Threaded Connections Utilizing Composite Materials

Many synthetic resin materials are now available for engineering applications and are widely used because of their particular advantages. Using such materials, products can be mass produced at relatively low cost for many uses, and the products are comparatively light weight, corrosion resistant, and can be designed to have very high strength. The structural characteristics of synthetic resin are enhanced by reinforcing with fibers, as in chopped, tow, roving, fabric or tape form, when forming composite or fiber reinforced plastic (FRP) bodies. Where the product shape needed is a closed surface, such as a tubular shape or a vessel, and when high force loading requirements must also be met, continuous filament winding is used. Continuous filaments of high tensile strength wound in predetermined patterns can achieve strength and stiffness properties along with strength to weight ratios that exceed conventional structural materials.

The advantages of FRP materials have not, however, been fully realized where threaded connections are employed because of both production and stress distribution problems. Use of the potential properties of filament wound reinforcement has often been limited by the fact that the geometrical discontinuities at the threads prevent optimum relationships from being achieved between filament orientation and the desired ratio of filament to resin matrix. Furthermore, while a female member can be wound on a male mold having a properly placed thread profile, fiber reinforced threads cannot be molded into the outside surface of a male member with comparable results. Instead, the thread profile must be cut into the outer surface, weakening thread strength and also creating surface irregularities which are incompatible with molded female thread surfaces.

There are a great many potential applications for FRP tubular products, which have in fact been used under specialized conditions in various industries for more than the past 40 years. Composites of these kinds have been used to a limited extent in the chemical and storage cavern industries, and to a greater but still minor extent in the pipeline industry, where usage has been in the range of 11% to 13% of total pipe consumed. The barriers have been the inability to contain internal pressures of the range of 3,000 psi and above, and premature degradation of the threads on repeated makeups and breakouts. The same factors have restricted use of composite pipe in drilled oil, gas and injection wells to a level of 3% to 5% of total pipe consumed. Where drilling is to be done, FRP pipe with sufficiently robust connections can be used if the force loading is light, as in workover drilling.

To obtain proper sealing against high internal pressures (e.g. greater than 3,000 psi), male and female threaded members must be engaged with a high level of torque to achieve high surface bearing pressure. In the prior art, however, this deforms the FRP pipe such that it either cracks or internally "leaks between layers" (delaminates). In addition, where the male threads have been cut into the FRP part, they deny the benefits of the reinforcement and leave filament ends flush at the surface. With wear or high bearing pressure these filament ends form highly frictional cutting points. On makeup and breakout the threads are quickly worn and galled, and breakout becomes increasingly more difficult.

In consequence, when FRP pipe is used, the makeup torque for a given pipe has been confined only to a low range (280-300 ft. lbs. for 2-7/8" pipe, for example). This means that only a comparably low level of bearing pressure can be established when makeup is completed, and thus only low internal pressures, temperature cycles, and tensile loads can be withstood. Consequently, those many industries which can potentially use FRP tubular goods have not been able to rely on them except for low pressure and low duty cycle situations. This includes not only drilled well and down hole applications and workover situations, but also secondary recovery uses, the deep well disposal industry for hazardous materials and pipeline applications.

In the oil industry, defined physical standards for tubular goods for down-hole and horizontal applications have been observed for many years, primarily with respect to threaded steel pipe. Thread profiles, material grades and thicknesses, tapers and other properties have been established for threaded tubular goods by the American Petroleum Institute (API) in accordance with the tensile forces and pressures that must be met for a particular installation. The female member is usually referred to as the "box" and the male member is usually referred to as the "pin". With many API connections, the box is an exterior collar for receiving pins from opposite ends. In oil field parlance, smaller diameter tubular goods are referred to as "tubing" and larger diameter down-hole tubular goods are referred to as "casings".

In assembly of a pipe string for a conventional down-hole installation a length (typically 30 feet, about 9 meters) of a tubing is added (stabbed) into the open upper end of a collar on the upper end of the immediately prior pipe length. The new pipe is threaded into place, until a predetermined range of thread interference, and consequently surface bearing pressure, has been reached. This range is generally established in practice by rotating the newly added pipe length for a predetermined number of turns after initial firm contact (the so-called "hand-tight plane") or until a measured or estimated level of makeup torque has been applied. As more torque is applied, the box is increasingly stressed circumferentially, while the pin is compressed. The amount of deformation locally varies because of relative differences in wall thickness along the length of the threaded region. However, as stress is increased, the deformations tend to increase as well (although not precisely linearly) along the threaded length, as long as the stresses are within the elastic limit of the materials. Where one member ends and the other is continuous, however, the stress level variations become significantly non-linear. In FRP tubular products, these variations are more than twice as steep as those observed with steel.

