ANALYSIS AND RESEARCH ON CAUSES

OF COUPLING CRACK FOR 177.8×11.51mmV150 LCSG

Lu Shuanlu, Yang Long, Yuan Pengbing, Qin Changyi, Zhao Xinwei Zhang Guozheng, and Wang Xinhu
Tubular Goods Research Center of China National Petroleum Corporation
The key laboratory for mechanical and environmental behavior of tubular goods of CNPC
China 710065 Email: Lusl@tgrc.org

ABSTRACT
A casing coupling crack accident took place at the depth of 836.75m after casing string was run down
and lasted for less than 70 days in one well. This paper gives an account of the investigation of the
coupling crack accident and the quality of casing threading and connection make up. Fracture
morphology in macro and micro observation, residual stress measurement, material test and analysis of
makeup torque were conducted. It was found that crack origination located at the engagement position
of the pin and box, and then the whole fracture and the engagement position of the pin and box at mill
end were corroded severely after the coupling crack. The main cause of coupling crack was concluded
that making up torque of casing connection at the mill end was shown too high and the toughness of
coupling material was low.

1 BACKGROUND
1.1 Accident origin and jump out position
One well was completed at the depth of 5590m. Well testing was conducted 65 days after running
down the casing string. It was found that gas leaked from canula after 14 days of testing. It was found
that the 74th casing (from well head) was jumped out from the coupling at mill end after taking 177.8mm
casing out from the well and checking. The jumped out coupling was cracked and located at the depth of
836.75m.
1.2 Running and making up of 177.8mm production casing
The 177.8mm production casing string was run to the depth of 5456.86m and the depth of cement fill
top was 1400m. The grade of 177.8mm production casing string at the depth of 0~1016.02mm was
V150, and the wall thickness was 11.51mm. The make-up torque of the field end of casing connection at
the depth of 836.75mm was 11.52kNm The thread compound applied at the field end of casing
connection was CATTS101
The optimum make-up torque at the mill end of the casing connection was 17.5kNm the
minimum torque 14.7kNm and the maximum torque 20.4kNm. The thread of coupling was surface
treated by zincification. The thread compound applied at the mill end was SHELL TYPE
External annulus of 177.8mm casing above 1400m was salt water with density of 1.16g/cm3 after
running and before testing. Production was gas and oil, and the annulus between casing and tubing was a
mixture of oil and gas during testing.
The temperature at the production layer in this well was 120 , and 30 ~40 at the well head.
1.3 Internal pressure change in tubing and casing

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 Internal pressure change in tubing and casing during testing was shown in Fig.1.
1.4 Analysis result of oil and gas
The salt contained in oil was 34.77mg/L on May 3, and 39039.23mg/L on June 17 according to the
analysis result of oil and gas. There was big difference between them.
1.5 Samples for failure analysis
The crack coupling with pin made up at the field end (NO.1) and an unused coupling with pin made
up at the mill end (NO.2) were sampled as failure analysis.

2 MACRO-FRACTOGRAPHY
The wider part of crack on the coupling was basically along with longitudinal direction, and thin
crack extended in the direction of 75ºwith coupling generatrix at the middle of the coupling (Fig.2).
There was no bump mark along the crack.
The fracture was covered with corrosion deposits after opening the crack. There were radial lines
constringently from the crack origin position on the thread surface after cleaning (Fig.3). The crack
origination area was comparatively flat. There were a lot of corrosion pit with diameters of 0.2~0.5mm
on the fracture. The threads at the crack origination were badly corroded. The distance from the crack
origination to the mill end of coupling was 93mm. The mill end threads were also corroded besides the
crack position, and there were many corrosion pits on the thread surface.
The pin at the field end was 101.2mm in length. There was only rusty, but no corrosion pit on the
internal surface of the pin and mid-coupling (2J) unengaged with the pin.
It was shown from macro fractography that the coupling fracture is brittle and the crack origination
located at the box position engaged with the pin at the mill end. There were severe corrosion pits on
fracture and box position engaged with the pin at the mill end, and there was only rusty and no corrosion
pit on the internal surface of the casing connection.

