API SC5/WG Item 1033a API SC5/WG Item 1033a (or New Line Number) (or New Line Number)

7A1 Friction & Galling Test7A1 Friction & Galling TestSTATUS: January 2010STATUS: January 2010

Project Goals WG 1033aProject Goals WG 1033aBudget Year 2001 Deliverables- Budget Year 2001 Deliverables-

GoalGoal The Goal of the project is to complete The Goal of the project is to complete

development & testing bench-top test for development & testing bench-top test for galling & friction for the API C1/SC5 test galling & friction for the API C1/SC5 test program.program.

GrantPrideco & Stress will generate data GrantPrideco & Stress will generate data base comparing the new specimen base comparing the new specimen assembly to full scale connections.assembly to full scale connections.

New recommendations for API will be New recommendations for API will be documented & reported.documented & reported.

WG 1033a Project Goals WG 1033a Project Goals Budget Year 2002 Budget Year 2002 Status of Status of

DeliverablesDeliverables The Goal of the project to complete development & testing The Goal of the project to complete development & testing bench-top test for galling & friction for the API C1/SC5 test bench-top test for galling & friction for the API C1/SC5 test program. program. STATUS: The equipment shows good correlation STATUS: The equipment shows good correlation but many problems are encountered with the Honeywell but many problems are encountered with the Honeywell load cells and with bolts breaking.load cells and with bolts breaking.

GrantPrideco & Stress will generate data base comparing the GrantPrideco & Stress will generate data base comparing the new specimen assembly to full scale connections. new specimen assembly to full scale connections. STATUS: STATUS: Data was generated with full scale connections but Data was generated with full scale connections but problems were encountered with tong slippage and the problems were encountered with tong slippage and the placement of the strain gauges on the full sizeplacement of the strain gauges on the full size connections. connections.

New recommendations for API will be documented & reported. New recommendations for API will be documented & reported. STATUS: Due to the issues with bolt and load cell STATUS: Due to the issues with bolt and load cell reliability no formal recommendations were able to be reliability no formal recommendations were able to be drafted. The group will work to isolate the causes and drafted. The group will work to isolate the causes and make recommendations to resolve.make recommendations to resolve.

GOAL OF DRAFTING A GOAL OF DRAFTING A PROCEDUREPROCEDURE

The goal of drafting a procedure was The goal of drafting a procedure was not met due to failures in several of not met due to failures in several of the assembly components. The work the assembly components. The work group felt drafting a procedure in group felt drafting a procedure in which flaws were known was not to which flaws were known was not to the benefit of the API Community. the benefit of the API Community. Although correlations are superior to Although correlations are superior to the current 7A1 specimen set, the the current 7A1 specimen set, the procedure was not ready to draft.procedure was not ready to draft.

WG 1033a Project Goals WG 1033a Project Goals Budget Year 2002 DeliverablesBudget Year 2002 Deliverables

The Goal of the project is to establish standardized The Goal of the project is to establish standardized performance tests for evaluating the suitability of performance tests for evaluating the suitability of Environmentally acceptable thread compounds.Environmentally acceptable thread compounds.

Full Scale product performance experiments designed Full Scale product performance experiments designed for comprehensive evaluation of any thread compound for comprehensive evaluation of any thread compound would be made.would be made.

Identification of small scale test methods for friction Identification of small scale test methods for friction and galling will be more fully evaluated and compared and galling will be more fully evaluated and compared to available full scale data.to available full scale data.

Project Goals WG 1033aProject Goals WG 1033aBudget Year 2002 Status of Budget Year 2002 Status of

DeliverablesDeliverables The Goal of the project is to establish standardized performance tests for The Goal of the project is to establish standardized performance tests for

evaluating the suitability of Environmentally acceptable thread compounds.evaluating the suitability of Environmentally acceptable thread compounds. STATUS: The equipment continues to show good STATUS: The equipment continues to show good correlation but problems are still being encountered with correlation but problems are still being encountered with the Honeywell load cells and with bolts breaking. the Honeywell load cells and with bolts breaking. Omegadyne load cells were purchased.Omegadyne load cells were purchased.

Full Scale product performance experiments designed for comprehensive Full Scale product performance experiments designed for comprehensive evaluation of any thread compound would be madeevaluation of any thread compound would be made. . STATUS: Full STATUS: Full data reports were distributed to JIP participants and the data reports were distributed to JIP participants and the API and can be available for other interested parties .API and can be available for other interested parties .

Identification of Small scale test methods for friction and galling will be more Identification of Small scale test methods for friction and galling will be more fully evaluated and compared to available full scale data.fully evaluated and compared to available full scale data.