In view of the fact that male threads in an FRP member are not fully compatible with molded and reinforced female threads, workers in the art have used double ended steel pins or nipples to interconnect two abutting and internally threaded boxes. In this configuration, the deformation is taken up essentially entirely in the FRP member, which therefore must absorb the forces of make-up torque before failure. Existing connections of this type fail at levels which compare very unfavorably with steel tubing connections, in which the torque that can be applied is orders of magnitude greater. The industry has been searching for configurations which will accept substantially higher makeup torques and which will, in the field, indefinitely withstand internal pressures of 5,000 psi and greater. It is known from finite element analyses for steel, and observed failure patterns, that the stresses are highest at the region adjacent to the end of the box, because in this region the threads of the box are most often destroyed or the box itself tends to rupture or delaminate. Resolutions for those problems have not heretofore been found.

By minimizing stress discontinuities, without reducing other physical properties, apparatus and methods in accordance with the invention enable male and female members to be threaded together with substantially greater torque than has heretofore been attainable without failure. Sealing and other properties are therefore improved to levels at which the tubular goods can be used in situations not previously accessible.

As one example, a tubular threaded connection utilizing a combination of female tubular goods and male interconnecting members incorporate mating threaded areas on the male and female members. The male member is double ended to receive female members from each side. Adjacent each end of the threaded regions, low angle, conical gradient surfaces on both members reduce the localized deformation forces in the composite material so as to eliminate stress risers at the ends of the threaded regions. The length of and degree of interference between the engaging conical surfaces are selected relative to the thread interference to provide the desired result when the connection is fully made up. With such relationships, make-up torque on FRP boxes can be increased to a level more than 5-6 times greater than that which has heretofore been achievable, providing tensile and sealing properties which open a wide range of new applications to composite materials.

The advantages of this arrangement are best realized for most current needs by a steel male member and FRP female members. Although the composites in this combination undergo almost all the ensuing deformation when the needed bearing pressure level is reached, internal pressures of 5,000 psi or more are effectively sealed, and the connection can be made up and broken out numerous times while maintaining thread integrity. The same principles can, however, also be used with benefit in connections that are entirely of composite materials. The male thread profiles need not be cut but can be in the form of a hardened molded or steel insert. With such a feature to prevent galling, the tubular members can be directly threaded together in end to end relation for some applications.

Further in accordance with the invention, the FRP boxes are configured with diverging, internally threaded ends of substantially uniform wall thickness. The double-ended pin member is in the form of a pair of oppositely extending threaded nipples and incorporates a central crest portion with conical gradient surfaces on each side leading to a central flat. The pin member also includes an O-ring groove in each conical gradient surface adjacent the pin nose end for sealing the thread engagement region from internal pressures with an inserted O-ring. Flat ends of the FRP boxes engage the broad side faces of a radial ring disposed about the central flat on the pin. When the connection is fully made up, a substantial amount of makeup torque is absorbed in axial compression. This face to face contact under high compressive forces additionally seals against external pressure. A consequence of this approach is that the diverging end portions of the boxes are subjected to expanding hoop forces when the box and faces are compressively stressed. This would tend to decrease the interference stresses in the threads and the conical gradient surface because of radial spreading, but such effects are counterbalanced by winding the filaments so as to increase columnar strength. The metal faces also prevent surface abrasion from fiber ends from dramatically increasing friction due to interactions with the composite material surfaces. Consequently, a number of features contribute cumulatively to sealing, including interference in the thread region, interference in the conical stress gradient surfaces at each end of the threaded region, the O-rings, and the axial contact between the nose end of the pipes and the central radial ring.

