Use of Automated MPD to Eliminate Losses and Control Influx in Hot Fractured Rock Geothermal Wells

Presented during: The SPE Applied Technology Workshop on

Underbalanced and Managed Pressure Drilling: Technologies for Improving Drilling Performance, Enhancing Production, and Reducing Project Risk
12-15 O October 2008 Ho Chi Minh City, Vietnam C C

2008 At Balance All Rights Reserved

Australia Hot Fractured Rock Project

Map showing location of active drilling block GEL 98

Concept
Binary Geothermal Power Plant Heat Exchanger

Old dry gas wells

2

Insulating Sedimentary Rocks

4 4.5km

+ +

+ + +
270 C
0

+ +
Granite

Energy Production Potential

HFR potential
Defined resource potential > 10,000 MW 2.5 km2 will sustain 275 MWe (net) power station for 30 years

Reserves Equivalent
Thermal equivalent of 50 Bbbls of oil 12 x greater than NW shelf gas reserves in W.A.

Near term goal

500 MW by 2015 b

Long term goal

4,000 MW developed by 2030 25 percent of new energy generation Greenhouse gas reduction equivalent to 5 million cars
30 million tons of CO2

Project Drilling Status

Four Wells Completed To Date
Habanero 1 Habanero 2
Main hole Sidetrack 1 Sidetrace 2-4 UBD / MPD, 2004 MPD MPD, 2004 UBD, 2006 ,

Conventional, Conventional 2003

Habanero 3 Jolokia 1

UBD / MPD, 2008 UBD / MPD 2008 MPD,

Managed Pressure Drilling System

Constant Bottomhole Pressure Method

Habanero 2 Main & ST 1 MPD System

Manifold rated to 10,000 psi Experimental control system High pressure flow meter Rig pump #2 for backpressure HP & LP PRVs

Habanero 3 Equipment Layout

Manifold rated to 5,000 psi State of the art automation LP flow meter Dedicated pump

Connection Plot

BOP & Rotating Control Device

Rotating Control Device

Used to contain pressure during drilling and connections. Two different types used.
Smith HOLD 2500 and Weatherford 7100
Static 5000 psi / Dynamic 2500 psi.

Pack-off elements changed after each bit trip. No wear problems.

Habanero 1
Drilled conventionally with 5kpsi BOP stack. Started with 11.8 ppg 11 8 Weighted up to 15.8 ppg
Over pressured, required 10kpsi BOP pressured Added to energy potential

Recurring kicks, H2O, CO2 , Methane Gas. g , , Mud degraded by influxes. Lost circulation / kicks Drilling NPT = 60 days
Better method of controlling pressure required

Habanero 2
Drilled w/ MW below pore pressure (UBD).
Maintained BHP at 15.3 ppg with between 75 and 300 psi backpressure. Encountered first fracture and stopped influx by increasing backpressure. Mud M d system not tolerant to f l formation water. i Drilled ahead maintaining constant bhp at top fracture. ROP 6 -12 ft/hr. Approx 1.5 days to round trip. Using heavy mud. Total losses into lower fracture. Unable to establish circulation with LCM and still drill ahead Could not reduce BHP and prevent influx from top fracture. p p Drilled mud cap at reduced pump rate with no apparent plugging. BHA failure, fish left in hole.

Encountered a second (massive) fracture

ST- 1

MPD to maintain BHP at +/- 14 9 15 3 ppg 14.9 15.3 ppg. Did not intersect fractures. Suspected plugging due to mud cap but directional problems?

Would Prefer Not To Lose Heavy Mud Into Fractures

UBD Pressure Gradient

ST-2,3,4 HP UBD (increase ROP / prevent mud loss into Fractures)

Source: Presentation by Phil Frink Blade Energy Partners. Managed Pressure Drilling Geothermal applications SPE ATW, Phuket Thailand, June 11-14, 2006

Solution To Not Losing Mud Into Fractures

Habanero 2 ST 2,3,4 UBD

IADC Risk Class 3
> 5000 psi shut-in required.

ROP 5 20 ft / hr M 10 h Max hours d illi t drilling to reduce risk of bit failure. 3 days to round trip. Borehole stability? Hole cleaning problems. Drill string stuck / failures failures.
Source: Presentation by Phil Frink, Blade Energy Partners. Managed Pressure Drilling Geothermal applications SPE ATW, Phuket Thailand, June 11-14, 2006

High Pressure UBD Did Not Achieve Objectives

Bit Condition on Habanero 2 UBD st

3 Hours Using a High Speed Turbine

Habanero 3
Drilled 300 feet UBD for kick detection.
Minor kicks. Adjusted backpressure to stop influxes. Flow out increased > 500 gpm. 1.2 ft bit drop. Increased backpressure to control influx. 16.1 ppg equivalent. 1200 psi maximum surface pressure. New bit design ROP 10 12 ft / hr.

Drilled 150 feet MPD.

Mud weight increased to reduce surface pressure. Bottomhole pressure reduced to 15.3 ppg equivalent. New bit design ROP of 6 8 ft/hr ft/hr. No further kicks or losses.

Constant Bottomhole Pressure Effective in Controlling Well

14.8 ppg

In ncreased pump Q p

15.3 ppg

Ga at surface as
15.0 ppg

Flow Out Changes

16. ppg .1

Kick Detection & BHP Control

Flo owmeter Cali ibration Error used PVT r

15. ppg .2

Jolokia - 1
Drilled 3770 ft UBD and MPD 150 psi minimum / 1000 p maximum backpressure. p psi p Initial fracture identification via kick then MPD. Further identification assumed on drilling breaks and gas. Average ROP of 5 8 ft/hr Well circulated to heavy mud for trips. Backpressure t reduce swab effects while t i i out. B k to d b ff t hil tripping t Approximately 1.5 days to round trip. No mud losses losses. Objectives met without incident.

No NPT but need to improve ROP

Geodynamics Summary
Identified fractures using UBD. Initially stopped influxes with backpressure. Automated chokes with manual bhp setpoint. Minimized increase in mud weight. Eliminated NPT due to kicks / losses losses. HP UBD trips 2x as long as MPD. HP UBD / borehole stability / hole cleaning p y g problems. MPD borehole stability maintained. Short bit life due to granite and temperatures. Higher Hi h pressure RCD may b h l f l be helpful.
Reduce mud weight / solids. Reduce mud contamination problems.

Thank You

Special thanks to Geodynamics and Paul Fredericks, At Balance Americas for developing this presentation.

2008 At Balance All Rights Reserved