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OTC 7325 Coiled Tubing Life Prediction: Problem Statement
OTC 7325 Coiled Tubing Life Prediction: Problem Statement
OTC 7325 Coiled Tubing Life Prediction: Problem Statement
OTC 7325
This paper was presented at the 25th Annual OTC In Houston, Texas, U. S.A., 3-6 May 1993.
This DaDer was salacted for rxesentation bv the OTC Program Committee followinQ review of information contained in an abstract submitted by the author(s). Contents of the paper,
as presented, have not been’ reviewed by the Offshore Te~hnology Conference and are subject to correction by the euthor(s). The material, se presented, does not necessarily reflect
any peaition of the Offshore Technology Conference or ifs officers. Permission to COPYis restricted to an abstract of not more than 300 words. Illustrations may not be copied. The abstract
should contain conspicuous acknowledgment of where and by whom the papar is presented.
l%epaper aaliresses a recently developed mathematical model Design in fatigue is a relatively simple problem when
for coiled tubing fatigue lj$e prediction. It is shown that the a detail is subjected to a uniaxial stress state with steady
coiled tubing stress-strain condition is unique and is primarily stress cycle components. For high-cycle fatigue of ductile
characterized by plane elastic stress state induced by internal metals under multiaxial stress state, the Tresca criteria
pressure and superimposed over extremely high plastic (maximum shear stress failure theory) and von Mises
alternating bending strains. criteria (distortion energy failure theory) are the most
l%e model wm developed usingjidl-scale tubing fatigue tests.
popular. But in low-cycle fatigue, these simple theories are
In these tests three strength kve~ of coiled tubing material were
unable to correlate the experimental results.
tested at discrete pressure levels in ranges from O to 7500 psi
For instance, G. Z. Libertine [1] notes that the von
using two types of gripper blocks: standard semicircle and
universal V-shaped. It is revealed that the steady tangential
Mises criterion cannot allow for the effect of hydrostatic
stress component, induced by pressure, affects fatigue ll~e in a pressure. According to M. W. Brown and K.J. Miller [2],
nonlinear manner. Conventional failure theories do not work to this situation has led to many criteria being suggested for
describe and predict coiled tubing lije. Instead, an algorithm correlating low-cycle, multiaxial fatigue, but no single
based on equivalent strain as a fiinction of principal strains is criterion has been shown to have universal applicability.
proposed. Constants of the fiowtion are defined in a way to For example, M. Liddle and K.J. Miller [3] have tested
achieve maximum correlation between model predicted ll~e and tubes of 1% Cr-Mo-V steel in combined tension and
actual ll~e. Correlation coefficient became as high as 0.973. torsion, for lives between 200 and 5000 cycles. Tests were
Fatigue strength of coiled tubing material is expressed in controlled between constant strain limits, The authors were
terms of low-cycle S-N (strain versus lfe) fatigue line. Yhis line
unable to correlate the results satisfactorily with a single
is defined by reference point and slope. Fatigue ll~e scatter is
criterion. As an alternative, they presented a series of
de]ned by lognormal distribution and its variation coefficient
constant life contours on a graph of maximum plastic shear
(standard deviation in terms of mean) is 0.11. l’hat is, the test
results are in close agreement with the model prediction.
strain range against the total tensile strain range, which is
Cumulative damage is expressed using Miner’s rule and normal to the maximum shear plane.
equivalent strain. Nonlinear equivalent strain respectively leaak D. L. McDiarmid [4] ran a comprehensive series of tests
towara% nonlinear cumulative damage expression. on thin-walled tubes of an aluminum alloy subjected to
repeated internal pressurization and axial load. Using the
results of other researchers’ work on several materials he
derived an empirical correlation relating the maximum
Tables at end of paper shearstress,r,, atthefatigueIimitintermsof
alternating
627
2 COILED TUBING LIFE PREDICTION OTC 7325
628
OTC 7325 V. A. Avakov, J. C. Foster, E.J.Smith 3
relatively small, and they may be neglected in this logarithmic coordinates (Fig.3):
consideration.
S = GNb+FENc , (3)
‘The coiled tubing stress-strain condition is unique and
is primarily characterized by the following:
1. Alternating uniaxial plastic strains acting in the tubing’s where the first term on the right side of equation reflects
longitudinal direction. This direction is one principal the elastic portion of the total strain range, and the second
direction. Strain cycles are induced by (a) tubing bending term reflects the plastic portion of the total strain range. It
over the reel, and (b) tubing bending over the gooseneck. is evident that at short lives the plastic strain range
Bending strains are always far beyond the elastic limit, and dominates, that is, the second term of the total stress range
they are the most damaging. is the largest portion of the Coffin-Manson expression. At
2. Steady (or static) biaxial stress state induced by internal longer lives, the elastic stress range (the first term of the
pressure. Tangential and radial stresses due to pressure are equation) dominates.
the other two principal stresses, and they do not exceed the Coiled tubing life is always less than 300 strokes. That
elastic limit. The static stress state may be converted into is, plastic strains along with the respective second term of
the equivalent uniaxial stress acting, for instance, in the equation are decisive. For application purposes, the
longitudinal direction of the coiled tubing. Proportionality Coffh-Manson equation could be simplified and defined as
in this conversion between equivalent stress and actual (4)
biaxial stress state is in question and it is a subject of this S = MENC
presentation.
