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IMPROVED TUBULARS FOR BETTER ECONOMICS IN DEEP GAS WELL DRILLING USING MICROWAVE TECHNOLOGY

Description: The main objective of the research program has been to improve the rate-of-penetration in deep hostile environments by improving the life cycle and performance of coiled-tubing, an important component of a deep well drilling system for oil and gas exploration, by utilizing the latest developments in the microwave materials technology. This is being accomplished by developing an efficient and economically viable continuous microwave process to sinter continuously formed/extruded steel powder for the manufacture of seamless coiled tubing and other tubular products. The entire program has been spread over three phases with the following goals: Phase I--Demonstration of the feasibility concept of continuous microwave sintering process for tubular steel products. Phase II--Design, building and testing of a prototype microwave system which shall be combined with a continuous extruder for steel tubular objects. Phase III--Execution of the plan for commercialization of the technology by one of the industrial partners. The criteria for the success of the program is based on the performance of coiled tubing made by the microwave process. It is expected that this product will have superior quality and performance to the standard product, and will be economically viable.
Date: January 1, 2004
Creator: Agrawal, Dinesh
Partner: UNT Libraries Government Documents Department

Improved Tubulars for Better Economics in Deep Gas Well Drilling Using Microwave Technology

Description: The main objective of the entire research program has been to improve the rate-of-penetration in deep hostile environments by improving the life cycle and performance of coiled-tubing, an important component of a deep well drilling system for oil and gas exploration, by utilizing the latest developments in the microwave materials technology. Based on the results of the Phase I and insurmountable difficulties faced in the extrusion and de-waxing processes, the approach of achieving the goals of the program was slightly changed in the Phase II in which an approach of microwave sintering combined with Cold Isostatic Press (CIP) and joining (by induction or microwave) has been adopted. This process can be developed into a semicontinuous sintering process if the CIP can produce parts fast enough to match the microwave sintering rates. The main objective of the Phase II research program is to demonstrate the potential to economically manufacture microwave processed coiled tubing with improved performance for extended useful life under hostile coiled tubing drilling conditions. After the completion of the Phase II, it is concluded that scale up and sintering of a thin wall common O.D. size tubing that is widely used in the market is still to be proved and further experimentation and refinement of the sintering process is needed in Phase III. Actual manufacturing capability of microwave sintered, industrial quality, full length tubing will most likely require several million dollars of investment.
Date: September 30, 2006
Creator: Agrawal, Dinesh
Partner: UNT Libraries Government Documents Department

DEVELOPMENT OF ADVANCED DRILL COMPONENTS FOR BHA USING MICROWAVE TECHNOLOGY INCORPORATING CARBIDE, DIAMOND COMPOSITES AND FUNCTIONALLY GRADED MATERIALS

Description: The main objective of this program was to develop an efficient and economically viable microwave processing technique to process cobalt cemented tungsten carbide with improved properties for drill-bits for advanced drilling operations for oil, gas, geothermal and excavation industries. The program was completed in three years and successfully accomplished all the states goals in the original proposal. In three years of the program, we designed and built several laboratory scale microwave sintering systems for conducting experiments on Tungsten carbide (WC) based composites in controlled atmosphere. The processing conditions were optimized and various properties were measured. The design of the system was then modified to enable it to process large commercial parts of WC/Co and in large quantities. Two high power (3-6 kW) microwave systems of 2.45 GHz were built for multi samples runs in a batch process. Once the process was optimized for best results, the technology was successfully transferred to our industrial partner, Dennis Tool Co. We helped them to built couple of prototype microwave sintering systems for carbide tool manufacturing. It was found that the microwave processed WC/Co tools are not only cost effective but also exhibited much better overall performance than the standard tools. The results of the field tests performed by Dennis Tool Co. showed remarkable advantage and improvement in their overall performance. For example: wear test shows an increase of 20-30%, corrosion test showed much higher resistance to the acid attack, erosion test exhibited about 15% better resistance than standard sinter-HIP parts. This proves the success of microwave technology for WC/Co based drilling tools. While we have successfully transferred the technology to our industrial partner Dennis Tool Co., they have signed an agreement with Valenite, a world leading WC producer of cutting and drilling tools and wear parts, to push aggressively the new microwave technology ...
Date: November 1, 2000
Creator: Agrawal, Dinesh & Roy, Rustum
Partner: UNT Libraries Government Documents Department

DEVELOPMENT OF ADVANCED DRILL COMPONENTS FOR BHA USING MICROWAVE TECHNOLOGY INCORPORATING CARBIDE, DIAMOND COMPOSITES AND FUNCTIONALLY GRADED MATERIALS

Description: The microwave processing of materials is a new emerging technology with many attractive advantages over the conventional methods. The advantages of microwave technology for various ceramic systems has already been demonstrated and proven. The recent developments at Penn State have succeeded in applying the microwave technology for the commercialization of WC/Co and diamond based cutting and drilling tools, effectively sintering of metallic materials, and fabrication of transparent ceramics for advanced applications. In recent years, the Microwave Processing and Engineering Center at Penn State University in collaboration with our industrial partner, Dennis Tool Co. has succeeded in commercializing the developed microwave technology partially funded by DOE for WC/Co and diamond based cutting and drilling tools for gas and oil exploration operations. In this program we have further developed this technology to make diamond-carbide composites and metal-carbide-diamond functionally graded materials. Several actual product of diamond-carbide composites have been processed in microwave with better performance than the conventional product. The functionally graded composites with diamond as one of the components has been for the first time successfully developed. These are the highlights of the project.
Date: January 1, 2003
Creator: Agrawal, Dinesh & Roy, Rustum
Partner: UNT Libraries Government Documents Department

