E X TREME DRILLING LABORATORY Project Summary (May 2009)

Transcription

1 E X TREME DRILLING LABORATORY Project Summary (May 2009) Office of Research and Development Earth & Mineral Sciences Division William J. Ayers, Jr., P.E. Presentation Identifier (Title or Location), Month 00, 2008

2 NETL Mission Implement research, development, and demonstration programs to resolve the environmental, supply, and reliability constraints of producing and using domestic energy resources 2

3 National Energy Technology Laboratory More Than 1,800 Activities in the United States and 40+ Other Countries Only DOE GO/GO National Lab Research spans fundamental science to technology demonstrations In-house and Contracted Efforts Oregon Pennsylvania West Virginia 3 R. Boyle, 01/06/2009

4 Office of Research and Development Partnering & transferring collaborative research with universities and industry Applying advanced computational techniques and experimental facilities to solve problems & to facilitate development of advanced energy technology Four primary focus areas: Computational & Basic Sciences: Energy System Dynamics: George Geological & Environmental Systems Materials Science 4 R. Boyle 09/06/2008

5 CO 2 Storage Geological/Environmental Research Areas Science and engineering research of natural systems to enable the clean production & utilization of fossil energy. Capacity, injectivity, long-term fate Seal integrity (cement durability) Potential impacts (fluid-rock interactions) Monitoring and assessment (airborne, surface, subsurface; GIS; risk assessment) Oil, gas, unconventional fossil fuels Extreme drilling Environmental impacts Unconventional oil & gas Methane hydrates CO 2 -EOR 5

6 EPACT 2005, Subtitle J, Section 999 Funding Oil & Gas Lease Income - $50 million/year Allocation: 35 percent for Ultra-deepwater; $15 million* 32.5 percent for Unconventional Resources; $14 million* 7.5 percent for Small Producers; $3.2 million* 25 percent for NETL In-house; $12.5 million Management and Admin; $5.6 million 5 percent for NETL oversight; $1.88 million* 10 percent for Consortium Admin; $3.75 million* Applies only to Program Consortium funding (1-3) $100 million is authorized to be appropriated Cost Share 20% for R&D and 50% Demonstration 2009 Call - August/September Time Frame (Refer to RPSEA or NETL web site) * rounded 6

7 Research Objectives Mission: Advance the state-of-the-art of ultra-deep drilling technology by conceiving, testing and developing emerging technology, conducting experiments, and performing proof of concept testing. Research Thrusts Rock Mechanics Drilling Fluids State-of-the-Art Enhancements Smart Drilling Systems 7

8 XDL Components Ultra-deep Drilling Simulator Installation Completed Shakedown Testing Underway Baseline Tests XDL Support Labs Rock Lab (3-4 Months) Mud Lab (1-2 Months) Modeling Finalizing Road Map University Initiatives 8

9 Drilling Simulator (UDS) Objective: Explore the fundamental and essential parameters required to characterize cutter versus rock type interdependencies under extreme conditions. Artist s rendering of UDS internals showing cutter contacting rock test specimen 9

10 Ultra-deep Drilling Simulator (UDS) Current Activities: Tuning Essential Instrumentation Subsystems. Integration of subsystems. Planned Activities: Baseline Validation of Unit Operations Extreme Conditions Testing Front view of X-ray beam path into UDS window. PDC shown in line of sight. Shadow image on UDS back side. Image shown is an artist perception of cutter/rock interface and generated cuttings. 10

11 Confocal Microscope Rock Laboratory Primary Functions: Data Integration Analysis of Intrinsic Properties Experimental Rock Mechanics Scoping Studies CNC Water Jet Cutter TeraTek Scratch Tester 11

12 Hardness Tester Rock Laboratory (cont.) GEOTEK Multi Sensor Core Logger 12

13 Fluids Laboratory Drilling fluids preparation and handling for UDS. Verification, modeling and exploration of drilling fluid properties. Chandler Model 7600 Viscometer 13

14 Modeling Developing Modeling Road Map Closing on Initial Phase of University Work 14

15 Current Modeling Efforts Rock Mechanics Identify and develop discrete and continuum analysis methodologies suitable for predicting reliably the reaction forces on PDC cutter bits and the rock fragmentation process from drilling. Drilling Fluids Modeling: Combine and arrange atoms to form molecules with desired properties. The challenge being to determine interactions with solids under extreme conditions. 15

16 Current Modeling Efforts Drilling fluid flow and filter cake formation process Drilling fluid Fluid injection point Drill cutter Objectives Develop an experimentally-validated in-house CFD model of filter cake formation on a porous surface Construct a lab-scale filtration test rig for filter cake formation experiments Measure the evolution of the filter cake formation Benchmark in-house CFD model vs. commercial ANSYS Fluent CFD Compare model to filtration/filter cake experiments Figure modified from wikipedia.org Filter cake Rock formation (porous) Challenges Filtration test rig has required specialized parts which have delayed experimental setup Fluent Eulerian multiphase model not made to handle particle structures and multiphase flow; CMU drilling fluid CFD code being developed for this. Difficult to obtain digital images of filter cake 16

17 17 Deep Trek Data

18 18 Deep Trek Data