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Natural Gas Industry B 4 (2017) 374e381
www.elsevier.com/locate/ngib

Research Article

Design of an ultra-high torque double shoulder drill-pipe tool joint for


extended reach wells
Zhu Xiaohua*, Zhang Zhi
School of Mechanical Engineering, Southwest Petroleum University, Chengdu, Sichuan 610500, China
Received 4 January 2017; accepted 25 April 2017
Available online 20 November 2017

Abstract

Drill-pipe tool joints in extended reach wells often suffer a shear failure. In view of this, an ultra-high torque double-shoulder pipe joint was
designed according to the deformation compatibility relation of the drill-pipe tool joint under torque. It is structurally characterized by long
primary and secondary shoulders, small thread taper and large fillet radius of bottom tooth. First, a 3D numerical simulation model was
established for this type of joint, named the XSJ joint here, based on the principle of virtual work, the Von Mises yield criterion and the
nonlinear contact theory. Second, orthogonal optimization was performed on its key structural parameters by means of the orthogonal opti-
mization method. The optimal combination of key structural parameters of the XSJ joint is taper 1:16, thread pitch 6.55 mm, guiding surface
angle 29 , bearing surface angle 28 , and tooth height 3.755 mm. Finally, the bearing performance and fatigue performance of this tool joint
and the API tool joint were calculated and compared using the Simulia Abaqus fe-safe software. Compared with the API tool joint, the XSJ
joint is better, and its tensile strength, torsion strength, bending strength and compression strength increase by 10.65%, 62.5%, 2.75% and 52%,
respectively. Its tension compression fatigue life, bending fatigue life, torsion fatigue life and composite fatigue life increase by 1.19 times,
1.74 times, 550 times and 28.79%, respectively. It is concluded that the designed XSJ joint is significantly improved in term of torsion capacity
while its tension strength, bending strength and compression strength are not decreased, so it can better meet the drilling conditions of extended
reach wells.
© 2017 Sichuan Petroleum Administration. Production and hosting by Elsevier B.V. This is an open access article under the CC BY-NC-ND
license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

Keywords: Extended reach well; Tool joint; Shear failure; Torsion capacity; Bending capacity; Orthogonal optimization; Bearing property; Fatigue life

1. Introduction which are closely related to the drill-pipe tool joints, resulting
indirect economic losses of up to CNY40 million. At present,
In recent years, with the extensive application of extended more than 25% of the drill-pipe tool joints in China are im-
reach well drilling technology in drilling engineering, the ported directly from abroad. The import price is over 2 times
problem of shear failure of the drill-pipe tool joints caused by than the domestic price. Moreover, for 60% of the drill-pipe
large downhole drag and torque has become increasingly tool joints, their structures are just imported from other
prominent, which leads to increased drilling cycle and cost and countries, but the products are manufactured in China, with a
becomes one of the main factors that limit the drilling engi- large amount of patent royalties payable. These results in high
neering benefits. Statistics show [1,2] that, at the most con- investment, high risks and low profits for domestic drill-pipe
servative estimate, at least 500 drill pipe failure accidents tool joint manufacturers [3].
occurred each year in domestic oil and gas fields, most of In order to reduce the failures of the drill-pipe tool joints
during downhole operation, people have done a lot of research
on the drill-pipe tool joints in recent years. Reasonable me-
* Corresponding author. chanical models and numerical calculation methods have been
E-mail address: zxhth113@163.com (Zhu XH).
Peer review under responsibility of Sichuan Petroleum Administration.
established based on theories and experiments, which produce

https://doi.org/10.1016/j.ngib.2017.10.002
2352-8540/© 2017 Sichuan Petroleum Administration. Production and hosting by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Zhu XH., Zhang Z. / Natural Gas Industry B 4 (2017) 374e381 375

