Performance Considerations

The ability of a kelly to turn the drill string depends on how well it fits into the kelly
bushing. More specifically, it depends on the clearance between the drive flat
surfaces and the rollers in the kelly bushing. For the kelly to perform properly, this
clearance needs to be kept to a minimum.

Kellys most commonly wear out due to a rounding-off of the drive corners, as shown
in Figure 1 (new kelly with new drive assembly) and Figure 2 (worn kelly with worn
drive assembly) .

Figure 1

This rounding is a natural wear process caused by the compressive force of the
rollers on the drive flats and accelerated by rotary torque.
 Figure 2

As rounding progresses, it further accelerates the wear process by increasing the

For minimal rounding, there must be a close fit between the kelly and the roller
assembly, with the rollers fitting the largest spot on the kelly flats. Manufacturing
techniques and rig operating practices play important roles in determining this fit.

Both square and hexagonal kellys are manufactured either from bars with an "as-
forged" drive section, or from bars with fully-machined drive sections. While forged
kellys are cheaper to manufacture, machined kellys offer the following features,
which tend to result in longer useful life:

Machined kellys, unlike forged kellys, are not subject to the metallurgical process of
decarburization, or decarb. Decarburization leaves a relatively soft layer of material
(approximately V16" thick) on the drive surface that can accelerate the rounding process
and increase the potential for fatigue cracks;

Machined kellys, because they are made to closer tolerances than forged
kellys, are more likely to closely fit the roller assembly throughout their
length.
A square drive section normally tolerates a greater clearance between flats and rollers than does
a hexagonal drive section.

To minimize rounding, rig personnel should follow these guidelines (Brinegar, 1977):

Always use new drive-bushing roller assemblies to break in a new kelly;

If the rollers are adjustable, adjust them to provide minimum clearance;

Frequently inspect and periodically replace drive assemblies to ensure that

Lubricate drive surfaces to reduce friction and binding at the rollers, and to
allow the kelly to slide freely through the kelly bushing.

Because of the high-quality steels used in manufacturing kellys, fatigue failures are not often a
problem. Nevertheless, kellys should be regularly inspected for cracks and other signs of wear,
particularly within the threaded connections, in the areas where the flats join the upper and lower
upsets and in the center of the drive section.

The areas of highest stress concentration — and therefore the most likely locations
for fatigue failure — are the areas where the drive flats join the upper and lower
upsets.

In general, the stress level for a given tensile load is less in the drive section of a
hexagonal kelly than in the drive section of a square kelly of comparable size.
Hexagonal kellys are thus likely to last longer than square kellys before failing under
a given bending load.

Kellys can become crooked or bent due to improper handling. Examples of

dropping the kelly;

misaligning the kelly in the rathole exerting a side pull on the kelly;

using poor tie-down practices during rig moves;

not using the kelly scabbard;

using improper loading/unloading techniques.

Depending on where the bend is located, it may cause fatigue damage not only to the kelly but to
the rest of the drill string, and can also result in uneven wear on the kelly bushing.

Unusual side motions or swaying of the swivel are good indicators of a crooked kelly.
A good field service shop has equipment for straightening bent kellys, making this an
easily-corrected problem.
Up to a certain point, a worn kelly can be repaired either by reversing the ends, (
Figure 3 ) or by remachining it to a smaller size.

Figure 3

Auxiliary Equipment
A kelly saver sub should always be run between the kelly and the top joint of drill
pipe. This protects the kelly's lower connection threads from wear, as joints of drill
pipe are continually made up and broken out. A saver sub is much less expensive
and much easier to replace than the kelly itself, and it can also be equipped with a
rubber protector to help keep the kelly centralized and to protect the top joint of
casing against wear.

A kelly cock is a valve installed above or below the kelly, which prevents fluid from
escaping through the drill string if the well should begin to flow or "kick." As an extra
well control precaution, an upper kelly cock (having left-hand threads) should be
installed directly above the kelly, while a lower kelly cock (having right-hand threads)
should be installed below the kelly. Installing two kelly cocks ensures that at least
one of them is always accessible, regardless of the kelly's position.
Automatic check valves, designed to close when the mud pumps are shut off, are
also available, and can be installed below the kelly to prevent mud from spilling onto
the rig floor during connections.