Drilling is one of the costliest and risky activities in oil and gas industry due to complexity of interactions with downhole formation. Cyclic loads while drilling cause the initiation and growth of cracks in oil tubulars. This phenomenon, known as fatigue, results in permanent reduction of the failure-free service envelope of a certain tubular. Further, most of the drill string failures are triggered by fatigue, which results from repetitive cyclic bending loads and stresses in tensile or buckled drill strings. Fatigue is a cumulative and non-reversible condition induced by repetitive cyclic bending loads and tensile or buckled drill pipe stresses. Fatigue exists even though cyclic tension of the drill pipe material is much lower than static strength limit. Present work investigates fatigue capacity of the 4” WT38 drill pipe connection where cracks have been observed. In accordance with the geometry of connection, a hot spot stress from bending moment is calculated in the crack location in the first thread (upper) of the pin. The DNVGL-RP-C203 SN-curve B1 “in air” is used as relevant fatigue SN curve for the drill pipe thread location. Finite element method (FEM) is employed in modeling and analyzing of drill pipe on pin-box connections. With this method, various connections can be investigated relatively faster and cheaper compared with experimental tests. It is found that the fatigue failure may have been caused as a result of the cyclic load level and number of load cycles. A detailed discussion of the fatigue damage assessment concludes the paper.
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