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SUBSEA WELLHEAD CONNECTORSDXe™
• Testedwithnoboltsinstalled-loadpathisthroughtheconnectorupperbody,latchsegmentsandwellheadandnotthebolts
• Maximizesthedrillingvesselwatchcircle• Nogasketleaksduringworstcasesurvivalloadtesting(allload
cases)at20,000psiborepressure• Increasedhubfacecontactareaprovideshighbendingcapacity• Self-aligningprimaryandsecondaryDXeringgasketsstandard• Designiscompatiblewithexistingblowoutpreventerhydraulic
controlsystems• CanbeconfiguredforH4andSHDH4lockingprofile
Illustrationshown:DXe-30ConnectorwithDXelatchingsegment
Latch Segmentwith DXe locking
profile
Primary Unlock
Port
LowerBolts
Latch Segment Spreader
Ring Gasket
Retainer
Annular Piston/Cam
Ring
Secondary Unlatch Piston
DXe Ring Gasket
Upper Split Ring Retractor
UpperBolts
Lower Split Ring Retractor
Primary Lock Port
Upper Body
The DXe Wellhead Connector delivers a long service life with reliable field performance.
DXe™ WELLHEAD CONNECTOR
F E A T U R E S B E N E F I T S• 20KsiDXe-30isAPI17TR8approvedby13PandBSEE
• FullscaleloadtestedtoAPI16A4thEditionPR2andAPI17TR7qualificationrequirements
• DXegasketsqualifiedtoAPI6APR220,000psi(withgas),35°to400°F and 11,000 ft water depth
• Uniqueproprietaryhighlyengineeredmandrellockingprofileprovideslongestandunmatchedfatiguelifeandhighestloadcapacityproventhroughfullscaletesting
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DXe-27 SpecificationsRatedWorkingPressure(Ksi)Swallow(inches)MinimumAddedStackHeight(inches)MaximumOutsideDiameter(inches)Weight(lbs)FluidVolumetoLatch(gal)FluidVolumetoUnlatch(gal)FluidVolumeforSecondaryUnlatch(gal)MaxLatchingPressure(psi)
15
23.32 22.13 54.88
17,800 7.39
11.2613.663,000
DXe-30 SpecificationsRatedWorkingPressure(Ksi)Swallow(inches)MinimumAddedStackHeight(inches)MaximumOutsideDiameter(inches)Weight(lbs)FluidVolumetoLatch(gal)FluidVolumetoUnlatch(gal)FluidVolumeforSecondaryUnlatch(gal)MaxLatchingPressure(psi)
15 or 20
27.49 27.50 64.53
38,500 14.5320.5025.643,000
Ideallysuitedforstandardanddeepwaterdrillingapplications,Dril-Quip’sDXe-27WellheadConnectorisdesignedfor27"O.D.wellheadandisavailableina15,000psiworkingpressure.
Ideallysuitedforstandardandhighbendingdeepwaterapplications,Dril-Quip’sDXe-30WellheadConnectorisdesignedfora30"O.D.wellheadandisavailableina20,000psiworkingpressurerating.AnadapterkitisavailabletoconfigureaDXe-30tomatewitha15,000psi27"O.D.wellhead.
DXe-27 Connector
DXe-30 Connector
Capacities based on 3-D FEA, and validation testing with the following assumptions:• Internal pressure acting on 18-3/4" nominal bore with pressure end load included• Preload at 3,000 psi locking pressure
Contact Dril-Quip Engineering for capacities with various levels of tension/compression
Capacities based on 3-D FEA, and validation testing with the following assumptions:• Internal pressure acting on 18-3/4" nominal bore with pressure end load included• Preload at 3,000 psi locking pressure
Contact Dril-Quip Engineering for capacities with various levels of tension/compression
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Bending Moment (ft-kips)
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Bending Moment (ft-kips)
Rated Capacity (67% of yield) Extreme (80% of yield) Survival (100% of yield)
Rated Capacity (67% of yield) Extreme (80% of yield) Survival (100% of yield)
RatedCapacity
ExtremeCapacity
SurvivalCapacity
RatedCapacity
ExtremeCapacity
SurvivalCapacity
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Ring Gaskets are Self-AligningTheDXeConnectorringgaskethasbeendesignedwithaselfaligningfeature,whileprotectingtheprimaryandsecondarysealingsurfaces.Thisisaccomplishedwithauniquemetalsealingsurfacethatfeaturesupperandloweralignmentguidance.TheringgasketRetainerMechanismisspringloadedforautomaticringgasketretention.Theretentionmechanismreleasestheringgasketwithhydraulicpressure.IdealforinstallinggasketsontowellheadsusingROV.