3 THREAD AND DIMENSION INSPECTION

3.1 Thread and dimension inspection for coupling specimens
It was indicated from inspection that coupling connection is in accordance with API SPEC STD 5B
and API SPEC 5CT. There was no obvious pitch change for NO.1 cracked coupling. The diameter of
NO.2 coupling at the mill end was 195.21mm that is 0.73mm bigger than that at the field end without
make-up, and 0.26mm bigger than that of NO.1 coupling at the field end (194.95mm) made up with the
pin. J dimension was 13.14mm at the field end of NO.1 connection and 7.49mm at the mill end of NO.2
connection. The difference between them was 5.65mm (1.8 pitch). It was estimated that the connection
was not over tensioned during use and the make-up torque was higher at the mill end of connection than
that at the field end, i.e., engaged threads at the mill end of connection were approx 2 threads more than
that at the field end.

4 RESIDUAL STRESS MEASUREMENT

4.1 Location of residual stress measurement
The measurement locations were 4 points, and each of them was apart 90º, and the distance was
38mm from the field end of NO.1 coupling. The measurement locations were 4 points, and each of them
was apart 90º, and the distance was 38mm from the mill end and the field end for NO.2 coupling. The
measurement locations of 4 points were 93mm from the mill end of NO.2 coupling, and each of them
was apart 90º.

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4.2 Result of residual stress measurement
It was shown from measurement result that the hoop residual stresses were plus and minus, but
stress absoluteness value was not high at the field end of connection without make-up The hoop residual
stresses were plus and minus, and average stress value was 153MPa at the field end with make-up. The
hoop residual stresses were all plus, and maximum was 560MPa, and average was 438MPa at the mill
end of connection with make-up. The hoop residual stress was all plus, maximum was 399MPa, and
average was 311MPa at the location corresponding to the crack origination of NO.2. The axial residual
stresses were all plus, and average was 177MPa at the position corresponding to the crack of NO.2.

5 MATERIAL TESTS
5.1 Chemical analysis
The chemical components were in accordance with the specification of the mill according to the
test result.
5.2 Mechanical test
It was shown from test that yield strength was 1127MPa, tension strength was 1227MPa, and
elongation ratio was 17.5%. The toughness at 20 was 84J in longitudinal direction, and 38.5J in
transversal direction. The toughness at -20 was 41J in longitudinal direction, and 26J in transversal
direction.
5.3 Metallography
It was known from metallography that there were a lot of corrosion pits at the crack position and the
area away from the crack. The corrosion pits near the crack was 0.20 0.30mm in depth, and 0.20
0.50mm in diameter; The corrosion pits (Fig.4) away from the crack was 0.30 0.70mm in depth, and
0.25 0.70mm in diameter.

6 MICRO-FRACTOGRAPHY
There were corrosion pits on the fracture, and there were two semicircle corrosion pits that are not in
the same plane at the fracture origination, and the corrosion pits were 1.14 1.43mm in depth, and 2.86
3.57mm in diameter (Fig.5). It was indicated from micro-fractography that the fracture was brittle, and
there were corrosion pits on the fracture. It was shown from the analysis by energy chart that S were 0.03
0.47 in weight, and Cl were 0.51 1.17 in weight

7 TEST RESULT ANALYSIS

The rupture accident tends to take place easily for V150 grade casing during use and transport
because the technology for V150 grade casing is not very mature so far. Several V150 casing break
accident had taken place in China, and some V150 casing coupling crack accident had occurred during
conveyance in other countries, too. V150 grade casing was listed at Table 5.1 in API SPEC 5AX before
1988, but it was explained that V150 grade casing was only higher in grade than P110 grade casing
instead of standard grade. Then V150 grade casing was canceled from API SPEC 5CT published in 1988
due to fracture problems.
It was indicated from test results that the coupling fracture was brittle. The material and thread were
in accordance with the mill specification. The cause and course of the coupling crack are analysed as the
following.
7.1 Occurrence sequence of crack and corrosion pit
There were corrosion pits on the fracture and threads near the crack and away from the crack. The