A further advantage of this arrangement is that the tapers at each end of the pin are in the regions of smallest wall thickness of the pin. Any internal fluid pressure that tends to deform the pin ends and O-rings outwardly toward the surrounding boxes helps to increase bearing pressure and maintain the seal relationship. In addition, for corrosion resistance the pin can be of non-corrosive material or the interior surface of the pin can be coated with corrosion-resistant synthetic throughout its interior and around the end to the O-rings.

Also in accordance with the invention, all-FRP connections can be torqued to higher levels than heretofore by using conical gradient rings to provide stress relief adjacent each end of the threaded regions. The problems introduced by male thread profiles cut into FRP members can be reduced by use of molded thread inserts of solid high strength synthetic or metal inserts or surfaces. Nose end seal rings can be of elastomeric or metal or of layered laminates. These features may be used in direct box-to-box connections which may be of constant diameter or may be of upset configuration for greater wall thickness in the thread and shoulder regions.

A better understanding of the invention will be had by reference to the following description, taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view, partially broken away, of a connection for joining two lengths of tubular product of composite materials;

FIG. 2 is a side sectional view of the arrangement of FIG. 1;

FIG. 3 is a side sectional view of a double ended male member utilized in the combination of FIGS. 1 and 2.

FIG. 4 is a side sectional view of a fragment of the male member of FIG. 2 showing the O-ring used therein;

FIG. 5 is a side sectional view of a connection in which male and female members are both of fiber reinforced plastic;

FIG. 6 is a side sectional view of a connection using direct engagement of tubular FRP members, one of which has a metal threaded insert forming male threads;

FIG. 7 is a graphical representation of the results of a finite element analysis for a threaded connection; and

FIG. 8 is a table of test results for connections with FRP boxes and steel pins.

As shown in FIGS. 1 to 3, a connection in accordance with the invention comprises first and second female members or boxes, 10, 12, respectively, of composite FRP construction. Typically, these composites comprise continuous reinforcing filaments of properties chosen for cost and strength. The usual filamentary reinforcement is glass fibers, although carbon, graphite, Kevlar, boron and other filamentary reinforcements may be employed.

With FRP tubular products, a box is usually formed on a male mandrel, wrapping a continuous filament coated with resin in a "B" (partially cured) stage on a male mandrel which has thread forms at each end. The processes are carried out with a winding machine that lays up the filaments with both circumferential and axial patterns, although winding in the immediate thread region is circumferential in order to have continuous filaments extending through the thread profiles. The female members 10, 12 are wound to a desired thickness, and thereafter fully cured by a known conventional technique, such as catalytic reaction at an adequate desired temperature, ultra violet radiation, or infrared heating. The matrix in the composites is typically epoxy, vinyl esters, poly esters, Furan or mixtures thereof, although a wide variety of other resins is also available.

The male member in the connection is an internal double ended pin or nipple 14, usually of steel or an alloy. Since FRP tubular goods are usually employed for their corrosion resistance, the pin 14 also may be of a typical corrosion resistant material well known to those skilled in the art. The material may be of the class of corrosion resistant materials and including Inconel, titanium, stainless steel, and API corrosion resistant alloys such as 9 chrome, 11 chrome, 13 chrome, 17 chrome and 2205 chrome, or other suitable metals. Alternatively, the pin 14 may be coated on all of its internal surfaces with a known corrosion resistant layer of one of the synthetic resin (e.g. Viton), epoxy and phenolic types now widely used in the oil and gas industry. This layer preferably covers the end of the pin 14 and the outer diameter to near the threaded region. The combination is completed by a steel center radial ring 16 having broad side face disposed between the facing surfaces of the first and second boxes 10, 12.

The pin 14 has a constant inner diameter matching that of the inner diameter along the length of the boxes 10, 12. Threaded sections 20, 22 on the outer surface of the pin 14 diverge oppositely from the nose ends toward the central region of the pin 14. The two threaded sections 20, 22 of the pin lie along the taper angles, and the thread profiles are substantially uniform except at the end of the threaded segments.

Only one side of the pin 14 need be described because the pin is arranged symmetrically about the center. For convenience the different features will be described with respect to the "outer" or "nose" end and the "inner" or "central" end of a half of the pin. Adjacent the nose end, the pin 14 includes an O-ring groove 26 in which is seated an O-ring 28, which engages the associated box to provide a substantial degree of sealing against leakage from internal pressure. Between the nose end and the principal length of the pin threads 20, thread crests are truncated to define a conical stress gradient or ring section 24. The angle of the surface of the conical section 24 relative to the taper of the thread section 20 itself is in the range of 5.degree. to 20.degree., being 10.degree. in the present example.

