The XL Systems approach to connector design is comprised of two important steps:

     1. Developing advanced analytical models of connector performance using the latest available engineering tools, including solid modeling software and finite element analysis (FEA) methods.

     2. Testing full-scale connectors to demonstrate and measure performance under a variety of loading conditions and, perhaps most importantly, to calibrate our analytical models.

Both steps are critically important to the connector design process.

Uncertainty in connector performance creates measurable risk for our customers. XL Systems has developed this robust connector design and testing process to significantly reduce the uncertainty in connector performance and allow our customers to better evaluate and manage risk in their drilling and development projects.

Viper Connector Design
The Viper connector is the first modern design, large diameter product line to reach the market in a number of years. Its advanced design incorporates several field-proven features including a hooked threadform, self-aligning stab profiles, stress reduction grooves to enhance fatigue performance and an external seawater exclusion seal. The design process also created some industry firsts for weld-on connectors, such as the revolutionary ViperLock antirotation device and the engineered weld neck which enhances weld inspection and improves pipe-to-connector weld fatigue performance.

The development of the Viper connector represents an investment in analytical modeling and full-scale physical testing unprecedented in the large diameter connector industry. FEA models were created and analyzed for each of the 38 designs that make up the full product line. More than 70 full-scale physical tests were completed to measure connector performance and to calibrate the analytical models. The result is the most thoroughly analyzed and tested product available in the large diameter weld-on connector market.

Wedge Thread Connector Designs
XL Systems large diameter wedge thread connectors include integrally threaded products such as XLF and XLC-S, and weld-on connectors such as XLW, XLF-RB and XLC-S-RB. Each of the XL Systems wedge thread connectors uses a tapered wedge thread design. The tapered thread allows for a deep stab, requiring fewer turns from stab to full makeup. The wedge thread stores make-up torque energy, providing high resistance to connector back-off and excellent resistance to connector damage from over-torque.

XL Systems wedge threads each have a dovetail thread shape with negative load flank and stab flank angles. The dovetail threadform locks the pin and box threads together and effectively eliminates thread jump-out under extreme loading conditions.

All XL Systems wedge thread connectors use metal-to-metal pressure seals. XL Systems pioneered the use of metal seal technology in large diameter casing and conductor connectors.

XL Systems has produced large diameter wedge thread connectors for conductor and casing applications since 1985. Our approach to connector design has been consistent over the years, with an emphasis on both analysis and full-scale physical testing to characterize connector performance. Significant analysis and physical test data is available for our wedge thread connector products.