Primary and Secondary Metal-to-Metal Sealing
Dril-QuipDXe™seriesConnectorsisauniqueprofilethatmateswithaproprietaryDXeringgasket.ThisDXesealingprofilefeaturesapairofindependentmetal-to-metalsealingsurfaces,aprimaryandsecondindependentsealingsurface.
TheprimaryDXegasketisusedduringnormaloperationsandprotectsthesecondarymetal-to-metalsealingsurface.Intheeventofdamageorleak,asecondaryDXeringgasketcanbeinstalled.Thesecondaryringgasketutilizesthesecondarysealingsurfaceforareliablemetal-to-metalseal.
Internal Pressure Rating - 20,000 psiExternal Pressure Rating - 5,000 psiWater Depth Rating - over 11,000 ftTemperature Range - 35° F to 400° F
TheDXe ringgaskethasalignmentguidesthatengagetheringgasketsurfaceintheupperbodyoftheconnector.Thesealignmentguidesassistalignmentwhileprotectingthemetalsealingsurfaces.
Downwardmovementoftheconnectorandthealignmentguidesautomaticallyadjuststheringgasketintothepropersealingposition.Bothalignmentguidesassurethesealingsurfacesarenottouchedasthismovementoccurs.
Astheconnectorlandsout,theringgasketsettlesintothesealingpositionandispreloadedwhentheconnectorislockedandthelatchsegmentsareenergized.
H i g H l y E n g i n E E r E d U n i q U E r i n g g a s k E t d E s i g n
DXe ConnectorUpper Body
DXe ConnectorUpper Body
DXe ConnectorUpper Body
UpperAlignmentGuide
UpperAlignmentGuide
LowerAlignmentGuide
LowerAlignmentGuide
PrimarySealing
PrimarySealingHigh Pressure
Subsea WellheadHigh PressureSubsea Wellhead
High PressureSubsea Wellhead
Primary Ring Gasket Secondary Ring Gasket
H i g H l y E n g i n E E r E d U n i q U E r i n g g a s k E t d E s i g n
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DXe™ Connector and Assembly Bolt Standards
Somewellheadconnectorsusedinthesubseadrillingindustryhavealoadpaththatdrivesappliedpreloadthroughaseriesofboltsrequiredforassembly.Theseboltsareexposedtoseawaterandexperiencecyclicloadsfromthedrillingriserandtensionloadsgeneratedbyinternalpressure.Fatiguecyclescoupledwithmaterialimperfections,materialstrength,toughnessandcoatingvariationscometogethertoformcracksthatcanpropagatethroughthethreadsonthebolt,causingittobreak.Beingexposedtoseawateracceleratesthecorrosionprocess.
Inrecentyears,boltsintegraltosubseaequipmenthavefailedduetothisphenomenon.In2013,theU.S.DepartmentoftheInterior(DOI)startedaninvestigationafternumerousboltsoninserviceconnectorswerefoundtobebroken.Additionalindustrygroupsinvestigatedmetallurgicaldatatodetermineifalloysusedintheheavysteelboltsareductileenoughtosurviveharshsubseaenvironments.AsaresultAPIhasreleasedAPI20Etomandatebolttraceabilityandestablishstandardsforquality.
