Turbo Torque

TurboTorque™ Lightning Fast Torque on Demand

TurboTorque™

One Company

Unlimited Solutions

• Saves time, cuts cost • Increases torque capacity • Optimizes hydraulics • Improves clearance and fishability • Reduces risk of failure • Extends life

2

Introducing TurboTorqueTM Revolutionizing Rotary-Shouldered Connections OV Grant Prideco’s industry-leading eXtreme® Torque (XT®) connections have been

N

meeting the requirements of the most challenging drilling applications for years.

These patented connections have proven especially well suited for extended reach, horizontal, deep water, HPHT and ultra-deep environments. Now, NOV Grant Prideco introduces a new line of connections intended to drill deeper and further, faster than ever before. TurboTorque connections are the industry’s first family of connections designed to meet the specific and different needs of each pipe size. All TurboTorque connections feature a proprietary double-start thread form, making them radically faster than competitive connections. TurboTorque’s unique design reduces revolutions from stab to makeup by at least 50% to significantly cut drilling time and costs. Other benefits include increased torque capacity, optimized hydraulics, increased clearance and fishability, reduced risk of failure and extended life. Simply put, TurboTorque provides improved performance compared to XT, yet runs as fast or faster than API connections. TurboTorque connections have been thoroughly engineered and tested to validate both design and performance. Tests included finite element analysis, torque-to-yield, multiple make and break, comparative fatigue testing and several field trials.

3

TurboTorque Design Philosoph TM

F

or over 25 years, NOV Grant Prideco has taken the lead in the development of rotary-shouldered connections. The double-shouldered HI-TORQUE® (HT) connection is still a high-performance workhorse of the drilling industry. Even so, the HT design was based on API thread forms, ultimately limiting performance. The XT ® design departed from the constraints of API with an improved thread form and reduced taper. This design optimization resulted in additional improvements in torque capacity and streamlined profiles. For completions, under-balanced drilling (UBD) and other pressure sensitive operations, the Grant Prideco ® XT-MTM connection provided the industry’s first pressure rated rotaryshouldered connection. Still leading the industry, Grant Prideco has further refined the development and optimization of rotaryshouldered connection design. TurboTorque connections are the industry’s first rotary-shouldered connections that are designed to meet the specific and different needs of each individual pipe size. Taking a “one size does not fit all” approach, the TurboTorque product line is composed of four distinct configurations, optimized to best meet some very specific objectives. Historically, connections have been weak in comparison to the pipe body for the smallest sizes of drill pipe ranging from 2-3/8 to 2-7/8 inch diameter. In such a case, design must be focused on maximizing tension and torque capacity with secondary emphasis on larger inside diameters for improved hydraulics. Less important is speed of makeup.

For 3-1/2 to 4-1/2 inch sizes, connection torque capacity is of primary importance. The common use of these sizes makes speed of makeup more desirable than incremental hydraulic gains. The typical tool joint to pipe body torque and tension ratios for 5 to 5-7/8 inch sizes are relatively balanced. These sizes are commonly used offshore and in higher profile projects. Design must focus on speed of makeup and streamlined connection profiles for increased hydraulic performance. For the large 6-5/8 inch pipe size commonly run in elevated spread rate projects such as deep water, speed of makeup is a primary design objective. In addition, make-up torques can be excessive, at times surpassing the capacity of the rig equipment. Design parameters must be balanced to reduce the make-up torque and improve hydraulic performance.

The TurboTorque™ product line is composed of four distinct design configurations, optimized to best meet the design objectives specific to each pipe size. Drill Pipe Size (inches diameter)

4

Design Priority 1

2

2-3/8 to 2-7/8 in.

Increased tensile capacity

Increased torque capacity

Optimized hydraulics

3

3-1/2 to 4-1/2 in.

Increased torque capacity

Speed of makeup

Optimized hydraulics

5 to 5-7/8 in.

Speed of makeup

Optimized hydraulics

Increased torque capacity

6 -5/8 in.

