Composite Dual-Channel Drill Pipe for Lower ECD in ERD
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Solution Overview
Problem
Extended reach drilling (ERD) operations face challenges with conventional drill pipes due to high construction complexity, weight, and issues related to equivalent circulating density (ECD), which can lead to stuck pipes and reduced drilling reach.
Innovation Solution
A composite drill pipe design featuring an inner and outer pipe with a shared axis, pultruded as one piece using reinforcing fibers and a matrix material, incorporating multi-directional reinforcement and polymeric resin coating, and optionally embedded sensors for data collection and transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional steel drill pipes are used for extended reach drilling, then sufficient strength and structural stability are achieved, but the weight increases and construction complexity increases
Solution Approach 1:
The patent applies composite materials by combining carbon fiber reinforced polymer (CFRP) with steel. The drill pipe consists of a steel outer tube providing structural strength and a CFRP inner tube reducing weight. This composite structure achieves the required strength for extended reach drilling while significantly reducing the overall weight compared to conventional steel drill pipes.
2Stability of the object's composition
If conventional steel drill pipes are used for extended reach drilling, then structural stability is maintained, but construction complexity and cost increase
Solution Approach 1:
The patent uses composite materials with the steel outer tube providing structural stability and the CFRP inner tube contributing to buckling resistance. The combination of materials with different mechanical properties creates a structurally stable drill pipe that is optimized for extended reach drilling applications.
Solution Approach 2:
The patent implements the nesting principle by placing the CFRP inner tube inside the steel outer tube. This concentric arrangement allows both materials to work together, with the inner tube providing buckling resistance and the outer tube providing structural support, while simplifying the overall construction compared to more complex composite structures.
3Length of moving object
If dual channel drill pipes are used to reduce ECD issues, then drilling reach is enhanced, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the drill pipe into two separate flow channels: an inner channel through the CFRP tube and an outer annular channel between the CFRP and steel tubes. This segmentation allows independent fluid flow paths, enabling better control of equivalent circulating density (ECD) and enhancing drilling reach while keeping the structural design relatively simple.
Solution Approach 2:
The nested dual-channel structure is achieved by placing the inner flow channel within the outer annular channel. The CFRP inner tube forms the inner channel, while the space between the CFRP and steel tubes forms the outer channel. This nested arrangement provides two independent flow paths without requiring separate pipe structures, thus reducing overall complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite drill pipe is lighter, stronger, and resistant to buckling, reducing ECD issues and enhancing drilling reach while providing real-time formation data, thus improving drilling efficiency and safety.
Implementation Method 1
The inner pipe, the outer pipe, and the plurality of walls may be pultruded as one piece using a reinforcing fiber and a matrix material
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A composite drill pipe including an inner pipe having a first diameter, an outer pipe having a second diameter greater than the first diameter, and a plurality of flow channels formed between the inner pipe and the outer pipe. The plurality of flow channels are formed by a plurality of walls extending radially between an outer diameter of the inner pipe and an inner diameter of the outer pipe. A method of forming a composite drill pipe includes pultruding a drill pipe comprising an inner pipe having a first diameter, an outer pipe having a second diameter greater than the first diameter, and a plurality of flow channels formed between the inner pipe and the outer pipe. The method also includes providing a multi-directional reinforcement over an outer diameter of the outer pipe.