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Natural Gas Industry B 4 (2017) 73e80
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Research Article

Downhole vibration causing a drill collar failure and solutions

Zhu Quanta a,*, Zou Zongming b, Huang Bing c, Ma Linhu a, Xia Jiaxiang d
a
Beijing Office of NOV Grant Prideco, Beijing, 100007, China
b
Chuanxi Division of CNPC Chuanqing Drilling Co., Ltd., Chengdu, Sichuan, 610500, China
c
Chuandong Division of CNPC Chuanqing Drilling Co., Ltd., Chongqing, 432001, China
d
Sinopec Southwest Drilling Company, Deyang, Sichuan, 614000, China
Received 31 October 2016; accepted 25 December 2016
Available online 9 August 2017

Abstract

In large borehole drilling of some blocks or formations, due to serious downhole vibration, fatigue failure of a drill collar occurs frequently
and most washouts and fractures are in thread root. An analysis of the above failure shows that the drill collar fatigue failure is caused by the
cyclic bending stress due to serious downhole vibration. Therefore, downhole vibration modes were theoretically analyzed in terms of axial
vibration, lateral vibration, stick-slip, and the physical model established by the mechanical vibration field. Then the resonance damage caused
by the actual different downhole vibrations and its theoretical basis were analyzed; and according to the downhole drill string lateral vibration
and whirling law, the best area to ensure drilling parameter stability based on the given boundary conditions was figured out, and the theory was
clarified that in the best area of drilling, the maximum ROP will be achieved by maintaining the drill string stable or eliminating the vibration/
stick-slip, meanwhile the stress fatigue of BHA will be reduced or eliminated especially for drill collar. Finally, solutions were provided as
follows: (1) According to the special BHA, drilling conditions, together with physical and mathematical models listed above, downhole
resonance speed and related parameters to be avoided can be easily figured out. It was also clarified that resonance speed is exactly the vibration
speed that need to be avoided; and that the resonance frequency can be avoided with software for vibration analysis in BHA design and
application at well sites; (2) V-Stab is a new and efficient tool which can reduce or eliminate downhole lateral vibration and stick-slip.
© 2017 Sichuan Petroleum Administration. Production and hosting by Elsevier B.V. This is an open access article under the CC BY-NC-ND
license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

Keywords: Axial vibration; Lateral vibration; Stick-slip; Resonance; Drill collar; Fatigue failure; Software for vibration analysis; V-Stab

Through technical exchanges, field surveys and workshops
related to failures of drilling tools, some common phenomena
have been found. For example, frequent fatigue failures of drill
collars occurred during drilling in some blocks or formations,
especially in the drilling of wells with large diameters. Ma-
jority of these failures involved washout with fractures around
root sections of screws. Based on surface conditions and
drilling parameters, severe downhole vibrations were identi-
fied or speculated. Such vibrations may lead to premature
fatigue failures of drill collars. Analyses of root causes for
failures show that repeated bending stresses induced by severe
* Corresponding author.
E-mail address: quanta.zhu@nov.com (Zhu QT.).
Peer review under responsibility of Sichuan Petroleum Administration.
downhole vibrations are key causes for such fatigue failures.
Accordingly, theoretical analyses were made for patterns and
threats of downhole vibrations. Eventually, effective solutions
with breakthroughs in theoretical developments were identi-
fied to reduce and eliminate downhole lateral vibrations and
stick-slip.
1. Failures of similar drill collars
1.1. Case 1
Positioned in Yangliusi of Xingyi Town, Fengdu in
Chongqing, Well Shifu 1 [1] was initially drilled on Dec. 4.
From Dec. 16 to 30, drill collars failed four times during the
drilling of large-diameter boreholes at the interval of

http://dx.doi.org/10.1016/j.ngib.2017.07.013
2352-8540/© 2017 Sichuan Petroleum Administration. Production and hosting by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
74 Zhu QT. et al. / Natural Gas Industry B 4 (2017) 73e80

