Composite Drill Pipe for Superior Performance Dr. Jaromir Ufer, Voith Composites GmbH & Co. KG
Structure Voith and Voith Composites CDP: Overview and Scope of Development Motivation Principal Design and Properties Business Case Szenarios Qualification Process Testing Outlook
Voith Group One of the Biggest Family owned Companies in Europe In more than 60 Countries 19,000 Employees5Markets R&D Ratio 4.9 % Family-owned since 1867 Sales 4.25 billion
Voith Composites Business Lines Exploration Drill pipes and casings for the Oil & Gas Industry Machinery Rolls & shafts for Paper, Film and Solar Industries Transport Structural components and preforms for Automotive and other Transport Industries
Voith Composites - Services Project Feasibility Concept & Design Prototyping Production Component concepts & ideas (fiber and load path suitable) Technical feasibility analysis Component engineering Component optimization Process development CFRP machine design Tool concepts Process simulation Prototype production Sampling Tool engineering Quality assurance CFRP machine constr. Technical center for small scales Filament winding for small to medium scales Fully automated production line (direct fiber placement) for large scales
Composite Drill Pipe (CDP) Overview and Scope of Development CDP @ DEA Rig T160 Composite (lightweight) solution for drill pipe Compatibility with standard equipment Standard tool joint connection (composite pipe combined with metal tool joint) Easy service procedure (renewal of wear protection)
Motivation 120% 100% 80% 60% 40% 20% 0% -70% Composite S-135 Weight in MUD (1,13kg/m³) Reduction of weight in mud by 70-80% Density CFRP: 1,6to/m3 (drill pipe mean with metal interface 2,4to/m3) Very high stiffness and strength Reduction of required torque due to very low friction Low thermal conductivity Transparent to X-ray
Principal Design External Wear Protection Layer (renewable) Standard Tool Joint Connection (Steel) Carbon Fiber Pipe-Body Interface Design with Voith IP Internal Barrier Layer
Patented Design of interface
Simulation Simulation of the mechanical behavior of the CDP Simulation of the load transmission between composite pipe and steel tool joint Calibration of the models and validation with component tests
Hook Load [kn] Comparison Hook Load and Thermal Conductivity - 5 7/8 Composite vs. Steel Drill Pipe 3000 2500 2000 1500 1000 500 0 S-135 Composite Hook Load in a 25,000ft (7,62km) Vertical Hole Available Overpull Capacity Far smaller hook load compared to steel Higher overpull capacity compared to steel Very good thermal insulation compared to metals (far smaller thermal conductivity)
Tensile Strength [kn / kg] Torsional strength [Nm / kg] Weight Specific Comparison 5 7/8 Composite vs. Steel Drill Pipe 25 20 15 500 400 300 Higher tensile strength compared to steel 10 5 0 S-135 Composite Strength to Weight in Air Strength to Weight in Mud 200 100 0 S-135 Composite Torsional Strength to Weight Torsional Strength to Weight in Mud Significant higher torsional strength Composites have a high resistance against cyclic fatigue loads
MD [m] MD [m] MD [m] Load estimation for a 10km Well (3km TVD) Comparison Steel vs. Composites Torque [Nm] Hook load [t] for pulling out of hole Hook load [t] for sliding drilling 5-1/2 Steel Drill Pipe Composites Drill Pipe Loads on CDP are significantly lower than for steel drill string due to lower weight of the string The specific buckling resistance of composites drill string is comparable or higher than for the steel string (due to the high stiffness and low weight of composites)
Business Case Scenarios for the CDP CDP @ DEA Rig T160 Enabling ultra extended reach drilling Stretching the standard drilling length using existing equipment Upgrade solution e.g. for small drilling rigs Operational excellence, driving productivity of existing capex Significant smaller heat conductivity compared to steel Extending the BHA service interval (if cooled MUD is used) Lowering energy costs (reducing friction / torque, hookload and cooling power) Possible integration of wires for signal and power
Qualification Process No applicable standard for composite drill pipe available Qualification process of New Technology Development of Qualification Plan
Testing Pyramid for Qualification of CDP Fullscale tests: e.g. system tests Subcomponent tests: e.g. interface connection, pipe body Coupon tests: e.g. test of laminate properties, abrasive wear,... Material tests: e.g. pure resin test
Testing of CDP (1/3) Tensile Testing of prototypes Connections of metallic joint and composite laminate were successfully tested Specimen with and without pre-treatment (storage in MUD) show a very good performance Test results were used to calibrate the calculation models Qualification of technology in cooperation with DNV for certification CDP specimen in tensile testing machine
Testing of CDP (2/3) Impact Testing of Composite Pipe Body Subcomponent specimen were impacted with a 2kJ impact in lateral and axial direction No degradation in torsional behavior (stiffness) after impact The laminate and the tool joint connection were able to transfer high torsional loads after the impact on them (strength)
Torque / max. Torque Torque Test Validation of FE-Analysis 120% Test of the torsional stiffness after degradation of the laminate Good agreement of the result with the FE Simulation Validation of the simulation model 100% 80% 60% 40% 20% 0% 0% 20% 40% 60% 80% 100% 120% Strain / max. Strain Force Test result FE-Analysis
Testing of CDP (3/3) - Handling Tests CDP @ DEA Rig T160 Handling Interface Connection of metal-composites pipe, composites-composites Torque Lateral pressure Very positive feedback of drilling crew and engineers
Outlook Acquisition of potential customer Clarification of technical needs in detail Finishing development wear- Optimization of design and production (interface, liner, protection) Development and test of service procedure (QA, renewal of wear protection etc.) In-field testing Start of serial production
Thank you very much Contact: Dr. Jaromir Ufer Head of Business Line Exploration Voith Composites GmbH & Co. KG Daimlerstraße 27 85748 Garching bei Muenchen, Germany Tel +49 89 32001 854 Fax +49 89 32001 801 Mobile +49 151 43842129 Jaromir.Ufer@voith.com www.voith.com