reach drilling are also included. The following steps in the process are discussed: Selection of drill collar diameter Selection of BHA connections and features Stabiliser and jar placement Determine length of drill collar section Determine length of the heavy weight drill pipe section Other checks to make Drill pipe tension design nomenclature Calculate allowable load (P A ) (3) DRLG STRG DESIGN 11:54 AM 7/13/2007 M A-Mohsen Set margin of overpull (MOP) Calculate working load (P W ) Calculate the maximum length of the first drill pipe section Calculate the maximum length of the second drill pipe section Calculate the maximum length of the third drill pipe section Burst pressure Collapse pressure Combined loading Stability forces and drill pipe buckling Slip crushing Buoyancy factor for non-steel components Special considerations for extended reach wells 1.4.2.1 SELECT DRILL COLLAR DIAMETER Unless geometric sticking (see Topic 1.2.1 of Section 5, Part 1 - Stuck pipe prevention and fishing operations) is a problem, the largest diameter drill collars consistent with other needs are generally best. Their increased stiffness means more directional stability. Also, they will have fewer connections for a desired weight on bit. They allow shorter BHAs which can lessen the likelihood of differential sticking. Larger OD collars in a given hole also mean less lateral freedom of movement in the BHA. This decreases buckling stress and the rate of connection fatigue. In practice however, drill collar size is often determined by existing rig stocks. Other factors which come into play are: Fishability considerations. Capabilities of the rig handling equipment. Directional control requirements. Hydraulics. Desired exterior features (spiral grooves, elevator groove, or other features). 1.4.2.2 SELECT BHA CONNECTIONS AND FEATURES The following points apply not only to drill collars and HWDP from the rig inventory, but also to the many specialised tools that find their way into the hole. Stabilisers, motors, MWD and LWD tools, hole openers, under-reamers, jars and other tools are all subject to fatigue. Bending strength ratio: The predominant consideration, especially in selecting larger BHA connections is Bending Strength Ratio (BSR). BSR is a ratio of the relative stiffness of the box to the pin for a given connection type. If we select a connection with either a pin or box that is out of balance with the other member, we tend to increase the stress level and accelerate fatigue in the weaker member (see Figure 2.1.28) (4) DRLG STRG DESIGN 11:54 AM 7/13/2007 M A-Mohsen
Figure 2.1.28 : The effect of BSR of 2.5 on fatigue life. The traditional target BSR is 25, and acceptable BSR ranges centre on this point. However, BSR ranges are rough guidelines established by "experience" and should not be used as strict operating limits. Staying within recommended BSR guidelines does not eliminate connection fatigue failures, nor does exceeding the recommended ranges always lead to fatigue failures. In theory, high BSRs should cause accelerated pin failure, and low BSRs should cause accelerated box failures. A balanced BSR should provide maximum connection life. However, field experience shows that larger OD collars (8" and up) suffer predominantly from box fatigue cracks even when they operate at or near the ideal BSR of 25. This indicates that higher BSRs may be more appropriate for these sizes. On the other hand, 43/4"collars with BSRs as low as 18 are widely used but rarely experience box fatigue cracks. Therefore, the suggested BSR ranges in Table 2.1.5 are probably better. In every case however, experience under given conditions should be a major factor in BSR selection.
One frequently overlooked connection is the one between the top drill collar and the bottom joint of HWDP. If a straight (non- bottleneck) crossover sub is used, and the collar OD is larger than the HWDP tool joint OD, the resulting BSR of that one connection will be exceedingly high. Pin failures in the bottom joint of HWDP are not uncommon, and this is the probable reason. The problem is helped by using a bottleneck sub to smooth the change in cross section.