more accurate mechanical properties prediction of the drill- torque between the contact surfaces can be formed. When the
pipe tool joints. Van Wittenberghe et al. used the optical dy- drill-pipe tool joint is subjected to an external torque load, the
namic 3D displacement analysis technique to evaluate the sum of the friction torques on the thread tooth and the
fatigue crack propagation behavior of threaded pipe connec- shoulder is equal to the applied external torque according to
tion [4]. Shahani et al. conducted numerical calculation of the the static equilibrium, and the resultant force on the thread
contact stress and tensile stress concentration coefficient of tooth is equal to the force on the shoulder. Fig. 1 shows the
drill-pipe tool joints [5]. Korin et al. proposed the introduction mechanical characteristic of the drill-pipe tool joints under a
of controlled residual compressive stress at the maximum torque load.
stress of a joint to alleviate the generation of fatigue cracks [6]. If the drill-pipe tool joint has no shoulders, the applied
Akyildiz et al. studied the influence of machining parameters external torque will be borne entirely by the thread tooth;
on the strength of joints [7]. Santus et al. carried out in-depth otherwise, the torque borne by the thread tooth is equal to the
study on torsional strength comparison between two assem- external torque minus the friction torque on the shoulder.
bling techniques for aluminum drill pipes [8]. Ren Hui et al. Thus, the shoulder can protect the thread tooth to a certain
designed a new double shoulder drill-pipe tool joint and extent. Assuming that the external torque of the drill-pipe tool
analyzed its torsional performance [9]. Gao Lianxin et al. joint is T, the torque on the shoulder is TP, and the torque on
proposed a new directional HLBT-8ADE drill-pipe tool joint the whole thread is TT. According to the deformation
structure, and analyzed the torque sharing between the primary compatibility relation of the drill-pipe tool joint, T ¼ TP þ TT.
shoulder and the secondary shoulder and the thread under The relative value of TP and TT is related to the torsional ri-
yield torque [10]. Zhu Xianghua et al. established the three- gidity of the shoulder and the root of the external thread large
dimensional mechanical model of a drill-pipe tool joint, and end, so the following could be attained [15]:
conducted in-depth study on the failure of drill pipe thread
TT GIT IT
gluing at the exit side of horizontal directional drilling and ¼ ¼ ð1Þ
corresponding solution, and proposed an anti-bending drill- TP GIP IP
pipe tool joint [11]. Zhuang Yong et al. analyzed the stress of a where, G is the shear modulus; IT is the moment of inertia of
drill-pipe tool joint under different fastening turns through the the cross section of the external thread root; IP is the moment
drill-pipe tool joint 2D axis symmetric model [12]. Helian of inertia of the shoulder surface cross section.
Changlin designed a high torsional joint thread with a negative Under the torque load, the shoulder shares part of the tor-
angle thread tooth bearing surface using the orthogonal opti- que load for the thread tooth, reducing the torque load on it. In
mization method [13]. These researches mainly focused on the order to further reduce the torque load on the thread tooth, an
mechanical properties analysis and failure prevention of drill- auxiliary shoulder is proposed to share the load on the thread
pipe tool joints, but few researches deal with an ultra-high tooth and reduce the peak stress at the thread tooth to improve
torque double shoulder drill-pipe tool joint under large tor- the torsion resistance. So, the condition of high torque per-
que loads in extended reach wells. formance is proposed:
Under this background, a high torque double shoulder pipe
joint was developed according to the deformation compati- T ¼ TT þ TP þ x ð2Þ
bility relation of a drill-pipe tool joint. Based on the principle
of virtual work, Von Mises yield criterion and contact
nonlinear theory, a three-dimensional numerical simulation
model of high torque double-shoulder drill-pipe tool joint was
established. Orthogonal optimization method [14] was used to
optimize the critical structure parameters. Thus, an ultra-high
torque double shoulder pipe joint with a better performance
was attained and named the XSJ joint here. The comparison of
bearing and fatigue performance between the XSJ joint and
the API drill-pipe tool joint highlights the advantages of the
former in extended reach well applications.

