HGP-A

HELLHEAD GENERATOR PROJECT

WELL TEST REPORT

JANUARY 3 - 18, 1980

Department of Energy Contract

DE-AC03-78ET28420

HGP-A JANUARY 3-18, 1980 vJELL TEST REPORT Engineering Group

University of Hawaii Hawaii Geothermal Project

I. Introduction

The HGP-A well at Puna, Hawaii underwent a two-week flow test in

January, 1980:

1) To verify the quantity of steam flow for a 3-MW power plant.

2) To verify the quantity of non-condensible gases and percentage

of H2S, which are critical in the design of condensers and H2S

abatement system.

3) To prove out the effectivenesses of the caustic/peroxide H2S

abatement system and the noise abatement system of the rock pit.

4) To check out the steam collection system which will be used in

the final power plant operating system.

The test is judged to be a success because it has accomplished most

of our objectives. The following summarizes the Engineering Group's effort

of the well test. Separate reports will cover the results of the

reservoi r fl ui d chemi stry. and H2S abatement experiments.

II. Responsibilities of the Hawaii Geothermal Project

The Hawaii Geothermal Project (HGP) staff was responsible for the

operation of the well test under the direction of the well test manager.

Figure 1 shO\oJs the organization of the \1ell test.

Specifically the Engineering Group of the HGP "'Jas responsible for:

A.. Providing a test supervisor and a test data recorder 24 hours

per day throughout' the test period. The test supervisor had

the overall responsibility of maintaining the operation of the

well test under the direction of the well test manager.

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B. Maintaining a record of all well flow, pressure and temperature

data.

C. Maintaining a well test log including any complaints from the

residents.

D. Maintaining a chemical injection log including caustic dilution

records.

E. Checking the performance of the separator by steam calorimeter.

F. Implementing the safety plan.

G. Conducting downhole temperature and pressure measurements prior

to the well test and after the well test.

H. Monitoring the noise level to measure the effectiveness of the

rock pit muffler.

I I 1. Resul ts

A. Hell flow vs. wellhead pressure

Due to the incorrect sizing of the steam control valve, it was

not possible to control a steady flow much beyond 161 psig at the

separator, therefore we were not able to obtain meaningful data

beyond that point. Table 1 summarizes the well flow data vs. the

sepa rator pressure. Tab 1 e 2 is an abbrevi ated version of the \'Ie 11

flow data performed in 1977 duplicated here for comparison purposes.

In general, the wellhead pressure is approximately 10 to 15 psi

higher than the separator due to line loss and higher separator

elevation. Notice that the steam flow rate does not differ much

from the previous flow test but water flow rate is much higher.

This is due partially to the improper design of the weir measuring

methods employed in the previous test measurements.

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The final plant design calls for approximately 160 psig at the

separator. The metered steam flow will adequately generate 3 MH

of electricity.

B. Calorimeter I

An Ellison U-Path Steam Calorimeter was used to check the

effectiveness of the separator by measuring the steam quality of the

separated steam. Due to the placement of the calorimeter, there was

a 10 ft. length of inlet pipe between the steam line and the

calorimeter, It was very difficult to insure adiabatic condition in

the inlet pipe even though the pipe was insulated.

Nevertheless, calorimeter measurements \'1ere attempted and no

better than 96% quality was consistently obtained. These data do

not match up to the results of the chemistry chloride method

employed by the HGP Chemi stry Group. Thei r measurements consistently

show very little chloride in the steam and showed better than 99.9%

steam quality. Thus, we feel that the separator is performing

adequately and the performance of 99.9% separation is satisfactory.

C. Chemical Injection Rates

Throughout the test, we were able to maintain very constant

peroxide injection rate but were unable to maintain very constant

caustic injection rate without constant adjustment. The caustic

metering pump and its air actuator must be repaired. A separate

report covers the results of the H2S abatement experiments.

D. Noi se

Sound level measurements were taken to test the efficiency of

the newly installed rock muffler system. The measurements were

taken at various stations around the well site, 1/2 mile up and

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down the adjacent Pohoiki Bay Road and 1/2 mile up into the Leilani

Estates area. Initial measurements were obtained with the well

flashing through the twin stacks only. Later sound level measure­

ments were obtained with the rock muffler in operation.