Speed of makeup

Reduced make-up torque

Optimized hydraulics

4 Speed of makeup

phy

5

Features and Benefits DOUBLE- START THREAD TurboTorque™ connections are the industry’s first rotary-shoudered design to offer a double-start thread. Dual thread forms, 180 degrees apart, reduce the number of turns from stab to makeup by 50%. The increase in thread lead angle provides an increased torque capacity of up to 12%.

Optimized taper

Thread start 1

Benefits: Reduced rig time, reduced cost, increased torque capacity. STRONGER TOOL JOINTS Standard drill pipe tool joints are made of steel with specified minimum yield strength of 120,000 psi (120 ksi SMYS). Traditionally, efforts to increase tool joint yield strength have resulted in reduced fracture toughness and increased susceptibility to fatigue crack propagation. TurboTorque connections are engineered specifically for use with 130 ksi SMYS material, while meeting the increased fracture toughness required by proprietary manufacturing standards. In addition, TurboTorque’s thread form and tool joint geometry have been engineered to provide a step-change improvement in fatigue performance. Benefits: Increased torque capacity, reduced connection profile, improved fishability, increased hydraulic performance, reduced cost. OPTIMIZED CONNECTION TAPER Taper is one of the controlling factors in the final configuration of a rotary-shouldered connection. TurboTorque’s taper is engineered to ensure a balance between the pin and box, maximizing fatigue resistance. The taper is selected to provide for maximum trade-off in torque capacity and speed of makeup. Benefits: Balanced pin and box, fatigue resistance, reduced connection profile, improved fishability, increased hydraulic performance, reduced cost.

6

Thread start 2 TurboTorque™ is the industry’s first rotary-shouldered connection to offer a double-start thread and a taper that is fully optimized for each product size.

HIGH- PERFORMANCE THRE AD FORM TurboTorque’s proprietary thread form is optimized for each of the four design configurations. The thread form incorporates a unique dual-root radius – larger than the root radii of API and even XT® connections – significantly reducing peak stress in the thread roots.

T H R E A D FO R M C O M PA R I S O N S API NC V- 0.038R (0.038 ” root radius)

XT® (0.0 42 ” root radius)

Benefits: Enhanced fatigue performance, reduced cost. STRESS CONCENTR ATION FACTOR The design evaluation of TurboTorque™ connections led to the development of a novel approach for determining the Stress Concentration Factor (SCF) of rotary-shouldered connections (RSC). In most mechanical systems, SCF is defined as a ratio of the peak stress to applied normal stress in a similarly strained area. Peak stress is the highest principal stress that normally occurs at a geometric discontinuity, usually a thread root in the case of a rotary-shouldered connection. Current industry methods for determining the SCF do not consider the large pre-load stress induced by the make-up torque in a rotary-shouldered connection. Taking the large pre-load into account, NOV Grant Prideco has developed a new methodology for more accurately predicting the worst case peak stress for a given pipe load. This more accurate method uses Finite Element Analysis (FEA) as the primary tool to explore the maximum peak stress trends in rotaryshouldered connections and to calculate the SCF. The NOV Grant Prideco® RSC SCF methodology provides an accurate method to compare the relative peak stress trends and SCF values among various rotaryshouldered connection designs to assist in evaluation and selection of connections for drilling, completion and open water applications. The SCF values for TurboTorque 390, TurboTorque 585, API NC38 and 5-1/2 FH are shown for comparison in the adjacent table for various common tool joint sizes. TurboTorque connections provide a step-change improvement in peak stress reduction and enhanced fatigue performance while offering substantially more streamlined profiles. Benefits: More accurate prediction of peak stress and relative fatigue life, reduced cost.

(0.052” x 0.06 0” dual root radius)

API FH V- 0.05 0 (0.025” root radius)

XT® (0.0 42 ” root radius)

(0.065” x 0.065” dual- root radius) TurboTorque™ incorporates a unique large dual-root radius significantly reducing the peak stress in the thread roots.