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crack was caused by corrosion, or the corrosion pits were brought after the crack, and possibly the crack
was brought by little corrosion pits at the crack origination. The occurrence sequence of crack and
corrosion pits should be deduced first as the main reason of coupling crack.
It was indicated from the test results that there was no obvious difference in corrosion pit dimension
between those at the crack position and threads away from the crack, and it means that there was not big
difference in corrosion medium and time between them. There were no corrosion on the pin and the box
at the field end of the connection because the threads were protected completely by thread compound
and corrosion medium couldn’t access on the thread surface. The thread compound used at the mill end
of the connection was SHELL TYPE , which is good for preventing from corrosion. The corrosion
medium could only access to the threads away from the crack and corrosion could take place as long as
the crack occurred. It is to say that the crack had occurred before corrosion pits were produced, and the
severe corrosion on the fracture and threads at the mill end of the connection took place after the crack.
The distance between the crack origination and the end of coupling was 93mm. J dimension at the
mill end of the connection could not be measured after jumping out, but the engaged position (L) of pin
and box at the mill end of the connection could be deduced per J dimension 7.49mm coupling length
(230.57mm), pin length L4 (101.20mm) of NO.2 connection and the max. axial distance 6mm of 65º
bevel (rust) at the field end of NO.1.
If the distance between pin end and coupling end at mill end was L. Then,
L=230.57/2-7.49=107.80mm
The thread engagement distance was 101.8mm L 6 except max. axial distance of 65º bevel.
It was known from calculation above that the crack position located at the thread engagement of pin
and box where SHELL TYPE thread compound was filled and could not be corroded before cracking.
This accounted for that the crack took place before corrosion.
7.2 Deducing time of crack penetrating and mechanics analysis
7.2.1 Deducing time of crack
Change of internal pressure of tubing and casing reflects seal feature of tubular string. The internal
pressure of tubing and casing were going up normally from May 29 to June 10. The internal pressure of
casing first decreased from 17.8MPa to 2.8MPa on 10 12 of June. The internal pressure of tubing
decreased from 18MPa to 2MPa on 10 14 of June. The tubular string pressure decreased abruptly, and
internal pressure decline of tubing lagged behind that of casing. This indicated that casing string leaked
due to penetrable crack. It was found that gas leaked from annulus between 177.8mm casing and
339.7mm casing on 24 of June. I.e. gas had already leaked from coupling crack to the wellhead through
annulus liquid columniation. This indicated that the leakage was very severe, and the crack had already
occurred.
It indicated from brittle fracture that the time needed from crack origin to forming penetrated crack
was very short. In other words, crack penetrated soon after crack origination.
7.2.2 Mechanical analysis
The forces acting on coupling were internal pressure, circumference stress formed by make-up, and
tension during running. Mechanical analysis is as the followings.
1 Internal pressure change of casing and tubing could increase internal pressure of the
casing
The annulus of 0 1400m depth and inner of casing string were all filled with salt water at the
density of 1.16g/cm3 before well testing. Internal pressure and external pressure of casing string are the
same at the same depth, and internal pressure and external pressure counteracted each other, so internal

