SPE/IADC 67764

Cost Effective Composite Drill Pipe: Increased ERD, Lower Cost Deepwater Drilling
and Real-Time LWD/MWD Communication

Dr. J.C. Leslie, Mr. Jeff Jean, Mr. Lee Truong, Mr. Hans Neubert, Mr. James C. Leslie II

Advanced Composite Products & Technology, Inc.

Copyright 2001, SPE/IADC Drilling Conference

This paper was prepared for presentation at the SPE/IADC Drilling Conference held in
Amsterdam, The Netherlands, 27 February1 March 2001.
This paper was selected for presentation by an SPE/IADC Program Committee following
review of information contained in an abstract submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the Society of Petroleum Engineers or the
International Association of Drilling Contractors and are subject to correction by the author(s).
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Abstract
Extended Reach and Deep Water Drilling are constrained by
the weight of the steel drill pipe. Transfer of data between the
bottom hole assembly and the well head is currently
cumbersome, slow, and less precise than desired. Recognizing
these limitations, the U.S. Department of Energy, National
EnergyTechnology Laboratory, has funded a three-year
program to develop and qualify a cost-effective composite
drill pipe (CDP). This pipe will provide enabling capability in
all three of these areas. The program was started on
September 30, 1999 and has the goal of having composite drill
pipe approved and commercially available by September 30,
2002.
This paper reviews the first year of the program, presents
specifications for the proposed composite drill pipe, and
represents work-in-progress.
Introduction
Drill pipe weight and friction or drag in the horizontal
departure of the well limits the maximum distance of
Extended Reach from drilling platforms. Deep Water drilling
is limited by maximum length for which steel pipe can support
its own weight. Electronics within the bottom hole assembly

are temperature limited. In steel drill pipe, heat transfer

through the pipe wall from OD fluids to ID fluids is a major
factor in controlling instrumentation temperatures. Logging
While Drilling (LWD) and Mapping While Drilling (MWD)
operations are rendered nearly ineffective by the current
inability to transfer data in real time from the bottom hole
assembly to the well head. Similarly, direct transfer of power
to the bottom hole assembly is currently a technical challenge.
Cost Effective Composite Drill Pipe (CDP) can reduce costs
and improve capabilities in the three major areas now limiting
complex drilling operations. The composite drill pipe will:

Provide enabling technology for Extended Reach

and Deep Water Drilling by physical/mechanical
capability comparable to currently available
metal drill pipe, and
Provide a weight savings over metal drill pipe
by 40% to 50%, thus offering substantial weightrelated cost reductions for offshore and landbased operations, and
Provide substantially reduced heat transfer
through the pipe walls, and
Provide an opportunity for real time data and
power transmission from well head to bottom
hole assembly.

Theory and Definitions

Suitability of Composites for Tubular Applications.
Composites can be designed to meet or exceed the
physical/mechanical capabilities of metals in nearly all tubular
applications. An enabling feature is the fact that composite
structures are inherently anisotropic in mechanical and thermal
properties, while metals are isotropic (mechanical properties
nearly equal in all directions). As a result, the tubular portion

DR. J.C. LESLIE, MR. JEFF JEAN, MR. LEE TRUONG, MR. HANS NEUBERT, MR. JAMES C. LESLIE II

of the drill pipe can be customized and manufactured to meet

specific load conditions. Fiber is placed coincident with the
load direction, and of sufficient quantity to satisfy strength
requirements. As presented later, this will be accomplished by
the cost effective composite drill pipe (CDP) design developed
in this program. A typical cross section for the CDP design is
shown in Figure 1.
Tool Joints and Metal to Composite Interface. Composites
are ideally suited to plane stress applications and cannot match
the elastic-plastic behavior of steel in complex 3-D stress
fields. For structural efficiency, it is appropriate that the tool
joints be accomplished with metal. For this program, standard
steel pin and box type joints were chosen.
The major design problem in the development of CDP is
reduced to that of the interface between the tubular composite
pipe and metal tool joints. There are numerous patents
addressing this problem and ACPT, Inc. has successfully
designed, produced, and used tubular metal-composite joints
for power (torque) transmissions for automotive and
commercial applications. ACPTs previous work has been
applied to CDP designs, and patents have been applied for.
CDP Reduces Heat Transfer to the Drilling Mud. Data
presented below in Table 1 compares the heat transfer
coefficients of 4130 steel, 7075 aluminum, 6Al-4V-Titanium,
and the CDP in the thickness direction.
Table 1 Thermal Conductivity (Btu/Hr-Ft-Deg.F)
Steel
25.0