C O M PA R AT I V E S C F VA L U E S Connection

Tool Joint Size (inches)

Make-up Torque (ft-lbs)

SCF

API NC38

4-7/8 x 2-9/16

12,047

2.770

TurboTorque 390

4-7/8 x 2-11/16

25,467

0.899

7-1/4 x 3-1/2

43,342

0.919

7 x 4-1/2

62,108

0.930

API 5-1/2 FH TurboTorque 585

Stress Concentration Factor for TurboTorque™ 390, TurboTorque™ 585, API NC38 and 5-1/2 FH for popular tool joint configurations. The TurboTorque connections are made up to the Turbo-MUT™ values. Even with 24% less moment of inertia, TurboTorque 585 has SCF values comparable to API 5-1/2 FH and provides 43% greater torque capacity.

7

Testing and Design Validation

T

he TurboTorque™ connection design process included significant computer analysis and physical testing. The anticipated two most popular designs, TurboTorque 390 and TurboTorque 585, were chosen for initial evaluation. Results follow:

MAKE AND BREAK TEST Samples of TurboTorque 390 and TurboTorque 585 for each of the extreme manufacturing tolerance conditions were subjected to 100 make and breaks. Connections were made up to the recommended make-up torque. No galling or connection damage was observed.

FINITE ELEMENT ANALYSIS TurboTorque 390 and TurboTorque 585 were modeled using ABAQUS® finite element code. The von Mises equivalent (VME) stress distribution was determined for extreme manufacturing tolerance conditions. The stress plots for makeup to the maximum make-up torques (Turbo-MUT TM) are shown below.

FE A FOR TURBOTORQUE™ 390

Max. Internal Shoulder Gap Configuration

Min. Internal Shoulder Gap Configuration

VME Stress Distribution for TurboTorqueTM 390 (4-7/8” x 2-11/16”) Connection at Maximum Make-up Torque: 25,467 ft-lbs

FE A FOR TURBOTORQUE™ 585

Maximum Internal Shoulder Gap Configuration

Minimum Internal Shoulder Gap Configuration

VME Stress Distribution for TurboTorqueTM 585 (7” x 4-1/2”) Connection at Maximum Make-up Torque: 61,108 ft-lbs S. Mises (Avg Crit: 75%)

+1.300e+05 +1.200e+05 +1.100e+05 +1.000e+05 +9.000e+04

ABAQUS is a registered trademark of ABAQUS, Inc.

8

+9.000e+04 +8.000e+04 +7.000e+04 +6.000e+04 +5.000e+04 +4.000e+04

+4.000e+04 +3.000e+04 +2.000e+04 +1.000e+04 +0.000e+00

TORQUE-TO-YIELD The torsional yield strength for TurboTorque connections was calculated. Physical torque-to-yield tests were then conducted on TurboTorque 390 and TurboTorque 585. Samples for each of the extreme manufacturing tolerance conditions were tested. The physical test results displayed exceptional correlation with the values predicted by the calculations.

TO RQ U E-TO -Y I E LD 4 - 7/ 8 ” x 2 - 11/ 16 ” T U R B O T O R Q U E™ 3 9 0

60,000

50,000 44,552 Torque, ft-lbs

40,000

30,000

20,000

10,000

0

Degrees of Rotation

TO RQ U E-TO -Y I E LD 7” X 4 -1/2” TURBOTORQUE™ 585

120,000 102,038 100,000

Torque, ft-lbs

80,000

60,000

40,000

20,000

0

Degrees of Rotation

Torque-turn graphs for the TurboTorque™ 390 and TurboTorque™ 585 connections display exceptional correlation with calculated values. Based on the material properties for the actual material tested, the predicted torsional yield strength values are shown by the horizontal lines. The red and blue lines are the test results for each of the extreme manufacturing tolerance conditions. Red represents the minimum gap; blue represents the maximum gap.

9

Performance TORQUE PERFORMANCE TurboTorque™ connections provide more torque capacity than any other double-shouldered connections in the industry today, and the “torque on demand” feature provides an additional 8% of torque capacity for those unusual drilling situations. Three make-up torque (MUT) values are provided for each TurboTorque connection: • Minimum MUT • Recommended MUT • Turbo-MUT™

1

Includes finite element analysis, torque-to-yield, fatigue testing and SCF calculation.

