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At least 19 records

Significance and complications of drilling fluid rheology in geothermal drilling: A review

The harsh downhole conditions of high pressure and high temperature (HPHT) encountered in geothermal wells make the drilling operation challenging. Drilling in such environments requires a special drilling mud formulation with high thermal stability and good rheological properties to fulfill the drilling fluid functions. Therefore, great efforts should be put into selecting the suitable drilling fluid, optimize and monitor the drilling fluid properties throughout drilling operations, and predicting its performance under downhole conditions. Rheological properties significantly impact many drilling parameters such as hole cleaning, fluid and wellbore stability, wellbore hydraulics, torque and drag, and other drilling issues. This paper discusses water-based drilling fluids' flow behavior under HPHT conditions and highlights the significance of fluid rheology in geothermal drilling. The common challenges and complications related to fluid rheology encountered in geothermal drilling are addressed in this paper, such as hole cleaning, wellbore hydraulics, and drilling fluid stability. This article also reviews the recent advances in drilling mud systems, rheology enhancement, and rheological properties measurements at surface and subsurface conditions. Furthermore, the rheology models of drilling fluid at elevated temperatures are reviewed to fully understand their flow behavior and establish a method for drilling engineers to optimize fluid formulations for geothermal drilling.

58 GEOSCIENCES↗

Impact of drilling fluid rheology and wellbore pressure on rock cuttings removal performance: numerical investigation

Drilling fluids exhibit non-Newtonian behavior which is generally described in the literature by two rheological models: Power Law and Herschel-Bulkley models. We have used Eulerian- Eulerian multiphase flow model to evaluate the drilling fluid flow patterns and filter cake formation patterns for both models for ultra-deep drilling conditions. Simulated drilling fluid flow patterns clearly show that the Herschel - Bulkley model exhibits fewer vortices around the drilling pipe, indicating better rock cuttings removal performance. In addition to mud rheology, we have analyzed the pressure drop variation with the filter cake formation on the wellbore during ultradeep drilling process. We have shown that filter cake thickness at the wall linearly increases with differential pressure between the well and formation. This implies that the differential pressure needs to be optimized. Very thin filter cake may lead to excessive fluid seepage into the permeable subterranean vertical zone resulting in a loss of fluid circulation and hence in a loss of rock cuttings removal. Yet, very thick filter cake reduces the effective diameter of the hole which may lead to a poor rock cuttings removal performance and stuck pipe. The mathematical model presented here needs to be experimentally validated when filter cake thickness data in deep drilling conditions become available. The model could be useful to provide drilling engineers insight on the filter cake formation, drilling fluid flow pattern, and give guide-line to optimize the filter cake as field experimental data are scarce.

02 PETROLEUM↗

Rheological investigation of effect of high temperature on geothermal drilling fluids additives and lost circulation materials

High temperatures (HT) and the corrosive environment make the design of a geothermal drilling fluid a highly complex task. The presence of HT exacerbates the problems due to thermal degradation. Geothermal aquifers usually combine high-temperature and complex chemistry, making them highly corrosive. Although geothermal drilling fluids are exposed to thermal degradation, research of the effect on mud rheological properties in temperatures near or above 149°C (300°F) is limited. In this study, a High Pressure-High Temperature (HPHT) rheology setup was used to measure drilling fluids' properties up to 204.4°C (400°F). Rheological behavior of viscosity, density, lost circulation, and alkalinity control additives were analyzed at HT. It was found experimentally that Bentonite alone is thermally stable at HT. In contrast, Caustic Soda showed a tendency to gelate at temperatures above 93.3°C (200°F), adversely affecting mud rheology. Alkalinity control materials to replace Caustic Soda were evaluated. Among them, Lime presented the best thermal stability at 204.4°C with a range of variation of 0.0024 Pa.s (2.4 cP) on apparent viscosity after three consecutive tests. Besides, it was tested 11 different lost circulation materials (LCM) for understanding their rheological behavior at HT. Further, it was found that HT has less impact on fine granular materials rheological behavior with an average increase of 17.7% compared with the baseline. In contrast, flaky, fibrous, and coarse granular materials presented a more apparent impact in WBM rheology with a deviation of 166% compared with the baseline.