155e800 m. Two of these failures involve washout of root
sections of box ends of the Ø165.1 mm drill collar, breaking of
one drill collar and one Ø203.2 mm drill collar, as shown in
Table 1.
All of the four failures in the well occurred in intervals
shallower than 800 m. Visual inspections over fractures show
features of fatigue failures. All these drilling operations
involve BHAs equipped with stabilizers, and with torques of
6000e12000 Nm. In addition, extremely severe bit jumping
and bouncing happened during drilling, with bit weight of
50e400 kN. Fig. 1-a shows the second breaking of the drill
collar in Well Shifu 1.
1.2. Case 2
When Well Moxi 29 [2] was drilled to the depth of
885.42 m at 8:36, Sep. 19, 2013, the string suspending weight
reduced from 545 to 486 kN, the pumping pressure decreased
from 11.6 to 7.7 MPa, and the pumping rate increased from
105 to 108 strokes/min. No backward rotation was observed
during drilling tool lifting. It was determined on site that BHA
was broken. After tripping out at 13:50, the first 203.2 mm
drill collar broke at 0.13 m below the box end, as shown in
Fig. 1-b.
NOV Grant Prideco analysis data acquired in tests for
drilling tool fatigue [3] indicate that repeated bending was a
common form of drill string fatigue. Being cumulative and
irreversible, repeated bending is directly related to application
time. However, the application time is not the only factor
drilling tool fatigue, but stress is also meaningful [4].
Repeated bending induced by downhole vibrations is the main
driver for such fatigue failure, and it is directly related to
amplitudes and frequencies of such vibrations.
Researches related to fatigue and relevant failure mecha-
nisms of threaded connection in drill collars show that [5]
fatigue failure of drill collars predominantly occurs around
the 1e5 threads in the threaded connection, mainly due to the
concentration of stress at the root of threads. Through the
above analyses and theoretical discussion, it is determined that
detection and elimination of downhole vibrations are essential
to addressing fatigue failures.
2. Downhole vibrations and solutions
2.1. Classification of downhole vibrations
Downhole operations inevitably involve vibrations. Great
progress has been made in researches in this aspect [6].

Table 1
Statistics on failures and fractures of drill collars in Well Shifu 1.
Failed drilling tool Date Detection Application in the well Failures and solutions
Ø165.1 mm drill collar December 16 Onsite ultrasonic Deployed on Dec. 10, to drill On Dec. 16, the well was drilled to the depth of
washout inspection the interval of 155.2e301.5 m 301.50 m at 11:10 when the standpipe pressure
with the total application time of 140.33 h. decreased from 12.6 to 12.1 MPa, whereas the
pumping rate increased from 164 to 170 strokes/min.
Inspections showed no abnormal conditions in surface
facilities. After drilling assembly was tripped out,
the third Ø165.1 mm drill collar had fractures at
10 cm from the box end and the 4th drill collar
had pin end washout
Ø165.1 mm drill collar December 17 Onsite magnetic Deployed on Dec. 11, to drill On Dec. 17, the well was drilled to the depth of
washout powder inspection the interval of 178.8e331.41 m 331.41 m at 14:00 when the standpipe pressure
with the total application time of 155.67 h decreased from 5.8 to 5.7 MPa, whereas the
pumping rate increased from 160 to 165 strokes/min.
Inspections show no abnormal conditions in surface
facilities. After drilling assembly was tripped out,
the 4th Ø165.1 mm drill collar had fractures
at 9 cm from the box end.
Ø165.1 mm drill collar December 17 Onsite magnetic Deployed on Dec. 10 to drill On Dec. 19, the well was drilled to the depth
broken powder inspection the 136.6e383.79 m Interval of 383.79 m at 8:50 when the standpipe pressure
with the total application time of 218.33 h. decreased from 6.5 to 5.1 MPa, whereas the
