Michael Jellison

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and
Critical Deep Drilling
Michael Jellison (NOV Grant Prideco), Brandon Foster (K&M Technology Group), Greg Elliott,
Leianne Sanclemente (Workstrings, LLC), Andrei Muradov, Lucien Hehn (NOV Grant Prideco)
DEA Quarterly Meeting
23 March 2010

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
• Background
• Comparison with Aluminum & Titanium Drill Pipe
• Metallurgical Development
• Field History
• Third Generation Double-Shouldered Connection
• Example ERD Design
• Performance Properties – Collapse
Considerations
• Conclusions
Outline
2

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Strength to weight ratio comparisons of many steel grades to nonsteel
alternative materials including steel tool joints attached
Drill Pipe
Type
Grade
Yield
Strength
(psi)
Tube OD
(in.)
Tube ID
(in.)
Tube
C.S.A.
(in 2 )
Tube
Tensile
Strength
(lbf)
Joint
Length
(ft)
Joint Air
Weight
(lbf) 3
Joint Strength
to Joint Weight
(lbf/lbf)
%
Improvement
to S-135
Cost
Compared
to S-135
Titanium Ti 6Al-4V 120,000 5.875 5.153 6.254 750,421 46.24 741 1,013 37% ≈ 7 - 10X
Steel UD-165 165,000 5.875 5.153 6.254 1,031,829 46.24 1,145 901 22% NA
Aluminum 1 Al-Zn-Mg II 2 69,618 5.787 4.764 8.477 590,175 46.24 717 823 12% ≈ 1.5 - 2.5X
Steel V-150 150,000 5.875 5.153 6.254 938,026 46.24 1,145 819 11% NA
Steel Z-140 140,000 5.875 5.153 6.254 875,491 46.24 1,145 765 4% NA
Steel S-135 135,000 5.875 5.153 6.254 844,224 46.24 1,145 737 0% 1X
Aluminum 1 Al-Zn-Mg IV 2 50,763 5.787 4.764 8.477 430,335 46.24 717 600 -19% ≈ 1.5 - 2.5X
Aluminum 1 AI-Cu-Mg-Si-Fe III 2 49,312 5.787 4.764 8.477 418,034 46.24 717 583 -21% ≈ 1.5 - 2.5X
Aluminum 1 Al-Cu-Mg I 2 47,137 5.787 4.764 8.477 399,596 46.24 717 557 -24% ≈ 1.5 - 2.5X
Notes:
1 = Aluminum drill pipe design (drill pipe with protector thickening) from ISO 15546 Petroleum and natural gas industries — Aluminum alloy drill pipe
2 = Aluminum drill pipe grades from ISO 15546 Petroleum and natural gas industries — Aluminum alloy drill pipe
3 = includes weight of steel tool joints
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Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
High Strength Drill Pipe Manufactured to Date
960,000
900,000
939,413
840,000
780,000
720,000
660,000
600,000
Z-140
V-150
540,000
480,000
420,000
415,381
360,000
300,000
240,000
180,000
120,000
60,000
0
Jan-97
Jul-97
Jan-98
Jul-98
Jan-99
Jul-99
Jan-00
Jul-00
Jan-01
Jul-01
Jan-02
Jul-02
Jan-03
Jul-03
Jan-04
Jul-04
Jan-05
Jul-05
Jan-06
Jul-06
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
4

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Metallurgical Development
Grade Size Impact 1 Impact 2 Impact 3 Average Elong. Yield UTS Yield/UTS
(ft‐lbs) (ft‐lbs) (ft‐lbs) (ft‐lbs) (%) (ksi) (ksi) (%)
S135 (NS1) 3/4 76 78 75 76 20.2 147.4 160.8 92
V150 3/4 60 62 65 63 26.5 158.0 171.3 92
UD165 3/4 46 47 47 47 24.4 169.0 174.0 97
† Tests carried out in -20 ◦ C (-4 ◦ F).
CTOD CTOD CTOD CTOD CTOD
B 1 2 3 average average Yield UTS
Grade Type (mm) (mm) (mm) (mm) (mm) (inch) (ksi) (ksi)
S135 (NS1) BxB, L‐C 18.00 0.150 0.160 0.150 0.153 0.0060 147.4 160.8
V150 BxB, L‐C 18.00 0.079 0.094 0.088 0.087 0.0034 158.0 171.3
UD165 BxB, L‐C 18.00 0.090 0.090 0.090 0.090 0.0035 169.0 174.0
†CTOD tests carried out in three-point bending at 0 ◦ C (32 ◦ F).
5

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
S-N plot for fatigue testing program comparing UD-165 with V-150.
6

