Well Construction Technology Efficiencies - Research Efforts of the United States Department of Energy, Geothermal Technologies

Transcription

1 Well Construction Technology Efficiencies - Research Efforts of the United States Department of Energy, Geothermal Technologies 2013 IEA-GIA / EDC Joint Seminar Taal Vista Hotel, Tagaytay, Philippines 21 September 2013 Stephen Bauer Sandia National Laboratories representing U.S. Department of Energy SAND Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy s National Nuclear Security Administration under contract DE-AC04-94AL85000.

2 Presentation Objective Provide an overview of US DOE well construction research and introduce Annex VII Broad portfolio Description necessarily incomplete Examples are provided but biased by presenter s affiliation

3 EGS Cost Analysis Well Construction Costs Cement SAND (2008) Trip Drilling BHA Casing Cement BHA Trip Drilling Well cost (%) breakdown by task. Well construction task time percentages. Research Portfolio Intended to Address Major Cost Drivers

4 Drilling Technologies Pressure/Temperature Gradient Induced Drilling (Los Alamos National Lab) Microholes with Abrasive Slurry Jet Technology (Impact Technologies, LLC) Stinger Enhanced Bits (Novatek, Inc.) Wear-Resistant NanoComposite Coatings (Oak Ridge National Lab) HT Directional Drilling Systems (Baker Hughes, Inc. ) Field Trials of Drilling Systems (Sandia National Labs) HT Auto Indexers for DTHH (Sandia National Labs) HT Downhole Motors (Sandia National Labs)

5 Casing and Cementing Casing Material Corrosion/Erosion Studies (Oak Ridge National Lab) Improved Geothermal Cements (Trabits Group) Multi-Function Cement For Geothermal Wells Self Degrading and Expandable Cements (Brookhaven National Lab) Expandable Casing for HT Wells (Geothermal Expandables)

6 Zonal Isolation / Completion HT/HP Gel for Lost Circulation Control (Clean Tech Innovations, LLC) Temporary Sealer to Address Fluid Loss (Brookhaven National Lab) Geopolymer Sealing Materials (Brookhaven National Lab) Consumable Structural Elements/Packers (Sandia National Labs) Temporary Bridging Agents (CSI Technologies, LLC) Perforating Systems (Schlumberger) Controlled Rapid Wellbore Pressurization (Sandia National Labs) Acoustic Borehole Imaging (Baker Hughes) HT PT Flow Tools (Perma Works, LLC)

7 Enabling Technologies HT MWD Components (Honeywell International, GE Global Research, Sandia National Labs) Super Critical PTC / Fluid Sampler (Sandia National Labs) HT Borehole Seismic Monitoring Tool (Sandia National Labs) HT Copper/Fiber Wireline (Draka Cableteq USA) HT Fiber Optic Data Transmission System (Sandia National Labs) MCM Development for HT Accelerometer Measurements (Sandia National Labs) SiC Sensor Technologies (UC Berkeley) HT Circuit Boards (CTD, Inc.) HT Neutron Imaging (Oak Ridge National Lab) Acoustic Sensors for Fluid Monitoring (Los Alamos National Lab) Far Field Downhole EM (Argonne National Lab)

8 Field Trials of Drilling Systems Sandia National Laboratories Apply mature/proven rock penetration systems used in Oil & Gas/Minerals industry to improve geothermal drilling technology Partner with Ormat Navy Geothermal Program Barber Drilling National Oilwell Varco Reed Hycalog Atlas Copco

9 DTTH Research Sandia National Laboratories Hammers are a very efficient method to drill hard rock Current limitations in HT Environment Working with DOE and Industrial partners in HT hammers and downhole motors

10 Cements Brookhaven National Laboratory Corrosive-Resistant Foamed Cement Composites Thermal shock resistant, self-healing, ductile, corrosive resistant, thermally insulating cement Light weight (foam) cement capable of easy application. Protect the wellbore integrity against common geothermal failure risks such as, thermal cycling, thermal expansion, corrosion by H2S/carbonic acid. Compressive strength > 1000 psi, 200 o C Conventional foamed cement Corrosion-resistant foamed cement Self-Degradable Temporary Cementitious Sealers Developing a temporary cementitious sealer that is degrades through a combination of high temperature and water injection. Compressive strength >2000psi in most fracture networks Provide the geothermal industry with the reduction of total costs of sealing and multi-fracture drilling operations. Conventional well cement Before Thermal shockresistant cement After water-catalyzed self-degradation of cement at 200 C