M A K E - U P TO RQ U E CO M PA R I S O N 120,000 100,300

100,000 82,100

Make-up Torque

Minimum MUT is the least amount of MUT acceptable to assure that the connection will function properly. Minimum MUT is normally only considered in cases when the recommended MUT may exceed capacity of the rig equipment, such as large diameter drilling or landing strings. Recommended MUT is used for normal drilling operations. In most situations, recommended MUT provides enough torque to prevent downhole makeup while minimizing connection stress. TurboTorque is the first connection in the industry to provide a Turbo-MUT. Turbo-MUT is ideal for those unusual drilling situations when additional torque is required. This “torque on demand” feature provides an additional 8% of torque capacity. Most TurboTorque tests and design validation were conducted on connections made up to the Turbo-MUT value1. This allows the Turbo-MUT to be used confidently without having to consult NOV Grant Prideco.

80,000 62,100

65,500

63,100 (min.)

56,600

60,000 50,500 43,500

42,100

40,000 25,500

26,900

TT390 4.875 x 2.688

NC46 - 6.250 x 2.750

22,200

20,000 12,100

0 TT690 - 8.250 x 5.500

XT69 - 8.500 x 5.250

6-5/8 FH - 8.500 x 4.250

TT585 - 7.000 x 4.500

10

XT57 - 7.000 x 4.250

5-1/2 FH - 7.250 x 3.500

TT500 - 6.250 x 3.500

XT46 - 6.250 x 3.250

XT39 - 4.875 x 2.563

NC38 - 4.875 x 2.563

Connection

HYDR AULIC PERFORMANCE The TurboTorque™ connection optimizes hydraulic performance. The refinement of the TurboTorque design and 130 ksi SMYS tool joints means the tool joint ID can be increased for reduced pressure loss through the drill string. Relative to XT,® TurboTorque offers 1/8 inch larger IDs on smaller drill pipe sizes, and 1/4 inch or larger IDs on larger drill pipe sizes. For a given hole size, TurboTorque’s slim outside diameter often permits the use of a larger pipe size, significantly increasing hydraulic performance. More hydraulic horsepower at the bit saves operational cost and enables drilling of deeper wells.

11

FAT I G U E P E R F O R M A N C E TURBOTORQUE™ 390 AND API NC38

The TurboTorque™ connection’s proprietary double-start, dual-root-radius thread form results in a step-change improvement in fatigue resistance. To illustrate the TurboTorque connection’s fatigue performance, samples of TurboTorque 390 and TurboTorque 585 were fatigue tested to failure with comparable API NC38 and 5-1/2 FH connections. Three samples of each connection were tested on a harmonic fatigue testing machine at the NOV Grant Prideco Technology Center. In spite of reduced cross-sectional area and moment of inertia, both sizes of TurboTorque connections outperformed their comparable API connection as displayed on the adjacent S-N charts.

Increasing Bending Moment

FATIGUE PERFORMANCE

100,000

200,000

300,000

400,000

1,000,000

Cycles to Failure, N

4-7/8” x 2-9/16” NC38

4-7/8” x 2-11/16” TurboTorque™ 390

Increasing Bending Moment

FAT I G U E P E R F O R M A N C E TURBOTORQUE™ 585 AND API 5 -1/2 FH

100,000

200,000

300,000

400,000

1,000,000

Cycles to Failure, N

7-1/4” x 3-1/2” 5-1/2 FH

Using the moment of inertia to compare connection stiffness, TurboTorque™ 390 is 2% less stiff than API NC38, yet displayed a 234% greater fatigue life on average. TurboTorque™ 585 is 24% less stiff than API 5-1/2 FH, yet its average fatigue life is 174% greater.

12

7” x 4-1/2” TurboTorque™ 585

PERFORMANCE COMPARISON • Offshore 4.000 in. 14.00 lb/ft IU S-135 range 2 5.875 in. 23.40 lb/ft IEU S-125 range 2 • Onshore 5 in. 19.50 lb/ft IEU S-135 range 2

TurboTorque’s performance improvements are best illustrated by a comparison to both an API connection and to XT® for specific drill pipe sizes. The following drill pipe sizes with API connections are typically used:

The best fit API, XT and TurboTorque connections were selected for each pipe size. The results are shown in the table below. The TurboTorque connections meet stringent NOV Grant Prideco ® design criteria while providing a more compact profile resulting in improved clearance (fishability) and hydraulic efficiency. Also, TurboTorque provides make-up speeds comparable to or better than the API connections, resulting in efficient rig operations. TurboTorque connections offering the “torque on demand” feature provide improved torque capacity.