2. A mechanical model of high torque drill-pipe tool joints

2.1. Mechanical characteristics of drill-pipe tool joints


under a torque load

By applying torque to the end face of the pin or the box of


the drill-pipe tool joints, the thread tooth and the shoulder
surface will be compressed in engagement due to the influ-
ence of the lead angle. The roughness of the interacted surface Fig. 1. Mechanical characteristics of the drill-pipe tool joints under a torque
may induce a friction under torque loads, so that a friction load.
376 Zhu XH., Zhang Z. / Natural Gas Industry B 4 (2017) 374e381

2.2. Structure of the high torque double shoulder drill-


pipe tool joint

There is a gap between the engaged thread teeth, which


will be a flow path for the high pressure fluid. The seal of the
API drill-pipe tool joint is provided with the thread grease
filled in the thread and the contact pressure of the main
shoulder. In the high temperature wells, high pressure wells
and large friction wells, when the thread grease is washed out
by the drilling fluid or volatilized by heat, the drill-pipe tool
joint sealing performance and torsional performance will not
be able to meet the requirements of extended reach well
drilling conditions. In order to improve the torsional capacity
of the drill-pipe tool joint without compromising the tensile
strength, bending capacity and compressive capacity, it is
necessary to modify the structure of the drill pipe, as shown in
Fig. 2c.
Fig. 2c shows the structure of a high torque double
shoulder drill-pipe tool joint with the features of long pri-
mary and secondary shoulders, small thread taper and large
root radius. The purpose of such design is to ① improve the Fig. 2. Structural schematic of three drill-pipe tool joints.
torsional capacity of the drill-pipe tool joint; ② to provide
two-way visual seal for the drill-pipe tool joint; ③ to reduce shoulder drill-pipe tool joint has a total of 121680 mesh cells,
the peak stress on the thread teeth to improve fatigue life; ④ of which 69840 for pin and 51840 for box. The grid model is
to smoothen the inner diameter to induce smooth flow, shown in Fig. 3.
reduce turbulence, and minimize the erosion; ⑤ to improve As to the model boundary conditions, a reference point is
the efficiency and ability to pump balls into the downhole defined at the center of the non-threaded end of the pin to be
tool; ⑥ to enhance the ability to run various test instruments kinematically coupled to the end face. The clamped boundary
in the drill string; ⑦ to reduce the chance of cement and is applied at the reference point to eliminate the degree of
solid accumulation in the joint; and ⑧ to reduce the pres- freedom. Another reference point is defined at the center of the
sure loss in the drill pipe and improve the ability of joint non-threaded end of the box, which is also kinematically
fishing. coupled with the end surface, and is applied with required
external load. As to thread contact surface and shoulder sur-
2.3. Numerical simulation model of a high torque double face, the Coulomb friction form tangential contact defined by
shoulder drill-pipe tool joint penalty function method was adopted. The normal contact is
hard contact. The universal contact is used for contact control.
Taking the designed high torque double shoulder drill-pipe Considering the possibility of big turn or large displacement of
tool joint as the object, and by using the three-dimensional drill-pipe tool joint under load, the geometric non-linear
analysis and evaluation technology of thread joints [16,17], a switch is opened.
three-dimensional numerical simulation model of high torque
double shoulder drill-pipe tool joint was established. The
thread form dimension is in accordance with API SPEC 7-2.
The drill-pipe tool joint, made of 37 CrMnMo, has the elastic
modulus of 2.06  105 MPa, the Poisson 's ratio of 0.28, the
yield strength of 931 MPa and the tensile strength of
1035 MPa. The influence of thread grease has been considered
in the numerical calculation, so that the friction coefficient is
set to be 0.08 [18e20].
In order to improve the computational efficiency and ensure
the accuracy of the results, we made the following assump-
tions for the model: (1) the high torque double shoulder drill-
pipe tool joint is regarded as an isotropic, continuous homo-
geneous body; and (2) the effect of hardening and creep is not
taken into account. The C3D8R eight-node hexahedral linear
reduction integral unit is used for the high torque double
shoulder drill-pipe tool joint meshing. The mesh of the
threaded connection is refined. The high torque double Fig. 3. A grid model of a high torque double shoulder drill-pipe tool joint.
Zhu XH., Zhang Z. / Natural Gas Industry B 4 (2017) 374e381 377

