Design of continuous circulation sub for gas drilling and the mechanical analysis on the sub body

Gas drilling, as an important part of underbalanced drilling, can increase drilling speed. But in the process of conventional gas drilling, it tends to cause cutting settlement, borehole collapse, sticking and other safety hazards because gas circulation has to be interrupted. Therefore, this paper presents a continuous circulation sub which can be installed and removed easily. With this sub, gas circulation will not be interrupted when drilling tools are connected and removed. This sub is composed of body, main valve, bypass valve and side entry sub. The structure design of its key components (i.e. main and bypass valves) were fulfilled. Based on statics analysis on the sub body, its force situations under extension, torsion and internal pressure were simulated by using the ANSYS finite element analysis software. It is shown that its stress distribution trend is consistent with its elastic–plastic mechanics analysis results. Stress concentrates around the two round holes of the sub body, and the maximum deformation amount is still at the stage of elastic deformation. The analysis results are in line with the elastic–plastic mechanics analysis results, and the requirement of body strength is satisfied. This paper provides a new program to guarantee the drilling safety of extended-reach wells, underbalanced wells and narrow-density window wells.