drilling the limit - geothermal workshop
TRANSCRIPT
Drilling the LimitIncreasing Efficiency in Geothermal Drilling
Katherine YoungGeothermal Program Manager14 November 2018
Carsten SørlieProject Leader Geothermal Technology
NREL | 2
Current Drilling Rates
(Fro
ne
& B
oyd,
2018)
NREL | 3
Continuous Improvement
Source: de Wardt and Co 2018
TECHNOLOGY IMPROVEMENT
• 6” PDCs instead of Impregs, 8.5” PDCs
• Rotary steerable instead of bent-motor BHAs
• EM-MWD
PROCESS IMPROVEMENT
• DWOPs, DTL, performance analysis/feedback, incentive pay
• UBD with OBM, Eliminated liners at 12, 500’
• Dual mud systems for WBM & OBM
• Mitigating drilling dysfunction
NREL | 4
Drilling as Manufacturing
Lean Manufacturing is a systematic method for waste minimization within a manufacturing system without sacrificing productivity.
1Map &
Measure
Document process “as is”
2Explore & Evaluate
Identify Waste
3Define & Describe
Design Improvements
4Implement & Improve
Create Implementation
Plan
5Monitor &
Modify
Monitor improvements
for sustainability
Reported time savings of 20-50% - or more – translating to cost savings of 20-30%
NREL | 5
Drilling as Manufacturing
Lean Manufacturing is a systematic method for waste minimization within a manufacturing system without sacrificing productivity.
1Map &
Measure
Document process “as is”
2Explore & Evaluate
Identify Waste
3Define & Describe
Design Improvements
4Implement & Improve
Create Implementation
Plan
5Monitor &
Modify
Monitor improvements
for sustainability
NREL | 6
Review Available Data
CORE
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
CMTPL
STUK
MOVE
FISH
FISH
FISH
Daily NPT Breakdown
RIGU REAM CORE CIRC TRPI, TRPO WASH, SERV REPR CUT SURV WIRE WELD WIPE BOPO, BOPNU BOPT BHAOP CMTPL STUK CMTD MOVE OTHER WAIT (WOO, WOC) CASE FISH
RIGU0%
DRIL30%
REAM1%CORE
0%CIRC3%
TRPI, TRPO23%
WASH, SERV1%
REPR0%
CUT1%
SURV1%
WIRE0%
WELD1%
WIPE6%
BOPO, BOPNU
4%
BOPT0%
BHAOP2%
CMTPL2%
STUK0%
CMTD1%
MOVE0%
OTHER5%
WAIT (WOO, WOC)16%
CASE2%
FISH1%
Drilling Log Time Distribution
0
200
400
600
800
1000
1200
0.0
20.0
40.0
60.0
80.0
100.0
120.0
Depth Drilled (Ft)
Tim
e o
n B
it (
Hrs
)
Ave
rage
RO
P (
Ft/h
r)
Drill Bit Performance
Average ROP While On
Time on BHA
Depth Drilled
For example …
NREL | 7
Drilling as Manufacturing
Lean Manufacturing is a systematic method for waste minimization within a manufacturing system without sacrificing productivity.
1Map &
Measure
Document process “as is”
2Explore & Evaluate
Identify Waste
3Define & Describe
Design Improvements
4Implement & Improve
Create Implementation
Plan
5Monitor &
Modify
Monitor improvements
for sustainability
NREL | 8
Waste in Drilling
WasteLess than perfect
due to normal operations
ROOT CAUSES
IgnoranceNot knowing something
Wrong Design
OperationsLess than
perfect actionsRight Design
Wrong Action
LossLess than perfect
due to failure
TYPES OFWASTE
Operations-based Wastenew/inexperienced crew ‘always
done it that way’tripping slower than you could
Operations-based LossStuck because driller took wrong action, running the cone off a bit
Ignorance-based LossStuck because casing set in wrong place, Kicks, Geologic Side Tracks,
Wrong mud type for formation
Ignorance-based Wastecirculating bottoms up to check gas, conservative casing setting
depth,
cTechnology-based Waste
Multiple bits per hole section, Circulating bottoms up,
Technology-based LossStuck because no high-T
downhole tools
TechnologyTechnology limitations
Ad
ap
ted
fro
m: B
rett
(P
etro
Skill
s) 2
01
8
NREL | 9
Drilling as Manufacturing
Lean Manufacturing is a systematic method for waste minimization within a manufacturing system without sacrificing productivity.
1Map &
Measure
Document process “as is”
2Explore & Evaluate
Identify Waste
4Implement & Improve
Create Implementation
Plan
5Monitor &
Modify
Monitor improvements
for sustainability
3Define & Describe
Design Improvements
NREL | 10
The Perfect Well & Technical Limit
The Perfect Well time is the minimum time in which a well could possibly be drilled.• Calculated from physical factors that constrain the drilling
time (e.g. rock strength, equipment limits).