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Field History
• 30 joints of 5” 0.500” wall thickness UD-165 drill pipe deployed to Patterson UTI Rig
#30 in South Texas and successfully run in two wells in combination with 5” 19.50#
S-135 NC50 drill pipe. Wells in this area typically range in depth from 16,000 to
17,000 ft.
• First use was not planned. Rig did not have sufficient pipe to reach TD and topped
out the string with 12 joints of UD-165 pipe. (Additional 5” S-135 drill pipe readily
available; decision made to run UD-165 early.) Drill pipe performed as expected with
no unusual running or handling issues experienced.
• Second case history was a re-entry well in same South Texas area. Well kicked off
at 3,450 ft and a total of 13,274 ft was drilled to an MD of 16,724 ft with max
inclination angle of 23 deg. Average RPM’s were 65 running with a mud motor and
12,000 to 15,000 lb WOB. Penetration rates averaged 30 – 35 ft/hr with rotary table
and 15 – 20 ft/hr in sliding mode with mud motor drilling. Visual inspection revealed
no unusual or unexpected conditions and pipe showed typical signs of normal use.
• Since then 5-7/8” 0.500” wall thickness UD-165 pipe manufactured and awaiting field
trials.
• First lot of light weight 5-7/8” 0.300” wall thickness UD-165 drill pipe currently being
processed for evaluation and field trials. In addition, there are plans to build two
ultra-high capacity 6-5/8” UD-165 landing strings this year.
7

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
3 rd Gen. Double-Shouldered Connection
2 nd Gen. Double-Shouldered
Connection
≈ 13 revolutions
Starting Thread
Starting Thread 1
3 rd Gen. Double-Shouldered
Connection
≈ 4 revolutions
Starting Thread 2
8

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Cumulative footage by delivery date
(as of January 1, 2009)
450,000
Total: 417,250 ft
400,000
350,000
300,000
250,000
200,000
150,000
100,000
50,000
0
Sep-06 Jan-07 May-07 Sep-07 Jan-08 May-08 Sep-08 Jan-09 May-09
9

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Footage by connection size and material grade
(as of January 1, 2009)
220,000
210,000
200,000
190,000
180,000
170,000
160,000
150,000
140,000
130,000
120,000
110,000
100,000
90,000
80,000
70,000
60,000
50,000
40,000
30,000
20,000
10,000
0
15,704
72,038
14,000
SS-105
S-135
Z-140
V-150
31,205
20,000
56,020
141,998
57,047
9,237
380 390 485 525 550 585
10

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Estimated Cost Savings
Rig Type
Day Rate (1)
(USD)
Spread Rate (2)
(USD)
Cost per sec.
of time saved
(USD)
Min. Est. Time
Savings per
Well (3)
(hr)
Min. Est. Cost
Savings per
Well (3)
(USD)
Semisub 7,500' WD $ 214,439 $ 428,878 $ 4.96 7.22 $ 128,996
Drillship 3,000' WD $ 191,244 $ 382,489 $ 4.43 5.50 $ 87,676
Jackup 350' WD $ 123,798 $ 247,597 $ 2.87 4.49 $ 46,323
Jackup 200' WD $ 82,743 $ 165,487 $ 1.92 4.43 $ 30,566
Inland barge $ 43,863 $ 87,726 $ 1.02 4.36 $ 15,924
Notes:
(1) Average rig day rates from www.rigzone.com as of 31 July 2006.
(2) Spread rate assumes 2X rig day rate.
(3) Time and cost savings assumes mininum number of trips (one bit run per casing/liner size) for 20,000 ft typical well from the mud line with four casing strings and one liner.
11

