electro impulse drilling and innovative configuration of...
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Confidential. Not to be copied, distributed, or reproduced without prior approval. © 2017 General Electric Company - All rights reserved
Electro Impulse Drilling and Innovative Configuration of Advanced Drilling SystemsJoerg Lehr & Stefano Capodanno BHGE
Erik Anders & Matthias Voigt TU Dresden
Franziska Lehmann TU BA Freiberg
November 13, 2017
IEA-Geothermal Workshop Hanoi
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Table of content• BHGE Fullstream Geothermal Solutions
• Geothermal Drilling Solutions
- Integrated drilling service application research and development
- Innovative configuration of Advanced Drilling Systems
- Granite Drilling Application Example in Vietnam
• Geothermal Drilling Research
Alternative Drilling Technology
Electro Impulse Drilling Technology and Drilling System
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Fullstream Geothermal Solutions
Confidential. Not to be copied, distributed, or reproduced without prior approval.
~70,000+ employees
120 countries
The first and only fullstream company
+ =GE Oil & Gas
Since July 2017:
The Geothermal world cloud
Expected new installed capacity of
200 MW/yr in the next years
Available all year-longLCOE has reached grid parity
(from 40 to 120 $/MWh depending on the region) and is expected to
drop through 2050
Global geothermal power capacity by the end of 2016 is
12.7 GW - 0.3% of global electricity generation
Shift from Steam Turbines to ORC cycles
Deep and directional wells required for new capacities
Easy resoucres finished:Enhanced geothermal systems
Environmental, social and administrative barriers
Footprint required to
produce the same power with solar PV is around 10 times
higher
RENEWABLE
CHALLENGING GROWING POTENTIAL
Modulable baseload capacity
Risky and capital-intensive:50% CAPEX during surface
explorations and drilling operations
From high enthalpies to
medium/low enthalpies
Confidential. Not to be copied, distributed, or reproduced without prior approval.
6
The BHGE Fullstream Geothermal Solutions
Well• Submersible Pumps
• Well Head Equipment
• Logging Technology
Power Delivery• Primary Equipment
• Power Sensing & Quality
• Protection & Control
• Energy Services
• Automation
• Remote M&D
Power Island
• Steam Turbine & Generators
• ORC systems & expanders
• Condensate & Re-injection Pumps
• Air Cooled Condensers
• Power Services
• Remote M&D
Drilling• Drill-bits
• Directional Drilling
• Formation evaluation
technologies
• Cementing services
• Completion and
production technologies
• Fishing services
• Chemical services
Confidential. Not to be copied, distributed, or reproduced without prior approval.
7
Technology Solutions across the FullstreamBHGE a reliable geothermal partner
2007: Hybrid Plant (ST+ORC 58 MW) installed in Berlin, Salvador
2015: Full reinjection ORC Plant (5 MW) ordered at Castelnuovo, Italy
Since the 80’s Well Operations ServicesTuscany, Italy
1973: First Steam Turbine(132 MW) installed at The Geysers, California
2000: Dry Steam Turbines(180 MW) installed in Tuscany,
Italy
CENetic ESP(Increased Flow Rate 83%) installed in Reno, Nevada
Confidential. Not to be copied, distributed, or reproduced without prior approval.
8
Drill Bits Quantec™ Force PDC
Kymera™ HybridVanguard™ bits (>288º C )
Motors X-treme, Performance
(to 160- 200 Cº )
Automated drilling systems
Auto-Trak™ (175 Cº)
Fluids PYRO-DRILL™ drilling
fluids (340 Cº )
MWD/LWD (150 C - 175 Cº )
Wireline NAUTILUS ULTRA™
XMAC F1 (232 Cº)
Coring HT™ core barrels and disposable steel inner
barrels (>163 Cº )
Cementing eXtreme set (312 Cº)
Underground systems- Drilling and Evaluation
Confidential. Not to be copied, distributed, or reproduced without prior approval.
9
Completion systemsExternal casing packers
Casing exit systems
Hydraulic fracturing/ stimulation
Planning, monitoring, evaluating
Wellbore interventionretrieving tools
ESPCENetic Geothermal Pump
(200 Cº)
Specialty Chemical Flow assurance control
Scale Control, O2 scavenger, corrosion inhibitors, biocide
Underground systems- Completion and Production
Confidential. Not to be copied, distributed, or reproduced without prior approval.