Alum
97

Titanium
4.6

CDP
.50

It is hypothesized that the smooth walls and the absence of

constrictions within the current CDP design will reduce the
tendency toward turbulence in the fresh drill mud, further
reducing heat transfer and also reducing frictional power
(pressure) loss at the drill face.
Material Cost. The primary enabling factor for this program
has been the recent reduction in the price of graphite fibers.
This reduction occurred largely through the influence of
Zoltek, Inc. on the composites industry. The cost has
decreased from $30/$35 per pound of fiber to a committed
price of $5/lb. Previous oil patch tubular developments have
had to use combinations of fiberglass and graphite fibers to
achieve a lower-cost mechanical design. The current design
uses fiberglass only where it does not detract from meeting the
mechanical/physical specifications set forth for the CDP.
Graphite fiber is used for meeting all major load requirements.
Temperature. Resin rheology has limited previous oil patch
composite applications to maximum temperatures of 250F.
Data presented below (Table 2) indicates the current CDP

SPE/IADC 67764

design can operate up to 300F. The CDP design limitation is

the shear strength of the resin at elevated temperatures. Work
is also underway in an effort to extend this capability to 400F.
Table 2 Glass Transition Temperature, ASTM-E-831
(TMA Method)
Test 1
Test 2
Test 3

Dry Specimen
After 24hr Water boil
After 100hr-water boil

326F
313F
296F

Data-Power Transmission Capability Wiring has been

incorporated in the walls of the composite tubular structure
sections of CDP. Power and data will be transmitted in real
time through the walls of the CDP. The problem now becomes
one of transmission through or around the metal, (API or
otherwise) tool joints.
At present, this program is
concentrating on demonstrating transmission in a practical,
manufacturing capable manner.
Feasibility studies are
investigating methods for transmission through or around the
metal joints. Potential transmission methods through tool
joints include direct connect, acoustic and inductive.

CDP Configuration and Specifications

CDP Design. Figures 2 and 3 are schematic illustrations of
the current cost-effective CDP design. As shown in Figure 2,
the overall length is nominally 31.5 feet. The 4.25-inch ID is
smooth and uniform throughout.
The 5.88-inch OD
transitions to 7.0 inches maximum OD at the tool joint.
Figure 3 schematically illustrates the design of the composite
wall and a baseline metal-to-composite interface. Specific
details have been omitted for patent and proprietary reasons.
Materials
Table 3 summarizes the materials currently used in the CDP
Table 3 CDP Material
1. -Fibers
Carbon: Commercial Grade Tow Size: 48K to 50K
Grade-525 Ksi Fiber Strength, 33-34 Msi Fiber Modulus
(ACPT has currently qualified 2 Carbon Fiber types for the
CDP)
Fiberglass: E-glass commercial grade, Tow Size: 450 Denier
Grade: 225 Ksi Fiber Strength, 10 Msi Fiber Modulus
2. -Resin
350 F High Performance Resin
(Further resin development will be performed for higher
temperature wells.)

SPE/IADC 67764

COST EFFECTIVE COMPOSITE DRILL PIPE: INCREASED ERD, LOWER COST DEEP
WATER DRILLING, AND REAL TIME LWD AND NWD COMMUNICATION

3. -Adhesive
Low Viscosity, High Strength, 350F Service Temperature
Epoxy
(Further Adhesive development testing will be performed for
higher temperature wells with the resin research.)

The current program includes on-going manufacturing

development and quality control to assure that the CDP will
not be subjected to property variations through manufacturing
inconsistencies. The CDP will be manufactured by the lowest
cost process and will be optimally automated.

CDP Specifications CDP load capability requirements and

specifications are shown in Table 4. These values were
obtained through direct communications with numerous
industry individuals and major corporations involved in
offshore drilling operations. They have been reviewed and
revised at least quarterly11, since September 30, 1999.