11 High-Rate Well Stimulation Methods Sandia National Laboratories Develop new high energy stimulation techniques to enhance EGS permeability through dynamic loading of the formation Enable near wellbore fracturing along with shear destabilization in the far field Novel reactive gas generating materials and injection methods to fracture the formation are being developed suitable for use at EGS well temperatures

12 High Temperature PT/Flow Perma Works Nearingthe completion of a well monitoring systemfor EGS. Pressure and Temperature already exists Solid-state flow testing underway Continuous monitoring up to 280 o C 50 Hz recording Electronics are over temperature tolerant and tolerant of exposure to geothermal brines Flow loop testing

13 Chemical Sensing Tool Sandia National Laboratories Goal: Design and built a prototype chemical sensing tool that can measure tracer concentration along the length of a wellbore This tool will increase data resolution and provide new types of data for the characterization of fracture networks in enhanced geothermal systems Joint effort between Geothermal Research and Chemical Sensing Departments Tracer Injection Current Method Measure integrated tracer concentration at the surface New Method Measure tracer concentration in each fracture zone 13

14 High Temperature Seismic Tool Sandia National Laboratories Capabilities Operation up to 210 o C SOI electronics except FPGA and Primary ADC 24-bit ADC Three-axis accelerometer measurements 30 Hz 1000 Hz bandwidth 20 V/g sensitivity 295 μg 165 mg measurement range

15 GT-Mod: Geothermal Systems Analysis Sandia National Laboratories Physics based systems analysis for Economic Valuation and Risk Assessment Capture feedback between power production, reservoir performance, and system design Economic Valuation provided through two-way communication with GETEM Industry standard for economic evaluation Risk Assessment Probabilistic simulation of: All GETEM inputs Physical system inputs Probability based outputs Stochastic reservoir performance modeling Homogeneous Heterogeneous Well configuration (vertical, horizontal, etc.)

16 Example Sandia National Laboratories

17 Managing Exploration Costs Implementing Lower-cost Drilling Techniques Full size wells Core wells Slim Slim wells wells Full size wells Information Courtesy of 17

18 Advanced Geothermal Drilling and Logging Technologies IEA-GIA Annex VII 21 st September 2013 Tagaytay, Philippines Stephen Bauer (on behalf of the US DOE) Sandia National Laboratories Geothermal Drilling Research and Geomechanics Research Technical Manager Geomechanics Laboratory

19 Why Annex VII? Drilling is expensive as much as 50% of total project cost Drilling research < 10% of published geothermal papers Lower drilling costs are critical to access deeper resources

20 Annex VII History & Tasks Prepare a well cost model and performance database to collect and compare drilling costs among countries and sponsors Elucidate Best Geothermal Drilling Practices Advanced drilling and logging collaboration facilitates collaborative testing of drilling and logging tools and techniques among countries. Annex VII

21 Objectives Promote ways and means to reduce the cost of geothermal drilling Develop an understanding of geothermal drilling needs Elucidate best practices Foster an environment and mechanisms to share methods and means to advance the state of the art. Annex VII

22 IEA/GIA Annex VII Advanced Geothermal Drilling and Logging Technologies Official Participants: Australia European Commission Iceland Mexico New Zealand Norway United States Annex VII

23 Recent Accomplishments 1-Development of a well cost model to estimate Geothermal Well Construction Costs, Currently being Beta tested in GETEM Model by US DOE 2-Organized and Conducted Session at: 47th US Rock Mechanics/Geomechanics Symposium as part of ARMA Geomechanical Challenges Associated with Geothermal Drilling, Stimulation and Production Session: June 2013 in San Francisco, California, USA 20 Papers, from 7 countries: Australia, Germany, France, Iceland, Iran, Norway, USA 3- Geothermal Drilling Best Practices Handbook

24 Handbook of Best Practices for Geothermal Drilling Prepared for the International Energy Agency, Geothermal Implementing Agreement, Annex VII by John Finger and Doug Blankenship Sandia National Laboratories 2010 Abstract This Handbook is a description of the complex process that comprises drilling a geothermal well. The focus of the detailed Chapters covering various aspects of the process (casing design, cementing, logging and instrumentation, etc) is on techniques and hardware that have proven successful in geothermal reservoirs around the world. The Handbook will eventually be linked to the GIA web site, with the hope and expectation that it can be continually updated as new methods are demonstrated or proven. SAND

25 Discussion Comments Thank you GIA Annex VII

26 Thank You