A new generation of durable, lightweight materials that can withstand the difficult conditions encountered during deep drilling while delivering superior performance will play a key role in reducing costs and increasing rate of penetration.

Lighter weight drillstring components will extend the depth rating of conventional drilling rigs, currently limited by the weight of suspended drillstring they are designed handle. This could reduce the need to build new large rigs to meet increased depth requirements. In addition, lightweight components can help to reduce torque and drag, factors that reduce bit life under difficult drilling conditions.

Innovations in metallurgy and plastics technology and in the development of composite materials, show great potential for being adapted for drilling applications. For example, the recently developed composite carbon fiber-epoxy resins have been manufactured into lightweight drill pipe. One example is the drill pipe manufactured by Advanced Composite Products and Technology, Inc. (ACPT), of Huntington Beach, CA. These composite materials appear to be particularly suited for the incorporation of high-speed communication components that complement smart drilling systems. In addition to lowering drillstring weight, advanced composite drill pipe could enable drillers to drill more sharply curved "short radius" horizontal wells without creating fatigue stress on the drill pipe. This ability would increase opportunities to tap shallow reserves with horizontal wells, an important factor in unconventional oil and gas development.

Similar material manufacturing and metallurgical science breakthroughs can eliminate stress points and weaknesses at macro and micro levels, making these new materials durable enough to withstand high pressures, temperatures and corrosive fluids.

Technologically advanced steel and plastics, as well as conventional materials, can be further protected from premature wear, corrosion, and failure by coatings that protect and reduce friction. Coatings such as tungsten carbide are being successfully used today to help protect drilling and completion components. Future research must be devoted to developing durable, inexpensive coatings and application processes that will extend the life of critical parts and reduce the amount of downtime spent on maintenance and replacement.

During the drilling of deep wells, high pressures and temperatures, corrosive formation fluids, and abrasive cuttings in the drilling fluids can cause conventionally manufactured welded pipe to collapse, erode, or leak. Similar problems can occur in tubing or casing after a deep well is completed. One technology that may improve the performance of wellbore tubulars is the development of new ways to manufacture seamless coiled tubing and drill-pipe. One Deep Trek project deals specifically with that aspect of new materials technologies.

Improved Tubulars for Better Economics in Deep Gas Well Drilling Using Microwave Technology (DE-FC26-02NT41662)
Pennsylvania State University, University Park, PA, and Quality Tubing Inc., Houston, TX, are developing a continuous microwave process for the manufacture of seamless coiled tubing and drill pipe. The process will employ microwaves to sinter continuously formed/extruded steel powder into seamless metal tubes, efficiently and economically. Tubular drillstring components made by this process are expected to demonstrate superior quality and performance relative to conventionally manufactured tubular products, resulting in improved life cycle, reduced erosion rates, and lower failure rates.

These improvements will result in a better overall rate of penetration. The entire program is divided into three phases: Phase I and II will demonstrate the feasibility of the proposed concept and develop a prototype manufacturing system, while Phase III will scale-up, field-test and commercialize the system. Total cost of the project, scheduled for completion in September 2005, is $1.82 million, of which $670,000 will be a cost-shared contribution by Pennsylvania State University and Quality Tubing Inc.