Data and Results

Table 4 CDP Specified Performance Requirements

-Tension-Combined Case Load, Nominal Operation:
20,000 TVD+133,000 lb pull-up load +
30,000 ft-lb torsion +7500 psi internal
pressure.
-Compression-Combined Case Load, Nominal Operation:
30,000 lb load+30,000 ft-lb torsion+7500 psi
internal pressure.
-Torsion-Maximum Make-up Torque 45,000 ft-lb + 25%
for shock-loading and hard-to-break
connections.
-Tension+Bending-Combined Case Load, NominalOperation:
100,000 lb drag load+30,000 ft-lb torsion+7500 psi
internal pressure+10 degrees of bending/100Ft.
-External Pressure-12, 000 psi.
-Temperature-350F nominal use.
-Fatigue-2, 000,000 cycles (load and frequency TBD)
Manufacture and Marketing of Cost Effective CDP
Manufacture of the CDP will be accomplished by use of
filament winding and CNC machined tool joints, specifically
designed to accommodate the metal-composite interface.
Initial prototype and field qualification units will be filament
wound at ACPT. It is planned that this pilot plant facility will
support initial production rates. For full-scale production, a
dedicated manufacturing plant capable of meeting market
demands is planned. The number of manufacturing winding
stations put into production will be determined by market
requirements as of 2003 and beyond.
Manufacturing and marketing of the CDP will be
accomplished in cooperation with a well-established major
manufacturer(s) of drill pipe and/or oil patch equipment.
Negotiations are in progress toward establishing this
collaboration(s).

Semi-Annual reports are prepared, distributed, and orally

reviewed with contributing members of the CDP team. For
more information on participation in this team effort, please
contact Mr. Jeff Jean at ACPT, Inc., (714) 895-5544.

Overall Plan and Schedule. Table 5 presents a summary

schedule for the 3-year program being followed to achieve the
development and manufacture of Cost Effective CDP. The
program is on schedule.
Table 5
Major Schedule Milestones

Month Start

Month
Complete

Set CDP Mechanical and Performance

Requirements

Finite Element Modeling

29

Composite Materials Selection and

Verification Testing

18

Metal-To-Composite Interface (MCI)

Design

21

Coatings and Liners Research, Testing,

and Selection

29

1/3 Scale Mechanical Testing

12

Full Diameter-10Ft Section Mechanical

Testing-Static

12

17

Revised Mechanical/Physical CDP

Design Complete

13

21

Final Design of CDP Complete

29

29

Test 30 Ft CDP Sections-LAB

22

27

Well Site Tests

27

34

First Field Use Available

36

N/A

Materials Test. Mechanical Properties. A materials test plan

established the physical and mechanical composite property
requirements to ASTM standards at program initiation.
Testing was performed to confirm manufacturers published
results. In addition, industry input was solicited concerning
the applicability of the selected resin and fiber to down well
conditions. Materials screening was accomplished by use of

DR. J.C. LESLIE, MR. JEFF JEAN, MR. LEE TRUONG, MR. HANS NEUBERT, MR. JAMES C. LESLIE II

SPE/IADC 67764

NOL Short Beam Shear (SBS) testing. Tests were run

covering temperatures to 400F and with dry and wet
specimens. Wet specimens were conditioned by both 24 hour
and 100-hour water boil exposure. Specimen preparation and
testing was accomplished by certified test labs. A summary of
these test data is presented in Table 6.

of materials in Simulated Drilling Mud. Other candidate

coatings are still being evaluated. Data is presented in Table 7
from tested materials to date. An investigation to find and
validate the best, most cost-effective erosion/abrasion
protective material for the CDP is an ongoing process.

Table 6 Short Beam Shear Tests per ASTM D 2344

Table 7 Slurry Abrasion Response Determination Results

Per ASTM G75-95

Dry
200F
250F
300F
350F
400F

Avg. Shear (PSI)