The muffler system consisted of an earthen pit upon which rocks

were placed. Steam from the H2S treatment system was discharged

into the pit. Some of the steam condensed in the earthen pit and

emptied into the percolation pond. The uncondensed steam rose up

through the rock pile and disbursed into the atmosphere.

The rock muffler proved to be an effective noise abatement system.

At many stations over 30% noise level reductions were. experienced.

Figure 2 is a diagram of the well site and indicates the stations at

which noise level readings were taken. Table 3 lists the noise level

measurements obtained at each station. As added information, noise

level readings of previous flashings are included in Table 3.

E. Temperature and Pressure Profiles

Prior to the start of the two week flow test at HGP-A in

January 1980, a temperature-pressure profile was taken where the

temperature profile showed high temperatures at 4300 and 6250 feet

in the order of 320°C. Th~ temperature and pressure plots are shown

in Figures 3 and 4. No other downhole tests were conducted during

the flow test until after the well was shut-in.

The HGP-A well was reworked in September, 1979 to restore the

casing cement competency. The original 9 5/811 casing was set from

the surface to ~2200 ft. below casing head flange. Before the

repair work the well temperature profile showed high temperatures

all the way up to ~1500 ft. During rework several attempts were

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made to squeeze off zones around 2200 ft. and 1500 ft. The cement

bond logs showed only approximately 80% bond at best. Subsequently,

a new string of ]I' casing was run from surface to 3000 ft. The

temperature peaks at 1500 ft. and 2200 ft. on the temperature

profile prior to flashing reflect the zones where the conduction

of heat from outside of the casing exists.

Since the well shutdown, five temperature profiles have been

conducted. Two profiles taken immediately. after shutdown have shown

the flashing profile characteristics (semi-vertical straight-line),

while five days later, the temperature profile started to show

similarities to the preflash profile, The ten and thirty-one day

profiles display, in general, cooling in the upper sections and

heating in the lower sections. These plots are presented in Figure 3.

F. Water Level Recovery

Water level recovery after the two week flow test followed

similar patterns of other recoveries after production flow. This is

shown in Figure 5. Approximately twenty-three days after shutdown,

the water level was at ground level. This recovery was faster than

previous recoveries following production flows of similar time'

length. It is thought that the lengthening of the casing of HGP-A

to 3000 feet, thus closing the suspected cooler water influx, may

have increased the recovery rate.

G. Other Results

1. During the two-week test, Hawaii was hit by a severe storm and

the well site suffered numerous and long power outages. During

these periods, it was not always possible to chemically treat

the steam to remove hydrogen sulfide and to operate the equipment

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in the normal noise suppression mode. The final power plant

must have adequate stand-by power for noise and odor suppression

in the event of power outages.

2. During these periods where noise and odor were not suppressed,

we received several complaints from the nearby residents.

However, after the power was restored and the normal test

operation with full odor and noise abatement resumed, no further

complaints were received,

3. During the two-week·test, several weaknesses in the instrumen­

tation were discovered. These are:

a. Defective separator water level indicator and level

controller.

b. Continuous plugging of the venturi pressure sensing ports.

c. Defective badgemeters for mixing caustics.

d. Lack of weatherproofing of instruments and gages.

4. The maximum growth of the wellhead during flow is approximately

5 inches.

1 Mechanical

Data Recorder

1 Process

Engineer (Rogers)

J.T. Kuwada

TEST fi4.ANAGER

James T. Kuwada.

1 TEST SUPERVISOR

Bill Chen Paul Yuen

Deane .Kihara Art Seki

Process Engineer

(FMC)

Harry Castrantas

I Chemistry

Supervisor Don Thomas

Chemistry Data

Analyzers

.. Sampl e Takers Gas Analyzer Water Analyzer

Figurel

I Pi pe f'i tter E 1 ec t/ Ins t r .