pumping rate increased from 156 to 186
strokes/min and string suspending weight
decreased from 547 to 347 kN. Dafter drilling
assembly was tripped out, the first Ø165.1 mm
drill collar broke at 10 cm to the box end. A
taper tap was deployed to capture the fish
successfully in one trip.
Ø203.2 mm drill collar December 30 Onsite magnetic Deployed on Dec. 10 to drill On Dec. 30, the well was drilled to the depth of
broken powder inspection the interval of 101.5e787.46 m 787.46 m at 17:31 when string suspending
with the total application time of weight decreased from 691 to 480 kN. After
496.67 h in the well drilling assembly was tripped out, the third
Ø203.2 mm drill collar broke at 7 cm to
the box end. A taper tap was deployed to
capture the fish successfully in one trip.
 Zhu QT. et al. / Natural Gas Industry B 4 (2017) 73e80
Fig. 1. Broken drill collars.
Generally, vibrations of downhole drilling assembly can be
classified into three types: axial vibration (or bit jumping),
lateral vibration and stick-slip. These vibrations can be found
independently or jointly.
2.1.1. Axial vibration
Axial vibration, also known as bit jumping, is often induced
by exciting source which occurs when pressure fluctuation is
generated due to uneven bit weight or rough bottom hole. In
addition, the drilling tool itself has periodic amplitude. In case
of resonance, it may bounce, which is extremely serious
sometimes. This phenomenon is common in shallow boreholes
with large diameters, especially in alternate hard and soft
formations. Fig. 2 shows the original records for torques and
WOB for Well Shifu 1. It can be seen that torques change
greatly in 8200e13270 Nm. The field records (during normal
drilling on Dec. 17, 2015) show that from 10:00 a.m. on Dec.
17 to 3:00 a.m. on Dec. 18, bit weight fluctuated at
50e400 kN, revealing severe bit jumping. In the worst sce-
nario, it was impossible to proceed with the drilling
operations.
2.1.2. Lateral vibration
Lateral vibration refers to regular or periodic lateral vi-
bration of BHA. It is attributed to BHA itself, bit type, for-
mations and other conditions. Eddy turbulence is an
outstanding form of lateral vibration. Eddy turbulence in-
cludes positive eddy turbulence and negative eddy turbulence.
Fig. 2. Original records of torques and WOB for Well Shifu 1.
75
Negative eddy turbulence may present significant threats to
drilling tools and ROPs [7]. According to the plots of drilling
parameters of Well Moxi 29 (Fig. 3), WOB vary in
60e120 kN, while torques vary in 18000e24000 Nm.
Accordingly, severe lateral and stick-slip vibrations are sus-
pected in the borehole. Photos for washouts and fractures show
the existence of typical premature failures in the root parts of
threads in drill collars due to the accumulation of alternating
stress fatigue. It is commonly acknowledged that drilling op-
erations involving severe downhole vibration may have drill
collar premature or frequent failures expected [8].
2.1.3. Stick-slip vibration
Bits (both roller bits and PDC) at the bottom hole are al-
ways cyclic from penetration of formation, accumulation of
energy, releasing of energy and rock breaking. Abrupt
releasing of rotation energy of a drill string may lead to fast
rotation of a drilling bit. As the drill string unwinds, torque
reduces. Then, the rotation speed of the drilling bit slows down
again. The process repeats. In addition, fractions of the drill
string with sidewalls and other media in the borehole may also
excite or amplify such vibrations [9].
Theoretical researches on vibrations and dynamics of drill
strings in the borehole are fruitful. Instead of assumptions
based on visual observations, sophisticated physical models
have been built. Particularly, the most fundamental and
important model is the one proposed by Kreisle [10], namely
the partial differential equation with presumption that the drill
76 Zhu QT. et al. / Natural Gas Industry B 4 (2017) 73e80