2.4. Numerical simulation model validation Table 1


Orthogonal optimization factor levels.
For ensuring the accuracy of the calculation results, the Level A. Taper B. Thread C. Guide D. Bearing E. Tooth
numerical simulation model of the joint with the same pitch/mm surface surface height/mm
angle/( ) angle/( )
experimental specifications in Ref. [21] was established. The
tensile experimental conditions in Ref. [21] were studied. 1 1:6 6.15 28 28 3.555
2 1:8 6.25 29 29 3.655
The experiment was conducted with a Ø139.7 mm  3 1:10 6.35 30 30 3.755
7.72 mm thread joint to study the stress distributions under 4 1:12 6.45 31 31 3.855
different makeup turns, different compressive loads and 5 1:16 6.55 32 32 3.955
different tensile loads, in order to provide experimental data
for the theoretical analysis and numerical analysis of the
threaded joint. The threaded joint weighs 25.3 kg/m with a for API drill-pipe tool joints, its range was determined to be
steel grade of J55 and the thread type is LCSG. The stress of 1:6e1:16. For further illustration of the effect of the pitch,
the outer edge of the non-threaded section was studied under guide surface angle, bearing surface angle and the tooth
the experimental condition (with the axial tension of height on the torque capacity of the high torque double
1200.96 kN). The numerical simulation results were compared shoulder drill-pipe tool joint, the thread parameter values
with the experimental results, as shown in Fig. 4. were defined uniformly at the right and left of the parameters
It can be seen from Fig. 4 that the results of the two of API drill pipe thread while the correct engagement con-
methods are basically the same, with small overall numerical dition and no top width change of the thread tooth are
difference and good overall consistency, which verifies the ensured, so that the parameter values and calculation results
accuracy of the established three-dimensional numerical are more representative.
simulation model for the drill-pipe tool joint.
3.2. Analysis of orthogonal optimization test results
3. Optimization of a high torque double shoulder drill-
pipe tool joint For attaining the superior performance of the XSJ joint, the
stress results of 25 combinations of thread parameters under
3.1. Orthogonal optimization factors the torque load of 50 kN$m have been calculated. Range
analysis on the calculation results helped to attain the best
The designed high torque double shoulder drill-pipe tool parameter combination, as shown in Table 2. The Rang “R” is
joint has the same thread parameters with the equivalent API also called coverage errors or a full range, expressed in R,
joint, so the combination of thread parameters cannot ach- which reflects the changes of the index level when the factor
ieve the best results. For attaining an optimal parameter level fluctuates. The larger the R, the greater the effect of the
combination of the high torque double shoulder drill-pipe factor on the test index.
tool joint thread, based on the established calculation Table 2 shows the analysis results under the torque of
model, orthogonal optimization has been conducted on the 50 kN$m. It can be seen that the ranges of stress results vary
key structural parameters of thread like taper, pitch, guide according to factors, which could be used for determining the
surface angle, bearing surface angle and tooth height. The order of the influence of factors on the torsional capacity. The
parameters are shown in Table 1, which shows the levels of influence order of factors on the torsional capacity is: taper,
orthogonal optimization factors. As the taper of 1:6, the
internationally used in a special tool joint design, was used
Table 2
Orthogonal optimization results.
Sum of the A. Taper B. Pitch C. Guide D. Bearing E. Tooth
maximum stress surface surface height
(K value/MPa) angle angle
K1 1998.64 1987.45 1892.10 1849.94 1932.60
K2 1901.47 1894.81 1821.31 1909.42 1895.62
K3 1853.64 1893.16 1904.63 1871.65 1830.95
K4 1852.30 1835.04 1893.44 1909.10 1866.60
K5 1809.39 1804.98 1903.96 1875.33 1889.67
K1 399.73 397.49 378.42 369.99 386.52
K2 380.29 378.96 364.26 381.88 379.12
K3 370.73 378.63 380.93 374.33 366.19
K4 370.46 367.01 378.69 381.82 373.32
K5 361.88 361.00 380.79 375.07 377.93
Range R 37.85 36.49 16.67 11.89 20.33
Order A>B>E>C> D
Optimal level A5 B5 C2 D1 E3
Optimal combination A5B5C2D1E3
Fig. 4. Comparison of simulation and experimental results.
378 Zhu XH., Zhang Z. / Natural Gas Industry B 4 (2017) 374e381

thread pitch, tooth height, guide surface angle and bearing


surface angle (A > B > E > C > D). Within the study case, the
optimal combination of the thread parameters of the XSJ joint,
are as follows: A5-Taper (1:16), B5-thread pitch (6.55 mm),
C2-guide surface angle (29 ), D1-bearing surface angle (28 ),
E3-tooth height (3.755 mm), root radius (0.04 in ¼ 1.016 mm)
and the secondary shoulder clearance (0.15 mm).

