innovative drilling and production technology for deep geothermal...

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© 2016 BAKER HUGHES INCORPORATED. ALL RIGHTS RESERVED. TERMS AND CONDITIONS OF USE: BY ACCEPTING THIS DOCUMENT, THE RECIPIENT AGREES THAT THE DOCUMENT TOGETHER WITH ALL INFORMATION INCLUDED THEREIN IS THE

CONFIDENTIAL AND PROPRIETARY PROPERTY OF BAKER HUGHES INCORPORATED AND INCLUDES VALUABLE TRADE SECRETS AND/OR PROPRIETARY INF ORMATION OF BAKER HUGHES (COLLECTIVELY " INFORMATION"). BAKER HUGHES RETAINS ALL RIGHTS

UNDER COPYRIGHT LAWS AND TRADE SECRET LAWS OF THE UNITED STATES OF AMERICA AND OTHER COUNTRIES. THE RECIPIENT FURTHER AGREES TH AT THE DOCUMENT MAY NOT BE DISTRIBUTED, TRANSMITTED, COPIED OR REPRODUCED IN WHOLE OR

IN PART BY ANY MEANS, ELECTRONIC, MECHANICAL, OR OTHERWISE, WITHOUT THE EXPRESS PRIOR WRITTEN CONSENT OF BAKER HUGHES, AND MA Y NOT BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO BAKER HUGHES’ INTEREST.

Prof. Dr. – Ing. Joachim Oppelt Prof. Dr. – Ing. Sven Krueger Dipl.-Ing. Joerg Lehr

Dipl.-Ing. Matthias Moeller Dr.-Ing. Helmuth Sarmiento-Klapper Dr. – Ing. Ralf Mieting

Dipl.-Ing. Ingolf Wassermann Dr.-Ing. Michael Neubert M.Sc. Sergiy Grymalyuk

Technical University Dresden: Prof. Dr.- Ing. Günther Kunze Dipl. – Ing. Erik Anders

Technical University Freiberg: Prof. Dr.- Ing. Matthias Reich Dipl. – Ing. Franziska Lehmann

Leibniz University Hannover : Dr.- Ing. Thomas Hassel Dipl. – Ing. Aret Varahram

Innovative Drilling and Production Technology

for Deep Geothermal Wells

IEA Geothermal - Central and South America Workshop April 19th 2016 Cuernavaca

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PRESSURE PUMPING Cementing, hydraulic fracturing,

acidizing, stimulation, coiled tubing

About Baker Hughes

￭ Revenues: $24.6 billion

￭ R&D: $613 million

￭ 62,000 employees

￭ Facilities in 72 countries

Operations in 90+ countries

INDUSTRIAL SERVICES Refining, water management, petrochemical,

process and pipeline services, polymers and

well service products

COMPLETION and PRODUCTION Completion, intervention,

intelligent production systems,

artificial lift, completion fluids, oilfield

chemicals

*FY 2014: Baker Hughes

DRILLING and EVALUATION Drill bits, directional drilling,

formation evaluation, coring, surface

logging, wireline, drilling fluids

RESERVOIR DEVELOPMENT SERVICES Gaffney, Cline & Associates, reservoir engineering

and simulation, geological modeling and analysis,

software

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Motivation & Projects Goals

– Reduction of Cost per kWh „Stromgestehungskosten“

– Reduce non-productive time

– Reduce planning risks

– Improve safety and reliability

– Improved productivity over time

Source: BMU

Drilling

(70 %)

Production pumps (2%)

Stimulation (2%)

Planing (3%)

Else (3%)

Conversion equipment

(15%)

Thermal water cycle

(5%)

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Ways

￭ Innovative Wellbore Construction

￭ Drilling Process Control and Automation

￭ Advanced Drilling BHA

￭ Alternative Drilling Technologies

￭ Innovative Production Systems

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Innovative Wellbore Construction

VAM

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Well Designs

Standard Design Expandable Design

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Well Bore Construction Cost Analysis Workflow

￭ Well Bore Design

– Bore hole, casing, etc.

￭ Time

– Drilling, tripping, etc.

￭ Cost

– Drilling service, rig, fluid service, completion service, etc.

– Condensed Cost

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Innovative Monobore Wellbore Construction Cost Savings

26%

18%

10%

9%

7%

6%

6%

4%

4%

3%2%

2% 2% 1%

Standard Design 14.7 Million EUR

Contract Rig

Casing / Liner / Expandable

Drilling Fluid Services

Completion

Directional Drilling Services

Well Planning / -Preparation

Electric Wireline Logging

Drilling Bits

Cementing Services

Mobilization- / Demobilization Rig

Mud Logging

Waste Management

Personnel Cost

Coring Equipment Services

29%

11%

10%8%

7%

7%

7%

6%

5%

3%

3%2% 1%1%

Expandable Design12.8 Million EUR

Contract Rig

Casing / Liner / Expandable

Completion

Directional Drilling Services

Electric Wireline Logging

Drilling Fluid Services

Well Planning / -Preparation

Drilling Bits

Cementing Services

Mobilization- / Demobilization Rig

Mud Logging

Personnel Cost

Waste Management

Coring Equipment Services

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Innovative Monobore Wellbore Construction Process