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Example uERD Design
12

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
13

Drillstring Design Grade Tooljoints 1 Adj Wt.
(lb/ft)
Makeup
(k ft-lbs)
Tube Limitations Mechanical Load
Torque 2 Tension 2 Torque 3 Tension 4 SPP 5
(k ft-lbs) (kips) (k ft-lbs) (kips) (psi)
Stretch 6
(ft)
5⅞” 0.361” wall RII (45,000’) S135 7⅛”x4” 27.85 66 75 600 75 770 6,500 75
5⅞” 0.361” wall RII (45,000’) S135 7”x4½” 26.06 62 75 600 70 730 6050 72
5⅞” 0.361” wall RIII (45,000’) S135 7”x4½” 24.61 62 75 600 66 690 5950 67
5⅞” 0.500” wall RII (10,000’)
5⅞” 0.361” wall RII (35,000’)
S135
S135
7⅛”x4”
7”x4¼”
34.83
26.41
66
57
95
75
805
600
73
53
800
360
6,500 65
5⅞” 0.415” wall RII (10,000’)
5⅞” 0.300” wall RII (35,000’)
UD165
UD165
7⅛”x4”
7”x4¼”
30.78
23.32
66
57
102
78
832
617
65
48
710
320
6,100 67
5⅞” 0.361” wall RII (10,000’)
5⅞” 0.300” wall RII (35,000’)
UD165
UD165
7”x4½”
7”x4½”
25.94
22.84
62
62
90
78
733
617
63
46
660
320
5,800 70
5⅞” 0.361” wall RII (10,000’)
5⅞” 0.300” wall RIII (35,000’)
UD165
UD165
7”x4½”
7”x4½”
25.94
21.38
62
62
90
78
733
617
60
44
630
300
5,700 65
5⅞” 0.361” wall RII (10,000’)
5⅞” 0.250” wall RII (35,000’)
UD165
UD165
7⅛”x4”
7”x4¼”
27.85
20.71
66
57
90
67
733
520
58
42
640
295
5,800 72
5⅞” 0.361” wall RII (10,000’)
5⅞” 0.250” wall RII (35,000’)
UD165
UD165
7⅛”x4”
7”x4½”
27.85
20.32
66
62
90
67
733
520
57
41
630
290
5,700 69
5⅞” 0.361” wall RII (10,000’)
5⅞” 0.250” wall RIII (35,000’)
UD165
UD165
7”x4½”
7”x4½”
26.40
18.76
62
62
90
67
733
520
53
39
520
240
5,500 64
5⅞” 0.500” wall RII (45,000’) Group III 7 7”x4¼” 17.11 57 35 294 35 365 7100 82
5⅞” 0.361” wall RII (15,000’)
5⅞” 0.500” wall RII (30,000’)
S135
Group III 7
7”x4¼”
7”x4¼”
26.41
17.11
57
57
75
35
600
294
45
25
520
170
6,800 59
5⅞” 0.361” wall RII (45,000’) Ti-6Al-4V 7”x4¼” 18.16 57 66 530 45 460 6,200 82

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Difference in side forces for Range II vs. Range III
In order to manage side
force below 2,000 lbs per
tool joint, the upper
±10,000’ of the string
should be Range II
15

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Mechanical performance properties of various
drill pipe tubes (100% of API Premium Class)
Drillpipe Tube Grade Torque
(k ft-lbs)
Tension
(kips)
Burst
(psi)
Collapse
(psi)
5⅞” 0.500” wall S135 106 895 18380 14820
5⅞” 0.415” wall S135 93 757 15258 9368
5⅞” 0.361” wall S135 83 666 13270 6200
5⅞” 0.361” wall UD165 101 815 16220 6600
5⅞” 0.300” wall UD165 87 686 13480 3700
5⅞” 0.250” wall UD165 75 578 11230 2090*
5⅞” 0.500” wall Al Group III 49 ksi 39 327 6710 6460
5⅞” 0.361” wall Ti 120 ksi 74 592 11800 5880
*Note on 0.250” wall steel: 2100 psi collapse load is equivalent to 3100’ (>30 stands) of evacuated drill
pipe in 13.0 ppg fluid. Reduced collapse strength will require a.) diligent inspection of tubes to better
than premium class (“New” drill pipe tubes are rated to 3940 psi collapse) and b.) modified tripping
procedures (i.e. fill pipe more frequently on trips to reduce differential load to ±1,000 psi).
16

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Conclusions
• New drill pipe material grade that combines ultra-high strength
with excellent fracture toughness has been developed.
• This new drill pipe can help expand the extended reach
drilling envelop by enabling drill strings with excellent strength
to weight properties.
• Combining the UD-165 material with light weight, thinner wall
drill string designs can reduce torque and drag loads while
providing high axial tension capacities and torsional strengths
necessary to drill the next generation of ERD wells.
• The ultra-high strength material is also well suited to landing
string applications where the loading demands to run longer
and heavier casing strings in deep-water continue to increase.
• The authors anticipate that innovative drilling professionals
may also discover additional critical drilling applications that
can benefit from this new drill pipe technology.
17

Light Weight – Ultra-High Strength Drill Pipe for Extended Reach and Critical Deep Drilling
Jellison, Foster, Elliott, Sanclemente, Muradov, Hehn
Light Weight UD-165 DP Ready for Field Use
• NOV Grant Prideco has produced 175 joints
of 5-7/8” t=0.285 UD-165 drill pipe.
• 95 joints have the eXtreme Torque ® XT-57
connection
• 80 joints with TurboTorque TT-585
• All pipe has internal plastic coating and
Platinum casing-friendly hardband (3/32”
raised) on both pin and box.
• This drill pipe is ready for field application.
Questions?
18