Table 2.1.5 : Recommended BSR ranges
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Figure 2.1.29 : BHA thread forms BHA Connection Thread Form Thread forms with full root radii should be used in all BHA connections to maximise fatigue resistance. API Regular, NC, and 51/2" Full Hole connections meet this requirement, though the API NC thread form (V 038R) is superior to the others. The H90 thread form is also considered acceptable even though it does not have a full root radius. Remember, all connections that employ a "standard" V065 thread form, except the PAC, are obsolete. Therefore, you should specify "NC" instead of the obsolete "IF" or "XH" names. This eliminates the (very low) probability of receiving the fatigue prone V-065 thread form in your collars. Stress relief features Stress relief features as described in API Spec 7, should be specified on all BHA connections which are NC 38 and larger. These features include the "stress relief pin" and "bore-back box". They prolong connection fatigue life by eliminating un engaged thread roots which act as stress concentrators. Stress relief features are beneficial on HWDP connections. Pin stress relief grooves are not recommended for connections smaller than NC 38 because they may weaken the connection's tensile and torsional strength, and because fatigue is often less of a problem than static loads on small connections. Bore-back boxes could be used on smaller connections without weakening them, and should be considered if box fatigue is occurring. Cold rolling Cold rolling BHA thread roots and stress relief surfaces increases fatigue life by placing a residual compressive stress in the thread roots. Cold rolling is also beneficial on HWDP threads, though not on normal weight drill pipe tool joints. Fatigue is rarely a problem on normal weight drill pipe tool joints owing to the relative stiffness of the tool joint compared to the tube. BHA connection torsional strength Since torsion is transmitted from the top down, BHA connections are usually subjected to lower torsional loads than the connections above. However, if "stick/slip" is occurring, or if you are running a tapered or "slim" assembly, especially one using PAC connections, torsional strength should be checked to confirm that it is greater than the expected operating torsion at the BHA. Tool joint torsional strength tables cannot be used directly for this purpose because tool joint and drill collar materials have different yield strengths.
(6) DRLG STRG DESIGN 11:54 AM 7/13/2007 M A-Mohsen However, drill collar connection torsional strength can be calculated by the following equation: TS = MUT/f [Eq.1] where: TS = DC connection torsional strength MUT = Make up torque f is taken from Table 2.1.6 (all in consistent units)
Table 2.1.6 : Factors for converting drill collar MUT to torsional strength 1.4.2.3 STABILISER AND JAR PLACEMENT Stabilisers The size and placement of stabilisers is often determined by directional considerations. However, stabilisers also impact other important design concerns: In a vertical hole, the lower part of the BHA will be buckled and supported by the sides of the hole. Stabilisers reduce connection stress by restricting the freedom of lateral drill collar movement. This lengthens connection fatigue life, other things constant. If mechanical sticking is a concern, more or larger stabilisers may increase the chance of becoming stuck. On the other hand, stabilisers can reduce the probability of differential sticking by holding drill collars away from the side of the hole. When considering contact between drill collars and the wellbore wall both the stabiliser spacing and the collar OD should be taken into account. It is common to use the same stabiliser spacing in BHAs regardless of the collar size (OD). For example, 90ft stabiliser spacing in a 175" BHA with 9" collars will give much less wall contact than 90ft stabiliser spacing in a 6" BHA with 43/4" DCs. It is important to remember this fact when designing BHAs with a low risk of differential sticking. Tables 2.1.7 & 2.1.8 give an indication of the stabiliser spacing required to minimise contact between drill collars and the wellbore wall. Above 50 inclination the results would be substantially similar to Table 2.1.8.
