Development of Lightweight Steel

Drillpipe With a 165ksi Yield Strength

Yaauahl Taukano and Maaakatau Ueno, Nippon Steel Corp.

Summary. This paper describes the development of a lightweight steel drillpipe with a I65-ksi [1 I 37-MPa] yield strength. The drillpipe was developed according to three design objectives and verified by full-size and material-evaluation tests. The lightweight steel
drillpipe has two advantages over standard API G-I05 pipe with the same pipe-body OD-it weighs 25% less and has a 20% lower
hydraulic loss (loss of fluid pressure)-but maintains a performance level comparable with that of G-I05 pipe.
Introduction
Wider application of horizontal and extended-reach drilling has increased the need for lightweight drillpipe to reduce the greater torque
and drag caused by increasing hole angles. Lightweight aluminum
and titanium drillpipes were developed but are not widely used because they are much more costly than heavier steel drillpipe. Therefore, from an economic viewpoint, lightweight steel drillpipe is the
best type of pipe for horizontal and extended-reach applications.

3. The upset had to be as thin as possible on the basis of the allowable section modulus. The allowable section modulus was calculated with the following equation:

DeSign Concept
The weight of steel drillpipe is reduced by decreasing the pipe's
wall thickness. Performance is maintained by use of high-strength
steel. This is the ordinary way to design a lightweight pipe; however, in the case of drillpipe, it is only the starting point of development. For example, the upset configuration must be designed
so that it can be fitted to the thin pipe body. The tool joint also
needs to be selected on the basis of its adaptability to the upset.
Furthermore, both designs should minimize hydraulic loss in the
drillpipe.
We established three design objectives.
1. The ID had to be as large as possible to minimize hydraulic loss.
2. The stress concentration at upset transitions had to be reduced
to prevent fatigue failures.

Design
Pipe Body. A pipe OD of 5 in. [127 mm] was selected because
it is common in drilling. The pipe body was 0.256 [6.5 mm] thick
for practical reasons. The yield strength was 165 ksi [1137 MPa],
the highest commercial grade.

Copyright 1991 Society of Petroleum Engineers

where Zu =the allowable section modulus of upset, Zp = the section modulus of pipe body, Hp=the Vickers hardness of pipe body,
and Hu =the lowest Vickers hardness in upset.

Upset. External upset initially was used as the upset type for the
lightweight drillpipe because the large ID effectively reduced hydraulic loss; however, stress was concentrated at the external upset transition (see Fig. 1). To lessen the stress concentration, the
pipe thickness at the external transition was increased slightly by
use of the internal upset. Fig. 2 shows the final upset design.
Fig. 3 shows the upset's bending stress contours. Because the
stress concentrations at the upset transitions were reduced effectively, the maximum stress was not observed at either the external
or internal upset transitions.

(MPa)
1) 83.4
2) 103.0
3) 122.6
4) 142.2
5) 161.8
6) 181.4
n 201.0
8} 220.6

(MPa)

1)

Zu=Zp(HpIHu), _. _.......... -. _. _... _....... _..... (1)

83.4

2) 103.0
3) 122.6
4) 142.2
5) 161.8
6) 181.4
7) 201.0
8) 220.6

/Stress Concentration

F ~ '"S:?Y:m!rleJ 1
3 4

I_I 3 $ I 'jill Ild I

1
6

Fig. 1-Bendlng stress contours In external upset.

Fig. 3-Bendlng stress contours In upset for lightweight steel

drlllpipe.

5 -1/2 FH

38.1

.1

25.4

CO)
~

of
0

80.0

l.~o/

.~

IOJ

(mm)
580

(mm)

292.1

.1

50.0

-'--- .

Fig. 2-51ze and configuration of upset designed for lightweight steel drlllpipe.