15 GEOTHERMAL ENERGY↗

Experimental Investigation of Inhibitive Drilling Fluids Performance: Case Studies from United States Shale Basins

Shale formations are attractive prospects due to their potential in oil and gas production. Some of the largest shale formations in the mainland US, such as the Tuscaloosa Marine Shale (TMS), have reserves estimated to be around 7 billion barrels. Despite their huge potential, shale formations present major concerns for drilling operators. These prospects have unique challenges because of all their alteration and incompatibility issues with drilling and completion fluids. Most shale formations undergo numerous chemical and physical alterations, making their interaction with the drilling and completion fluid systems very complex to understand. In this study, a high-pressure, high-temperature (HPHT) drilling simulator was used to mimic real time drilling operations to investigate the performance of inhibitive drilling fluid systems in two major shale formations (Eagle Ford Shale and Tuscaloosa Marine Shale). A series of drilling experiments using the drilling simulator and clay swelling tests were conducted to evaluate the drilling performance of the KCl drilling fluid and cesium formate brine systems and their effectiveness in minimizing drilling concerns. Cylindrical cores were used to mimic vertical wellbores. It was found that the inhibitive muds systems (KCl and cesium formate) provided improved drilling performance compared to conventional fluid systems. Among the inhibitive systems, the cesium formate brine showed the best drilling performances due to its low swelling rate and improved drilling performance.

04 OIL SHALES AND TAR SANDS↗

UT-GOM2-2 Drilling Fluid (Technical Note)

It is proposed that a salt-saturated, water-based mud might improve borehole stability for UT-GOM2-2 relative to a fresh-water-based mud. However, the primary objective for UT-GOM2-2 is to safely and successfully acquire uncompromised hydrate-bearing sediment cores. This can only be done if conditions stay within the hydrate stability zone, and well away from the hydrate stability boundary. The addition of salt to the drilling mud, shifts the hydrate stability boundary closer to estimated conditions. This shift, by some estimates of pressure and temperature, where conditions now fall outside of the hydrate stability zone, may result in borehole enlargement and the release of free gas into the borehole. This shift by all estimates, even when coring conditions stay inside the hydrate stability zone, shrinks the window between the estimated conditions and the hydrate stability boundary. This shift is likely to compromise the hydrate-bearing cores while they are being recovered from the bottom-hole to the rig floor. In this report we present two examples: 1) Assuming temperature and pressure from in-situ estimates: Hydrate within the target reservoirs (Orange and Blue) at Walker Ridge Block 313 (WR 313) will be outside the hydrate stability zone in the presence of a drilling mud with 9.5 wt.% salinity (the salinity of the proposed 10.5 ppg salt-based mud) at in situ pressure and temperature. Thus, the hydrate will be unstable. A 10.5 ppg salt-based mud may result in dissociation of the hydrate into its components: water and gas. 10.5 ppg salt-based mud may enlarge the borehole, release free gas into the borehole, and compromise the cores. 2) Assuming temperatures equal to the measured LWD borehole temperatures at this location: Hydrate within the target reservoirs will be stable with a salinity of 9.5 wt.% (the salinity of the proposed 10.5 ppg salt-based mud), but possibly unstable (just at the methane hydrate stability boundary) for a salinity of 17.2 wt.% (the salinity of the proposed 13.5 ppg salt-based kill mud). if the borehole has the same temperature as recorded during previous LWD drilling at this location. A 13.5 ppg salt-based kill mud may destabilize the borehole. More importantly, a 10.5 ppg salt-based mud does not provide a large enough window between the estimated conditions and the hydrate stability boundary. Core temperatures and pressures fluctuate from the bottom-hole conditions as the core is brought up from the bottom-hole to the rig floor. These fluctuations are likely to cause the hydrate in the cores to touch or cross the stability boundary. Therefore, cores captured using a 10.5 ppg salt-based mud are likely to be compromised during core recovery to the rig floor.

03 NATURAL GAS↗

Pahute Mesa Well Development and Testing Analyses for Wells ER-20-7, ER-20-8 #2, and ER-EC-11, Revision 1

This report analyzes the following data collected from ER-20-7, ER-20-8 No.2, and ER-EC-11 during WDT operations: (1) Chemical indicators of well development (Section 2.0); (2) Static hydraulic head (Section 3.0); (3) Radiochemistry and geochemistry (Section 4.0); (4) Drawdown observed at locations distal to the pumping well (Section 5.0); and (5) Drilling water production, flow logs, and temperature logs (Section 6.0). The new data are further considered with respect to existing data as to how they enhance or change interpretations of groundwater flow and transport, and an interim small-scale conceptual model is also developed and compared to Phase I concepts. The purpose of well development is to remove drilling fluids and drilling-associated fines from the formation adjacent to a well so samples reflecting ambient groundwater water quality can be collected, and to restore hydraulic properties near the well bore. Drilling fluids can contaminate environmental samples from the well, resulting in nonrepresentative measurements. Both drilling fluids and preexisting fines in the formation adjacent to the well can impede the flow of water from the formation to the well, creating artifacts in hydraulic response data measured in the well.