10
BHGE Main Drilling Projects
Iceland
France /Germany
NicaraguaEl Salvador
Costa Rica
Italy
Hawaii
Nevada
California
Mexico
Denmark
Sweden
Chile
Azores
Kenya
Djibouti
Indonesia
Philippines
Australia
Japan
New Zealand
Canada
144 projects – 1,800+ wells
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Research and Development Motivation & GoalsFurther Reduction of Cost / MWh Reduction of Capital Cost / kW installed
Efficient Wells- Reduce planning risks- Improved reliability- Improved safety at reduced cost
Optimized Production- Optimize power efficiency
Improved Recovery - Accumulated production at and over time
Secure Abandonment- Reduction of environmental impact and avoidance of consequential charges
Geothermal Power Plant Cost Distribution
Source: BMU Germany
Drilling
(up to 70 %)
Production pumps (2%)
Stimulation (2%)
Planing (3%)
Else (3%)
Conversion equipment
(15%)
Thermal water cycle
(5%)
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Geothermal Drilling SolutionsIntegrated drilling service application research and development
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Research & Development Focus
• Innovative Wellbore Construction
• Drilling Process Control and Automation
• Advanced High Temperature Drilling BHA
• Alternative Drilling Technologies
• Innovative Production Systems
Confidential. Not to be copied, distributed, or reproduced without prior approval.
November 18, 2017 14
Integrated Drilling Services
Total wellbore planning, construction, and management….
Feasibility studies,
well cost estimation,
and field
development plan
assistance
Advanced well engineering
and design, well placement
reviews; geo-mechanical,
reservoir and borehole
stability analysis
Detailed wellbore
construction
program with
maximum
efficiency and
less surprises
Client
BHGE
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Problem Statement
15
• Drilling operation in sediments or in deep crystalline hot rock are characterized by inconsistent performance and high bit wear
• Depth and horizontal reach of wells are limited by weight of the BHA (WOB) and mechanical and hydraulically transmission of power
• In the E&P industry, drilling and completion expenses and return on investment are comparable
Geothermal Applications
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Problem Statement
16
Representative Reduction of Rate of Penetration vs. Depth and Rock Strength
Source: MAURER, novel drilling techniques
confirmed at Continental Deep Drilling Project in Germany
Total Vertical Depth of
Well [m]
Rate of Penetration ROP - [meter/hour]
Rock-type
„Soft“
(σD˂ 50 MPa)
Medium
(σD = 50-100 MPa)
Hard
(σD ˃ 100 MPa)
0 – 2.000 15 – 50 5 – 15 1 – 5
2.000 – 4.000 10 – 30 4 – 10 1 – 4 (4 – 8)*
4.000 – 6.000 6 – 20 2 – 6 1 – 2 (2 - 3)**
6.000 – 8.000 N/A 1 – 2 1 – 2
(Source*: Baker Hughes Motors, RSS and WOB & vibration control SPE 122690, Promising Results from First Deployments of Rotary Steerable Technologyin Vietnam Basement Granite)
8.000 – 10.000 N/A N/A 1 or 2 ?
10.000 – 12.000 N/A N/A 0,5 or 1 ?
(Source**: Deep Geothermal Well in Granite Europe )Alternative
Technologies
DrillingOptimization
Based on summariesd data of mentioned literature sources – current ROP of drilling systems on the market might be different depending on geology and application
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Problem Statement
17
Geothermal Hard Rock Applications
• Drill bit wear in deep Hard Rock drilling (4500 - 5000 m Vertical Depth)
conventional
drilling head70 m heavy wear2 - 3 m/h
weight on
bottom
high NPT and
bit consumption400 m/h 7 times
trippinghigh costs
source: http://www.icyte.comsource: http://www.frbiz.com
Click on Picture to start Video
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Solutions
18
•Utilization of Innovative Drill Bits
•Optimized Bottom Hole Assemblies (BHA) for each section of well path
•Precise Wellbore placement and High Build Steering capability
•Virtualization and Automation
•Research and Development on alternative Drilling Technologies
Geothermal Applications
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Geothermal Drilling SolutionsInnovative Configuration of Advanced Drilling Systems
Confidential. Not to be copied, distributed, or reproduced without prior approval.