2667

f..--/'

t - . - - . - - - - - - - - ---+-+-\--

SPE Drilling Engineering, September 1991

1651

---- . - -

II

---1U;;;
- o

---IH-------

""

r-

-f-

Fig. 4-51ze and configuration of tool Joint designed for lightweight steel drlllpipe.
209

TABLE 1-PERFORMANCE PROPERTIES OF LIGHTWEIGHT STEEL AND G10S DRILLPIPES

Property

Lightweight Steel

G-105

127 x 6.5 [5 X 0.256)

173 X 110 [6.81 X 4.33)
(5V2-in. full hole)

127 X 9.1 [5 x 0.359)

165.1 X 82.55 [6 1/2 X 3V4)
(NC50)

Torsional yield, N m [Ibf-ft)

Pipe body
Tool joint

92176 [68,116)
81 625 [60,319)

77 938 [57,594)
69 554 [51,300]

Tensile yield, kN [Ibf]

Pipe body
Tool joint
Pipe-body burst pressure, MPa [psi)
Pipe-body collapse pressure, MPa [psi)
Weight" (approximate), N/m [Ibflft)
Hydraulic loss ratio

2805 [629,956]
6158 [1,383,259]
116 [16,825)
54 [7832]
242 [16.6)
0.785

2461 [552,863)
5648 [1,268,722)
92 [13,340]
90 [13,050]
320 [21.9]
1.000

Size
Pipe body (00 x wail thickness), mm [in.)
Tool joint (00 x 10), mm [in.)

'Tool joint plus drilipipe. for Range Z pipe.

TABLE 2-CHEMICAL COMPOSITIONS AND MECHANICAL PROPERTIES OF FULLSIZE SAMPLES

Element
(wt%)
C

Si

Mn

Cr

Mo

Nb

0.28

0.21

0.51

0.006

0.001

1.48

0.73

0.03

0.14

0.28

0.21

0.51

0.006

0.001

1.48

0.73

0.03

0.14

Pipe Body
Tool Joint

Tool Joint. A yield strength of 165 ksi [1137 MPa] was also selected
for the tool joint (Fig. 4) to reduce its weight. The ID was equal
to that of the upset, and a 5 Jh-in. [140-mm] full-hole connection
was used. The final design met the following criteria: (I) the tooljoint/pipe-torque ratio was more than 0.80, I and (2) the tool-joint
tensile strength was greater than that of the pipe body .
Performance Properties. Table 1 compares the designed performance properties of the lightweight steel drillpipe and 5-in. [127mm], 19.5-1bm/ft [2367-kg/m] G-105 drillpipe. For all properties
except collapse, the design capabilities of the lightweight steel drillpipe are superior to those of the G-105 pipe. The lightweight steel
drillpipe weighs about 25 % less than the G-105 pipe and experiences 20% less hydraulic loss. The lower collapse pressure of the
lightweight drillpipe will not cause any practical problems because
there are few occasions when the outside mud pressure of drillpipe
greatly exceeds the inside pressure during drilling.

Performance Evaluation
Torsional, tensile, fatigue, burst, and collapse tests were performed
with full-size samples to verify the performance of the lightweight

Yield
Strength
MPa (ksi)

Tensile
Strength
MPa (ksi)

1167
(169.3)
1232
(178.7)

1284
(186.2)
1339
(194.2)

steel drillpipe. Table 2 lists the chemical compositions and mechanical properties of the samples.
Torsional Test. Fig. 5 shows the power tong used in the torsional
test. The accuracy of applied torque is good, as Fig. 6 shows.
The tool joint was made up at a torque of 62,300 Ibf-ft [84 500
N' m], which is 103 % of the designed torsional yield, and broken
out for inspection. The inspection was conducted with a profile
gauge. Figs. 7 and 8 show the inspection results. Note that neither
pin stretch nor box flare is evident.
A torque of 62,300 Ibf-ft [84 500 N' m], which is 91 % of the
designed torsional yield, was applied to the pipe body . During the

90
80

E 70
I

Z 60
~

30

20

-Calculation
x Strain Gauge
8000

Fig. 6-Callbratlon results of power tong used In the test.