Table 2.1.8 : Wellbore contact with inclination 30 - 50
Table 2.1.7 : Wellbore contact with inclination 0 - 3 (7) DRLG STRG DESIGN 11:54 AM 7/13/2007 M A-Mohsen Jars The two main considerations for jar placement are preventing jar fatigue failure and maximising jar impact at the probable sticking location. For fatigue failure prevention in vertical or near vertical wells, the "rule of thumb" is to run jars in "tension" (or more precisely, above the axial neutral point - see Topic 1.3). More recently, jar companies say that it's acceptable to run jars in "compression" (below the axial neutral point) but not at the "axial neutral point" itself. To simplify matters, we should apply the following rule: Don't run jars buckled at any time. Obviously, this rule prohibits running jars in compression (below the buckling neutral point) in vertical or near vertical hole sections. In high angle holes, the compressive load a jar may carry without buckling will depend on many factors, but can be easily estimated using jar dimensions and the Dawson-Pasley relationship for drill pipe buckling. Regarding the prohibition against running jars at the "axial neutral point", this will not always be practical in high angle holes. For example, in a recent North Sea extended reach well, with a hole inclination of 75, bit weights varied between 5,000 and 25,000 lbs as stringers were drilled. In the soft formations it was necessary to limit the ROP to clean the hole, thus the lower bit weight. The higher bit weight was necessary to drill the harder rock. The upshot was that the "axial neutral point" was constantly moving over a range of about 1,800 feet in the string (and past the jars). Although the jars cycled from open to closed, the change in position occurred at low energy levels because care was taken not to add bit weight too fast, and no problem occurred with the jars. If you expect a situation like the one above, you should discuss the circumstances with your jar company and develop operating limits to prevent cycling the jar while too much energy is stored in the drill string. For maximising jar impact see Section 5, Part 1 - Stuckpipe prevention and fishing operations. 1.4.2.4 DETERMINE LENGTH OF DRILL COLLAR SECTION The length of the drill collar section will be determined in part by whether or not HWDP is to be used for bit weight and by the BHA configuration. Three types of BHA configurations are covered in these design recommendations and are illustrated in Figure 2.1.30.
Figure 2.1.30 : Types of BHA
Type A: This configuration uses heavy weight drill pipe above the drill collars as a transition to smooth the abrupt section change. Full weight on bit is still applied with drill collars. Type B: This configuration has only enough drill collars to achieve desired directional control or other objective and applies bit weight with both collars and HWDP. It provides easier and faster rig floor handling of the BHA, reduces differential sticking tendency and has apparently reduced drill collar connection failures. Type C: The Type C configuration has more than one drill collar size but still applies bit weight with both collars and HWDP. (8) DRLG STRG DESIGN 11:54 AM 7/13/2007 M A-Mohsen Type A BHAs If the Type A BHA configuration is used, the minimum length of the drill collar section is calculated as follows:
The design factor for excess BHA weight (DF BHA ) is chosen to ensure that the neutral point stays below the top of the BHA. This factor is assigned a value of 115 in most Shell applications. Hard drilling conditions may require higher values. After the minimum drill collar section length is calculated, it is usually rounded to the next full stand of collars for convenience. Type B and C BHAs If a Type B or Type C BHA configuration is used, the number of drill collars is determined by directional control, equipment availability or other considerations. The amount of HWDP required to apply the necessary WOB and keep the neutral point in the BHA can be determined by Equation 3.
1.4.2.5 DETERMINE LENGTH OF THE HEAVY WEIGHT DRILL PIPE SECTION
Type A BHAs For a type A BHA configuration, the amount of HWDP for transition is determined by past experience. Anywhere from 12 to 30 joints is common.
Type B and C BHAs When HWDP will be used for bit weight, the minimum length of HWDP to provide the desired weight on bit is calculated as follows: {eq.3} (9) DRLG STRG DESIGN 11:54 AM 7/13/2007 M A-Mohsen
Where: L HWDP = Minimum length of HWDP section WOB = Maximum weight on bit DF BHA = Design factor for excess BHA length W HWDP = HWDP air weight W DC1 = Air weight of drill collars in first section L DC1 = Length of first drill collar section W DC2 = Air weight of drill collars in second section L DC2 = Length of second drill collar section K B = Buoyancy factor * = Maximum hole angle at BHA (all in consistent units) As hole angle increases, the point is reached when a heavy BHA is more detrimental due to increased tensile and torsional drag than it is beneficial for adding weight on the bit. Equations 2 and 3 for calculating necessary BHA weight will not apply if the hole angle exceeds the critical angle. Beyond this point, it is customary to apply bit weight by running the normal weight drill pipe in the high angle hole section in compression. (These issues are covered in Topic 1.4.2.20). 