Published on January 4, 2008
SPE 37646 Extended Reach Composite Materials Drill Pipe: SPE 37646 Extended Reach Composite Materials Drill Pipe G. Hareland and W. C. Lyons, New Mexico Inst. of Min. and Tech. D. D. Baldwin and G. Briggs, Lincoln Composites R. K. Bratli, Saga Petroleum a.s. SPE 37646 - Outline Extended Reach Composite Materials Drill Pipe: SPE 37646 - Outline Extended Reach Composite Materials Drill Pipe Objective Introduction Composite Materials Drill Pipe Design/ Description/Manufacturing Extended Reach 5 1/2” Drill Pipe Properties Advantages and Limitations Technical Discussion Torque and Drag - Comparison of Steel vs Composite 5 1/2” Drill Pipe in Oil and Water Base Muds Conclusions Objective: Objective The objective of this paper is to present a new composite material design drill pipe, show some advantages and limitations and present a sample application. Introduction: Introduction Current extended reach is limited by torque, drag and hydraulics Using a light weight drill pipe will reduce the torque and drag to the point where it might float in the mud Number of platforms in field development might be reduced Marginal fields might be found economical due to larger drainage area from existing platforms The cost of the new composite material drill pipe is higher than steel pipe, but the overall economics of the new composite pipe is better in some cases Technical Discussion: Technical Discussion = drag force (lbs) = specific weight of pipe (lb/ft^3) = specific weight of mud (lb/ft^3) = volume of drill pipe (ft^3) = gravitational constant (ft/s^2) = angle of inclination (degrees) = coefficient of friction (dimensionless) Technical Discussion: Technical Discussion =drill pipe outer diameter (ft) =drill pipe torque (ft-lbs) Composite Drill Pipe Description Flexible Drill Pipe : Composite Drill Pipe Description Flexible Drill Pipe Properties of Composite Materials Drill Pipe: Properties of Composite Materials Drill Pipe Properties of Composite Materials Drill Pipe: Properties of Composite Materials Drill Pipe Extended Reach 5 ½” Drill Pipe Properties (Single Load Values at Minimum Build Radius) End Fittings 4140 Steel 4140 Steel Titanium Length - ft (30-50 ft possible) 30 42 42 ID-in 4.250 4.250 4.250 Tube OD-in 5.530 5.530 5.530 Tool Joint OD-in 7.200 7.200 7.200 Weight-lbs/ft (incl. Tool joints) 12.04 10.50 8.78 Zero Net Weight @ Mud Density -lbs/gal 20.3 18.42 15.39 Minimum Build Radius-ft 1,000 1,000 1,000 Ultimate Tensile Load-lbs 200,000 200,000 200,000 Operating Tensile Load-lbs 100,000 100,000 100,000 Ultimate Compression Load-lbs 200,000 200,000 200,000 Operating Compression-lbs 60,000 60,000 60,000 Ultimate Torque Rating-ft lbs 55,000 55,000 55,000 Operating Torque Rating-ft lbs 24,000 24,000 24,000 Ultimate Internal Pressure Rating-psi 6,000 6,000 6,000 Operating Internal Pressure Rating-psi 3,000 3,000 3,000 Ultimate External Pressure Rating-psi 4,000 4,000 4,000 Operating External Pressure Rating-psi 2,000 2,000 2,000 Temperature Rating-degrees F 230/325 230/325 230/325 Properties of Composite Materials Drill Pipe: Properties of Composite Materials Drill Pipe Properties of Composite Materials Drill Pipe: Properties of Composite Materials Drill Pipe Composite Drill Pipe Design: Composite Drill Pipe Design Drilled and Pinned System Joining the End Connectors to the Composite Tube Body Two Rows of Pins are Held in Place by the Outer Sleeve, which also Provides Tonging Surface The Interior of the Composite Tube Body has a Permeation Barrier, which Allows the Pipe to Contain the Required Internal Pressures The Exterior is Protected by Centralizers or Wear Knots, which Keep the Tube Body off the Wall of the Hole and Reduce Buckling under Compressive Loading Composite Drill Pipe Design: Composite Drill Pipe Design The Composite is a Filament Wound Hybrid Carbon/Glass/Epoxy Fiber Layer which is Wound at Angles from 5 to 85 Degrees The Centrilizer Areas are Gradually Built up to the Required OD Using Fiberglass Cloth which Allows for the Installation of the Metal Wear Knots The Resin System used will Determine the Maximum Operating Temperature for the Pipe and it’s Corrosion Resistance Current Tool Joints are Fabricated Using AISI 4140 Steel, and with the Installed Sleeves, Provide a Conventional Tonging Surface Composite Material Drill Pipe Manufacturing Process: Composite Material Drill Pipe Manufacturing Process The Composite Materials Drill Pipe is Manufactured by a Typical Composite Material Windling Process Carried Out in Lincoln Composites Manufacuring Facilities Located in Lincoln, Nebraska, USA. Advantages and Limitations: Advantages and Limitations Advantages Light weight High strength to weight ratio Improved drill bit control and stability Increased horizontal reach Simplified handling procedures Increased bore size with non-magnetic material for surveying Corrosion resistant Limitations Cost Outer layer erosion Tool joints/composite connection interface Handling system design required High temperature Drag - Example Comparison (Steel vs Composite): Drag - Example Comparison (Steel vs Composite) Torque - Example Comparison (Steel vs Composite): Torque - Example Comparison (Steel vs Composite) Torque - Example Comparison (Steel vs Composite): Torque - Example Comparison (Steel vs Composite) Conclusions: Conclusions 1. New composite drill pipe design concepts have been developed, field tested and operated in limited commercial applications. The testing and operational applications have yielded excellent results. 2.Current composite drill pipe designs utilize AISI 4140 steel tool joints and mixed layers of carbon and glass fibers in the pipe body between the tool joints. 3.New 42 foot long composite drill pipe designs utilizing titanium tool joints have an overall specific weight of 15,4 ppg equivalent. Conclusions: Conclusions 4.The new composite drill pipe designs can significantly reduce drill pipe applied torque and axial drag forces. The example shown herein shows a 5 to 15 reduction in applied torque. 5.The new composite drill pipe designs can have an important impact on overall oil and gas field development economics in that fewer numbers drilling locations should be required. This is due to the expected increase in horizontal reach that will be achieved with this new technology. 6.Continued field testing and development plans are under way that will quantify ultimate lateral reach distances, pipe body fatigue life, and life of the wear resistant coating.