• Used to normalize differences between wells and create a purely objective indicator of well construction effectiveness. c
The Technical Limit is the best possible well construction performance for a given set of design parameters.• Estimated by a drilling team and therefore may not
necessarily be an objective standard measurement.
• Estimate is that it takes about 15 minutes per well to calculate and define a non-ambiguous technical limit.
Ignorance Waste
Operations Waste
Technology Waste
OperationsLoss
Ignorance Loss
TechnologyLoss
Physical Limit
Drilling Efficiency Non-Productive Time
Perfect Well
Technical Limit
RemoteWildcat
Well
Adapted from: Brett (PetroSkills) 2018
NREL | 11
Drilling as Manufacturing
Lean Manufacturing is a systematic method for waste minimization within a manufacturing system without sacrificing productivity.
1Map &
Measure
Document process “as is”
2Explore & Evaluate
Identify Waste
5Monitor &
Modify
Monitor improvements
for sustainability
3Define & Describe
Design Improvements
4Implement & Improve
Create Implementation
Plan
NREL | 12
Drilling the Limit*
Drilling The Limit* (DTL) represents an alternative planning methodology through which incredible gains can be made. Used to improve performance by working down from a point of perfection based on the current levels of technology, rather than from incremental improvements in today’s performance.
What is the current performance? “Normal” averageWhat is possible? Theoretical limitWhat is needed to get there? Resource investment
Applying the DTL methodology results in a significant step change
in performance.
*Drilling the Limit is a registered trademark of Shell
Ignorance Waste
Operations Waste
Technology Waste
OperationsLoss
Ignorance Loss
TechnologyLoss
Physical Limit
Drilling Efficiency Non-Productive Time
Perfect Well
Technical Limit
NREL | 13
DTL requires a significant change in mindset and attitude, with full support from all levels within the company.
Reports indicate the engineers and rig personnel had fun. They enjoyed:
• the thrill of success,
• the peer competition (between rigs),
• the sense of achievement and professional pride.
Implementing DTL
NREL | 14
Drilling as Manufacturing
Lean Manufacturing is a systematic method for waste minimization within a manufacturing system without sacrificing productivity.
1Map &
Measure
Document process “as is”
2Explore & Evaluate
Identify Waste
3Define & Describe
Design Improvements
4Implement & Improve
Create Implementation
Plan
5Monitor &
Modify
Monitor improvements
for sustainability
NREL | 15
PDCAPDCA is a Lean problem solving method for continuous process improvement
NREL | 16
Hard-rock geothermal (with fewer wells per
site) will be slower than soft rock oil and
gas drilling, so the number of hours of
drilling for both industries starts to look comparable in
the millions-of-hours-per-year range
hrs
Significant Drilling Hours per Year
Increased Drilling Market
That’s an extra 1,000 wells per year in the
U.S. every year for the next 30 years. That’s a
huge increase over the current rate of
<10 or so/year. But still is quite shy of the
15-20k U.S. oil and gas wells drilled each
year.
Increased Market CompetitivenessSince drilling makes up ~50% of project costs, faster drilling
can significantly increase market competitiveness.
Recent market deployment modeling
suggests this could amount to an added
50 GW by 2050.
Cost Savings
Time savings equate to cost savings – both
in drilling costs, as well as increase NPV.
Additionally, costs savings reduce risk, which could equate to better loan rates.
Market Impact
Faster drilling
Efficiency in drilling has been shown to
decrease drilling time by 20-50% -
and sometimes up to 60%
THE “PERFECT GEOTHERMAL WELL”
DRILLING THE LIMITS – EQUINOR PERSPECTIVES
Open
Drilling the Limits
“The Perfect Well” concept in Equinor• PRINCIPLE:
• Shorten
• Execute in parallel
• Delete
• ACHIEVEMENTS:
• US onshore drilling time: from >50 days to <10 days!
• NCS well cost: 2-for-1!
• SUCCESS FACTORS
• Focus on continuous improvement in the drilling operation
• Setting stretch goals, i.e. budget vs. “the perfect well”
• Incentives for competitive mindset and collaboration
• Digitalization
• HSE is non-negotiable!
18 |
cycle time reduction
Open
Drilling the Limits
«Perfect Geothermal Well» workshop
• Equinor expert facilitated IDDP-2 pre-drill workshop
• More than 100 improvement opportunities were identified
• Potential for reducing drilling time to 1/3 of current average?
• NEXT STEPS:
• Capture O&G practices
• Define the «perfect geothermal well»
• Test potential in geothermal drilling
• Joint industry initiative?19 |
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NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiencyand Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
NREL advances the science and engineering of energy efficiency, sustainable transportation, and renewable power technologies and provides the knowledge to integrate and optimize energy systems.