210

SPE Drilling Engineering, September 1991

92~ L Torsi oral YieldofPipe 681161bf-ft

81.4~r--B_ody---"-_ _ _----r""----::I60319 Ibf -ft
Torsi oral Yield of
Tool Joint

80

70

I
60
Z
j/.
....., 50

40

{!.

30

a.

20

Calculation
Strain Gauge
10000

Fig. 9-Results of pipe-body torsional test.

(mm)

1050
2100
Fig. 10-Slze and configuration of full-size tensile-test sample.

SPE Drilling Engineering. September 1991

211

-.-

c:

Fig. 12-Results of full-size tensile test.

(mm)

1700 ( Test Portion)

_ _ _

'1--;;--- ~":f~-i' '''--'T'

_f--i,t----f-.-=-t;i-:..-f--i-.---

800

450

900

450

2600
Fig. 13-Slze and configuration of full-size fatigue-test sample.

TABLE 3-RESULTS OF BURST AND COLLAPSE TESTS

TABLE 4-CHARPY V-NOTCH IMPACT TEST RESULTS

Pressure
Burst
Collapse

MPa

149
148
56.9
56.9
55_9

21,622
21,479
8,250
8,250
8,108

Charpy V-Notch Impact Energy at Room

Temperature
Drillpipe*
Tooljoint**

N'm

Ibf-ft

55.9
101.0

41.3
74.6

'10x5-mm, half size,

"lOx 10-mm, full size.

212

SPE Drilling Engineering, September 1991

l.

Nace Sol.
05-135
light-_ight
Orillpipe

400

:E

'""'300

:I
f

U;

50 150 250 350 450 550 650 750

50

o Yield Strength

40

.Tensile St .. _o+WI200

30'.

200
Light -_ight
.Orillpipe

".!
1100

5-135

c"F )

60

10

100
300 500
Time to Failure (h)
30

50

20

.II:
.....

190

10

180

170 'Ii
~

Fig. 15-Comparison of SSC properties of lightweight steel

and S-135 drlllpipe.

160
150

test, shear strains were measured to detect plastic deformation of

the pipe. Fig. 9 illustrates the torque/strain relationships. As Fig.
9 shows, plastic deformation was not observed until a torque of
62,300 Ibf-ft [84 500 N' m] was reached.
We did not apply 100% of torsional yield on the pipe body because safety was a priority; however, the torsional property of the
pipe body does not limit the practical performance of drillpipe because it exceeds the designed torsional yield of the tool joint.
Tensile Test. Fig. 10 shows the size and configuration of the tensiletest sample. The sample was made up at a torque of 37,700 Ibf-ft
[51 100 N 'm], which is 62.5% of the tool-joint torsional yield,
and tested until tension failure. The sample failed at the pipe body
(Fig. 11). This test demonstrates the integrity of friction welding
and the validity of the design.
Fig. 12 shows the load-elongation relationship. Note that the sample yielded at a load greater than the designed tensile yield (629,956
Ibf [2805 kN]).
Fatigue Test. Fig. 13 shows the size and configuration of the
fatigue-test sample. The makeup torque of the sample was 37,700
Ibf-ft [51100 N m]. The test was conducted with a four-point bending fatigue-testing machine. 2
Fig. 14 shows the fatigue crack in the sample. The fatigue crack
began at the pipe body, not the upset transitions.
Burst and Collapse Tests. Table 3 gives the results of the burst
and collapse tests. The experimental values met the design criteria.

Material Evaluation
Fracture Toughness. Table 4 gives the results of the Charpy Vnotch impact-test results of the pipe body and tool joint. In spite
of the drillpipe's high strength, its fracture toughness is fairly good
because of its cleanliness and metallurgical structure (tempered martensite).
Sulfide Stress Cracking (SSC). Fig. 15 compares the SSC properties of the lightweight steel drillpipe and API standard S-135 pipe.
The SSC test followed the procedures in Ref. 3. Although the SSC
properties of the lightweight steel drillpipe are not good because
of the pipe's high strength, they are almost equal to those of the
S-135 pipe.
High-Temperature Strength. Fig. 16 shows the high-temperature
strength of the lightweight steel drillpipe. Although the tensile
strength decreases with increases in temperature, the reduction ratio is not high. For example, the tensile strength at 392F [200C]
is only 12 % below that at room temperature.
Corrosion Fatigue. Fig. 17 compares the corrosion-fatigue properties of the lightweight steel drillpipe with those of API standardSPE Drilling Engineering, September 1991

140

Fig. 16-High;temperature strength of lightweight steel

drlllpipe.