Improved Tubulars for Better Economics in Deep Gas Well Drilling using Microwave Technology

Description: The objective of the research program has been to improve the rate-of-penetration in deep hostile environments by improving the life cycle and performance of coiled-tubing, an important component of a deep well drilling system for oil and gas exploration. The current process of the manufacture long tubular steel products consists of shaping the tube from flat strip, welding the seam and sections into lengths that can be miles long, and coiling onto reels. However, the welds, that are a weak point, now limit the performance of the coil tubing. This is not only from a toughness standpoint but also from a corrosion standpoint. By utilizing the latest developments in the sintering of materials with microwave energy and powder metal extrusion technology for the manufacture of seamless coiled tubing and other tubular products, these problems can be eliminated. The project is therefore to develop a continuous microwave process to sinter continuously steel tubulars and butt-join them using microwave/induction process. The program started about three years ago and now we are in the middle of Phase II. In Phase I (which ended in February 2005) a feasibility study of the extrusion process of steel powder and continuously sinter the extruded tubing was conducted. The research program has been based on the development of microwave technology to process tubular specimens of powder metals, especially steels. The existing microwave systems at the Materials Research Laboratory (MRL) and Dennis Tool Company (DTC) were suitably modified to process tubular small specimens. The precursor powder metals were either extruded or cold isostatically pressed (CIP) to form tubular specimens. After conducting an extensive and systematic investigation of extrusion process for producing long tubes, it was determined that there were several difficulties in adopting extrusion process and it cannot be economically used for producing thousands of feet long green ...
Date: February 1, 2006
Creator: Agrawal, Dinesh; Gigl, Paul & Dennis, Mahlon
Partner: UNT Libraries Government Documents Department

IMPROVED TUBULARS FOR BETTER ECONOMICS IN DEEP GAS WELL DRILLING USING MICROWAVE TECHNOLOGY

Description: The main objective of the research program has been to improve the rate-of-penetration in deep hostile environments by improving the life cycle and performance of coiled-tubing, an important component of a deep well drilling system for oil and gas exploration, by utilizing the latest developments in the microwave materials technology. Originally, it was proposed to accomplish this by developing an efficient and economically viable continuous microwave process to sinter continuously formed/extruded steel powder for the manufacture of seamless coiled tubing and other tubular products. However, based on the results and faced with insurmountable difficulties in the extrusion and de-waxing processes, the approach of achieving the goals of the program has been slightly changed. In the continuation proposal an approach of microwave sintering combined with Cold Isostatic Press (CIP) and joining (by induction or microwave) is adopted. This process can be developed into a semi-continuous sintering process if the CIP can produce parts fast enough to match the microwave sintering rates. Originally, the entire program was spread over three phases with the following goals: Phase I: Demonstration of the feasibility concept of continuous microwave sintering process for tubular steel products. Phase II: Design, building and testing of a prototype microwave system which shall be combined with a continuous extruder for steel tubular objects. Phase III: Execution of the plan for commercialization of the technology by one of the industrial partners. However, since some of the goals of the phase I were not completed, an extension of nine months was granted and we continued extrusion experiments, designed and built semicontinuous microwave sintering unit.
Date: March 1, 2005
Creator: Agrawal, Dinesh; Gigl, Paul; Dennis, Mahlon & Stanley, Roderic
Partner: UNT Libraries Government Documents Department

Improved Tubulars for Better Economics in Deep Gas Well Drilling using Microwave Technology

Description: The main objective of the entire research program has been to improve the rate-of-penetration in deep hostile environments by improving the life cycle and performance of coiled-tubing, an important component of a deep well drilling system for oil and gas exploration, by utilizing the latest developments in the microwave materials technology. Based on the results of the Phase I and insurmountable difficulties faced in the extrusion and de-waxing processes, the approach of achieving the goals of the program was slightly changed in the Phase II in which an approach of microwave sintering combined with Cold Isostatic Press (CIP) and joining (by induction or microwave) has been adopted. This process can be developed into a semicontinuous sintering process if the CIP can produce parts fast enough to match the microwave sintering rates. The main objective of the Phase II research program is to demonstrate the potential to economically manufacture microwave processed coiled tubing with improved performance for extended useful life under hostile coiled tubing drilling conditions. After the completion of the Phase II, it is concluded that scale up and sintering of a thin wall common O.D. size tubing that is widely used in the market is still to be proved and further experimentation and refinement of the sintering process is needed in Phase III. Actual manufacturing capability of microwave sintered, industrial quality, full length tubing will most likely require several million dollars of investment.
Date: July 31, 2007
Creator: Agrawal, Dinesh; Gigl, Paul; Hunt, Mark & Dennis, Mahlon
Partner: UNT Libraries Government Documents Department