At the inner end of the thread section 20, in the central region of the pin 14, is a central crest ring 30 defined by oppositely tapered inner conical stress gradient or ring sections 32, 34. These tapered sections 32, 34 are separated by a thin center flat 36 approximately corresponding in width to the thickness of the center radial ring 16. The tapers of the two inner conical gradient sections 32, 34 are again in the range of 2.degree. to 20.degree. and in this example are 5.degree. relative to the taper of the associated thread sections 20 or 22. For most designs, the tapered conical sections 20, 32, 34 will lie at angles of 5.degree. to 15.degree. relative to the tapers of the threaded sections. Between the crest ring 30 and the inner end of the thread section 20 is a machining relief groove 38 employed for practical reasons. In fabrication of the pin 14, the presence of such a groove enables completion of the last thread without chip or spur accumulation.

The female members or boxes 10, 12 are again alike, and the following description of one female member or box suffices for the other as well. The terminal length of the body of each box diverges on a taper substantially matching that of the outer taper of the associated half of the pin 14. The diverging section 40 is built up in a continuous process with the constant diameter control portion of a box 10 or 12, and is of substantial thickness along the length of its internally threaded region 42 when formed on a male mold. Because of the winding and curing process, however, wall thickness may diminish slightly toward the end of the box, although being only slightly thinner along the threads than in the constant diameter principal length of the box. Conical stress gradient or ring surfaces 46, 48 will be referred to as the interior conical surface 46 and the end conical surface 48 respectively. These surfaces 46, 48 match, in taper angle, the outer section 24 and the inner conical section 32 of the pin 14, respectively, in complementary fashion, being sized both axially and diametrically to establish desired levels of interference and stress when the connection is fully made up.

As shown in FIG. 2, when the unit is fully assembled, the end faces 50, 52 of the boxes 10, 12, respectively, abut the broad side faces of the center radial ring 16. The tapers at the outer diameter along the length of the pin 14 are angled to merge into the constant inner diameter of the boxes, leaving only a slight discontinuity. The pin nose end can in some instances engage an inner shoulder in the box to eliminate discontinuities altogether. However, unless the shoulder and the nose end are of adequate radial dimension, makeup torque used in this configuration will be so high as to destroy the shoulder.

Significant advantages are derived from this configuration, beginning with the fact that a much higher range of makeup torque can be applied before box failure occurs. As thread engagement increases, stresses result in deformation of the composite member, ultimately to the point of failure, because the metal male member is much less yielding. Box failure tends to occur at the limits of the threaded region, or in end threads, circumferential deformation in the thread region is relatively uniform, but that beyond the end of the threads, the wall seeks to return to its original size, necking down and non-linearly increasing the local stresses. Study of the problem led to a finite element analysis of torque distribution in a steel connection, as depicted graphically in FIG. 7. A finite element analysis of an FRP structure is inordinately difficult, because the computation of the stresses in differently wound multiple filaments within a physically restraining matrix is difficult to specify, let alone implement. However, threaded steel members that form a connection that is of like configuration can more readily be analyzed, because steel is a homogeneous material, and the results of this analysis are applicable and instructive as to FRP structures. As seen in FIG. 7, torque demands and resultant deformation increase very sharply adjacent each end of a threaded region, and rise to a peak before dropping off at some distance from the end of the threaded section. The peak values each absorb about 10% of the total, the remainder being distributed across the threads. This confirms why box failure occurs in the last threads, or at the box end, especially if the taper of the threaded section reduces wall thickness.

The lengths and interference between the engaging conical gradient surface are selected relative to the thread interference when the connection is fully made up. Along the length of the threads (see FIG. 7 as an example), the torque that is absorbed is substantially level, thread by thread, in the midregion and the stress is therefore also substantially level. At the end threads, the necking down phenomenon that occurs outside the thread region introduces a substantial stress riser. The interfering conical gradient sections absorb a part of the stress by limiting the adjacent deformation as full engagement is approached and reached. While this is achieved by angle and diameter selection, the length of a conical gradient section is also important. If too short, it provides little stress distribution and if too long, it serves more as a seal than a stress gradient distributor.