(ksi)

75

, 220

95

115

135

f-

155

175

195

100 rpm
Seawater, pHl0
Room Temperature

: 200 f-

30

'0

~ 180 f-

~ 160
x
N
... 140

,"

s:. 120 f-

100 f-

(J)

80

...
.j
...
lo

25
Light -weight Drillpipe

.---

E-75

_....

.Ar'-

_.....

5-135
15

- - eG-105
X-95

10

60
~L-~__~I__~I~~I~~~L-~__~I__~~I

500

1000

1400

Yield Strength (MPa)

Fig. 17-Comparlson of corrosion-fatigue properties of lightweight steel and API standard-grade drlllpipes.

grade drillpipes (Grades E, X, G, and S). Fig. 17 shows that the

properties of the lightweight steel drillpipe are slightly better than
those of the standard-grade drillpipes.

Review
A lightweight steel drillpipe with a yield strength of 165 ksi [1137
MPa] was developed. The 5-in. [127-mm] -OD, 0.256-in. [6.5-mm]
-wall pipe weighs 25% less than standard G-105 drillpipe and experiences 20% less hydraulic loss than G-105 pipe. Torsion, tension,
fatigue, burst, and collapse tests verified the pipe's performance
capabilities. The 165-ksi [1137-MPa] yield strength was confirmed
by impact, SSC, corrosion-fatigue, and high-temperature-tensilestrength tests.
213

Authors

Ya......IT...kano
Is a senior reaea~
er at the Central
R&D Bureau of NI~
pon Steel Corp.,
where he has developed drlllplpes
for several years.
He holds BS and
MS degrees In mechanIcal engIneerUeno
Ing from Kyoto U.
Tsukano
Masakatsu Uano
Is a chIef researcher at the Central R&D Bureau of NIppon
Steel Corp., where he develops IIneplpe and oll-country tubular goods and studIes metallurgy of steel products. He holds
a Dr.Eng. degree In metallurgIcal engIneering from Kyushu U.

Acknowledgment.
We thank Teikoku Oil Co. Ud. for its technical recommendations
on the design of the lightweight steel drillpipe. We also appreciate
the cooperation and technical assistance of Japan Petroleum Exploration Co. Ltd., which provided the power tong used in the fullsize torsional test.

Reference.
1. API RP 7G, API Recommended Practice for Drill Stem Design and Operating Limits, 10th edition, API, Dallas (Jan. 1981) 4.
2. Tsukano, Y. et aI.: "Appropriate Design of Drillpipe Internal Upset Geometry Focusing on Fatigue Property," paper SPE 17206 presented at
the 1988 IADC/SPE Drilling Conference, Dallas, Feb. 28-March 2.
3. NACE Standard 1MOl77-90, Laboratory Testing ofMetaisfor Resistance
to Sulfide Stress Cracking in H2S Environments, Nat!. Assn. of Corrosion Engineers, Houston (1990).

SI Metric Conversion Factor.

ft x 3.048*
E-Ol
in. x 2.54*
E+OO
lhf x 4.448222
E+OO
E+OO
psi x 6.894 757
Conversion lactor is exact.

m
cm

=N

kPa

SPEDE

Original SPE manuscript received lor review Feb. 27, 1990. Paper accepted for publICa
tlon July 8, 1991. Revised manuscript received Jan. 28. 1991. Paper (SPE 19960) first
presented at the 1990 IADC/SPE Drilling Conference held In Houston. Feb. 27-March 2.

214

SPE Drilling Engineering, September 1991