Laborer

I "'-J I

• • FIGURE 2 DIAGRAM SHOWING STATIONS FOR NOISE LEVEL READINGS

33 0 (Property Line)

12 11 1

0 27 percolation 0 percolation

pond 26 pond

22 23

2 l,'l~ 1e: 10

21]29 31 '. 30

instrument shed

3 4

WIND DIRECTION

12/28/79 t 1/3/80 ./

10:00 - 10:30A 11 :00 - 11 :30A ./'

2:25 - 2:55P ~ 6:00 - 6:30P

10

'.of

sparger pit

5

9

11/3/76 1/26/77 1/7/80

t I::"" /

6

8

7.f-- about 100 ft. ~

I 00

(diagram is not to scale)· I

1000

2000

3000 .... w w u.. .. :J:.

li: 4000 w o·

5000

6000

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100

Before Start-up • • 12/13/79

After Shut-in . o 0 1118180 8 A 1/18/80 E1 0 1/23/80 5 days after shut-in ",?---:t.l 1/28/80. 10 days after shut-in @---® 2/25/80 38 days after shut-in

"r", •

. ,' .

7000~------~--------~------~--------~------~--------~~-----

Figura 3

"

o 50

-10-

PRESSURE. kg/cm2 100 150

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o 012/13/79

Figure 4

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- ..... ~: DAYS

, '.

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Table I Throttled Flow Data 1/3/80-1/18/80

Separator Total Mass Steam Flow Water Flow . Steam Pressure Flow Rate Rate Rate Quality (PSIG) (Klb/hr) (Klb/hr) (Klb/hr) (% )

56 111 .5 70.9 40.6 63.6

110 110.3 64.7 45.6 58.7

132 108.0 61.0 47.0 56.5

'161 105.9 56.6 49.3 53.4

Table 2 Throttled Flow Data 1/26/77-2/10/77

Wellhead Total Mass Steam Flow Water Flow Steam Pressure Flow Rate Rate Rate Qual ity (PSIG) (KlbLhr) (Klb/hr) (Klb/hr) (%)

\. '

54 99 65 34 66

100 93 57 36 64

165 89 54 35 60

-t

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TABLE 3

NOISE LEVEL READINGS ON DBA SCALE

STATION NO ABATEr.1ENT PARTIAL ABATEMENT PREVIOUS FLASHING ABATEr~ENT

12/28/79 1/3/80 1/3/80 11/3/76 1/26/77 1/7/80 10:00-10:30A 11 :00-11 :30A 2:25-2:551' 6:00-6:30P

1 93 91 94 75 73 100 96 57 2 99 100 99-100 82 78 104 100 66 3 84 83 82 65 75 98 93 51 4 7r:; -- 84-85 70 70 98 96 64 ,oJ

5 86 -- -- -- -- 97 -- --6 79 -- 76 64 63 98 89 50 7 88 -- 82 67 64 96 90 52 8 75 83 78 63 80 98 91 46 9 82 -- 76-78 67 67 99 93 52

10 81 -- 91 71 80 98 94 57 11 86 -- -- -- -- 99 96 --12 88 -- -- -- -- 100 90 --13 100 -- 100 . 84 82 107 100 69

14 101 -- 102 85 83 110 103 60 .. 15 98 96 98-99 81 79 107 100 56

16 100 98/99 103 -- -- 106 102 --17 102 100 103 83 82 104 101 71

18 102 -- -- 84 80 110 103 68

19 104 -- -- -- -- 110 101 --20 99 -- -- -- -- -- -- --21 98 94 -- -- -- 103 99 -- .

22 98 -- 96 82 80 104 98 67

23 93 92 73 71 100 94 63 , -- , . 24 91 94 94 76 75 99 95 69

25 97 -- 99 82 80 106 95 74

26 94 -- 94 74 73 106 93 58

27 93 -- -- -- -- 100 96 --28 97 -- 96 81 -- 106 100 68

29 98 97 97 80 -- 110 102 70

30 96 92 83 77 -- 96 91 72

31 94 -- 93-94 75 -- 108 101 66

. 32 79 83 83 60-62 -- 87 80 44

33 -- 94-95 94 73 -- -- -- 56

34 -- 41-42 42 41 -. ~~ ~. 37

35 -- 50 48 40 .- -- -- 34

36 -- 40-42 38 36 -- ~- -. 42