Stresses due to pressure are not damaging unless At c=-%, [11,12,13], and assuming that life has
alternating axial stresses are applied. Damage due to Iognormal distribution [14] for reliability assessment:
alternating plastic strain cycles is intensified when pressure
is increasing. For instance, during full-scale tests at
negligible pressure, tubing life is close to 300 strokes
:(;)2 =
MM
exP(lv4
(5)
s=Sa+m,[+)””” ‘ $JCvnv”
- (L)
aaao
mall
S=o ly S6 5 Sy
lC+KI
Boo
where stresses are in consistent units.
OcQ
SOO
10 m so Im !200 Soo moo
Low-cycle S-N (Stress/Strain - Number of cycles to
FATIGUELIFE, Cycles N
failure) curve is defined by so-called Coffin-Manson
equation (see Appendix A). ‘l%e curve is the sum of two F@re 1
lines, which are straightwhen plotted in double-
629
—_ ——— __—=_
.—— — —-
— .—
—
.—
—
—
4 COILED TUBING LIFE PREDICTION OTC 732S
FATIGUE TESTS reeled off until a section that had not been cycled came off
the reel and reached the top of the casing. This resulted in
A series of full-scale fatigue tests is planned to be a tubing sample length of approximately 125 ft long for
conducted at company facilities. The program includes each test and, therefore, this tubing length was discarded
coiled tubing OD ranging from 1 to 1.75 in. at various after each test. The tubing was filled with water and
wall thicknesses and materials. The first full set of tests pressurized to the desired level. Failure was defined as
was accomplished in spring 1992 using 1.25-in. OD by when water squirted out of a crack or pin hole.
0.087-in. wall coiled tubing. With standard semi-circular
gripper blocks tests were run with three different materials:
TEST RESULTS
1. QT-70, SY=79.5 kpsi, and SU,=85.7 kpsi,
2. SYMAX-80, SY=91.9 kpsi, and SU,=101 kpsi, It is assumed that low-cycle fatigue strength is
3. SYMAX-1OO, SY=95.6 kpsi, and SU,=113 kpsi. proportional to the material ultimate strength. Under this
With universal gripper blocks [15], tests were run using assumption all test results have been converted to one
QT-70 coiled tubing. standard strength level of 80 kpsi. For each sample,
A conventional coiled tubing unit was set up at a fatigue life in stress/strain cycles, NJ, was defined by
shallow test well 65-ft deep. The injector unit was equation (7). Then, expected life in strokes-to-failure
equipped with 72 in. radius gooseneck. The coil diameter becomes
on the reel was in the range from 82 to 95 in. Tubing was
run off the reel, over the gooseneck, and through the NM NMS: . ~nst
M, = —= (lo)
injector until the tubing’s free end was below the top of the N1 S:+2S; S:+2S;
well casing. Each test stroke consisted of running the free
end of the tubing 65 ft to the bottom of the well and back
to the top of the casing. Tubing was run back and forth at In this evaluation, the constants, m and A, are links
constant internal pressure. Number of strokes to failure, between actual life, M, and predicted life, M,. We need to
M, was recorded. During a stroke, the most loaded and define such values of m and A at which correlation
damaged sections had one cycle of bending stresses, Sw, coeftlcient, R, between M and M, becomes maximum and
over the reel, and two cycles of bending stresses, Sw, close to the unity:
over the gooseneck.
For these sections, it may be counted as three strain (m,A) = (m,AlR2=max)
cycles only when imposed stresses are identical, that is,
radii of the reel and the gooseneck are identical. Actually,
such condition is unlikely to happen. In general, In other words, if there exists a function
summation should be performed using Miner’s cumulative
R2 =f(m,A) (12)
damage rule [7]:
~~(m,A) = 0, ~~(m~) .0
where am aA
and (13)
‘, = SO+AS, ()_!_ (8)
s C7mv “-1 a2fim#$ <O, a2f(m,A) <()
am2 aA2
y m-l
S8 = S~~+AS, _
()
s mv
(9) On Fig.2 the correlation coefilcient is traced against m
at A =1. By this graph, it has been chosen that m=l.985
and A =1 as solution for the test data.