• Offshore 3-1/2 in. 13.30 lb/ft EU S-135 range 2 5-1/2 in. 24.70 lb/ft IEU S-135 range 2 • Onshore 4-1/2 in. 16.60 lb/ft IEU S-135 range 2 Due to their streamlined profile, TurboTorque™ and XT connections permit use of a larger pipe size than do API connections for similar hole sizes.

P E R FO R M A N C E C O M PA R I S O N – T U R B O T O RQ U E™, X T ® A N D A PI A S S E M B L I E S Typical minimum hole size (1) (in.)

Tool Joint OD (in.)

3-1/2 in. 13.30 lb/ft EU S-135 NC38

6

4 in. 14.00 lb/ft IU S-135 XT39 4 in. 14.00 lb/ft IU S-135 TurboTorque™390

Flowrate (gpm)

Internal pressure loss through DP per 10,000 ft (4) (psi)

Turns from stab to makeup (5) (each)

12,100

250

2,059

5

2.563

22,200

250

1,032

11

4.875

2.688

25,500

250

962

5

7-7/8

6.250

2.750

26,900

500

2,008

5

7-7/8

6.250

3.250

42,100

500

1,093

12

5 in. 19.50 IEU S-135 TurboTorque™500

7-7/8

6.250

3.500

50,500

500

982

4

5-1/2 in. 24.70 lb/ft IEU S-135 5-1/2 FH

12-1/4

7.250

3.500

43,500

1,000

2,495

6

5-7/8 in. 23.40 lb/ft IEU S-135 XT57

8-1/2

7.000

4.250

56,600

1,000

1,369

13

5-7/8 in. 23.40 lb/ft IEU S-135 TurboTorque™585

8-1/2

7.000

4.500

62,100

1,000

1,283

4

6.5/8 in. 27.70 lb/ft IEU S-135 6-5/8 FH

12-1/4

8.500

4.250

65,500

1,500

2,145

6

6.5/8 in. 27.70 lb/ft IEU S-135 XT69

12-1/4

8.500

5.250

100,300

1,500

1,698

13

6.5/8 in. 27.70 lb/ft IEU S-135 TurboTorque™690

12-1/4

8.250

5.500

82,100 (3)

1,500

1,645

3

Tool Joint ID (in.)

Maximum MUT (2) (ft-lbs)

4.875

2.563

6

4.875

6

4-1/2 in. 16.60 lb/ft IEU S-135 NC46 5 in. 19.50 IEU S-135 XT46

Drill Pipe (DP)

TurboTorque™ connections accommodate larger internal diameters through the tool joint to reduce system pressure losses, provide increased torque capacities to XT ® and make up in equal or fewer turns than API. Simply stated, TurboTorque provides improved performance over XT and runs as fast or faster than API.

(1) Assuming overshot fishability considerations for common hole sizes. (2) Maximum MUT is API recommended MUT for API connections, maximum recommended MUT for XT® connections and Turbo-MUT™ for TurboTorque™ connections. (3) Reduced MUT in larger DP sizes is often desired for rig capacity considerations. Minimum MUT for TurboTorque™ 690 is 63,100 ft-lbs. (4) Pressure loss calculations based on Hershel-Buckley modeling regime and assume a 12 ppg mud system, dial readings of 4-5-13-20-30-52, PV = 22 eq. cp., YP = 9 lbf/100 ft 2 and 2 inch longer than standard (LTS) tool joint lengths. (5) Turns from stab to makeup are estimated based on nominal dimensions and crest-to-crest contact at stab. Actual results may vary depending on connection features.

13

An Economic Value SAVE TIME, CUT COST TurboTorque™ connections require similar running procedures as API and XT® connections. However, TurboTorque’s double-start thread form radically reduces the number of turns to makeup and breakout. The resulting time saved has a marked effect on rig economics. Compared with competitive premium rotary-shouldered connections, TurboTorque often pays for itself on the first well, then continues to provide operational savings.