4. Contrast calculation of load bearing capacity

4.1. Tensile capacity

A contrast calculation was made on the maximum Mises


stresses of the XSJ joint and the API drill-pipe tool joint,
shorten as the API joint, under axial tension of Fig. 6. Torsional capacity comparison of XSJ and API joints.
1000e5000 kN, as shown in Fig. 5.
It can be seen from Fig. 5 that the maximum Mises stress
of the API joint is greater than that of the XSJ joint under the 4.3. Bending capacity
same axial tensile load. The maximum Mises stress of the two
kinds of drill-pipe tool joints is linearly related to the axial The maximum Mises stresses of the XSJ joint and the API
tensile load. Under the tensile load, the maximum Mises joint under the bending moment of 50e250 kN$m were
stress of the pin of the API joint is greater than that of the calculated, as shown in Fig. 7.
box, but the case is opposite for the XSJ joint. The tensile It can be seen from Fig. 7 that the maximum Mises stress of
capacity of the XSJ joint is 10.65% higher than that of the the pin of the XSJ joint is greater than that of the box under the
API joint. bending moment load, and the API joint has the same case.
Given the same bending moment load, the maximum Mises
4.2. Torsional capacity stress difference between the two drill-pipe tool joints is small.
The maximum Mises stresses of them are proportional to the
The maximum Mises stress of the XSJ joint under the bending moment load. The bending capacity of the XSJ joint
torque of 90e135 kN$m and that of the API joint under the is 2.75% higher than that of the API joint.
torque of 50e90 kN$m are shown in Fig. 6.
It can be seen from Fig. 6 that the maximum Mises stresses 4.4. Compression capacity
of the two kinds of drill-pipe tool joints are linearly related to
the torque loads. Under the torque loads, the maximum Mises The maximum Mises stress of the XSJ joint under the axial
stress of the API joint is greater than that of the XSJ joint. The compression of 6000e10000 kN and the API joint under the
API joint box has a larger maximum Mises stress than the pin, axial compression of 3000e7000 kN were calculated, as
while the XSJ joint has a reversed result. The intersection shown in Fig. 8.
points in Fig. 6 are the limit torsional capacity of the two kinds It can be seen from Fig. 8 that the maximum Mises stresses of
of drill-pipe tool joints. The torsional capacity of the XSJ joint the two kinds of drill-pipe tool joints increase with the axial
is 62.5% higher than that of the API joint. compressive load. The pins have a greater maximum Mises

Fig. 5. Tension capacity comparison of XSJ and API joints. Fig. 7. Bending capacity comparison of XSJ and API joints.
Zhu XH., Zhang Z. / Natural Gas Industry B 4 (2017) 374e381 379

significantly with the axial alternating tension-compression


load. Assuming that 107 times is used as the infinite cycle
life of the drill-pipe tool joint, the fatigue life of the XSJ joint
and the API joint is in the limited fatigue life zone with fatigue
strength of less than 1500 kN when the alternating tension-
compression load is 1500 kN. The XSJ joint has a fatigue
life 1.19 times more than the API joint.

