Alcoa piping for Brunei Shell project

SERIA, Brunei — Alcoa’s oil & gas business has deployed 1800 metres of aluminium alloy drill pipe (AADP) in the Iron Duke Well C offshore Seria, Brunei.

Alcoa partnered with oil and gas producer Brunei Shell Petroleum. (BSP) and service partner AMRTUR Corp. on the project.

The well is considered among the most complex and deviated in the BSP system, with three “S” curves and a long horizontal section of approximately 5,000m. It was drilled to a total depth of 7,485m in about 60m of water.

The AADP is produced in 9.1-meter aluminium tube sections and joined together using standard steel connections, is about 40% lighter than all steel pipes.

It has the potential to reduce drill string hook load and related drilling torque and drag, said Jay Grissom, Alcoa oil & gas marketing director.

Alcoa’s drill pipe starts with a tapered, high strength, aluminium alloy tube. This tube is coupled with a steel tool joint using a proprietary thermal connection technology that allows steel tool joints to be attached to the aluminium pipe body.

Alcoa produces the aluminium tubes at its Lafayette, Indiana, facility and assembles the finished drill pipe at its Oil & Gas facility in Houston, Texas.

“We are constantly challenged to push the drilling envelope further to maximise recovery and minimise cost,” said Shayne Dustin, BSP’s senior well engineer.

“Light alloy pipe was listed as a performance opportunity to help us tackle some of the challenges we face with reduced cantilever loading, high torque, high drag, high side force, and casing wear concerns,” he added. “Without a light alloy alternative, the furthest reaches of the platform would require a modification to well design.”

Brunei Shell plans to use AADP on additional wells in Brunei. Shell is also planning a drilling project using AADP in New Zealand.