DRILL DEEPER, STEP OUT FURTHER TurboTorque’s torque capacity exceeds that of all double-shouldered connections on the market. TurboTorque’s streamlined profile decreases pressure loss through the tool joint and often allows the use of a larger pipe size. The result: more mechanical and hydraulic horsepower to the bit, enabling successful completion of world class wells.

14

REDUCE TOTAL COST OF OWNERSHIP TurboTorque’s proprietary thread form allows more fatigue resistance with less material, extending industry performance. TurboTorque’s increased torque capacity enables more outer diameter wear before downgrade. In addition, TurboTorque connections incorporate superior NOV Grant Prideco® technology such as engineered materials, fatigue-resistant upset/weldneck geometries, quench and tempered weld zones, quality processing and Platinum™ HB hardband - all proven to provide extended life, increased reliability and reduced total cost of ownership.

TURBOTORQUE™ MECHANICAL CHAR ACTERISTICS

Product Type

OD (in)

Nominal weight (lb/ft)

Grade

Premium tube tensile strength (lbs)

TurboTorque™ Connection

Tool joint OD (in)

Tool joint ID (in)

SmoothEdge ® OD (in) (1)

Adjusted weight (lb/ft)

Minimum MUT (ft-lb)

Recommended MUT (ft-lb)

TurboMUT™ (ft-lb)

Standard

3.500

13.30

S-135

381,900

TurboTorque 380

4.750

2.688

14.42

16,800

20,200

21,900

Standard

3.500

15.50

S-135

451,100

TurboTorque 380

4.813

2.500

16.88

19,900

23,900

25,900

Streamline

4.000

14.00

S-135

403,500

TurboTorque 390

4.875

2.688

15.44

19,600

23,500

25,500

Standard

4.000

14.00

S-135

403,500

TurboTorque 420

5.250

2.938

15.79

23,700

28,400

30,800

Standard

4.000

15.70

S-135

456,900

TurboTorque 420

5.250

2.938

17.36

23,700

28,400

30,800

Streamline

4.500

16.60

S-135

468,300

TurboTorque 435

5.375

3.125

17.96

24,700

29,600

32,100

Standard

4.500

16.60

S-135

468,300

TurboTorque 485

6.000

3.563

18.50

31,500

37,800

40,900

Standard

4.500

20.00

S-135

581,200

TurboTorque 485

6.125

3.250

22.72

39,700

47,600

51,600

5.063

5.563

Streamline

5.000

19.50

S-135

560,800

TurboTorque 500

6.250

3.500

22.29

38,900

46,600

50,500

Standard

5.000

19.50

S-135

560,800

TurboTorque 525

6.500

3.875

6.438

22.11

38,200

45,800

49,600

Standard

5.000

25.60

S-135

746,400

TurboTorque 525

6.625

3.563

28.51

48,000

57,600

62,400

Streamline

5.500

21.90

S-135

620,600

TurboTorque 550

6.625

4.250

23.71

39,100

46,900

50,900

Standard

5.500

21.90

S-135

620,600

TurboTorque 585

7.000

4.500

24.08

47,800

57,300

62,100

Standard

5.500

24.70

S-135

704,300

TurboTorque 585

7.125

4.313

27.33

55,500

66,600

72,200

Streamline

5.875

23.40

S-135

666,500

TurboTorque 585

7.000

4.500

7.188

25.78

47,800

57,300

62,100

Streamline

5.875

26.30

S-135

757,100

TurboTorque 585

7.000

4.500

7.188

28.37

47,800

57,300

62,100

Standard

6.625

27.70

S-135

760,400

TurboTorque 690

8.250

5.500

30.15

63,100

75,800

82,100

6.813

(1) SmoothEdge ® dual-diameter box tool joints are recommended on streamline sizes for adequate elevator capacity and maximum wear allowance.

15

© 2 0 0 8 Na t i o na l O i l we l l Va r co D3920 01531- MK T- 0 01 Rev. 01