Dynamic failure analysis and lifetime estimation of Tool-string in rotary drilling system under Torsional-Axial coupled vibrations

Abstract

Failure analysis and lifetime assessment of drilling systems are very important to reduce maintenance costs. Of all the failure modes, coupled vibration due to the stick–slip phenomenon is the most common problem that can affect rotary drilling systems. The main objective of this study is to estimate the number of cycles before failure (useful life) of the lower part of rotary drilling system toolstring under axial and torsional vibrations. To achieve this goal, a complete procedure based on different methods and approaches, such as: finite element method (FEM), rainflow counting method (RFM), Goodman approach (GA), S-N diagram and Miner’s rule, has been proposed. To this end, the FEM has been used to determine the loading cycles (equivalent stress); whereas, the number of stress cycles in the loading cycle diagram has been counted using RFM. The GA has been used to select the main cycles that can cause failure on the toolstring and to calculate their amplitudes. Then, S-N diagram has been used to determine the number of cycles to failure of the toolstring. Finally, Miner’s rule has been applied to find the approximate time to failure of the drilling system. Regarding the estimation of the toolstring lifetime, the results obtained have shown a good agreement with real data recorded in an oil field in Algeria.