54 ENVIRONMENTAL SCIENCES↗

High Temperature 300°C Directional Drilling System

Many countries around the world, including the USA, have untapped geothermal energy potential. Enhanced Geothermal Systems (EGS) technology is needed to economically utilize this resource. Temperatures in some EGS reservoirs can exceed 300°C. To effectively utilize EGS resources, an array of injector and production wells must be accurately placed in the formation fracture network. This requires a high temperature directional drilling system. Most commercial services for directional drilling systems are rated for 175°C while geothermal wells require operation at much higher temperatures. Two U.S. Department of Energy (DOE) Geothermal Technologies Program (GTP) projects have been initiated to develop a 300°C capable directional drilling system, the first developing a drill bit, directional motor, and drilling fluid, and the second adding navigation and telemetry systems. This report is for the first project, “High Temperature 300°C Directional Drilling System, including drill bit, directional motor and drilling fluid, for enhanced geothermal systems,” award number DE-EE0002782. The drilling system consists of a drill bit, a directional motor, and drilling fluid. The DOE deliverables are three prototype drilling systems. We have developed three drilling motors; we have developed four roller-cone and five Kymera® bits; and finally, we have developed a 300°C stable drilling fluid, along with a lubricant additive for the metal-to-metal motor. Metal-to-metal directional motors require coatings to the rotor and stator for wear and corrosion resistance, and this coating research has been a significant part of the project. The drill bits performed well in the drill bit simulator test, and the complete drilling system has been tested drilling granite at Baker Hughes’ Experimental Test Facility in Oklahoma. The metal-to-metal motor was additionally subjected to a flow loop test in Baker Hughes’ Celle Technology Center in Germany, where it ran for more than 100 hours.

15 GEOTHERMAL ENERGY↗

Self-decomposable Fibrous Bridging Additives for Temporary Cementitious Fracture Sealers in EGS Wells

This study evaluates compatibility of a self-degradable temporary fracture sealer with the drilling mud and plugging and self-degrading performance of different fibers to be used in combination with the sealer. The sodium silicate-activated slag/Class C fly ash (SSASC) cementitious sealer must plug fractures at 85oC to allow continuous well drilling and it must degrade and leave the fractures open for water at later times when exposed to temperatures above 200oC. The sealer showed good compatibility with the mud. Even the blend of 80/20 vol.% of sealer/mud reached a compressive strength of more than 2000 psi set as one of the material criteria, mostly due to the additional activation of the slag and Class C fly ash by the alkaline ingredient present in the drilling fluid. In contrast, the drilling fluid was detrimental to the compressive strength development in conventional Class G well cement, so that it failed to meet this criterion. Among several organic fibers tested both polyvinyl alcohol (PVA)-and nylon-based fibers showed adequate plugging of the sealer in slot nozzles of 1-in. wide x 6-in. long x 0.08 in. and 0.24 in. high under pressures up to 700 psi. PVA fibers displayed better compressive toughness and self-degrading properties than nylon. The compressive toughness of sealers made by adding 1.0 wt% 6 mm-length PVA and 0.5 wt% 19 mm-length PVA was 9.5-fold higher than that of a non-bridged sealer. One factor governing the development of such high toughness was an excellent adherence of PVA to the SSASC cement. The alkali-catalyzed self-decomposition of PVA at 200°C led to the morphological transformation of the material from a fibrous structure to a microscale flake-like structure that helped the desirable conversion of the sealer into small fragments. In contrast, nylon’s decomposition provided a reticular network structure in the self-degraded sealer resulting in bigger fragments compared against the sealer with PVA. The PVA fiber has a high potential as a self-decomposable bridging additive in the SSASC cement sealer.