Fig. 3. Drilling parameters of intervals with broken drill collars in Well Moxi 29.

string is an elastic beam supported by hinges on both ends which can trigger eddy turbulence and torsional vibrations, are
[11]: predictable. As is shown in Fig. 4, the boundaries of steady
drilling parameters are given, and the area enclosed by the
v2 u 2v u
2
coordinates is considered as the best area. Generally, eddy
¼ a ð1Þ
vt2 vz2 turbulence may present two forms: reversed eddy turbulence
(reverse to the rotation direction) and positive eddy turbulence
in which, z is the coordinate of axis along the drill string; u is
(along the rotation direction). Reversed eddy turbulence
the vertical displacement of the cross section of the drill string
originates from the friction between the bit and sidewalls.
at certain distance from the coordinate origin; t is time;
Circumstantial fractions between the lower drill string and
a2 ¼ E/rd (rd: the density of steel for the drill string); E is the
sidewalls may produce reversed eddy turbulence equivalent to
elastic modulus of the drill string.
reversed rolling of the drill string along sidewalls. These
Initially, majority of researches were performed on patterns
fractions may accelerate downhole lateral vibrations. In
of downhole vibrations and construction of relevant models.
extreme cases, their frequencies may exceed the rotation speed
Since the mid-late 1980s, focus of researches related to
of the drill string. These high-frequency vibrations and
movements of drilling tools within China shifted from axial
resulted inversed bending alternating stress may produce
vibrations, torsional vibrations and bending to lateral vibra-
extremely unfavorable conditions for drilling operations. They
tions and coupling of lateral vibrations and other movements.
may lead to fatigue failures of drilling tools, premature fail-
Moreover, significant progress has been made with respect to
ures of bits and especially of gauge teeth in a very short time.
prediction of downhole resonances. In the late 1980s, more
Accordingly, drilling parameters within the best area can be
researches were conducted on eddy turbulence. Massive data
used to maintain the stability of drilling tools. In turn, stability
acquired while drilling show severe lateral vibrations in dril-
of drilling tool stability, or eddy turbulence elimination and
ling tools, which presents threats much higher than those
stick-slip vibration can be used to achieve the maximum ROP,
presented by axial and stick-slip [12].
and at the same time, may reduce or eliminate alternating
stress fatigue of drilling tools, especially of drill collars. In this
2.2. Solutions
way, software should be used in BHA design to check for the
existence of resonances.
2.2.1. Software for analyses of drill string vibrations
Based on drill string vibrations and kinetic physical models
As for lateral vibrations and patterns of eddy turbulence of
and the fundamental vibration partial differential Equation (1),
drill strings, research results show [13] that, under specific
and depending on boundary conditions, the partial differential
conditions, the critical bit weight and rotation speed (RPM),
 Zhu QT. et al. / Natural Gas Industry B 4 (2017) 73e80
Fig. 4. Diagram of the best area for downhole vibrations.
equations for axial and lateral vibrations of drill strings can be
built. Thus, it is possible to provide theoretical foundations for
the calculation of axial, lateral and stick-slip vibrations of drill
strings, together with other resonance frequencies through
simulation of actual downhole vibrations.
Given specific BHA and drilling environments (including
drilling fluids and bits), the above-mentioned physical and
mathematical models can be used to determine rotation speeds
and relevant parameters that may induce downhole resonance.
In fact, the resonance rotation speed is the optimal vibration-
proof rotation speed. Some engineering software companies
(such as T.H. Hill, Schlumberger and Paradigm, etc.) have
well-developed software available for downhole vibration
analysis [14]. Cares shall be taken in the design of such BHAs
to avoid application of components, specifications and ele-
ments that may lead to downhole vibrations. In addition, it
may provide necessary guidance to avoid resonance fre-
quencies and parameters during on-site applications.
2.2.2. An instrumental solution e V-Stab
Through deeper analyses and researches on downhole vi-
brations of drill strings, relevant researchers and experts have
been working out solutions to reduce or eliminate such
downhole vibrations. Based on the vibration absorption by
Fig. 5. Diagram of the V-Stab.
77
using springs, the axial shock absorber can effectively elimi-
nate the problems related to downhole axial vibrations (bit
jumping). However, for the more destructive lateral vibrations
and stick-slip vibrations, no satisfactory solutions have been
identified [6]. In recent years, some scholars proposed to use
the simple and practical V-Stab [15] to address downhole
lateral vibrations and torsional vibrations, especially reversed
eddy turbulence. This is a brand new concept and a break-
through for conventional stabilizers. It is still not well known
and not widely promoted on site.
2.2.2.1. Structures and working principles. V-Stab is simple in
structure, as is shown in Fig. 5. It has one stabilizing wing fewer
than the conventional stabilizer. In addition, both wings in V-
configuration have been adjusted to ensure proper overlapping
of external circular center of the stabilizer with the V-Stab.
By using two wings, the V-Stab positively generates desir-
able positive synchronized eddy turbulence, which can signifi-
cantly interfere and eliminate downhole lateral vibrations
dominated by reversed eddy turbulence. Moreover, there is a
buffer for torsional vibrations. Fig. 6 shows the working prin-
ciples of the V-Stab. With rotation of drill strings, the V-Stab
generates positive synchronized eddy turbulence movements
under the reacting force between the initial and the second stress
points. With further intensification of the movement, the second
stabilizing wing contacts the sidewalls, while the reacting force
drives the V-Stab back to its original position, as is shown in
Fig. 6-b. In this way, regular positive synchronized eddy tur-
bulence can be generated. Since the eddy turbulence is both
positive and synchronized, it may eliminate majority of detri-
mental reversed eddy turbulence. On the other hand, the positive
synchronized eddy turbulence also serves as an auxiliary brake
for the existing stick-slip. In the case of low rotation speeds or
stop of the drill string, the stabilizing synchronized eddy tur-
bulence may accelerate the system. In the case of high speed
rotation of the drill string, the turbulence may serve as a brake by
absorbing the energy in stick-slip.
2.2.2.2. Features of the V-Stab. According to on-site down-
hole measurement results, the V-Stab can positively excite and
generate positive synchronized eddy turbulence. The positive
78 Zhu QT. et al. / Natural Gas Industry B 4 (2017) 73e80

Fig. 6. Working principles of the V-Stab.

synchronized eddy turbulence enables the drill string to resist absorb the energy in downhole lateral vibrations. With low
high-frequency vibrations and reduce random impacts. The V- velocities and outstanding stability performances, the positive
Stab produces positive synchronized eddy turbulence with synchronized eddy turbulence generated by the V-Stab can
frequency at only 1/6 of that of the concentric stabilizer to serve as an effective auxiliary brake for downhole stick-slip