Gesamtansicht

http://www.dea-group.com/de/technologie/bohrung/expandable-tubular-verrohrung

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Innovative Monobore Technologies for Geothermal Applications

High Temp Metal to Metal Hanger/Packer

Expansion System

Monobore Installation

Welded Connections

VAM

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Expandable Welding Technology

Magnetic Impelled Arc Welding

• Short welding times

• High level of automation

• Combinations of materials

• High welding quality

• High temperature gas tight

Welded 9.5/8” N80 Tubular at Leibniz University Hannover

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Drilling Process Control and Automation

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Drilling Systems Automation

• Reduce Well Delivery Costs • Reduce Operational Risk

OBJECTIVES

* 10 levels of automation following Sheridan & Verplank

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Conventional vs. Automated Drilling Systems Control

Driller <<action>>

<<monitor>>

Rig Sensors: RPM, WOB, …

set point control and validation

Controller (PLC)

Rig Actuators - Drawworks - Top drive - Mud pump

in-the-loop control

<<actuate>>

<<measure>>

Field Engineer

<<m

on

ito

r>>

Conventional

Service Company Displays

Automation

Driller Advisor App Monitor App

<<recommend>>

<< feedback >>

<<recommend>>

<< feedback >> Control App

<<ac

tio

n>>

<<m

on

ito

r>>

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Remote Operating

Center

OPC UA

Operators

Remote Operating

Center

OPC UA

OPC UA

Drilling Fluid

OPC UA

Downhole

DSA Applications

OPC UA

OPC UA

Surface Logging

Service Companies

Remote Operating

Center

OPC UA

Driller's Display

OPC UA

Drilling Rig

Drilling Rig

Gateway

OPC UA

Rig Contractors

OPC UA Aggregation Server

Equipment Suppliers

Drilling Automation System Architecture

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Advanced Drilling Technology

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Advanced Drilling BHA

with integrated GaugePro™ Echo Reamer and AutoTrak Steering Unit

Near Bit Gamma +5 ft.

MWD/LWD Steering Unit

8 ¼" BHA, 10 5/8" x 12 ¼"

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Alternative Drilling Technology Future

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Bit Example 6“ Electrode – Granite drilling test in Water under atmospheric pressure

Electro Impulse Drilling

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High Pressure Performance Feasibility

Electro Impulse Research Lab and Team TU Dresden and TU Freiberg

500 Bar (~7k psi) Granite Test-samples

Drilling Simulator of TU Clausthal in Celle

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BHA Example Electric Impulse Drilling

Mud Motor + Gear Box

Alternator + Transformer

Marx Generator + Trigger

Rectifier

Electrode

System Concept: TU Bergakademie Freiberg and TU Dresden

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Innovative Production Systems

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Innovative and Reliable Production Systems

• Geothermal ESP

• Heat Exchanger Design

• Tubular Connection

• High Temperature Packer

• Scaling and Corrosion

Monitoring

• Reservoir Monitoring

• Self-driving after initiation?

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Baker Hughes, Geothermal ESPs

ESP swap at Unterhaching

None Public Picture

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Challenges of Geothermal Applications

Combination of

High motor power requirements (voltage max. 6,5kV)

Frequent speed adjustments / power cycles

Frequent thermal cycles

High fluid flow, high flow velocities

Temperatures > 140°C

Shallow installation depth (low ambient pressure)

Scales from thermal water (calcium carbonate)

scaling from production tubing

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ESP-Development in Celle

Team of 5 conducts

￭ Lab and field testing

￭ Failure investigation, materials examination

￭ Reliable motor bearing development

￭ Scale resistant pump development

￭ Geothermal seals development

for reliable oil containment

￭ 175°C ESP-gauge electronics development

with failure prediction board layout for 175°C gauge electronics

geothermal pump prototypes (100 l/s, 200l/s)

Non Public Picture

Non Public Picture

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Hi-Tempemperature Test-Bench: „HotLoop“

High temp pressure vessel

control room

High-flow pump-test-bench

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„Thermal cycle“ tests

• automated thermal cycle testing (5 cycles/day)

• increased stress on insulation materials

• increased load for length and oil compensation

• permanent temperature measurement on outer face seal

resistance &

insulation measurement

140°C

65°C

pre-heat 1 cycle

60Hz 38Hz

Stop /

Start

Stopp /

Start

Stopp /

Start

60Hz

water temperature

t

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FLEX- ESP Development

High Power FLEX-pumps

developed for:

￭Wider, more flexible, flow operating

range for power plant demand

adjustment

from 75 – 100% => 40 – 100%

￭Optimized power efficiency

from 79 => 82%

Operational Flexibility in Liter/second

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Design Improvement of Pump Bearings

￭ Scaling on bearings after short time

￭ Bearings get blocked, ESP shafts twist off

￭ Improved and tested design

￭ No failures after implementation in 7 wells

Non Public Picture

Non Public Picture

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Long Term Corrosion Investigation in North German Brine

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© 2009 Baker Hughes Incorporated. All Rights Reserved. 32

Our Purpose: enabling safe, affordable energy, improving people’s lives. Martin Craighead, Chairman and CEO

innovative drilling and production technology for deep geothermal...

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