5800
4690
4240
3920
2010

24hr Boil
200F
250F
300F
350F
400F

5260
4270
3820
3030
1520

100hr Boil
200F
250F
300F
350F
400F

4860
4180
3520
2730
1210

It has been concluded that composite degradation is caused by

moisture hydrolysis of the resin matrix when subjected to
elevated temperature. In order to confirm this hypothesis,
additional SBS specimens are currently being subjected to
combined temperature, pressure, and chemical/fluid exposure
closely simulating actual down well conditions. These data
will be provided, as available, at the oral presentation and in
future publications.
It is important to note that the application of ID and OD liners
or coatings will also tend to minimize the hydrolysis process,
further protecting the resin matrix from molecular bond
scission.
Physical Wear of the Composite. Composites are typically
much more quickly and severely abraded by physical wear
than steel. This program includes significant effort to protect
the composite drill pipe from abrasion and erosion.
Industry consultations indicate that internal wear is not
significant with steel drill pipe. It has been pointed out that
the light plastic coating currently applied to some steel drill
pipe to provide lubricity to the interior does not experience
significant wear in normal use. An anti-erosion coating will
help to protect the exterior of the CDP. Several candidates
have been tested using the Slurry Abrasion Response
Determination per ASTM G75-95 (SAR Number). The
purpose of the test is to determine the relative wear resistance

Material

4130 Steel
2201 XXX
2221 XXX
UV Urethane
SPG XXX
2000 XXX

2hr Mass Loss

(milligrams)
(Baseline)

25
40
45
125
158
175

Exterior coatings and other techniques are also being

evaluated to protect the CDP from the much harsher exterior
down well and handling environments. It has been ascertained
that the exterior wear problem is manageable.
One-Third Scale Testing. Design properties have been
confirmed by 1/3 scale tubular testing. All specimens were
filament wound and the 1/3 scale requirement was met in tow
size, plies, and ply thickness, as well as, all other physical
dimensions, except for total length. The design specifications
for tension, and torque and compression were confirmed.
Figures 4 and 5 show the 1/3 scale compression and
torque/tension specimens.
Table 8 compares the required torsion, tension and
compression capabilities with the 1/3 scale test results. As
shown below, the primary strength levels required by the
specification have been met. Analysis of the 1/3 scale data
leads to the conclusion that the other required mechanical
specifications will also be met, although not yet tested. This
conclusion will be verified in the planned testing of full-scale
10.0 and 31.5-foot sections of CDP.
Table 8 1/3 Scale Test Averages

Tension
Compression
Torque

1/3 Scale
Test Value
Avg.

Factored to
Full-Size

Performance
Requirement

63,600
37,600
1,960

X (9) =572,400
X (9) =338,400
X (27) =52,920

403,000
30,000
56,250

Weight Predictions. Based on the current design, it is

estimated that a 31.5-foot section of CDP, including steel tool
joints per the ICD drawing (Figure 2), having a constant 4.25

SPE/IADC 67764

COST EFFECTIVE COMPOSITE DRILL PIPE: INCREASED ERD, LOWER COST DEEP
WATER DRILLING, AND REAL TIME LWD AND NWD COMMUNICATION

inch ID will weigh 425 pounds, or less. Comparable 135 ksi

strength steel tubular, including joints, weighs approximately
866 pounds.
Conclusions
ACPT is encouraged by the progress towards meeting all the
performance requirements expected of a fully functional and
qualified CDP. Much work, however, remains to be
accomplished. Increased temperature capability remains a
challenge, with a goal of meeting 400F service temperature.
The metal-to-composite interface (MCI) requires additional
analysis and testing to guarantee that CDP failure will always
occur in the pipe section. LWD and MWD details, including
reliability issues, need to be demonstrated. Continuation of
this program, now at the start of the 2nd year, focuses on these
challenging opportunities.
FIGURE 2 Interface Control Drawing

FIGURE 1 Typical Cross Section of CDP Composite Pipe

DR. J.C. LESLIE, MR. JEFF JEAN, MR. LEE TRUONG, MR. HANS NEUBERT, MR. JAMES C. LESLIE II

FIGURE 3 Metal-Composite Interface (MCI)

FIGURE 4 Subscale Compression Specimens

FIGURE 5 Subscale Torsion Specimen

SPE/IADC 67764

SPE/IADC 67764

COST EFFECTIVE COMPOSITE DRILL PIPE: INCREASED ERD, LOWER COST DEEP
WATER DRILLING, AND REAL TIME LWD AND NWD COMMUNICATION

Disclaimer
This report was prepared as an account of work sponsored
by an agency of the United States Government. Neither the
United States Government nor any agency thereof, nor any of
their employees, makes any warranty, express or implied, or
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those of the United States Government or any agency thereof.