15 GEOTHERMAL ENERGY↗

Evaluating sealability of blended smart polymer and fiber additive for geothermal drilling with the effect of fracture opening size

Geothermal formations often contain extensive fracture networks. These fracture networks contribute to the significant loss of drilling fluids during geothermal drilling. Multiple loss circulation materials (LCM) such as fiber, granules, and pills have been proposed to tackle this problem but with only limited success. Recent advances in materials science have led to the development of thermoset shape memory polymers (SMP) to address the lost circulation problem. In this paper, we evaluate a thermoset SMP performance in sealing near wellbore fractures of different sizes in geothermal wells. The SMP performance was assessed using granite disks and cylindrical granite cores having fracture sizes of 1000 μm and 3000 μm. A static filtration test was performed using cedar fiber, CaCO 3 , and SMP. Results showed cedar fiber performed better than the CaCO 3 ., reducing fluid loss by 89% and improving sealing pressure by 200 psi. A novel dynamic testing unit that allows for high-temperature testing under flowing conditions was used in this study. The analysis showed that 3% by weight SMP and fiber blends could bridge and plug the 1000 μm fracture. For a larger fracture of 3000 μm width, there was a need to increase the weight concentration of the SMP to 6% to plug the fracture opening effectively. We showed the influence of key parameters such as the type of LCM, concentration, and particle size distribution in optimizing the performance of drilling fluid loss treatment.

02 PETROLEUM↗

Geothermal Drilling: A Baseline Study of Nonproductive Time Related to Lost Circulation

A single production geothermal well costs up to seven million dollars and a typical geothermal field contains 10 to 20 wells for a development cost of potentially $140 million according to a Geothermal Resources Group study. Capital cost coupled with exploration and resource uncertainty lead to high upfront project risk. This study analyzed the time and cost of detailed geothermal drilling operations. We found the largest cause of nonproductive time in geothermal wells is advancing through lost circulation zones, where drilling fluid is lost from the well. Mitigation measures implemented during lost circulation events can increase drilling time by a significant fraction of the drilling days. There is opportunity to reduce the drilling costs by addressing logistical inefficiencies and ineffective mitigation measures to minimize nonproductive time. This study reviewed daily drilling data for 38 geothermal wells drilled since 2009 in the U.S. The analysis presented here summarizes the lost circulation events identified in the available drilling data by assessing time per event, costs incurred, materials used, success of mitigation strategies, and resolution time. This study found that wells averaged over 100 hours of unprogrammed nonproductive time due to lost circulation, adding an estimated $185,000 to each well in rig costs. A plan for future research aimed at reducing lost circulation nonproductive time and cost is presented. operations. We found the largest cause of nonproductive time in geothermal wells is advancing through lost circulation zones, where drilling fluid is lost from the well. Mitigation measures implemented during lost circulation events can increase drilling time by a significant fraction of the drilling days. There is opportunity to reduce the drilling costs by addressing logistical inefficiencies and ineffective mitigation measures to minimize nonproductive time. This study reviewed daily drilling data for 38 geothermal wells drilled since 2009 in the U.S. The analysis presented here summarizes the lost circulation events identified in the available drilling data by assessing time per event, costs incurred, materials used, success of mitigation strategies, and resolution time. This study found that wells averaged over 100 hours of unprogrammed nonproductive time due to lost circulation, adding an estimated $185,000 to each well in rig costs. A plan for future research aimed at reducing lost circulation nonproductive time and cost is presented.

15 GEOTHERMAL ENERGY↗

Environmental Restoration of Diesel-Range Organics from Project Chariot, Cape Thompson, Alaska - 16147