5.2. Bending fatigue life

A symmetrical alternating moment load of 60e100 kN$m


was applied on the XSJ joint and the API joint respectively to
study their fatigue life sensitivity to the radial alternating load
components. The alternating moment loads were loaded with
Fig. 8. Compression capacity comparison of XSJ and API joints. sinusoidal excitation for the same period. The calculation re-
sults are shown in Fig. 10.
It can be seen from Fig. 10 that under the action of sym-
stresses than the boxes for both XSJ and API joints. Given the
metrical cyclic alternating bending moment load, the fatigue
same axial compressive load, the maximum Mises stress of the
life of the two kinds of joints are greatly reduced with the
XSJ joint is smaller than that of the API joint and The XSJ joint's
alternating bending moment loads. The radial alternating load
compression capacity is 52% higher than that of the API joint.
has a great impact on the fatigue life. With the increase of the
alternating bending moment load, the fatigue life dispersion
5. Contrast comparison of fatigue life
increases, which is mainly distributed in the double dispersion
zone of the XSJ joint. Given the alternating moment load of
5.1. Compression fatigue life
60 kN$m, the fatigue life of the API rod joint is in the limited
fatigue life area, while the XSJ joint is in the infinite fatigue
The fatigue life sensitivity of the XSJ joint and the API
life area. The XSJ joint has a bending fatigue life 1.74 times
joint to the axial alternating load components was studied by
more than the API joint.
applying a symmetrical alternating tensile and compressive
load of 1500e2500 kN. The alternating tensile and compres-
5.3. Torsional fatigue life comparison
sive loads were loaded with sinusoidal excitation for the same
period. The calculation results are shown in Fig. 9.
A symmetrical alternating torque load of 40e60 kN$m was
It can be seen from Fig. 9 that under the symmetrical cyclic
applied on the XSJ joint and the API joint respectively to study
alternating pressure and compression load, the fatigue life of
their fatigue life sensitivity to the alternating torque load
the two drill-pipe tool joints is greatly reduced with the in-
components. The alternating torque load was loaded with si-
crease of the alternating tension-compression load. The axial
nusoidal excitation for the same period. The calculation results
alternating load has a great influence on the drill-pipe tool
are shown in Fig. 11.
joint fatigue life. Fatigue life is distributed in the vicinity of
It can be seen from Fig. 11 that under the symmetrical
the double dispersion zone. The dispersion increases
cyclic alternating torque load, the fatigue life of the two type

Fig. 9. Comparison of tension-compression fatigue lives of XSJ and API


joints. Fig. 10. Comparison of bending fatigue lives of XSJ and API joints.
380 Zhu XH., Zhang Z. / Natural Gas Industry B 4 (2017) 374e381

joints when the wellbore curvature is less than 4 /30 m. When


the wellbore curvature exceeds 4 /30 m, the compound fatigue
lives of them are significantly reduced with the increase of the
wellbore curvature, which plays a leading role in the drill-pipe
tool joint fatigue life. The XSJ joint has a compound fatigue
life 28.79% longer than the API joint. When the wellbore
curvature is greater than 4 /30 m, the XSJ joint with reduced
RPM is recommended.

6. Conclusions

1) Based on the deformation coordination of drill-pipe tool


joint, a new type of XSJ joint was designed using
orthogonal optimization method. The order of influ-
encing factors on torque capacity is taper, pitch, tooth
Fig. 11. Comparison of torsional fatigue life. height, guide surface angle and bearing surface angle.
Under torque load, the optimal combination of the
of joints are greatly reduced with the increase of the alter- thread parameters of the XSJ joint has a taper of 1:16, a
nating torque load, which shows that the effect of the alter- pitch of 6.55 mm, a guide surface angle of 29 , a bearing
nating torque load on the fatigue life of the joint is significant. surface angle of 28 and a tooth height of 3.755 mm.
Fatigue life limit is far from the XSJ joint's double dispersion The tension, torque, bending and compression capacity
zone, presenting a significant torsion capacity improvement. of the XSJ joint is 10.65%, 62.5%, 2.75% and 52%,
The fatigue life of the API joint is less than 105 times under respectively, more than that of the API joint.
the alternating torque load of 40 kN$m, while the fatigue life 2) Based on the critical plane damage model, the relative
of the XSJ joint is more than 107 times under the alternating fatigue life of the XSJ joint and the API joint under
torque load of 60 kN$m. The XSJ joint has a torsional fatigue various alternating loads have been calculated. The XSJ
life 550 times more than the API joint. joint has tension-compression, bending and torsional
fatigue lives 1.19, 1.74 and 550 times more than the API
5.4. Compound fatigue life joint, and a compound fatigue life 28.79% longer than
the API joint. When the wellbore curvature exceeds 4 /
An axial tensile force of 1000 kN, a torque of 15 kN$m and 30 m, the XSJ joint with reduced RPM is recommended.
wellbore curvatures (2 /30 m, 4 /30 m, 6 /30 m, 8 /30 m, 10 / The new XSJ joint can better accommodate the drilling
30 m respectively) were applied on the XSJ joint and the API conditions of extended reach wells.
joint to study their fatigue life sensitivity to compound alter-
nating load. The results are shown in Fig. 12. References
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