20
Innovative Drill Bits𝐊𝐲𝐦𝐞𝐫𝐚𝐓𝐌 Hybrid bits: • Drill more than twice as fast as premium
roller-cone bits• Excellent directional performance on
steerable motor• More efficient drilling using less WOB
than roller-cones
Ensure Performance at High Temperatures:
Insert 𝐓𝐫𝐢𝐜𝐨𝐧𝐞𝐓𝐌 bits: • Patented in 1923, developped to
maximize performances• Higher ROP with lower cost-per-foot
𝐕𝐚𝐧𝐠𝐮𝐚𝐫𝐝𝐓𝐌 Geothermal bits:• Patented metal-face seal allowing
continuous drilling up to 550°C• Reduces bit trips
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Optimized BHA Solutions
21
•Rotary Steerable Systems (RSS, AutoTrak TM)
•Rib Steered Motors (VertiTrak TM, CoilTrak TM)
in combination with advanced DH Motor systems and innovative BHGE Drill Bits
50 – 100 % improved drilling performance with Semi Automated Rotary Drilling Systems utilization
MWD/LWDRSS Steering Unit BitStabilizerFlex
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Drilling Solution Example
22
Deployment of BHGE Rotary Steerable Technologyin Vietnam Basement Granite
BHGE Express BHA RSS Type A
Planned well path of Azurite 8 ½” section in basement granite
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Drilling Solution Results
23
Advanced BHA design enables potential to drill >2 timesof a typical bit run time and distance
less Bit consumption less Non Productive Time ‘NPT’ less Cost per Foot
Online drilling parameter observation and control
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Geothermal Example
24
Geothermal Wells in BavariaDuerrnhaar and Kirchstockach KST GT2
AutoTrak Express BHA
Well path example of Geothermal Well in Molasse Basin
• Central Well places
• Cost ~ 25 Mill EUR
• High build rate 8 ½“ hole to secure 125 – 140 l/s production rate
• BHGE Drilling Service enables ~80 % increase in drilling efficiency,saving 16 days of KST GT2
• 8 days saved for completion of welldue to high wellbore quality
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Driller<<action>>
<<monitor>>
Rig Sensors: RPM, WOB,
…
set point controland validation
Controller(PLC)
Rig Actuators- Drawworks- Top drive- Mud pump
in-the-loop control
<<actuate>>
<<measure>>
BHGE Field
Engineer<
<in
tera
ctio
n>
>
Conventional
Automation
PRIDIX
<<recommend>>
<< feedback >>
<<
acti
on
>>
<<
mo
nit
or>
>
<< interaction >>
Solution
Assisted Automated Drilling Systems Control
Real-time reservoir navigation plot of a record well
Real-time drilling performance plot of record well
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Automated Drilling Vision
26
Continuous Drilling and Navigation with fully Automated Coiled Tubing System
Continuous Drilling
with automated reservoir navigation
“Geo-Steering”
to drill multilateral wells of heat exchanger
of Geothermal Well with Monobore Completion
WildCat Project Video , High Build Automated Motor System for CT Drilling BHGE, 2014
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Geothermal Drilling ResearchAlternative Drilling Technology Research
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Problem Statement
28
Still Bit Wear and Depth/Reach Limitations in Geothermal Hard Rock Applications
• Drill bit wear in deep hard rock drilling (granite, 4500 - 5000 m)
conventional
drilling head70 m heavy wear2 - 3 m/h
weight on
bottom
high NPT and
bit consumption400 m/h 7 times
trippinghigh costs
source: http://www.icyte.comsource: http://www.frbiz.com
Click on Picture to start Video
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Solutions
29
Research and Development on alternative Electro Impulse Drilling Technology
EIT-drilling head 500 mclose to no wear
of electrodes3 m/h
electric contact
to bottom
low NPT single trip400 m/h>20 %cost saving
Click on Picture to start Video
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Electro Impulse Drilling
30
Working Principle of Electro Impulse Drilling Technology
time in ns
granite
water
die
lectr
icstr
ength
puls
e fie
ldstr
ength
in k
V/m
m
Confidential. Not to be copied, distributed, or reproduced without prior approval.