1.4.2.6 OTHER CHECKS TO MAKE Check tool joint torsional capacity To prevent downhole makeup and resulting torsional failure, maximum operating torsion should never exceed tool joint makeup torque. API "standard" tool joint dimensions fix tool joint torsional strength at about 80% of the drill pipe tube torsional strength. Therefore, if a string fails due to simple torsion loading, failure nearly always occurs in the tool joint. Moreover, all API tool joints employ material of the same specified strength, so the torsional capacity of a given drill string is established by its tool joint ID and OD and not by drill pipe weight and/or grade. Be aware that some tables exist that give make-up torque as a function of pipe weight and grade. Such tables cannot be trusted and should not be used. (10) DRLG STRG DESIGN 11:54 AM 7/13/2007 M A-Mohsen Drilling contractors and rental companies often order non-API standard dimensions in tool joints; it is therefore essential to base the torsional performance limit on measured dimensions and not on an assumed standard. Recommended values of tool joint makeup torque are tabulated in the Well Engineers Notebook (pages C-8 to C-12). These are based on a tensile stress of 50% of the minimum tensile yield strength for Class I (new) tool joints and 60% for the other classes. When high operating torsion is expected, makeup torque may be increased above the standard recommended value. However, this must not be done without checking the tool joint combined tension/torque capacity to ensure that the increased make-up torque doesn't reduce pin tensile strength below an acceptable level. This is discussed further in Topic 1.4.2.16. Always be sure to confirm connection dimensions and check the accuracy of torque gauges, whether or not you plan to exceed standard makeup torque. Calculate Stiffness Ratio The Stiffness Ratio (SR) of the sections above and below each transition must be compared to help quantify the abruptness of the section change and determine the need for transition pipe. This is accomplished by dividing the section modulus (Z) of the lower section tube by the section modulus of the upper.
The section moduli for tubular elements are given by:
Like BSR, stiffness ratio is not a strictly quantitative performance limit, and experience should be a major determinant in setting the desired maximum SR. If drill pipe failures are occurring near the top of the BHA despite adequate drill collar weight for applied WOB, transition pipe may be needed to smooth the section change. Criteria for permissible stiffness ratio varies between different operators and areas. The following maximums are typical: For routine drilling or very low failure rate experience, keep SR below 5.5. For severe drilling or for significant failure rate experience, keep SR below 3.5 .4.2.7 DRILL PIPE TENSION DESIGN NOMENCLATURE The basis for selecting various pipe grades to make up a drill string is to always maintain at least the desired Margin of Overpull (MOP) at all points in the string. This is accomplished by adding the lowest pipe grade a joint at a time starting from the top of the BHA and working upward. Each joint must support the BHA weight plus the drill pipe below that joint. When the working load (PW) is reached for that grade of drill pipe, the drill pipe is switched to a higher grade. This process continues until the string is complete. Tensile design nomenclature is reviewed below and illustrated in Figure 2.1.31. (11) DRLG STRG DESIGN 11:54 AM 7/13/2007 M A-Mohsen . Figure 2.1.31 : Drill pipe tension design nomenclature
Tensile Load Capacity (P T ) : This is the calculated tensile pull to yield the pipe body. Values for the different sizes and grades of drill pipe are given in the Well Engineers Notebook. Design Factor in Tension (DF T ) : The factor used to derate the tensile load capacity to obtain allowable load (P A ). Allowable Load (P A ) : This is the maximum load we are comfortable placing on the pipe, including an allowance for possible trouble. It is the tensile capacity derated by the design factor. Margin Of Overpull (MOP): The design excess pull capacity above working load (PW) to compensate for expected drag, possible sticking, slip crushing and the effect of circulating pressure on tension. Working Load (PW): Working load is the expected maximum tension that will occur during normal operations. Drill pipe weight : Like the "IF" connection, the "nominal weight" of drill pipe is what we call it, not what it is. For example, "1950 lb/ft" drill pipe doesn't actually weigh 1950 lb/ft. - its approximate real weight (in air) is called "adjusted weight" or just "air weight" and will be something between 20.89 and 22.60 lb/ft, depending on the grade of pipe, the tool joint, and whether or not the contractor bought standard tool joint diameters. This "adjusted weight" (estimates of which are available in the IFP Drilling Data Handbook) is the one to use for design and displacement calculations. Nominal weights are useful only to communicate the type of pipe with which we're dealing.
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Refer to Topic 1.4.2.18 for instructions on how to include slip crushing forces when setting MOP.