TheDXeConnectordesignaddressesthisproblem.Itfeaturesradiallatchsegmentsthataredrivenintomatingloadprofileswithanannularpiston/camring.Thisactionprovidesthenecessarypreloadrequiredbetweenwellheadhubfaceandtheupperbodyoftheconnector.Whentheconnectorislockedandinoperation,theloadpathtravelsthroughtheconnector,thewellheadmain
bodyandthelatchsegmentsviathelockingprofile.Asthesegmentlatchestothewellhead,itclampstotheconnectorupperbodysimultaneouslyandcreatesaclosedloopwithanearstraightloadpath.Anyloadsappliedtotheconnectortravelonlythroughthesegmentsthataremadefromductilealloysteelanddonotpassthroughbolts.BoltsintheDXeConnectordonotseecyclicstressesattheoperatingloadsandarenotsubjectedtothefailedboltproblemsassociatedwithotherindustryconnectors.
TodemonstratetheDXeConnectorhasnoboltsintheloadpath,acombinedloadtestfollowingAPI16Aspecificationswasperformed.Thistestconsistedoflockingaconnectortoateststumpwithstandardlockingpressure.Theteststumphada30"O.D.DXewellheadlockingprofile.Lockingpressurewasbledoffandthelockingcircuitwasvented.Allexternalattachmentboltswereremoved,includingboltsintheupperandlowerbodies.Astructuralloadtestwasperformed,whichincludedtension/compressionto1.0MMLbscombinedwithbending,andpurebendingtoasmuchas8.2MMft-lbs.Theloadtestswereperformedbothwithoutborepressureandwithborepressureappliedinincrementsof5,000psiupto20,000psi.The"no-bolts"connectorsuccessfullypassedeachtestanddemonstratedidenticalperformancewiththestandardconnectortestedwithalloftheboltsinstalled.
Bolts not in the load path
Bolts not in the load path
Connector Bolts Removed
Piston Up (Bending Moment Applied)
nO BOlts tEst
DXe Connector Load Path
DXe Connector Load Test with No Bolts
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Verification AnalysisHighlysophisticateddesigntools,anextensive3-Dadvancedfiniteelementanalysis(FEA)wereusedtooptimizeeverydetailoftheconnectorlockingprofile.Theanalysissimulatesconnectorinstallationandoperatingconditionswhichincludespreloadingandapplicationofinternalandexternalloads(pressure,bending,tension/compression,andloadcombinations)whileobservingthestressbehaviorthroughouttheconnectorcomponents.Particularattentionhasbeenpaidtoachieveuniformloaddistributionandminimizingpeaksurfacestressesthataredirectlyrelatedtothefatigueperformanceoftheconnector.ThismethodologyhasallowedthecompanytodeveloptheDXe™lockingprofile.Theanalysisandtheresultshaveenabledthecompanytocreateawellheadconnectordesignwithhighloadcapacityandhighfatigueresistance,allwithinthesmallestpossibledimensionalenvelope.
Validation Testing - StructuralDril-QuiputilizesitsownHorizontalandVerticalTestMachinestoperformphysicalvalidationtestingofitswellheadconnectors.Atestspecimenthatconsistedofawellheadconnector,18-3/4"wellhead,lockedintoa36"conductorhousingwasassembledandinstalledintothecompany'sHorizontalTestMachine.Testswereconductedusingnormal,extremeandsurvivalloadconditions,perAPI17TR7requirements.