Cape Thompson, Alaska, is located approximately 120 miles north of Kotzebue, Alaska, within the Ogotoruk Creek valley. The remote Alaskan location is also home to the US Atomic Energy Commission (AEC) Project Chariot study area. Project Chariot was part of the Plowshare Program, created in 1957 by the AEC to study peaceful uses for atomic energy. Project Chariot began in 1958 when a scientific field team chose Cape Thompson as a potential site to excavate a harbor using a series of nuclear explosions. Between 1959 and 1962, AEC was responsible for over 40 pretest bio-environmental and geotechnical studies of the Cape Thompson area. Strong public opposition to the tests developed, which caused the project to be cancelled with no nuclear explosions ever conducted at the site. In the early 1960's, several deep boreholes were drilled to obtain subsurface, temperature, and high-explosive testing data. Refrigerated diesel was used as a drilling fluid to keep the boreholes open so that thermistors could measure subsurface temperatures. The test boreholes were named Able, Baker, Charlie, Dog, and X-1. In the summer of 2014, the US Department of Energy, Office of Legacy Management (LM) completed the remediation of remnant diesel at these sites. Prior to the 2014 remediation activities, LM conducted two separate characterization field studies to determine the nature and extent of the contamination from the 1960's drilling activities. In 2013, LM developed a remediation plan that was submitted and approved by the Alaska Department of Environmental Conservation (ADEC). The 2014 Project Chariot remediation had some unique logistical challenges and historic issues with stakeholders to overcome. Many of the historic issues centered on previous AEC scientific actions and a general mistrust of the government by the local stakeholders. Prior to and during the 2014 remediation work, an outreach campaign was implemented to discuss prior activities at the site and include stakeholders from Point Hope, Alaska, in the remediation-planning process. The remoteness of the region also provided unique logistical challenges. Because of the short field season, LM initiated several subcontracts over a year in advance. The field camp, heavy equipment, and soil storage containers were shipped by barge to the site. Personnel, food, and small materials were flown in by bush plane from Kotzebue, Alaska. Previous site characterization had identified diesel-range organics (DROs) as the primary contaminant. The cleanup levels for the site were provided by the Alaska Administrative Code (AAC) for the Arctic Zone region. The AAC cleanup level for DROs on gravel pads is 500 mg/kg and 12,500 mg/kg tundra in the arctic-zone region. To help determine the extent and direct soil excavation in the field, photoionization detectors (PIDs) were used for field screening. While the PID results provided rough limits for excavation, laboratory confirmation sampling was required to provide actual excavation guidance. All excavation locations remained open until laboratory results met AAC criteria and ADEC approved closure. The laboratory sample protocol required the bush plane to pick up samples almost daily and transfer them to Anchorage for analysis. In order to meet holding time requirements, all laboratory samples were analyzed on an expedited basis. Analytical results and ADEC approval notifications were e-mailed back to the site via satellite connection. A total of 202 laboratory analyses were needed to complete the remediation effort. At each location (Able, Baker, Charlie, Dog, and X-1), the boreholes were plugged and abandoned in accordance with ADEC regulations. Contaminated soil was excavated, and the material was placed in super-sacks and hauled to connex boxes located near the sea shore. Approximately 786 tons of material was removed and shipped by barge to the Columbia Ridge Landfill in Arlington, Oregon, for disposal. The well casings were cut and sealed below ground surface. Each location was graded to its original contours and reclaimed with native vegetation, and a geodetic survey was conducted. Tours with leaders of the Village of Point Hope and the land owner (Arctic Slope Regional Corporation) were conducted prior to the final demobilization. All remediation equipment and camp facilities were removed at the completion of the project. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Fluid driven drilling motor

A motor assembly is disclosed that includes a vane motor coupled to an output shaft by a drive section. The drive section includes hammers that engage the output shaft to provide improved torque.