In contrast, combinations in accordance with the present invention can withstand makeup torques at least five times greater than heretofore recognized as a limit. For 2-7/8" (7.3 cm) round, for example, a practical limit of 220-300 ft. lbs. (about 30-46 kg-meters) has been regarded as the stress boundary. In accordance with the invention, however, as much as 1,250 ft. lbs. (about 395 kg-meters) of torque have been applied. When a connection is made between male and female members arranged in accordance with the present invention, and the bearing members are threaded together, the increased bearing surface engagement at the threads increases the necessary makeup torque. When the position is reached at which the tapered sealing ring sections at each end of the threaded regions come into contact, makeup torque is further increased, beyond that required for thread engagement. Because of the greater tapers of the conical gradient surfaces or rings, they take up increasing amounts of torque, in relation to torque required for the thread engagement region. The angles of the conical surfaces, relative to the thread tapers, thus introduce a gradual but increasing outward deformation that resists the "necking down" tendency in the box members, allowing greater makeup torque before failure occurs. A further important loading force is the engagement, at final closure, between the flat ends of the boxes and the central radial ring about the pin member. This is estimated to provide a sealing pressure in the range of 10,000 psi on each face.

With the diverging end portions of the boxes under axial compression of substantial magnitude, the tendency is for the diverging lengths to expand radially as face-to-face contact with the center ring increases. The consequence would be a tendency to reduce thread interfere and conical gradient surface interference, especially close to the box end. However, winding the filaments at low angles to increase columnar strength in the diverging sections counteracts this effect, keeping the stresses in the chosen range.

The cumulative benefits of features in accordance with the invention are depicted in the sample tests reported in the Table of FIG. 8. In the conventional sample, at the top row, torque is limited to 210 ft. lbs. and internal pressure to 6,000 psi over 4 repetitions. Placing the box ends in face to face relation, under axial compressive load, the applicable torque reached 440 ft. lbs. However, by winding the boxes to include low angle filament components on ID and OD for greater columnar stiffness (sample 2), a torque increase to 600 ft. lbs. was achieved. With the insertion of a radial steel ring between the box faces (sample 3) and an O-ring, there is an increase in the number of repetitions attainable. With this configuration, the addition of a 5.degree. sealing ring adjacent the pin center and end of the boxes (sample 4), and further high angle filament windings for greater hoop strength, makeup torque is increased to 900 ft. lbs. and an internal pressure of 8,500 psi is withstood for 7 cycles. In sample 5, the addition of the 10.degree. tapers on the nose ends of the pin and the inner ends of the boxes gives a makeup torque reaching 1,250 ft. lbs., capable of confining up to 9,750 psi internal pressure as confirmed by tests.

Further increases in properties are achieved (sample 6) by putting a thread fill paste on the threads, especially one with fine chopped fiber reinforcement. This assists sealing without diminishing makeup torque, with the fibers acting as a thixotropic or thickening agent which assures more uniform coverage of the thread surface.

Thus, the cumulative effect of the various sealing features that are utilized aids in assured resistance to internal pressure, so that for the first time FRP tubular goods can be utilized at guaranteed pressures of 5,000 psi or greater. This is assured because of substantial repetitions of pressure cycles at 8,500 psi or greater internal pressure without failure. The thread engagement along the length of the threaded sections, of course, provides a primary barrier. In addition, the O-ring at each end, within the end conical surface region, further introduces a meaningful barrier. The limiting position defined by the box end engagement against the radial ring adds the high face-to-face pressure that aids sealing against both internal and external pressures.

Those skilled in the art will recognize that although API round threads are used, other thread types, including buttress threads, may be utilized. Also, the same arrangement can be used with different taper angles, and with buttress-type threads as well as round threads, and different lengths of taper. An internal shoulder for providing a flush central bore along the tubing or casing string can be used to eliminate internal turbulence and reduce sealing requirements. Where external pressures are the primary factor, such a shoulder configuration, which adds to required wall thickness, will not be needed.

