Unveiling the root cause failure 3-1/2" parted drill in onshore environment

Authors

DOI:

https://doi.org/10.15587/1729-4061.2026.352272

Keywords:

sulfide stress cracking, hydrogen embrittlement, sulfur content, drill pipe failure

Abstract

The object of this study is HSS API 5DP Gr 105 which has been used as drill pipe and was found leak during drilling activity, causing a delay in the delivery of drilling products. The interaction among the high partial pressure of H2S, a high-hardness material, and the injection of high-density completion fluid (HDCF) remains poorly understood, leading to sulfide stress cracking. Despite offering substantial benefits, the detected trace amounts of hydrogen and sulfur indicate a localized corrosion, which can lead to unprecedented drilling shutdowns and consequently impose greater operational costs. Recently, the API 5DP 3-1/2’’ drill pipe experienced failure with a significant hardness value of 26 HRC, exceeding the standard specified by NACE MR 0175. The material was in service in rich H2S gas well, where HDCF was injected to maintain hydrostatic pressure and serve as a control fluid. Multiple field and laboratory investigations have been undertaken to identify the root cause of this failure, including visual inspections, macrophotography, chemical composition analysis, completion fluid testing, tensile testing, metallography, and SEM-EDX analysis. The shear-slip and step-like markings on the failed material clearly indicate a brittle nature, correlating with a noticeable tensile strength of 907.80 MPa and an elongation limit of 18.18%. The increase in hardness beyond 22 HRC indicates susceptibility to sulfide stress cracking (SSC) where the hydrogen permeation increases with the increasing H2S partial pressure. These facts align with water chemistry analysis results to show S2– and HS–levels exceeding one ppm. Additionally, metallography reveals intergranular cracking in the tempered martensite, likely initiated at a local stress concentrator before propagating and confirmed by scanning electron microscope (SEM) images

Author Biographies

Sidhi Aribowo, Universitas Indonesia

PhD Student

Department of Metallurgical and Materials Engineering

Johny Soedarsono, Universitas Indonesia

Doctor of Engineering, Professor

Prof Johny Wahyuadi Laboratory

Department of Metallurgical and Materials Engineering

Sopar Mangarapot Simanullang, Pertamina Drilling Services Indonesia

Assistant Manager Quality Control

Ario Oktora, Pertamina Drilling Services Indonesia

Senior Supervisor QC 5th Area

Warneri Warneri, Pertamina Drilling Services Indonesia

Manager Rig Operation V

Rini Riastuti, Universitas Indonesia

Doctor of Engineering, Senior Lecturer

Prof Johny Wahyuadi Laboratory

Department of Metallurgical and Materials Engineering

Agus Kaban, Universitas Indonesia

Doctor of Engineering

Prof Johny Wahyuadi Laboratory

Department of Metallurgical and Materials Engineering

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Unveiling the root cause failure 3-1/2" parted drill in onshore environment

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Published

2026-02-27

How to Cite

Aribowo, S., Soedarsono, J., Simanullang, S. M., Oktora, A., Warneri, W., Riastuti, R., & Kaban, A. (2026). Unveiling the root cause failure 3-1/2" parted drill in onshore environment. Eastern-European Journal of Enterprise Technologies, 1(1 (139), 59–69. https://doi.org/10.15587/1729-4061.2026.352272

Issue

Vol. 1 No. 1 (139) (2026): Engineering technological systems

Section

Engineering technological systems

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Copyright (c) 2026 Sidhi Aribowo, Johny Soedarsono, Sopar Mangarapot Simanullang, Ario Oktora, Warneri Warneri, Rini Riastuti, Agus Kaban

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