03 NATURAL GAS↗

Heat Transfer in Complex Fluids

Amongst the most important constitutive relations in Mechanics, when characterizing the behavior of complex materials, one can identify the stress tensor T, the heat flux vector q (related to heat conduction) and the radiant heating (related to the radiation term in the energy equation). Of course, the expression 'complex materials' is not new. In fact, at least since the publication of the paper by Rivlin & Ericksen (1955), who discussed fluids of complexity (Truesdell & Noll, 1992), to the recently published books (Deshpande et al., 2010), the term complex fluids refers in general to fluid-like materials whose response, namely the stress tensor, is 'non-linear' in some fashion. This non-linearity can manifest itself in variety of forms such as memory effects, yield stress, creep or relaxation, normal-stress differences, etc. The emphasis in this chapter, while focusing on the constitutive modeling of complex fluids, is on granular materials (such as coal) and non-linear fluids (such as coal-slurries). One of the main areas of interest in energy related processes, such as power plants, atomization, alternative fuels, etc., is the use of slurries, specifically coal-water or coal-oil slurries, as the primary fuel. Some studies indicate that the viscosity of coal-water mixtures depends not only on the volume fraction of solids, and the mean size and the size distribution of the coal, but also on the shear rate, since the slurry behaves as shear-rate dependent fluid. There are also studies which indicate that preheating the fuel results in better performance, and as a result of such heating, the viscosity changes. Constitutive modeling of these non-linear fluids, commonly referred to as non-Newtonian fluids, has received much attention. Most of the naturally occurring and synthetic fluids are non-linear fluids, for example, polymer melts, suspensions, blood, coal-water slurries, drilling fluids, mud, etc. It should be noted that sometimes these fluids show Newtonian (linear) behavior for a given range of parameters or geometries; there are many empirical or semi-empirical constitutive equations suggested for these fluids. There have also been many non-linear constitutive relations which have been derived based on the techniques of continuum mechanics. The non-linearities oftentimes appear due to higher gradient terms or time derivatives. When thermal and or chemical effects are also important, the (coupled) momentum and energy equations can give rise to a variety of interesting problems, such as instability, for example the phenomenon of double-diffusive convection in a fluid layer. In Conclusion, we have studied the flow of a compressible (density gradient type) non-linear fluid down an inclined plane, subject to radiation boundary condition. The heat transfer is also considered where a source term, similar to the Arrhenius type reaction, is included. The non-dimensional forms of the equations are solved numerically and the competing effects of conduction, dissipation, heat generation and radiation are discussed. It is observed that the velocity increases rapidly in the region near the inclined surface and is slower in the region near the free surface. Since R{sub 7} is a measure of the heat generation due to chemical reaction, when the reaction is frozen (R{sub 7}=0.0) the temperature distributions would depend only on R{sub 1}, and R{sub 2}, representing the effects of the pressure force developed in the material due to the distribution, R{sub 3} and R{sub 4} viscous dissipation, R{sub 5} the normal stress coefficient, R{sub 6} the measure of the emissivity of the particles to the thermal conductivity, etc. When the flow is not frozen (RP{sub 7} > 0) the temperature inside the flow domain is much higher than those at the inclined and free surfaces. As a result, heat is transferred away from the flow toward both the inclined surface and the free surface with a rate that increases as R{sub 7} increases. For a given temperature, an increase in {zeta} implies that the activation energy is smaller and thus, the reaction rate is increased leading to an increase in the heat of the reaction. As a result the flow is chemically heated and its temperature increase. The results shown here indicate that for all values of {zeta} used the chemical effects are significant and the temperature is always higher than both the surface temperature and the free surface temperature. The heat transfer is always from the flow toward both the inclined surface and the free stream. It is also noticed that for all values of m chosen in this study, the temperature is higher than the surface and the free stream temperature. The heat transfer at the inclined surface and at the free stream increase slowly for negative values of m to about m=0.5, but it begins to significantly increase for m greater than 0.5.

01 COAL, LIGNITE, AND PEAT↗

Robust Method to Identify Groundwater Affected By Redox Conditions at Los Alamos National Laboratory Legacy Cleanup Site - 20497

To facilitate the mission of the Department of Energy's (DoE's) Environmental Management Program at Los Alamos National Laboratory (LANL), a significant number of groundwater monitoring wells with depths ranging from 152-396 meter were completed for characterization and monitoring. Groundwater at Los Alamos tends to be oxygen saturated with very low concentrations of organic matter. Drilling fluids can introduce residual carbon causing an increase in microbial activity and local reducing conditions around the well, potentially impacting representativeness of groundwater data quality for redox sensitive constituents. We assert that the redox state of the wells can robustly be identified by aqueous solution concentrations of iron and manganese. An automated review process has been built into a computer-based data management system enabling an efficient screening process for identifying reducing conditions that are not caught using standard data-validation protocol, and ensures that important data quality issues are thoroughly identified and addressed in an efficient and timely manner. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Repurposing Drilling Control Diagnostics for Subsurface Edge Detection and Boundary Advisement During Planetary Drilling