Fig. 7. Case of Performance of the V-Stab in shock absorption in a well, Australia (Note: 1 kpsi ¼ 6.894 MPa; 1 kft$lbf ¼ 1.355 8 kNm).
 Zhu QT. et al. / Natural Gas Industry B 4 (2017) 73e80
Fig. 8. Performance of BHAs with a V-Stab in eliminating downhole vibrations in 5 neighboring wells in the same area of the Gulf of Mexico (Note: 1 ft ¼ 0.304
8 m).
vibrations. To ensure the generation of positive synchronized
eddy turbulence, the V-Stab should be installed above the
neutral point of the drill string and maintained at a desirable
rotation speed.
2.2.2.3. Application of the V-Stab. Application of the V-Stab
in a large-diameter (Ø311.2 mm) well in Australia effectively
reduced downhole vibrations in identical well and formation
conditions, as shown in Fig. 7. Sections above the red line are
measured plots for rotary steering of BHA without V-Stab in
the 15th trip. Particularly, Columns 3 and 4 highlight the
torques and surface rotation speeds, respectively. Significant
fluctuations in these plots reflect severe stick-slip vibrations in
the well. Columns 5 and 6 highlight the lateral acceleration of
X- and Y-axis and accelerations of XeY coordinate system.
Significant fluctuations in these values indicate the existence
of severe lateral vibrations and eddy turbulence. Sections
below the red line are measured plots for rotary steering of
BHA with V-Stab deployed in the 16th trip. BHA with V-Stab
installed almost eliminated all the downhole vibrations.
Furthermore, plots in Column 2 indicate dramatic increases in
ROPs.
Fig. 8 shows the performance of BHA with a V-Stab in
eliminating downhole vibrations in 5 neighboring wells in the
same area of the Gulf of Mexico. The first three wells have
identical conditions with BHA used with no V-Stab deployed.
Measured plots are black box data analyses results for lateral
acceleration. Yellow and red sections represent total lateral
79
accelerations of X- and Y-axis in the interval with severe lateral
vibrations or eddy turbulence. The latter two wells involve
identical BHA with V-Stab deployed. By comparing these
plots, it can be seen that majority of downhole vibrations in the
interval have been eliminated effectively.
On-site applications show that low-frequency positive
synchronized eddy turbulence produced by positive excitation
of the V-Stab may effectively eliminate detrimental reversed
eddy turbulence produced downhole. In addition, it may
dramatically absorb detrimental stick-slip vibrations down-
hole. Accordingly, it can serve as an effective tool to reduce
and absorb lateral and stick-slip. With simple structures and no
spare parts, it involves no risk related to lost fish of conven-
tional shock absorbers. It can be considered as a perfect so-
lution to eliminating downhole vibrations [1].
3. Conclusions
1) Severe axial vibrations (or bit jumping), lateral vibra-
tions and stick-slip vibrations in wellbores may lead to
premature failures in the root sections of screws in drill
collars. Generally, repeated bending induced by down-
hole vibrations can be seen as a key contributor to fa-
tigue failures, which is directly related to amplitudes and
frequencies of such vibrations.
2) Downhole axial vibrations, lateral vibrations, stick-slip
vibrations and other movements may lead to resonance
and eddy turbulence, which are extremely detrimental to
80 Zhu QT. et al. / Natural Gas Industry B 4 (2017) 73e80
drilling operations because they may lead to fatigue
failures of drilling tools, together with premature fail-
ures of bits and gauge teeth within short time spans.
3) With consideration to downhole lateral vibrations of the
drill string and patterns of eddy turbulence, desirable
drilling parameters should be maintained within optimal
ranges to ensure the stability of drilling tools.
4) By using the newly constructed physical and mathe-
matical models, it is possible to determine rotation
speeds and relevant parameters that may induce down-
hole resonance. The resonance frequencies can be
avoided in design and in on-site application of BHAs.
5) Low-frequency positive synchronized eddy turbulence
produced by positive excitation of the V-Stab can
effectively eliminate detrimental reversed eddy turbu-
lence produced downhole. In addition, it can dramati-
cally absorb detrimental stick-slip vibrations downhole.
Therefore, it can serve as an effective tool to reduce and
absorb lateral and stick-slip. With simple structures and
no spare parts, it involves no risk related to lost fish of
conventional shock absorbers. Generally, it can be
considered as a perfect solution to eliminating downhole
vibrations.
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