STATUS: Evaluations of the bench scale test equipment STATUS: Evaluations of the bench scale test equipment continue with the goal of the group to isolate the causes continue with the goal of the group to isolate the causes and make recommendations to resolve.and make recommendations to resolve.

Current Project Goals WG 1033aCurrent Project Goals WG 1033a The Goal of the project is to provide a The Goal of the project is to provide a

RELIABLERELIABLE bench-top test which correlates bench-top test which correlates to full scale drill string connections.to full scale drill string connections.

Evaluate whether the apparatus or Evaluate whether the apparatus or procedure can be modified to provide a procedure can be modified to provide a correlation to API noninterference and correlation to API noninterference and proprietary mechanical seal tubing & proprietary mechanical seal tubing & casing thread designscasing thread designs

Utilize the bench top test apparatus to Utilize the bench top test apparatus to measure relative galling resistance of measure relative galling resistance of thread compounds.thread compounds.

WG 1033aWG 1033a- CURRENT STATUS –- CURRENT STATUS –

The current goal is to fabricate the new Jet-Lube/Stress The current goal is to fabricate the new Jet-Lube/Stress Engineering Services specimen set design which utilizes a 1 ¼ Engineering Services specimen set design which utilizes a 1 ¼ inch bolt to eliminate issues with the 1 inch. inch bolt to eliminate issues with the 1 inch.

Move the API Committee torque turn equipment from Stress Move the API Committee torque turn equipment from Stress Engineering Services to Texas A&M University.Engineering Services to Texas A&M University.

Generate a formal proposal from Texas A&M University to do Generate a formal proposal from Texas A&M University to do the project work in 2010. The formal proposal would include the project work in 2010. The formal proposal would include itemized list of raw materials to purchase or fabricate, what itemized list of raw materials to purchase or fabricate, what compounds or types to test, list the required tests and time for compounds or types to test, list the required tests and time for preparing the reports. preparing the reports.

Compare the data to full scale connection data run on the Compare the data to full scale connection data run on the same products as shown on next slide deliverables.same products as shown on next slide deliverables.

Deliverables with API FundingDeliverables with API FundingDeliverables:Deliverables:Friction & Galling resistance test assembly or assemblies;Friction & Galling resistance test assembly or assemblies;

- For Rotary shouldered connections, more substantial assembly - For Rotary shouldered connections, more substantial assembly for measuring contact pressures up to 150Kfor measuring contact pressures up to 150K

-- For noninterference connection designs such as 8-round or For noninterference connection designs such as 8-round or buttress the current assembly in test for contact pressures up to buttress the current assembly in test for contact pressures up to 55K using spring disk washers and load cell for greater sensitivity 55K using spring disk washers and load cell for greater sensitivity in this contact pressure limit.in this contact pressure limit.- For proprietary mechanical seal connection designs a new - For proprietary mechanical seal connection designs a new assembly to test for contact pressures up to 150K using spring disk assembly to test for contact pressures up to 150K using spring disk washers and load cell.washers and load cell.- For galling resistance testing the current assembly has shown to - For galling resistance testing the current assembly has shown to correlate to full scale connections and coating wear.correlate to full scale connections and coating wear.

To test the on the above a wide range of coefficients of friction on To test the on the above a wide range of coefficients of friction on several thread compounds used in the past which showed the API several thread compounds used in the past which showed the API RP 1 inch bolt did not work.RP 1 inch bolt did not work. These include a 15% PTFE nonmetallic These include a 15% PTFE nonmetallic compound, 60% lead reference compound, API RP 5A3 reference compound, 60% lead reference compound, API RP 5A3 reference compound, a commercial nonmetallic (Yellow) compound for compound, a commercial nonmetallic (Yellow) compound for proprietary mechanical seal connection designs, 50% zinc and a proprietary mechanical seal connection designs, 50% zinc and a high performance commercial Copper compound with 1.15 friction high performance commercial Copper compound with 1.15 friction factor.factor.

ACTION ITEMSACTION ITEMS Complete design & fabrication of a test assembly which Complete design & fabrication of a test assembly which

provides a correlation to field data on full scale thread provides a correlation to field data on full scale thread designs. Current API RP 7A1 has very little correlation.designs. Current API RP 7A1 has very little correlation.

Test the suitability and reliability of the compressive Test the suitability and reliability of the compressive load cell designed by Mr. Jack Smith of Stress load cell designed by Mr. Jack Smith of Stress Engineering Services for repeated loads of up to Engineering Services for repeated loads of up to 150KSI. Alloys used: One of 4140, the other with 17-150KSI. Alloys used: One of 4140, the other with 17-4PH4PH

Replace the 60 percent lead reference compound Replace the 60 percent lead reference compound which plates onto the specimens and has an effect on which plates onto the specimens and has an effect on the subsequent compound test data.the subsequent compound test data.