Informed decision-making during lunar drilling and sampling missions will require data monitoring tools and specialized ground data systems. Accurate and updated situational awareness, with ongoing data monitoring, is critical for timely responses by to incoming science data. Traverse plans and scheduled activities may need to be flexibly changed in order to react to unexpected data or situations. Unlike (for example) Mars missions, the relative lightspeed closeness of the Moon allows for near-real-time ground processing of incoming mission and instrument data. An Apollo-class lunar regolith drill will in a sense “travel” a meter or two vertically at a given subsurface characterization site. As the drill penetrates into lunar regolith, it is likely to encounter a range of material densities, orientations, fracture toughness, and (perhaps) ice percentages. Lunar drill telemetry can provide science teams with a valuable first look into the subsurface structure, the regolith bulk properties, and constituents at each drilled site. Real-time AI-based recognition and reaction to downhole situations has been developed for automated deeper drilling on Mars and beyond. We can leverage the same knowledge bases and pattern-matching as areal-time interpreter of the subsurface, a situational awareness tool during drilling operations. We recently (Sept. 2019) demonstrated this AI drilling monitoring and analysis capability, in control of in-situ drilling and sampling operations, mounted on a KREX-2 rover in Chile’s Atacama Desert. Terrestrial automated drilling log analyses in oil exploration have used similar machine learning techniques in classifying and identifying features in drilling logs –but these typically are designed assuming a drilling fluid influencing downhole measurements and data (permeability, resistivity). Drilling models and existing AI software designed to detect and respond to drilling faults and hard materials can be repurposed, for near-real-time (ground-based) interpretation of drilling telemetry –a potentially valuable advisory tool for strata boundaries and changes in drilling parameters. On the Moon, this approach could be used to study the structure and to some extent the composition of lunar regolith vs. borehole depth, based on recognizable variations in fracture hardness, drilling energy and penetration rates while actively drilling. Since the early 2000s, a series of increasingly-capable real-time drilling telemetry interpretation and characterization software tools have been developed. These subsurface models and software tools have monitored the real-time drilling data received, and automatically identified changes in drill behavior (e.g., encountering a harder target layer, bit inclusions, drill choking due to infall downhole, and others) correlating these with subsurface structures and features. We discuss the mappings between drill borehole parameters, faults or events detected, and modeled changes in rock layer boundaries, in examples drawn from field testing at analog sites in an Arctic impact crater, Rio Tinto, and Chile’s Atacama Desert. These demonstrate how subsurface structural boundaries led to fault detections and responses by the software.

drilling advisor↗

Summary: High Temperature Downhole Motor

Directional drilling can be used to enable multi-lateral completions from a single well pad to improve well productivity and decrease environmental impact. Downhole rotation is typically developed with a motor in the Bottom Hole Assembly (BHA) that develops drilling power (speed and torque) necessary to drive rock reduction mechanisms (i.e., the bit) apart from the rotation developed by the surface rig. Historically, wellbore deviation has been introduced by a “bent-sub,” located in the BHA, that introduces a small angular deviation, typically less than 3 degrees, to allow the bit to drill off-axis with orientation of the BHA controlled at the surface. The development of a high temperature downhole motor would allow reliable use of bent subs for geothermal directional drilling. Sandia National Laboratories is pursuing the development of a high temperature motor that will operate on either drilling fluid (water-based mud) or compressed air to enable drilling high temperature, high strength, fractured rock. The project consists of designing a power section based upon geothermal drilling requirements; modeling and analysis of potential solutions; and design, development and testing of prototype hardware to validate the concept. Drilling costs contribute substantially to geothermal electricity production costs. The present development will result in more reliable access to deep, hot geothermal resources and allow preferential wellbore trajectories to be achieved. This will enable development of geothermal wells with multi-lateral completions resulting in improved geothermal resource recovery, decreased environmental impact and enhanced well construction economics.

42 ENGINEERING↗

Loss circulation prevention in geothermal drilling by shape memory polymer

Geothermal formations are naturally fractured with large fracture openings and networks. This can often lead to frequent drilling fluid loss events which is a major contributor to the cost and non-productive time in geothermal drilling. Development of smarter technologies and methods to tackle problem lost circulation is vital for geothermal drilling cost reduction required for geothermal energy to be recognized as a competitive alternative energy source. Mitigation of this problem and other drilling problems such as stuck pipe can minimize overall project cost. In this report, a thermoset shape memory polymer that can be activated by formation natural heat was assessed to seal near wellbore fractures in geothermal wells. The performance of the shape memory polymer (SMP) was evaluated using artificial fractures created in aluminum discs and cylindrical granite cores. Rheology and particle size distribution were considered. A novel testing setup was built for this work, which allows testing of sealing efficiency under dynamic conditions at high temperature. Analysis showed that the SMP has efficiently succeeded in forming a strong plug inside the fractures and stopped fluid loss at high sealing pressure. This smart loss circulation material can expand within the fractures to reduces non-drilling time and strengthen the wellbore in high-temperature drilling operations.

58 GEOSCIENCES↗