Carbon Fiber Pipe Permits Horizontal Oil and Gas Drilling

WASHINGTON, DC, May 18, 2004 (ENS) - The Department of Energy (DOE) announced Monday the development of a new composite drill pipe that is lighter, stronger and more flexible than traditional steel drill pipe. The new carbon fiber resin drill pipe can drill horizonally, allowing it to drain more oil and gas from rock than the standard vertical wells.

Energy Secretary Spencer Abraham said, “To reach and recover untapped domestic oil and gas reserves, we must have the ability to inexpensively drill highly deviated or horizontal holes.”

Using older wells as entry points reduces the environmental footprint of drilling and production operations, the Energy Department said.

The new drill pipe was developed under a four year, $3.6 million cooperative agreement with Advanced Composite Products and Technology of Huntington Beach, California.

The agreement was managed by the DOE’s National Energy Technology Laboratory (NETL). "It could revolutionize the drilling industry because of its versatility and strength," said Gary Covatch of NETL's Gas Technology Management Division.

"The composite pipe is more flexible than steel drill pipe. This flexibility is an especially important advantage in permitting producers to re-enter old wells and drill horizontally to reach untapped natural gas formations. It could provide an important new tool for the industry to recover more gas, keep recovery costs low, and extend the life of many of the nation's gas wells," said Covatch.

The flexible pipe is manufactured by winding graphite fibers and epoxy resin around a spindle. The composite tube is cured, and the supporting spindle is removed. The pipe is machined, and then coated to resist abrasion.

The first commercial order for the device was placed by Integrated Directional Resources of Lafayette, Louisiana, a company that describes itself as an engineering oriented directional drilling company interested in improved oil recovery.

The composite pipe is more flexible than steel pipe, so it can better withstand the stress and fatigue of drilling short-radius horizontal holes. It is more expensive than traditional steel pipe, but can cycle or rotate through a short radius bend for extended periods of time without suffering fatigue damage.

The most recent field test was conducted in the summer of 2003 in Le Flore County, Oklahoma, at a depth of 1,385 feet in a formation that was hard and abrasive. This test was conducted in a new well using air-hammer drilling to propel the 2.5 inch diameter pipe.

The air hammer severely challenged the pipe's fatigue life, mechanical strength, and ability to deal with stress. After a week of drilling, the pipe was extracted and examined. It showed little sign of wear.

The new carbon fiber pipe can be reused in multiple wells for lower drilling costs.

Future developments might include the design of larger carbon fiber pipes for deepwater applications.

Researchers may also be able to embed an electrical wire in the resin to provide a high-speed data link for transmitting electronic information to and from the drill bit. Such smart drilling systems can give operators real-time data to monitor drilling progress, avoid stresses on the drill pipe, and make instantaneous decisions to better target the drilling operation.