See current API RP 7A1

Example of Obsolete API Bulletin Example of Obsolete API Bulletin 7A1 Test Apparatus7A1 Test Apparatus

TORQUE CALIBRATION SUBSTORQUE CALIBRATION SUBS

API RP 7A1 SPECIMEN SET API RP 7A1 SPECIMEN SET DESIGNS DESIGNS

1992 RP 7a1 vs. Full Scale NC-461992 RP 7a1 vs. Full Scale NC-46

Late 1990’s Small Rotary Late 1990’s Small Rotary Shouldered Tool Joint Torque Turn Shouldered Tool Joint Torque Turn

SpecimensSpecimens

CURRENT FRICTION & GALLING CURRENT FRICTION & GALLING TEST SPECIMEN SET DESIGNSTEST SPECIMEN SET DESIGNS

PROPOSED SPECIMEN SET PROPOSED SPECIMEN SET DESIGNDESIGN

PROPOSED ASSEMBLY PROPOSED ASSEMBLY DESIGNDESIGN

1st Attempt at 150K Load Cell1st Attempt at 150K Load Cell

Next 150K Load CellNext 150K Load Cell

ISSUES WITH CURRENT API ISSUES WITH CURRENT API RP 7A1 METHODRP 7A1 METHOD

PROPERTYPROPERTY RESULTSRESULTS

API RP 7A1 - 1 inch Bolt API RP 7A1 - 1 inch Bolt SpecimenSpecimen

Limited relative surface travel.Limited relative surface travel.No correlation with nonmetal No correlation with nonmetal

compoundscompounds

Current 60% Lead Reference Current 60% Lead Reference CompoundCompound

Plates interfering with subsequent Plates interfering with subsequent results, Toxicityresults, Toxicity

Current RP 7A1 ProtocolCurrent RP 7A1 Protocol Cannot measure contact pressureCannot measure contact pressure

Comparison by slope at a set Comparison by slope at a set torque limit torque limit

Correct method should be to Correct method should be to determine torque to achieve a determine torque to achieve a

desired loaddesired load

Current Apparatus and methodCurrent Apparatus and method Absolutely no correlation with Absolutely no correlation with Tubing and casing thread designsTubing and casing thread designs

ISSUES WHICH STILL NEED ISSUES WHICH STILL NEED TO BE RESOLVEDTO BE RESOLVED

Determine the composition & properties Determine the composition & properties for a bolt lube with consistent COFfor a bolt lube with consistent COF

Determine whether the proposed Determine whether the proposed enhanced specimen design eliminates enhanced specimen design eliminates current load cell, bolt & nut failurescurrent load cell, bolt & nut failures

Determine whether the new specimen Determine whether the new specimen design & bolt lube can test up to 150 KSI design & bolt lube can test up to 150 KSI

Compare the results to full scale Compare the results to full scale connection dataconnection data

Coefficient of friction graphs for same product Coefficient of friction graphs for same product where only particle size varies. where only particle size varies.

Experimental Batches 4343 (medium), 4344 Experimental Batches 4343 (medium), 4344 (Std/Micro) & 4345 (larger size)(Std/Micro) & 4345 (larger size)

AVERAGE COEFFICIENT OF FRICTION FOR XP 4343, 4344 AND 4345

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0 100 200 300 400 500 600

Degree of Rotation, Make-up

Coeffi

cien

t of

Fri

ction

AVERAGE OF RUNS - XP 4345

RUN AVERAGE - SG XP 4344

AVERAGE OF RUNS - XP 4343

Torque Turn Graph for Typical Torque Turn Graph for Typical Galling TestGalling Test

Proposed Galling Specimen Showing Proposed Galling Specimen Showing Only WearOnly Wear

Proposed Galling Specimen Showing Proposed Galling Specimen Showing Only WearOnly Wear

Proposed Galling Specimen Showing GallingProposed Galling Specimen Showing Galling

ScheduleSchedule Review of expected schedule milestones Review of expected schedule milestones

with additional funding with additional funding

The timeline is based upon the expectation the proposed test assembly will not have long lead times to machine or purchase, will correlate well

and allow many tests without components yielding.

August Oct Dec Feb Apr June

Machine new load cell and getit strain gauged & calibrated

Machine new load cell and getit strain gauged & calibrated

Fabricate new assembly & purchase Specimen sets &

Run Broad range testing

Fabricate new assembly & purchase Specimen sets &

Run Broad range testing

Complete data review & draft test procedure

Complete data review & draft test procedure