To begin the next test, a new tubing “sample” was
630
.
OTC 7325 V. A. Avakov, J. C. Foster, E.J.Smith 5
1,5 1.6 1.? 1.8 1.9 2.0 al 2,2 2.3 $3,4 2,5 4. McDiarmid, D. L.: FAILURE CmTERIA AND CUMULATIVE
1.0 ,. .$,
., ,., —
‘....:.. ..................................
... Din-AGEIN-FATIGUE
UND~ MULTZ&AL S’kms COND~ONS.
,,. .
City University, London, UK; Ph.D. Thesis, 1972;
. . . . . . ... . . . . . . . . . ... . . . .
— cosRmAnON cow CIEli T,...,.
5. Tipton, S. M. and Newburn, D. A.: PLASTICmY AND
FATIGUEDAMAGE MODELING OF SEVERELYLOADED TUBING.
Advances in Fatigue Lifetime Predictive Techniques, Proc. 1st
Symposium, San Francisco, CA, April 1990; Philadelphia,
u ASTM, 1992; 369-382
g
6. Newman, K.R. and Newburn, D. A.: COILED TUBING LIFE
i MODELING. SPE 22820, SPE Annual Techical Conference &
., LJFE
VARIATION
COEFFICIENT Exhibition, Proceedings; Dallas, TX, October 6-9, 1991;
,,,
,,. 7. Miner, Milton A.: CUMULATIVE DAMAGE IN FATIGUE.
-------:
----:.
-----
0.11-----
1.6 1,6 1,7 1.8 1.9 2.0 2.1 E.z 2.3 $?,4
~,50.r J. Appl. Mechanics, Vol. 12, Trans. ASME, VO1.67, 1945; A159-
2TRESS STAT2 EXPON2NT m A164
Figure 2
8. Collins, J.A.: FAILURE OF MATERIALS IN MECHANICAL
DESIGN,ANALYsrs,PREDKXION, PREVENTION.New York,
J.Wiley, 1981; 629
CONCLUSIONS
9. Smith, L. W.: M~HODS OF DETERMINING THE
1. Low-cycle fatigue life for coiled tubing of 1.25 in OPERATIONAL LIFE OF INDIVIDUALSTRINGSOF COILED
outside diameter can be predicted using empirical TUBING. SPE Workover and Well Intervention Seminar,
equivalent stress expressed by equation (2) in terms of November 16, 1989, Aberdeen, Scotland
alternating stress range and hoop stress.
2. Fatigue S-N lines are defined by hyperbolic equations 10. Walker, E. J.: How LoADsAmmcr COILEDTUBINGLrFE.
(5) and (6). They become straight lines when plotted in a World Oil, VOL213, No. 1; January, 1992; 47-49
double-logarithmic coordinate system.
3. The practical advantage of the equations (5) and (6) is 11. Coftin, L. F.: DESIGN ASPECTS OF HIGH TEMPERATURE
that they simplify Miner’s fatigue damage summation FATIGUE wrrH PARTICULAR REFERENCE TO THERMAL
procedure. STRESSES.
Trans. ASME, VO1.78; April, 1955; 527-532
631
6 COILED TUBING LIFE PREDICTION OTC 7325
.l\
w
~
S = GNb+FENc , (14)
#2 id
V2
lh+tion
M
\
Ltfe
. . . . ....
I@ 1+ I& K) Id I& 10
F = 0.83DT, (18)
(19)
(20)
632
OTC 7323 V. A. Avakov, J. C.Foster, E.J.Smith 7
Table 1
COIL TUBING
TYPICAL STRESS/STRAIN CYCLE PATTERN AT VARIOUS LOCATIONS
u, - axial stress due to hoisting load or bending over reel and gooseneck; bending stress is defined as
u,= ub= * CE= * dE/(2R), where R is bending radius over reel or gooseneck; a, - radial stress; at - tangental stress;
al ,uz,u3 - principal stresses.
Stresses are defined at following conditions: (1) Tubing size 1.25-in. OD x 0.087-in. Wall Thickness; (2) Yield
strength 70000 psi (22251 lb axial yield load); (3) Applied allowable tensile stress 70000/1.25=56000 psi or 17800
lb hoisting load; (5) Inner pressure 5000 psi; (6) Bending radius over gooseneck 72 in.; (7) Bending radius over
reel 42.25 in.; and (8) Pressure beam unit load 1287 lb/in. of beam length inducing +31785 psi tangental bending
stress, compression is neglected.
633
8 COILED TUBING LIFE PREDICTION OTC 7325
Table 2
COILED TUBING TEST DATA
1.25 in. OD, 0.087 h. Wd thickness
m=l.R9<
... -.-= -
Mean 130021352
STD 14449594
STD/Mean 0.111
634
— .——