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pressure of casing is 0. The external annulus of casing was still filled with water at density of 1.16 g/cm3,
and inner of casing was filled with oil and gas after well testing. Internal pressure was higher than
external pressure due to oil and gas pressure from stratum, and the internal pressure of casing was equal
to the pressure difference between inside and outside of the casing in such condition.
External pressure of casing at crack coupling position is calculated as the following.
Po H×ρ
In the formula
Po……External pressure of casing at crack coupling position(MPa);
H ……Depth at crack coupling position (836.75m);
ρ……Density of liquid at outside the casing (1.16g/cm3);
Po 836.75×1.16×9.8×103 9.5MPa.
The max. internal pressure of casing was 17.8MPa on 10 of June, so internal pressure of casing at the
crack coupling location was 8.3MPa (17.8-9.5). I.e. the internal pressure at the crack coupling location
increased 8.3MPa up to June 10 during well testing. The penetrated crack on coupling was formed
behind June 10, and internal pressure increased could cause crack initiation and extension.
2 Circumference stress formed by make-up
The crack originated on the box thread surface. There was some stress concentration at the thread
root because every thread root corresponds to a special gap according to thread configuration. If the
coupling was only acted by axial tension, then crack should originate and extend from the stress
concentrating position. Thread ascending angle of connection was 0.33º versus transversal direction, or
89.67º versus axial direction. The fracture at crack origination was 75º versus axial direction, and one
end of crack extended along 75º versus axial direction, and another end of crack extended along axial
direction. It was caused by circumference stress of coupling formed by make-up.
Circumference stress formed by make-up on coupling at the mill end was determined by torque. The
torque was calculated in accordance with the formula in API SPEC 5C3. The optimum torque at the mill
end of the connection was 43.4 higher than that at the field end, and the maximum torque at the mill
end of the connection was 59.8 higher than that at the field end, and the minimum torque at the mill end
of the connection was 33.3 higher than that at the field end.
It was indicated from residual stress measure result that the average residual stress (438MPa) at the
mill end was 2.84 times of one at the field end in the same position. The average loop residual stress was
311MPa, and the average axial residual stress was 177.8MPa at the location corresponding to crack
origination. It was more accounted for that the coupling bore big tensile stress due to high make up
torque.
Maximum grade for casing is Q125 in API SPEC 5CT, and there is no V150 grade casing so far.
Calculating torque with the formula in API BUL. 5C3 is not always suitable to the grade not specified in
API SPEC 5CT, and the torque calculated may be bigger. It was proved that torque was high by short J
dimension and bigger residual stress at the mill end of the coupling.
3 Load analysis on casing string during running
The casing near the well head bore maximum weight of casing string during running. Crack coupling
located at the depth of 836.75m instead of the well head position, so the coupling crack was not related
to casing string weight. It was proved from thread gage result that the cracked coupling didn’t bear much
axial load, so over loading during running could be eliminated.
7.3 Resistance to cracking of coupling material
Toughness requirement for preventing material brittle fracture is related to (KIC/σy )2. The higher

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torque, the higher toughness is required.
1
The investigation indicated that the minimum toughness requirement in transverseness was as the
following.
CVN(J)≥σy MPa /10, So
CVN>103J for V150 grade σy 1034MPa
CVN>97J for 140 grade σy=965MPa
Now the toughness in transverse of the 140 grade casing at -20ºC raised to 122J[2], so it was satisfied
to the formula above.
The toughness of the cracked coupling at 20ºC was 38.5J ,which is lower than the requirement above,
so the brittle fracture of the coupling was all related to the material toughness.
The toughness and strength of steel is generally relation of eating and flowing. High strength steel
has low toughness and ductibility, whereas the steel with high toughness and ductibility has low strength.
It is a topic to discuss in the future that the V150 grade steel needs very high toughness.

8 CONCLUSION AND SUGGESTION

(1) Coupling failure was brittle fracture. The reason of the coupling crack was due to over torque of
make-up and low material toughness;
(2) Suggesting evaluation for casing material and design should be done and safety use for V150
casing should be investigated.

20
Pr essur e( MPa)

15
Tubi ng
10
Casi ng
5
0
6. 11
6. 18
6. 25
7. 2
7. 9
5. 29

Dat e

Fig.1 Internal pressure change along with date in Fig.3 Crack origination morphology
tubing and casing

Fig.2 The coupling crack morphology Fig.4 Corrosion pit far from crack 50×

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 Fig.5 Corrosion pits at fracture origination

Reference
[1] Gao Huilin, Microstructure, performance, and weld behavior for line pipe steel. Science and
technology publishing company of Shaaxi, China, First edition, January 1995
[2] Tubular goods research center, Proceeding of basic application on oil tubular goods engineering,
Petroleum Industrial Press Company, China, August 2001.