The length and angle of taper can be varied dependent upon the characteristics of the composite as well as the needs of the particular application. However, it is preferred that the wall thickness of the divergent portion of the tubing or casing be substantially constant, at least in the region of the threaded section, to achieve the high levels of makeup torque that are attainable with the invention. Thread winding patterns for both columnar strength and resistance against hoop stresses enable the makeup torque to be absorbed. The central radial ring, together with the abutting end faces of the boxes, contributes substantially to effective sealing, and also provides a smooth surface resistant to abrasion by fibers interior to the matrix, since direct contact between composite surfaces results in surface irregularities that create extremely high friction and introduce wear that limit the reuse of the tubing or casing. Alternative engineering plastics can be used for such applications, however.

Referring now to FIG. 5, a cross-sectional view of an all-FRP connection, a construction similar to that of FIGS. 1 to 4 is utilized to advantage even though the results are below those attainable with the arrangement of FIGS. 1 to 4. The FRP pin 60 (again symmetrical about its center) has a pair of molded inserts 62 affixed in place to provide male thread profiles. The inserts 62, as will be described, may be fiber-reinforced or not. They are bounded in the central region by oppositely inclined conical sealing ring tapers 64, and at the nose ends by a tapered sealing ring 66, the angles of which may be the same as in the example of FIGS. 1-4. In the central transverse plane, a radial sealing ring 68 engages the end faces of first and second boxes 70, 72 respectively. An end shoulder 74 at the inner end of the boxes engages the adjacent nose end of the pin 60 through a radial seal ring 76 which may be of steel, an elastomer, or a layered laminate.

In FIG. 5, the wall thicknesses of the boxes 70, 72 are increased, to accommodate the end shoulder 74 that is at the inner end of the threaded region of the box. An added difference is in the use of the separate pre-molded threaded inserts 62 that are adhered to the pin 60. Using this approach, relatively high strength synthetic resin parts with male threads may be provided without filament winding or fiber reinforcement to engage threads on the opposing FRP body 70 or 72, although the remainder of the pin 60 is a filament wound structure. The insert 62 may be fitted onto the body 60 by splitting and rejoining the insert or body (not shown) by molding in place or by incorporating the conical gradient section in the insert. While an insert without fiber reinforcement (or with random fiber orientations) has lesser properties than achievable when continuous filaments are incorporated, as in a female thread structure, the net result is satisfactory for many purposes because the principal body is fiber-reinforced plastic.

On the other hand, because the inserts can be relatively small, filament winding steps can be carried out to provide male threads. As on example, impregnated filaments can be wound in thin layers on a male mold, and outer thread profiles can be precisely shaped by encompassing in a split female mold or threading into a female member for curing. The inner surface of this shell can then be filled to provide a conical inner diameter of the shape shown.

FIG. 6 depicts a combination in which connections may be made directly between a first box 80 having male threads and a second box 82 having female threads. This combination, also of substantial wall thickness or of upset construction, uses cut male threads 84 in the male member 80, but superimposes a metal threaded sleeve insert 86 against which the female threads 88 of the second box 82 may be engaged without surface incompatibility, while retaining significant male thread strength. The steel insert 86 may be locked against circumferential movement by radial pins or a longitudinal slot (not shown) to permit repeated make and break operations. The nose ends of the boxes 80, 82 do not seat directly on shoulders 90 of the other element, but engage radial rings 92 that are transverse to the central axis. The rings 92 may be loose or attached to one or the other of the elements. The first box 80 includes conical gradient rings 94, 96 adjacent the nose end and inner end respectively.

In the arrangement of FIG. 6, the boxes are shown to be of substantially constant outer diameter, and the thread tapers are angled relative to the axial length of the tubular goods, with the conical gradient rings 94, 96 angled relative to the angles of thread tapers at the larger and nose ends respectively of the first box 80. The second box 82 likewise has complementary conical rings 98, 100 adjacent its nose end and inner end respectively. O-rings 102, 104 are mounted in grooves in the nose end sealing ring sections of the first box 80 and second box 82 respectively. The box-to-box connection of FIG. 6 provides sealing and stress equalization as previously described, with the capability for repeated makeup and breakout. The tensile stress which the connection will accept is determined by wall thickness in the threaded region.

Although a number of different forms and modifications in accordance with the invention have been described, it will be appreciated that the invention is not limited thereto, but encompasses all modifications and alternatives within the scope of the appended claims.