StraingaugeswereinstalledatallcriticallocationsofthetestspecimenanddatacollectedforcomparisontostrainsfromtheFEAat thesamelocations.Bendingmomentswereappliedtothespecimenwithavarietyofcombinedloads.Testresultswerecollectedandacomparisonof3-DFEAandvalidationtestresultsindicate aclosecorrelationbetweenanalysisandtestdata.Variationsbetweenanalysisandtestingresultswereattributedtoseveralidealizedassumptionsmadeintheoriginal3-DFEA.Factorssuch asstraingaugeerror,gaugeorientation/alignment,componenttolerances,out-of-roundnesseffects,
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Rated Capacity (67% of yield) Extreme Capacity (80% of yield) Survival Load (100% of yield)
C O n n E C t O r v E r i f i C a t i O n a n d v a l i d a t i O n t E s t i n g
RatedCapacity
ExtremeCapacity
SurvivalCapacity
2-D and 3-D FEA Analysis Used In Design
Dril-Quip’sHorizontalTestMachinewithaWellheadandaConnectorSpecimen
3-DFEAAnalysisShowingNormal,ExtremeandSurvivalCapacitiesOn20KsiDXeConnectorwith30”WellheadProfile
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positioningofcomponentsrelatedtotheplaneofbending,non-uniformityinmaterialpropertiesandfrictioncontributedtothevariationsrecorded.
The3-DFEAwasperformedtogeneratecapacitychartswhenNormal(66.7%ofyield),Extreme(80%ofyield)andSurvival(100%ofyield)loadconditionsareappliedtothewellheadsystem.Thesethreeloadconditionsareappliedinboththeverificationanalysisandphysicalvalidationtestingofthewellheadsystemandisbelievedtobethemostaccuraterepresentationofconnectorperformancetodate.
StructuraltestingisonlyonecomponentoftheCompany'soverallvalidationprogram.Thesecondvalidationcomponentisarigorousfatiguetestingprogram.
Physical Validation Testing - Fatigue ResistanceTheaimoffatigueresistantdesignistoensurethestructureconsidered,inthiscaseawellheadconnectorlockedtoawellheadsystem,hasanadequatefatiguelifetomeetthecustomersperformancestandardsthroughoutthelifeoftheproject.Toproperlyevaluatefatiguecharacteristicsofthewellheadsystemandwellheadconnector,met-oceandata(waveandcurrentprofiles),drillingvesselmotionsandsoilconditionswerecollectedonspecificwellsitesfromseveralseveredrillingcasesaroundtheworld.Aglobalriseranalysiswasperformedtoidentifyarepresentativefatiguespectrumandapredictedfailurepoint.Thedatawasusedtodevelopandconductafullscalefatiguetestprogram.
Afatiguetestmachine,designedandbuiltbyDril-Quipwasusedtoacceleratethefatiguephenomena.Thesametestspecimenusedinthestructuralvalidationtest(acompletewellheadsystemincludingthewellheadconnector)wasusedforthistest.Thespecimenwasinstalledinthemachine,straingaugeswereappliedandpressurewasintroducedinthebore.
Themachinewasoperatedwithaneccentricloadthatintroducedanalternatingstressleveltothespecimen.Achangeinthevibrationspectrumwasmonitoredforanyvariationthatwouldindicatetheonsetofafatiguecrackthatwouldultimatelyresultinapressureleak.Continuouscyclicstresswasappliedtothespecimenuntilthepredictedfailurepointwasreachedinthe5thweekoftesting.Therewasnochangeinvibrationspectrumorleakageoccurrence,sothetestwascontinueduntil60millioncycleswereapplied,anumberthatfarexceededanymaximumfatigueconditionsevaluated.Thetestspecimenwasdisassembled,andinspectionofallcomponentsindicatednofatiguedamagewasfound.
ItisbelievedthatDril-Quipisthefirstcompanytoapplyrigourousfatiguetestprogramtoacompletewellheadsystemandconnector.ThisvalidationmethodologyisanotherexampleofDril-Quip'scommitmenttodelivertechnologicalinnovationwithreliableperformance.
WellheadConnector,HighPressureWellheadandConductorSpecimenInDril-Quip’sFatigueTestFixture
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W O R L D W I D E S A L E S & S E R V I C E
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TIWWestern HemisphereTIW Corporate HeadquartersP.O. Box 35729Houston, Texas 77235Tel +1 713 729 2110Fax +1 713 728 4767
DRIL-QUIP
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