High Voltage / High Pressure Drilling Simulator
November 18, 2017 31
Design and Test
Plasma Light Reflection
Rock Sample
Confidential. Not to be copied, distributed, or reproduced without prior approval.
High Voltage / High Pressure Drilling Simulator
32
• High Pressure Tests with OBM completed
• Significant reduction of Mechanical Specific Energy (MSE) with optimized Electrode
• MSE close to PDC bit in OBM
• High pressure dependency of MSE in Water and WBM.
• Improvement of Hole Cleaning required
Results
0 100 200 300 400 500
MSE [kJ/cm³] over Pressure [bar]
BHGE PDC
BHGE OBM & Optimized Electrode
State of the art
BHGE OBM & TUD Ring Electrode
Confidential. Not to be copied, distributed, or reproduced without prior approval.
High Voltage / Low Pressure Test Results
33
Real Size Granit Rock excavation in Oil Based Drilling Fluid under Lab conditions
311 mm , 12.5 inchHole in Granite Sample
Star Electrode Design
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34
• How to reduce high pressure dependency of MSE in Water and WBM ?
• How to achieve High Volume excavation ?
• Hole Quality, Cutting shape and size?
• Influence of - Electrode design- Test equipment- Electrical properties of Rock sampleand Fluid ‘impedance, permittivity’
- Porosity of samples
0
2
4
6
8
10
12
14
16
18
0 50 100 150 200 250 300 350 400 450 500
MSE [kJ/cm³] over pressure [bar]
MSE [kJ/cm³] TUD Electrode in Water 100 %
MSE [kJ/cm³] TUD Electrode in BHGE OBM
Linear (MSE [kJ/cm³] TUD Electrode in Water 100 %)
Linear (MSE [kJ/cm³] TUD Electrode in BHGE OBM)
Rock Excavation Efficiency under Pressure – Open Questions
High Volume Rock Excavation under Atmospheric pressure conditions in Water with 4” electrode design (16 cm³)
Confidential. Not to be copied, distributed, or reproduced without prior approval.
System- Evaluation and Test
TU BA Freiberg / TU DresdenField Lab
First Real Size Low Pressure In-Situ Test with an 12 ¼” Electrode
Logging of bottom of the wellborerevealed hole cleaning problems
November 18, 2017
35
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Results of in-situ Test
• First electric impulse drilling rig lab setup at University
• High Voltage Generator Module ‘HVG’ and Electrode tested in water under low pressure drilling conditions
• Excavation of 50 mm of cement with a diameter of 12 ¼”
• Logging of wellbore revealed hole cleaning problem as reason for low ROP
• High voltage insulation of HVG to be improved to avoid short circuits
• Additional test with improved hole cleaning and HVG required in 2018
Confidential. Not to be copied, distributed, or reproduced without prior approval.
Conclusion and Outlook
• Advanced Drilling Technology enables faster drilling of complex well profiles and reduction of non productive drilling time > 50%
• Alternative Deep Drilling technologies have to be developed to reduce bit exchange trips and related NPT with acceptable ROP under pressure
• Further research on physics of EIT is required to secure performance under DH pressure conditions
• Utilize Virtualization and Automation tools to maximize productivity and recovery with predictable performance as a foundation for future drilling technologies
Confidential. Not to be copied, distributed, or reproduced without prior approval.
39
Fullstream Geothermal Solutions in Competition
Geothermal
• Base Load
Available every day
over the entire year
• Independent from
Supply chain and fuel price
• Low CO2 emission and
ecological footprint
Source: LAZARD Levelized Cost of Energy Analysis - Version 10.0 Dez 2016 page 8https://www.lazard.com/perspective/levelized-cost-of-energy-analysis-100/
Levelized Cost / MWh in operation
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40
Fullstream Geothermal Solutions in Competition
Geothermal
• High Capital Cost
• High Capital Cost Variation
• Reservoir Risks for
Hydrothermal Resources
Source: LAZARD Version 10.0 Dez 2016 page 11
Capital Cost / kW installed